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Coated poultry products. Coated poultry products are starchy products / coated products on the market are Nuggets, Sticks, Spicy Wing and Karage (export products). Chicken nuggets are the most popular coated chicken products and have a high market share. ready to eat products
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Coated poultry products are starchy products / coated products on the market are Nuggets, Sticks, Spicy Wing and Karage (export products).Chicken nuggets are the most popular coated chicken products and have a high market share.
ready to eat products • ready to serve products • Attractive (taste, shape, size and appearance) • Practical and economical • Safe (material) • Halal (spiritual) • Quality
Meat source • Breast meat - its uniformly soft texture and its light color. • Skin – it increases fat content and compromises texture.. • Thigh, drumsstick, rib meat, dark meat and mechanically deboned poultry meat - reduce production costs and also to improve flavor due to its higher fat content.
Ingredients - Salt • Salt is the most important ingredients added in chicken nugget. • Salt has two main functions in the production of nuggets, adds flavor and aids in myofibrillar protein extraction. • It is added at a concentration of less than 2% of the formula.
Sodium tripolyphosphate (STP) • Sodium tripolyphosphate (STP) is another ingredient used to aid in protein extraction. • STP helps to increase water-holding capacity by increasing the pH and unfolding muscle proteins to allow for more water-binding sites. • STP helps to retard oxidative rancidity. • Sodium tripolyphosphate can only account for 0.5% in the finished product.
Other ingredients • Water is also often added for moisture and to aid in mixing of the product. • Other ingredients such as starches and soy proteins are also used as binders, extenders, and fillers. • Isolated soy proteins can also retard oxidative rancidity, improve water-holding capacity, and lighten dark meat.
Other ingredients • A variety of spices and seasonings can also be added depending on product specifications.
Prepare formulation • The first step in the production of nuggets and patties is to prepare or develop a formulation for the product. • Considerations for formula: consumer demands, marketing, technology, and creativity. • Proper amounts of meat and other ingredients should be measured and ready to use.
Prepare formulation • It is important that the ingredients are precisely measured so that the product will remain consistent.
Reduce particle size • The next step is to reduce the particle size of the meat in order to increase the surface area for protein extraction. • Chopping or grinding the meat using a bowl chopper or grinder to reduce particle size. • Ingredients such as salt and STP will aid in myofibrillar protein extraction. • The goal is that the salt and STP will contact the meat surface and aid in protein extraction.
Reduce particle size • Water is added to solubilize the salt and STP so that maximum protein extraction can occur. • Water is added in the form of ice in order to maintain the low temperatures of the meat. • If the meat temperature increases too much, protein denaturation can occur and result in poor product binding.
Reduce particle size • It is also important not to overchop or overblend the meat because protein denaturation can occur from is process as well.
Reduce temperature • During particle reduction and before forming, the temperature of the meat formulation must be reduced to aid in product forming. • If the meat temperature is not cold enough, the meat batter will be too soft and will not retain the desired shape when formed. • Batter adhesion can occur with formed meat that is above 2.2°C because the meat surface is wet.
Reduce temperature • The temperature can be reduced during the chopping process using ice and by using a frozen meat source. • Carbon dioxide snow can also be used in the forming machine hopper to reduce product temperature, but this process can become expensive.
Form the product • After the meat is chopped, blended, and cooled, the meat is ready to be formed. • The meat mixture is placed in a hopper where the meat is then augured to the forming apparatus. • Nuggets have been formed in various shapes including dinosaurs, stars, cartoon characters, rings, and athletic balls.
Coating the product • The next step in the production of nuggets and patties is to coat the product. • The three parts • in a coating system are the predust, the batter, and the breading steps.
Predust • Predusts are often used in coated products to improve batter adhesion. • This predust step is very important to products with wet or oily surfaces such as whole-breast tenders or drumsticks. • The predust can seal in moisture and provide a dry, rough surface for the batter process.
Predust • A predust typically consists of flour or a dry batter mix and possibly some seasonings. • The predust provides only a small percentage of coating pickup. • The application of predust is tumbling and sprikling. • The final step of predust is removing excess predust, because excessive predust on products can cause problems in the batter process.
Batter • Batters play a very important role in the coating process. • There are two classifications of batters that can be used in products: leavened or unleavened. • The use of one type or the other depends upon product specification. • These batter types can be used for either coating or adhesion purposes.
Batter • Batters consist of a mixture of various ingredients which can include flours, starches, eggs, milk, spices and seasoning, leavening agents, and stabilizers. • The leavened, or tempura, batters are used for coating. • A coating batter provides a protective outer covering to the product
Batter • Tempura batters are leavened, which means that upon cooking, the batter will rise creating a fluffy appearance and cake-like texture. • Tempura batters are used at high viscosity levels so that the product is well coated.
Batter • Adhesion batters are used in combination with breadings. • They serve to bind the breading to the meat product as well as to add flavor and texture to the product.
Breading types • There are many different types of breadings that can be used in a coating system. • The five major types of breadings are American bread crumbs, Japanese bread crumbs, cracker meal, flour breaders, and extruded crumbs. • They can vary in size, shape, texture, color, and flavor.
Breading types • These breadings can be used alone or in combination with other ingredients such as spices and seasonings. • American bread crumbs are somewhat round in shape and are similar to homemade bread crumbs. • Japanese bread crumbs are made from crustless bread and have a sliver shape.
Breading types • Cracker meal is a fine, flat, dense crumb that is similar to cracker crumbs. • Flour breadings are very popular and traditional because they provide a flaky, homemade appearance to the product. • Extruded crumbs are generally used as a low cost alternative to the other types of breadings.
Breading characteristics • There are several breading characteristics that can affect the final outcome of the product’s appearance and texture. • “Pickup” is a term used to describe the amount of breading that a product picks up upon application. • The thickness of the batter and the size of the crumb particles can affect the pickup of breading onto the product.
Breading characteristics • Thicker, more viscous batters will tend to pick up more breading than a thin, less viscous batter. • Coarse crumbs will provide good pickup compared to a finer crumb. • Fine crumbs will provide a uniform coverage of breading to the product. • Fine crumbs provide a smooth texture whereas coarse crumbs provide an irregular, nonuniform • texture.
Breading characteristics • A medium crumb could provide a uniform texture with some highlights in the breading. • Finer crumbs offer a tender texture whereas the coarse crumbs offer a crisp, crunchy texture.
Breading application • Breading is applied using a recirculating system. • The battered product passes under a curtain of flowing crumbs so that the top surface of the product is coated. • Pressure rollers are further down the conveyor to apply pressure to the coated product.
Breading application • Excess breading is blown off and the fully coated product is then transferred to the cooking step.
Cooking • After the product is coated, it is then cooked. • The formed product is typically fully cooked by either frying or baking, depending on the product specifications. • Frying the formed products is probably the most popular cooking method; however, with more consumers concerned about their eating habits, baked products have also become popular.
Cooking • The cooking process causes the product to change to a golden color that can also have color highlights depending on the breading used. • There are two methods that the processor can use to cook the products: full cook and prefrying.
Cooking • Most processors use a two-step cooking process. • The nuggets are first cooked in oil at 179.4 to 198.8oC for 30 to 45 seconds and then removed for a short period of time. • This first cook “sets the coating,” or cooks the surface of the meat and batter/ breading.
Cooking • This first cook, known as “par frying” or “flash frying” also helps to reduce the number of nuggets. • The nuggets are again submerged into a second fryer and cooked at 165.5 to 179.4oC for a varying amount of time, depending on the product. • The purpose of the second fryer is to fully cook the product.
Cooking • An alternative to frying is baking the product. • Baking helps to reduce the amount of fat in the product. • The current challenge with baking coated products is to produce a baked product with the same crunchy coating texture and golden color as is produced with frying.
Cooking • Innovative combinations of ingredients and cooking conditions/equipment (time, temperature, air flow, and humidity) are making progress toward this goal.
Freezing and packaging • As soon as the cooking process is completed, the nuggets/patties travel on the conveyor to the freezer where they are frozen. • After freezing, the products are packaged and prepared for distribution. • Because these coated products are cooked and frozen before distribution, bacterial growth does not usually limit shelf-life.
Freezing and packaging • Dehydration can be greatly reduced by moisture barrier packaging with good integrity and cold tolerance. • Rancidity is reduced by using fresh frying oils that contain antioxidants (such as vitamin E) and using modified atmosphere packaging
Freezing and packaging • Lipid oxidation is the chemical degradation process of fats and oils that leads to the development of off-flavors and odors known as rancidity. • The carbon double bond of an unsaturated fatty acid is attacked by an activated form of oxygen, known as a peroxidide.
Freezing and packaging • The fat then breaks at the site of the double bond, resulting in a variety of degradation products with a range of off-flavors and odors. • The formation of peroxides is catalyzed by ultraviolet light, heat, pressure, and metals so the exclusion of these factors (as well as oxygen and the use of unsaturared oils) would reduce rancidity • development.
Freezing and packaging • Lipid oxidation is determined by sensory evaluation, by measuring the degradation products with the TBA or TBARS method (thiobarbituric acid reactive substances or by measuring the level of peroxides with the peroxide value.
Oxidation Unsaturated Fats Degraded fats O2, Fe, heat, UV, pressure, peroxides Peroxides (an active type of oxygen molecule that attack unsaturated fats Rancid by-products (off flavor, oddor, color)
