Pre-cooked Breaded Meat Crispness Retention
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Solution Overview
Problem
Pre-prepared, breaded, or battered meat products often fail to maintain the texture, taste, and crispiness of freshly fried products when cooked using methods like air fryers or microwaves, resulting in a soggy coating that does not adhere properly to the meat.
Innovation Solution
A method involving marinating and coating pre-cut meat, followed by par-frying to achieve a crispy coating, then sous vide cooking in a vacuum-sealed film to lock in the crispness and flavor, allowing the product to be quickly frozen and reheated for consumption, mimicking the characteristics of an oil-fried product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If pre-prepared breaded meat products are cooked using air fryers or microwaves, then cooking time is reduced, but the coating becomes soggy and loses texture
Solution Approach 1:
The coating is pre-browned in oil before packaging, establishing the desired texture and color in advance. This preliminary action ensures that when the product is later reheated in an air fryer or microwave, the coating maintains its crispy texture without requiring extended cooking time that would otherwise be needed to achieve browning.
Solution Approach 2:
The invention changes the physical state of the coating by pre-cooking it to a browned state, then preserving this state through vacuum sealing and controlled refrigeration. This parameter change allows the coating to maintain its texture during storage and rapid reheating, resolving the contradiction between quick cooking and texture preservation.
2Ease of operation
If pre-prepared breaded meat products are stored in packages, then convenience is improved, but the coating adheres poorly to the meat
Solution Approach 1:
The coating is applied and pre-browned while the meat is still in its raw state, establishing strong adhesion before packaging. This preliminary bonding action ensures that the coating remains firmly attached to the meat throughout storage, freezing, and reheating, maintaining composition stability while preserving convenience.
3Shape
If the coating is browned to desired color, then appearance is improved, but the meat may overcook during browning
Solution Approach 1:
The cooking process is segmented into two distinct stages: first, the coating is browned in oil at high temperature to achieve desired color and texture; second, the meat is cooked separately at controlled lower temperatures during sous vide processing. This segmentation allows the coating to be browned without necessarily cooking the meat to completion, as the meat cooking occurs in a separate, controlled stage.
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 produces a pre-cooked meat product with a crispy, browned coating that adheres well to the meat, maintaining the desired texture and flavor when reheated, unlike traditional reheating methods which typically result in a soggy coating.
Implementation Method 1
The marinated product can be coated with breading or batter
Implementation Method 2
the coated product can be quick frozen to freeze the outer layer
Implementation Method 3
The product can be cooked, such as par-fried, to cook the coating to a desired color and crispness
Implementation Method 4
the browned meat product can be vacuum sealed in a barrier cooking film
Implementation Method 5
The packed product can additionally be sous vide cooked until the meat product is cooked to a pre-selected temperature for a pre-selected amount of time
Data Source
AI summary
One or more methods are disclosed for producing a pre-cooked and coated meat product that can be later heated in a dry-heat type oven appliance, resulting in a meat product with a coating that mimics an oil fried product. Pre-selected meat cuts can be marinated and coated, such as with a breading or batter. The crust of the coated product can be quick frozen, and subsequently cooked to brown and cook the coating and produce a desired color. The cooked and coated product can be vacuum sealed in cooking barrier film and sous vide cooked. The resulting product maintains the color and crispness of an oil fried product when it is later heated for eating, such as in an oven or air-fryer.