Method for manufacturing cooked duck skin products

Abstract

To provide a production method of processed duck skin food, capable of being stored at a room temperature, capable of sustaining the flavor and texture and being excellent in the aspect of hygiene.SOLUTION: A first step is heating and grilling up duck skin which was already processed by applying sauce on the surface and roasting. Specifically, the processed duck skin is heated and grilled at 90-110°C for 45-55 minutes, then is further heated and grilled at 130-150°C for 5-15 minutes and is kept at remaining heat for 25-35 minutes. A second step is cooling the processed duck skin after roasting and keeping it at 5-10°C for 55-65 minutes. A third step is cutting the processed duck skin after roasting and cooling, for example in portions for one person. Processed duck skin food is made by performing the steps in this order.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a method for producing cooked domestic duck skin products. [Background technology]

[0002] Peking duck, a famous high-end Chinese dish, is unique in Japan in that, unlike in China, where a whole roasted duck is usually served cut into small pieces with the skin still attached, only the skin is served, with the meat removed. In other words, only the skin is used in cooking in Japan, with the meat removed. For this reason, when food providers (restaurants, hotels, etc.) received orders for cooked duck (which is made by roasting whole ducks native to China, shaping them into a specific shape (whole), applying a molasses-based sauce to the skin, and then freezing them), they would thaw the duck and reheat it by pouring hot oil over it, then remove the skin, cut it up, and serve it.

[0003] However, removing only the skin from a cooked duck whole that has already been roasted requires skill, time, and effort, making it cumbersome for a food provider to do this in their kitchen. Furthermore, in Japan, only the skin is used in cooking, so the remaining parts (meat, bones, etc.) remain as waste, creating problems for food providers. Furthermore, even though only the skin is used in cooking, the remaining parts (meat, bones, etc.) that are to be discarded, which take up a large volume and weight, must still be transported and stored, creating a serious problem for food providers who do not have a large storage space.

[0004] Therefore, a technology has been proposed in which a continuous piece of skin taken from the raw material, domestic duck, is held in a sheet form, a sauce is applied to it, and then it is baked (roasted) to obtain only the skin portion of the domestic duck after roasting (Patent Document 1). [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Patent Publication No. 2018-117551 Summary of the Invention [Problem to be solved by the invention]

[0006] The technology of Patent Document 1 eliminates the need for the time-consuming task of extracting only the skin from whole roasted ducks; instead, it is sufficient to simply cut the skin, dramatically improving the cooking efficiency of the food provider receiving the supply. Furthermore, since the food provider can obtain only the roasted duck skin portion needed for cooking, the food provider eliminates the problem of storing the ducks whole, which takes up freezer space, and the problem of disposing of most of the remaining portion (meat, bones, etc.) other than the skin, which must be discarded. Furthermore, the volume and weight of the skin portion obtained are dramatically smaller than that of whole ducks, which can also contribute to reducing transportation costs. In other words, the technology of Patent Document 1 offers these benefits.

[0007] However, the skin of the roasted duck obtained by the technology of Patent Document 1 is raw and therefore easily spoils at room temperature. As a result, it must be frozen or refrigerated to prevent spoilage, requiring considerable freezer or refrigerator storage space. Furthermore, if the entire cut portion cannot be served, the remaining portion must be frozen or refrigerated again, posing a challenge in terms of maintaining flavor and texture. Furthermore, the cut edges of the remaining portion are prone to spoilage, posing a hygiene challenge.

[0008] The present invention has been made in consideration of the above points, and its object is to provide a method for producing cooked domestic duck skin processed products that can be stored at room temperature, maintain their flavor and texture, and are also hygienic. [Means for solving the problem]

[0009] To achieve the above object, the method for producing cooked domestic duck skin products according to the present invention comprises at least a first step, a second step, and a third step.

[0010] The first step is the roasting process, in which the cooked duck skin, which has been coated with sauce and grilled, is heated and grilled. The cooked duck skin is then heated and grilled at 90-110°C for 45-55 minutes in the low-temperature roasting process, and after the low-temperature roasting, the cooked duck skin is heated and grilled at 130-150°C for 5-15 minutes. The rest and a high-temperature roasting step in which the heat is maintained for 25 to 35 minutes.

[0011] The second step is a cooling step of cooling the cooked duck skin after roasting, which involves cooling the cooked duck skin after roasting and maintaining it at 5 to 10°C for 55 to 65 minutes.

[0012] The third step is the cutting process, where the cooked duck skin after roasting and cooling is cut into portions, e.g., serving sizes. [Effects of the Invention]

[0013] According to the present invention, the process includes a specific roasting process (two-stage roasting) in which cooked duck skin is heated and roasted, followed by a specified cooling process, resulting in a crispy roast that can be stored at room temperature. This eliminates the need for freezer or refrigerator storage space, improving convenience for food providers (restaurants, hotels, etc.) who receive the supply. Furthermore, since the process includes a specified cutting process, food providers who receive the cut pieces only need to use the amount needed to cook the order, preserving the flavor and texture of the remaining pieces. Furthermore, since there is no need for separate cutting, there is no need to worry about spoilage from the cut ends, which previously occurred, and this is advantageous from a hygienic standpoint.

[0014] That is, the present invention can provide a method for producing cooked domestic duck skin products that can be stored at room temperature, maintain their flavor and texture, and are also hygienic. [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 is a process diagram showing an example of the method of the present invention. [Figure 2] FIG. 1 is a plan view showing a skewer frame as an example of a skin fixing frame used for preparing ingredients in the method of the present invention. [Figure 3] FIG. 3 is a left side view of FIG. 2. [Figure 4A] FIG. 1 is a diagram showing an example of a processing target prepared in one step for preparing raw materials in the method of the present invention. [Figure 4B] FIG. 1 shows a series of hides taken in one step for preparing the raw material for the method of the present invention. [Figure 4C] FIG. 1 is a diagram illustrating an example of a process for preparing raw materials in the method of the present invention. [Figure 4D] FIG. 1 is a diagram illustrating an example of a process for preparing raw materials in the method of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0016] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0017] (1) Cooked duck skin First, the raw materials shown in Figure 1 are prepared (S1). The cooked duck skin used as the raw material may be any skin obtained by applying a sauce to the surface of a continuous piece of skin taken from an edible duck, drying it, and baking it. Cooked duck skin includes, for example, "a continuous piece of skin 22 shown in Fig. 4B is taken from an uncooked domestic duck 20 shown in Fig. 4A, and then, as shown in Fig. 4D, the taken continuous piece of skin 22 is stretched from the center toward the periphery E on the skewer frame 10 shown in Figs. 2 and 3, and the area near the periphery E of the skin 22 is brought into contact with both ends of each of the skewer members 12 constituting the skewer frame 10 from the back surface 22b toward the front surface 22a, and each skewer member 12 is pierced near the periphery E of the skin 22 to hold it in a sheet-like state, and while held in a sheet-like state, a sauce is evenly applied to the entire surface of the continuous piece of skin 22, dried, and grilled." However, this is not intended to be limited to skins obtained by this method. Cooked duck skin includes those stored at room temperature after roasting, as well as those that have been vacuum-packed or otherwise frozen for transportation. If the duck skin is frozen, it may be thawed prior to the roasting step described below.

[0018] For example, the edible duck 20 is prepared by slaughtering a live domestic duck, plucking the feathers, removing the internal organs, draining the blood, removing the tongue, wings, and feet, and then sterilizing it in boiling water at around 95°C (see, for example, Figure 4A). Examples of domestic ducks that can be used for food include the Peking duck, a domestic duck native to China, and the Cherry Valley breed of domestic duck. Peking ducks are a type of domestic duck, but they are extremely special. Towards the end of the Qing dynasty, some native Chinese breeds were introduced to the UK and then reintroduced after selective breeding. Compared to ordinary domestic ducks, Peking ducks are larger, meatier, grow faster, are more resistant to disease, and are more adaptable to their environment. While the standard weight of an ordinary domestic duck (after slaughter and evisceration) is around 2.0 kg, Peking ducks weigh around 2.5–3.0 kg. While it takes about 40 days for an ordinary domestic duck to mature (for consumption) from chick, it takes about 60 days.

[0019] When a continuous piece of skin 22 is harvested from the domestic duck 20, it is preferable to work so that the meat on the underside of the skin 22 is scraped off. If a large amount of meat remains on the underside of the skin 22, the flavor and texture after grilling tend to deteriorate, but a small amount (about a few grams) does not pose a problem. The method for harvesting the skin 22 is not particularly limited, and may be carried out carefully by hand as shown in Fig. 4C, or a dedicated peeler (skin peeling and harvesting device, not shown) may be used. After the continuous skin 22 has been harvested, the remaining meat and bone portion 24 (see Fig. 4C) of the edible duck 20 can be disposed of at this time.

[0020] The skewer frame 10 used as a skin fixing frame for holding a continuous piece of skin 22 taken from domestic ducks 20 in a sheet form may have a substantially rectangular structure in which a plurality of (11 in the illustrated example) skewer members 12 with sharp ends are arranged at intervals both vertically and horizontally, and all of the skewer members 12 are connected at their intersections, as shown in Figures 2 and 3. At the intersections, one skewer member 12 can be connected by, for example, passing one skewer member 12 through the other (see Figure 3). The outer edge of the skewer frame 10 is preferably approximately the same size as a continuous piece of skin 22 taken from a domestic duck 20 and spread out into a flat sheet. The skewer member 12 can be formed of a cylindrical or prismatic rod with sharp tips. There are no particular restrictions on the material, and examples include bamboo, metal, and resin. The thickness can be determined depending on the material as long as it can maintain strength; for example, if the material is bamboo, the thickness should be approximately 3 to 10 mm.

[0021] The composition of the sauce to be applied to the continuous skin 22 is not particularly limited, and examples include a sauce mainly containing molasses, starch syrup, etc. The roasting is performed, for example, by placing the continuous skin 22 in a state of being held in a substantially flat sheet shape in a kettle (oven), and roasting the entire front and back surfaces of the skin 22 for about 20 to 25 minutes at an oven temperature of about 120°C to 130°C.

[0022] (2) Roasting process As shown in FIG. 1, cooked duck skin, which is the raw material, is subjected to specific roasting steps (S21, S22). The present invention is characterized in that the roasting step of heating and roasting the cooked duck skin is carried out in two stages. The inventors have discovered that this process makes it possible to obtain a roasted product with a crispy texture that can be stored at room temperature. The roasting method is not particularly limited, and can be appropriately selected from well-known methods such as direct flame, hot air, semi-hot air, charcoal fire, far-infrared, microwave, and superheated steam.

[0023] Low temperature roast In the present invention, in the first step, cooked duck skin is heated and roasted at a temperature and in an atmosphere that does not cause cracks in the cooked duck skin (low-temperature roasting step, S21). The low-temperature roasting step is carried out in air and includes at least a temperature-raising step and a temperature-maintaining step, and may include a subsequent residual heat-maintaining step. The temperature increasing step is a step of increasing the temperature inside the kettle (furnace) to a holding temperature at a predetermined temperature increasing rate. The temperature holding step is a step of holding the temperature at the holding temperature. In the temperature holding step, it is preferable to hold the holding temperature in air for a certain period of time without changing the atmosphere. The holding temperature is preferably 90 to 110°C, more preferably 95 to 105°C. If the holding temperature is too high, problems such as cracking of the cooked duck skin may occur. The holding time at the holding temperature is preferably 45 to 55 minutes, more preferably around 50 minutes.

[0024] In the low-temperature roasting step, after the temperature increasing step and the temperature maintaining step, The rest A heat holding step may be included. After the temperature holding step, the process may proceed to a high-temperature roasting step, which will be described later. The rest The heat holding step stops heating the furnace, The rest This is a process of maintaining the temperature, not a temperature-reducing process in which the temperature is actively lowered to a predetermined temperature (for example, room temperature: 25°C) at a predetermined temperature-reducing rate. The rest The heat holding step is carried out in air without changing the atmosphere from that in the temperature holding step.

[0025] High-Temperature Roast In the present invention, in the second step, the cooked duck skin after low-temperature roasting is heated and roasted at a temperature and in an atmosphere that will not cause the cooked duck skin after low-temperature roasting to burn (high-temperature roasting step, S22). The high-temperature roasting step is also carried out in air, like the low-temperature roasting step, but unlike the low-temperature roasting step, it includes a temperature-raising step, a temperature-maintaining step, and a The rest The high-temperature roasting process must include a heat retention step. The rest It has a heat retention step.

[0026] In the temperature-raising step, similarly to the low-temperature roasting step, the temperature inside the furnace is heated in air at a predetermined temperature-raising rate up to the holding temperature. As in the low-temperature roasting step, the temperature holding step is preferably performed in air for a certain period of time without changing the atmosphere. The holding temperature is preferably 130 to 150°C, more preferably 135 to 145°C. If the holding temperature is too high, problems such as scorching of the cooked duck skin after low-temperature roasting may occur. The holding time at the holding temperature is preferably short, preferably 5 to 15 minutes, more preferably around 10 minutes.

[0027] The rest The heat holding step is carried out in air without changing the atmosphere used in the temperature holding step. The holding time is preferably 25 to 35 minutes, more preferably around 30 minutes. This has the advantage of completely removing excess fat remaining in the cooked duck skin after high-temperature roasting.

[0028] (3) Cooling process Next, the cooked roasted duck skin is cooled (cooling step, S3). The cooling step is preferably carried out by cooling the cooked roasted duck skin at about 5°C to 15°C (preferably around 10°C) for about 55 to 65 minutes (preferably around 60 minutes). This has the advantage of inhibiting bacterial growth in the cooked roasted duck skin.

[0029] (4) Cutting process Next, the cooked duck skin is cut after roasting and cooling (cutting step, S4). This allows the food provider receiving the cut material to use only the amount needed for cooking, preserving the flavor and texture of the remaining portion. Furthermore, since there is no need to cut it separately, there is no need to worry about spoilage from the cut ends, which was a problem in the past, and it is also advantageous from a hygienic standpoint. The size and shape of the cut pieces are not particularly limited. The cut size may be, for example, a single serving size (a size appropriate for one person to eat; for example, approximately (20 mm x 60 mm) if the shape is a rectangular parallelepiped), a bite-sized size (a size that fits in the mouth as is; for example, approximately (40 mm x 40 mm) if the shape is a rectangular parallelepiped), etc. Examples of the cut shape include a cube, a rectangular parallelepiped, a cylindrical shape, and a fan shape. Through the above steps, the cooked domestic duck skin product of the present invention is completed (final product).

[0030] The final cooked duck skin product after cutting can be packaged in a bag with a set number of pieces (for example, 10 pieces), or individually in a bag. By packaging each piece individually, the flavor and texture of the finished product can be maintained as much as possible without compromising the results of the above process. Furthermore, if the individually packaged products are further double-packaged in units of a set number, the flavor and texture can be maintained even more thoroughly.

[0031] According to the manufacturing method of this example, roasted meat with a crispy texture can be obtained and stored at room temperature, eliminating the need to secure storage space in a freezer or refrigerator, improving convenience for the food provider receiving the supply. Furthermore, the food provider receiving the cut meat only needs to use the amount needed to cook the order, allowing the flavor and texture of the remaining portion to be maintained. Furthermore, since there is no need to cut the meat separately, there is no need to worry about spoilage from the cut ends, which previously occurred, making it more hygienic. That is, this example provides a method for producing cooked domestic duck skin products that can be stored at room temperature, maintain their flavor and texture, and are also hygienic.

[0032] The above-described embodiments have been described to facilitate understanding of the present invention, and are not intended to limit the present invention. Therefore, each element disclosed in the above embodiments is intended to include all design modifications and equivalents that fall within the technical scope of the present invention. [Example]

[0033] The present invention will be described in more detail below with reference to specific examples of the present invention. First, the raw material, cooked duck skin, was prepared by applying a sauce to the surface of a continuous piece of skin taken from an edible duck, drying it, and baking it. Next, the prepared cooked duck skin was subjected to a low-temperature roasting process, a high-temperature roasting process, a cooling process, and a cutting process to obtain a predetermined number of piece-cut products (cooked processed duck skin products) as finished products.

[0034] Low-temperature roasting process Holding temperature: 100℃, Holding time: 50 minutes, Atmosphere: In air.

[0035] High-temperature roasting process Holding temperature: 140℃, Holding time: 10 minutes, Atmosphere: In air, The rest Heating time: 30 minutes.

[0036] cooling process Holding temperature: 10℃, Holding time: 60 minutes, Atmosphere: In air.

[0037] cutting process After roasting and cooling, the cooked duck skin is cut into rectangular pieces of approximately 20mm x 60mm each to obtain the finished product.

[0038] The finished products were then individually wrapped, one per bag, and these individually wrapped products were then double-wrapped in groups of 10 bags. The finished product obtained through the above steps gives off the unique aroma of domestic duck skin processed products as soon as the bag is opened, and has a good flavor and a crispy texture when eaten.

[0039] In addition, a questionnaire survey was conducted on the finished products of the present invention manufactured based on the above examples, covering the following items: (1) aroma (whether the product has the unique aroma of cooked duck skin), (2) flavor and texture (whether the umami of the duck skin is preserved and it is easy to eat), and (3) overall. The results are shown in Table 1. The evaluation method was to have participants select "very good," "good," "average," or "bad" for each of the above items. This comparative evaluation was conducted on a total of 30 people (16 men and 14 women) aged 20 or over.

[0040] [Table 1]

[0041] From the above comparative evaluation, the overwhelming majority of people rated (1) the aroma as very good, with no one rating it as average or bad. Furthermore, with regard to (2) the flavor and texture, only one person rated it as average, but the rest of the people rated it as very good. Furthermore, with regard to (3) the overall rating, all but one person rated it as very good. Thus, the results showed that the finished product was favorable in all categories: aroma, flavor, texture, and overall. [Explanation of symbols]

[0042] 10. Skewer frame (skin fixing frame) 12 Skewer member 20. Domestic duck (without sauce applied to the skin surface or grilled) 22··· leather (skin of code 20) 22a...Surface 22b...Back side 24. Meat and bone parts

Claims

1. A method for producing a cooked domestic duck skin product, comprising: a roasting step of heating and roasting cooked domestic duck skin that has been coated with a sauce on its surface and roasted at 120-130°C for 20-25 minutes; a cooling step of cooling the cooked domestic duck skin after roasting; and a cutting step of cutting the cooked domestic duck skin after roasting and cooling, The roasting process includes a low-temperature roasting process in which the cooked duck skin is heated and roasted at 90-110°C for 45-55 minutes, and a high-temperature roasting process in which the cooked duck skin is heated after the low-temperature roasting process, roasted at 130-150°C for 5-15 minutes, and then maintained in residual heat for 25-35 minutes. The cooling step comprises cooling the cooked duck skin after roasting and maintaining the cooled duck skin at 5 to 10°C for 55 to 65 minutes.

2. The method of claim 1, wherein the cutting step comprises cutting the cooked duck skin into portions after roasting and cooling.

3. 3. The method of claim 1, wherein the packaging is carried out in a single bag with a predetermined number of sheets.

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