Meat Chip Microwave Vacuum Drying for Texture
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Solution Overview
Problem
Existing methods for producing meat chips lack superior flavor and mouthfeel, and do not effectively enhance the organoleptic characteristics of meat products using natural ingredients.
Innovation Solution
A method involving blending a meat product with high oleic oil and optional seasoning, extruding into a casing, cooking, and microwave vacuum drying at temperatures not exceeding 200°F to create meat chips with improved organoleptic properties, using preservatives and stabilizers like phosphates and natural gums, and optionally fermenting to specific pH levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional dehydration methods are used to make meat chips, then the chips can be produced, but they lack superior flavor and mouthfeel with poor organoleptic characteristics
Solution Approach 1:
The patent applies parameter changes by controlling water activity to 0.05-0.20 (lower than conventional 0.3-0.6), processing at low temperatures not exceeding 200°F, and adjusting pH through fermentation to 5.4-5.6. These parameter modifications improve organoleptic characteristics including flavor, texture, and mouthfeel while maintaining product integrity
Solution Approach 2:
The patent uses composite materials by combining meat product with high oleic oil (3-15% emulsion), natural gums (xanthan gum, guar gum, or k-carrageenan), and optional natural preservatives. This composite approach enhances mouthfeel and texture while providing structural stability during processing
2Productivity
If high drying temperatures are used to reduce processing time, then productivity increases, but the organoleptic characteristics and quality of meat chips deteriorate
Solution Approach 1:
The patent utilizes phase transitions by employing microwave vacuum drying that controls the phase change of water from liquid to vapor at low temperatures (not exceeding 200°F). This allows rapid moisture removal while preventing thermal degradation of meat proteins and fats, thereby maintaining superior organoleptic characteristics
Solution Approach 2:
The patent employs vacuum drying conditions that create a low-oxygen environment during the drying process. This inert atmosphere prevents oxidative rancidity of the high oleic oil and maintains the freshness and quality of the meat chip while enabling efficient moisture removal
3Reliability
If natural ingredients and preservatives are used to improve flavor and preservation, then product quality and safety increase, but the number of processing steps and complexity increase
Solution Approach 1:
The patent applies self-service by using naturally occurring preservatives (celery powder, green tea extract, rosemary extract, mixed tocopherols) and stabilizers (k-carrageenan, xanthan gum, guar gum) that provide preservation and structural functions without requiring additional complex processing steps. The fermentation process also self-regulates pH to 5.4-5.6, providing both flavor development and preservation
Solution Approach 2:
The patent demonstrates multi-functionality by selecting ingredients that serve multiple purposes: high oleic oil provides both flavor enhancement and structural emulsion stability; natural gums provide both texture improvement and water binding; celery powder or other natural preservatives provide both flavor and preservation. This reduces the need for separate functional additives and processing steps
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 results in meat chips with enhanced flavor, texture, and mouthfeel, achieving a water activity of 0.05 to 0.20 and a thickness of 1 to 5 mm, providing a crunchy and palatable product with improved organoleptic characteristics.
Implementation Method 1
microwave vacuum drying at a temperature not exceeding 200° F. the meat slices into the one or more meat chip
Implementation Method 2
microwave vacuum drying at a temperature not exceeding 200° F. the meat slices
Implementation Method 3
blending a meat product and a high oleic oil, and optionally a seasoning, into a meat batter
Implementation Method 4
one or more preservatives and stabilizers selected from at least one of: phosphates, k-carrageenan, green tea extract, rosemary extract, mixed tocopherols
Data Source
AI summary
The present invention includes meat chips and methods of making meat chips comprising: blending a meat product and a high oleic oil, and optionally a seasoning, into a meat batter; extruding the meat batter into a casing; cooking to the meat batter; slicing the meat batter into meat slices; and microwaving at a temperature not exceeding 200° F. the meat slices into a meat chip.