Frozen Breaded Food Crumb Coating Moisture Barrier
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Solution Overview
Problem
Microwaveable frozen breaded food products with water-containing fillings face challenges in maintaining a crispy outer coating due to water migration during storage and reheating, as freezing temperatures do not prevent water uptake by the crumb layer, leading to loss of crispiness.
Innovation Solution
A process involving a plastically deformable farinaceous dough with a high fat content is used to envelop the filling, followed by pre-coating, breading, frying, and freezing, which creates a moisture barrier that prevents water migration and maintains crispiness even after prolonged storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If frozen breaded food products are stored in a freezer, then they can be preserved for long-term storage, but water migration occurs during frozen storage which adversely affects the crispiness of the microwave heated product
Solution Approach 1:
A barrier layer comprising hydrocolloid and fat is applied between the filling and the crumb coating. This intermediary layer prevents water migration from the filling to the crumb during frozen storage and microwave heating, thereby maintaining crispiness while enabling long-term storage
Solution Approach 2:
The coating system uses a composite structure with multiple layers: an inner barrier layer made of hydrocolloid and fat, and an outer crumb coating. This composite material approach combines the water-blocking properties of hydrocolloid-fat composite with the crispy texture-providing properties of the crumb layer
2Speed
If microwave radiation is used to heat frozen breaded food products, then heating is rapid and convenient, but water in the filling is preferentially heated which drives water migration towards the dry crumb coating, destroying crispiness
Solution Approach 1:
The hydrocolloid-fat barrier layer acts as a mediator that interferes with the water migration pathway during microwave heating. It prevents the preferentially heated water from the filling from reaching and softening the crumb coating, thus preserving crispiness during rapid microwave heating
Solution Approach 2:
The invention changes the physical and chemical parameters of the coating system by introducing hydrocolloid and fat components with specific functional properties. These parameter changes create a barrier that alters the water migration behavior during microwave heating, maintaining crispiness despite rapid heating
3Ease of manufacture
If a traditional coating method is used without hydrocolloid and fat barrier layer, then the manufacturing process is simple, but the product loses crispiness after prolonged frozen storage
Solution Approach 1:
The hydrocolloid-fat barrier layer is applied as an intermediary coating step in the manufacturing process. While this adds a step to the process, it uses readily available materials and straightforward application methods to achieve long-term crispiness stability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method ensures that microwave-heated frozen breaded food products retain a crispy outer coating for up to half a year, outperforming similar products made with batter by effectively preventing water uptake and maintaining crispiness during storage and reheating.
Implementation Method 1
surrounding a portion of the filling with a barrier layer comprising hydrocolloid and fat which prevents water migration from the filling to the crumb coating
Implementation Method 2
providing a plastically deformable farinaceous dough; enveloping a portion of the filling composition with a layer of the farinaceous dough
Implementation Method 3
pre-coating the surface of the enveloped filling with an adhesion composition; applying a crumb onto the surface of the pre-coated product
Implementation Method 4
frying the breaded product to produce a fried product
Implementation Method 5
freezing the fried product
Implementation Method 6
heated in a microwave to produce a ready-to-eat product having a crispy outer coating
Data Source
AI summary
The invention relates to a process of manufacturing a microwaveable frozen breaded food product, said method comprising a) providing a filling composition; b) providing a plastically deformable farinaceous dough comprising 40-70 wt.% flour, 10-40 wt.% fat and 12-40 wt.% water; c) enveloping a portion of the filling composition with a layer of the farinaceous dough to produce an enveloped filling, the portion having a weight of 5 to 90 grams and the layer of dough having an average thickness of 0.5-2 mm; d) pre-coating the surface of the enveloped filling with an adhesion composition to produce a pre-coated product; e) applying a crumb onto the surface of the pre-coated product to produce a breaded product; f) frying the breaded product to produce a fried product; and g) freezing the fried product to a core temperature of less than -12 °C. The frozen breaded food product can be heated in a microwave oven to produce a ready-to-eat product with a crispy outer coating, even if the product has been stored for in a freezer for up to half a year.