High-Gluten Batter Coating for Fresh Protein Storage
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Solution Overview
Problem
Existing methods for preparing fried protein dishes face challenges such as contamination risks from spoiled or raw batter, spoilage of protein, and the need for freezing to preserve, which complicates large-scale commercial production and handling.
Innovation Solution
A method involving coating uncooked protein with a high-gluten batter, sealing it in pouches, and cooking below the batter-hardening temperature, followed by chilling and optional spoilage inhibitor application, allowing for later breading and flash frying at serving temperature without the need for freezing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If liquid batter is applied to protein pieces for coating before frying, then the protein pieces achieve a crispy crust, but the batter may spoil when kept at room temperature or in chilled state, creating hygiene problems
Solution Approach 1:
The batter is applied to the protein pieces in advance during manufacturing, and the coated pieces are then flash-fried to set the coating. This preliminary coating action eliminates the need to store liquid batter at the restaurant, preventing spoilage while maintaining coating quality
Solution Approach 2:
The patent changes the physical state and application method of the coating from liquid batter to a dry mix that is applied as a dusting or light coating. This parameter change allows the coating to be stable at room temperature and eliminates spoilage issues while still achieving the desired crispy crust when flash-fried
2Loss of time
If protein pieces are coated with batter and kept at room temperature for prolonged period, then preparation time is reduced, but the protein and batter may spoil, creating contamination risks
Solution Approach 1:
The protein pieces are pre-coated with the dry mix during manufacturing and then flash-fried to set the coating. This preliminary preparation eliminates the need for extended room temperature storage, reducing both preparation time at the restaurant and contamination risks
Solution Approach 2:
The patent uses flash-frying to quickly cook the pre-coated protein pieces, rushing through the cooking process to minimize the time the food spends in the temperature danger zone where bacterial growth occurs, thereby reducing contamination risks
3Stability of the object's composition
If protein pieces are refrigerated in chilled but not frozen state for extended period, then freshness is maintained, but the protein may spoil, creating hygiene problems
Solution Approach 1:
The patent changes the coating from liquid batter to a dry mix formulation that is stable at room temperature and in chilled storage. This parameter change allows extended storage without freezing while maintaining both freshness and preventing spoilage, eliminating the hygiene problems associated with prolonged chilled storage of liquid batter
4Productivity
If cooking is completed while food product is in the pouch, then processing efficiency is improved, but it requires varying ingredients for different food products, increasing complexity
Solution Approach 1:
The patent uses a universal dry mix coating formulation that can be applied to various types of protein pieces (chicken, fish, other animal proteins). This universal coating system maintains processing efficiency while eliminating the need to vary ingredients for different food products, reducing complexity
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
This method minimizes contamination risks, delays bacterial growth, and allows for 'fresh-never frozen' advertising, streamlining the preparation process while maintaining food safety and quality.
Implementation Method 1
the batter is made from high-gluten flour and the gluten content of the batter is selected such that the batter remains tacky after the pieces of food product are thoroughly and completely cooked
Implementation Method 2
an effective amount of a spoilage inhibitor to delay growth of toxigenic bacteria
Implementation Method 3
a heating unit that receives the sealed plastic pouches containing the uncooked food product coated with the batter from the packaging machine and cooks the battered food product pieces in the plastic pouches
Data Source
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AI summary
A system for cooking a food product, in particular pieces of protein, includes an optional first station that receives uncooked pieces and applies an effective amount of a spoilage inhibitor to the pieces to delay growth of toxigenic bacteria; a batter applicator that receives the pieces of uncooked protein, optionally with the inhibitor from the first station, and applies a high-gluten batter to the outer surfaces of the pieces of uncooked protein; a packaging machine that receives the pieces of uncooked protein coated with the batter from the batter applicator and seals the pieces of protein in plastic pouches; and a heating unit that receives the sealed plastic pouches containing the uncooked protein coated with the batter from the packaging machine and cooks the battered protein pieces in the plastic pouches at a time and temperature below which the batter hardens.