FROZEN BATTERED FISH PRODUCT

Abstract

A frozen battered fish product, method and apparatus for production. The product comprises a fried batter coating with a pre-defined pattern of ridges and troughs which create a textured batter surface. A frozen aqueous protective layer is disposed over a part of the batter coating to protect textured features including the pattern of ridges and troughs. The aqueous protective layer is designed particularly to provide protection when a more brittle frying batter is used, as a result of using a frying medium with lower saturated fat content.

Claims

1. A frozen battered fish product, comprising: a fish substrate with an external surface; a fried batter coating with an internal face and an external face, wherein the internal face is adjacent the external surface of the fish substrate and the external face is separated from the external surface of the fish substrate by a separation distance; the fried batter coating having first regions and second regions, wherein the separation distance of the second regions is greater than the separation distance of the first regions; the first and second regions of the coating representing a pre-defined pattern extending over a portion of the external face of the coating; and an aqueous-based protective layer covering the coating at at east the portion of the external face of the coating with the pre-defined pattern.

2. The fish product of claim 1, wherein the protective layer comprises one or more of a group comprising potable water, beer, ale, cider or lager.

3. The fish product of claim 1, wherein the protective layer represents between 0.9 wt % and 3 wt % of the frozen battered fish product.

4. The fish product of claim 3, wherein the protective layer represents between 1.1 wt % and 2.2 wt % of the frozen battered fish product.

5. The fish product of claim 1, wherein the external surface comprises an upper surface, an opposed planar underside surface and at least one side surface.

6. The frozen battered fish product of claim 5, wherein the portion of the coating with the pre-defined pattern extends over a majority of the upper surface.

7. The frozen battered fish product of claim 6, wherein the protective layer covers a majority of the fried batter coating adjacent the upper surface and the at least one side surface.

8. A process for preparing a frozen battered fish product, comprising: coating a frozen or semi-frozen fish substrate with a batter containing a leavening agent; introducing the fish substrate having the batter coating into a fryer containing a frying medium; modifying the coating on the fish substrate by creating a pre-defined pattern of ridges and troughs on at least a region of the batter coating; removing the fish substrate having the patterned batter coating from the fryer; applying an aqueous-based liquid to the patterned batter coating to form a protective layer on at least the region of the coating having the pre-defined pattern; freezing the fish substrate having the batter coating with the pre-defined pattern and protective layer.

9. The process of claim 8, wherein the batter containing a leavening agent is at a temperature of between 5° C. and 12° C. when applied to the fish substrate.

10. The process of claim 8, wherein the batter containing a leavening agent is at a temperature of between 8° C. and 10° C. when applied to the fish substrate.

11. The process of claim 8, wherein the frying medium comprises less than 50 wt % saturated fats.

12. The process of claim 8, wherein the frying medium comprises a vegetable oil comprising sunflower oil and/or rapeseed oil.

13. The process of claim 8, wherein the aqueous-based liquid contains one or more of a group comprising potable water, beer, ale, cider and lager.

14. The process of claim 8, wherein the yield of the fish substrate having the fried batter coating is in the range of from 101% to 103% after application of the aqueous protective layer.

15. The process of claim 8, wherein the yield of the fish substrate having the fried batter coating is in the range of from 101.2% to 102.2% after application of the aqueous protective layer.

16. The process of claim 8, wherein one or more spinning discs are used to atomise the liquid during the step of applying the liquid to the coating.

17. The process of claim 8, wherein one or more nozzles are used to atomise the liquid during the step of applying the liquid to the coating.

18. The process of claim 17, wherein the nozzles are arranged in rows with each row aligned perpendicular to a longitudinal travel direction of a conveyor belt that transports the fish substrate.

19. The process of claim 8, wherein a time period between the removal of the fish substrate having the patterned batter coating from the fryer and the application of the protective layer is in a range between 1 seconds and 15 seconds.

20. The process of claim 19, wherein said range is between 5 seconds and 9 seconds.

21. The process of claim 8, wherein a time period between the application of the protective layer and the fish substrate entering a freezer is in a range between 1 and 15 seconds.

22. The process of claim 21, wherein said range is between 1 and 5 seconds.

23. The process of claim 8, wherein the time between the fish substrate having the coating and protective layer entering a freezer and the time when the fish product is completely frozen is not more than 120 minutes.

24. Apparatus for making the frozen battered fish product of claim 1 by the process of claim 8.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0040] A specific implementation of the present invention will now be described, by way of example only, and with reference to the accompanying drawings in which:

[0041] FIG. 1 is a schematic representation of apparatus capable of preparing a battered fish product according to one specific implementation of the present invention;

[0042] FIG. 2 is a longitudinal cross-sectional view through a fryer according to one specific implementation of the present invention;

[0043] FIG. 3 is a magnified view of the inlet region of the fryer of FIG. 2;

[0044] FIG. 4 is a magnified view of a region of the fryer of FIG. 2;

[0045] FIG. 5 is a plan view of an arrangement of slats on a first submerger conveyor in the fryer of FIG. 2, showing a pre-defined pattern of ridges and recesses;

[0046] FIG. 6 is a magnified view showing the interaction of a batter coating of a fish substrate with the ridges and recesses of slats on the first submerger conveyor within the fryer of FIG. 2;

[0047] FIG. 7 is a simplified representation showing the arrangement of the fryer and spray chamber according to one specific implementation;

[0048] FIG. 8 is a top view of the spray chamber of FIG. 7, showing an arrangement of atomising nozzles according to one specific implementation;

[0049] FIG. 9 is a perspective view of the spray chamber of FIG. 7;

[0050] FIG. 10 is a magnified view of the batter coating of a fish substrate showing the application of atomised liquid according to one specific implementation;

[0051] FIG. 11 is a simplified schematic of the process for creating a frozen battered fish product according to one specific implementation;

[0052] FIG. 12 is a perspective view of an example frozen fish product according to one specific implementation;

[0053] FIG. 13 is a top view of an example frozen fish product according to one specific implementation;

[0054] FIG. 14 is a cross-sectional view of an example frozen fish product according to one specific implementation.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT OF THE INVENTION

[0055] Referring to the accompanying drawings, and initially to FIG. 1 and FIG. 2, apparatus capable of making a frozen battered fish product is provided. The apparatus is capable of operation as a continuous production line and comprises a series of conveyor belts to transport a fish substrate 32, including a batter section conveyor 62, a frying in-feed conveyor 12, a frying base/exit conveyor 14, a spraying section conveyor 46 and a post-freezing conveyor 68. The apparatus further comprises a battering section 60, a fryer 10, a spraying section 45 and a freezer 50.

[0056] Referring now to FIG. 2-5, fryer 10 further comprises a frying medium 15 with an oil level 11. At least partially within frying medium 15 is frying in-feed conveyor 12, a first end of frying base/exit conveyor 14, a first submerger conveyor 16 and a frying out conveyor 18. First submerger conveyor 16 is equipped with a chain 20 to which slats 22 are attached. Slats 22 are aligned substantially parallel and when on an underside of first submerger conveyor 16, lower faces of slats 22 define a substantially planar surface 27. Within substantially planar surface 27, adjacent slats 22 are separated by a separation distance 23. A pre-defined pattern of ridges 26 and troughs 24 extend over substantially planar surface 27 defined by slats 22. Troughs 24 are generally of constant width 25, and are arranged in an asymmetrical pre-defined pattern on surface 27. First submerger conveyor 16 and frying out conveyor 18 are separated by a gap 17. Frying out conveyor 18 comprises a wire belt. Referring now to FIG. 1 and FIG. 7-9, a second end of frying base/exit conveyor 14 is outside fryer 10 adjacent spraying section conveyor 46 which extends through spraying section 45. Spraying section 45 comprises a hood 48, an arrangement of atomising nozzles 42, liquid inlet pipe 47 and air inlet pipe 49. An exit of fryer 10 and an entry of spraying section 45 are separated by distance 54. Nozzles 42 are arranged in two rows across a width of spraying section conveyor 46 to give spray coverage over the full belt width. An entrance to freezer 50 is separated from an exit of spraying section 45 by distance 52. Conveyor 46 extends into freezer 50. Freezer 50 comprises a series of conveyors in a low temperature environment with a total path length designed for a given freezing time. Post-freezing conveyor 68 connects freezer 50 with a packaging area.

[0057] With reference to FIG. 11, the process for creating a frozen battered fish product according to this specific embodiment comprises batter coating at step 70, par-frying at step 71, coating in an aqueous protective layer at step 72 and freezing at step 73. Referring again to FIG. 1, a fish substrate 32 travels generally in direction 43, although lateral and vertical movement may also occur.

[0058] Fish substrate 32 is a frozen fish substrate shaped generally to resemble a natural fish fillet shape. The mass of fish substrate 32 is approximately 64 g. Fish substrate 32 travels along batter section conveyor 62 in direction 43 until it enters battering section 60. Within this section, fish substrate 32 is coated in batter using standard equipment in a three-coat process comprising an initial adhesion layer of batter, a layer of crumbs and a top coat of batter containing leavening agent.

[0059] The adhesion batter comprises the following ingredients (mass percentages of dry ingredients shown in brackets): wheat flour (47.0 wt %); wheat starch (29.0 wt %); modified starch (19.0 wt %); salt (3.1 wt %); pepper (2.0 wt %). The yield after the adhesion layer is applied is approximately 107% relative to the uncoated fish substrate 32.

[0060] The layer of crumbs comprises the following ingredients (mass percentages of dry ingredients shown in brackets): breadcrumbs (89.3 wt %); flavouring (5.0 wt %); wheat flour (3.0 wt %); salt (1.4 wt %); oil (1.3 wt %). The yield after the layer of crumbs is applied is approximately 130% relative to the uncoated fish substrate 32.

[0061] The top coating of leavened batter comprises the following ingredients (mass percentages of dry ingredients shown in brackets): wheat flour (70 wt %); fat (10 wt %); salt (5.0 wt %); starch (5.0 wt %); raising agents (3.5 wt %); skimmed milk powder (2.5 wt %); flavouring (2.0 wt %); dextrose (1.0 wt %). The raising agents consist of 1.48 wt % sodium bicarbonate, 1.65 wt % of sodium acid pyrophosphate and 0.37 wt % of monocalcium phosphate. The yield after the top coating of batter is applied is approximately 172% relative to uncoated fish substrate 32. The top coating of batter is at a temperature of between 8° C. and 10° C. upon application to the coated fish substrate 32.

[0062] Before application to the fish substrate, the viscosities of the batter of the adhesion layer and of the top coat are measured to maintain consistency using a flow cup measuring device, as typically used in the art. The viscosity of the adhesion batter is represented by a flow time of 30 seconds through a flow cup of a volume of approximately 106 cm.sup.3 having an aperture of 4.75 mm in diameter, taking the end of the flow as being the point at which the flow ceases from the aperture. The viscosity of the top coat of batter is represented by a flow time of 40 seconds through a flow cup of approximately 106 cm.sup.3 and an aperture of 7.00 mm in diameter, taking the end of the flow as being the point at which the flow ceases from the aperture.

[0063] Fish substrate 32 having batter coating 34 then exits battering section 60 and passes onto frying in-feed conveyor 12, whereupon it travels downwardly into frying medium 15 within fryer 10. Frying medium 15 is a mixture of oils comprising sunflower oil, rapeseed oil and palm oil. Referring now to FIGS. 1-3, fish substrate 32 having batter coating 34 is carried by in-feed conveyor 12 until it is completely submerged by frying medium 15 (its uppermost surface is below oil level 11) and it is beneath the first submerger conveyor 16. The incline of in-feed conveyor 12 may be adjusted between position 12a and position 12b to control the rate of entry of fish substrate 32 into fryer 10 to achieve a pre-patterning residence time of between 2 and 3 seconds. The gap between the upper run of in-feed conveyor 12 and the lower run of first submerger conveyor 16 is sufficient to allow the batter coated fish substrate to pass through with a clearance of 10 to 20 mm.

[0064] Once in the frying medium 15, which is at a temperature of from 205° C., batter coating 34 starts to release steam and other gases including carbon dioxide as water in batter coating 34 evaporates and the leavening agent in batter coating 34 starts to react. As shown in FIG. 14, gases become trapped in gas pockets 56 within the batter 34 or gas pockets 58 between external surface 31 of fish substrate 32 and internal surface 40 of batter coating 34. These air pockets cause the batter coated fish substrate to become buoyant. The pre-patterning residence time is 2 seconds. Fish substrate 32 then rises into contact with the patterned surface of ridges 26 and recesses 24 created by slats 22 on the underside of first submerger conveyor 16.

[0065] Referring now to FIGS. 5 and 6, once in contact with the substantially planar surface 27 with a pattern of ridges 26 and recesses 24 created by the arrangement of slats 22, the batter coating 34 of fish substrate 32 expands upwards in direction 28 into recesses 24. Water vapour and other gases escape upwards through openings at the top of recesses 24 (not shown). Gases also escape through the gaps 23 between slats 22. The interior of recesses 24 contain frying medium, which promotes setting of at least part of the outer batter coating 34. The degree of expansion into recesses 24 is dependent on the proportion of leavening agent in batter coating 34, the temperature of frying medium 15, the level 11 of frying medium 15 and the time that coated fish substrate 32 remains in contact with surface 27. Oil level 11 is arranged such that it is immediately above the uppermost part of the recesses 24 of slats 22. Expansion of batter coating 34 will typically not occur above oil level 11. This arrangement therefore allows for sufficient expansion of batter 34 into recesses 24 without expanding above the uppermost end of recesses 24, which would create difficulties in the release of fish substrate 32 from first submerger conveyor 16. The gaps 23 between slats 22 are not sufficient for there to be any significant expansion of batter coating 34 into these spaces.

[0066] As the substantially planar surface 27 with the pre-defined pattern is carried through the oil on the first submerger conveyor 16, fish substrate 32 is maintained in contact with and stationary relative to it under the action of its own buoyancy and expansion into recesses 24. Fish substrate 32 remains in contact with the patterned surface for a period of between 9 and 20 seconds. At the end of this period, batter coating 34 is sufficiently set for the pattern of ridges to be retained on the surface of the batter 34 after fish substrate 32 leaves the patterned surface of the first submerger conveyor 16.

[0067] Referring now to FIG. 4, at the end of first submerger conveyor 16, chain 20 turns upwardly and slats 22 flex apart. This causes the set batter coating 34 of fish substrate 32 to peel away from slats 22. Slight tapering of recesses 24 aids in the release of the coated fish substrate from the first submerger conveyor 16.

[0068] As shown in FIG. 6, regions 38 of batter coating 34 adjacent ridges 26 may have been shielded from the oil and not cooked to the same extent as exposed regions within recesses 24. As the fish substrate 32 is separated from first submerger conveyor 16, it is held under the oil by frying-out conveyor 18. This allows less cooked regions 38 of batter coating 34 to become set, so that the coated fish substrate acquires a more uniform colour over its patterned surface.

[0069] Fish substrate 32 with batter coating 34 having a pre-defined pattern travels the remainder of the path through fryer 10 in contact with the wire belt of the frying-out conveyor 18. The time period that the batter coated fish substrate is in contact with frying-out conveyor 18 is between 15 and 30 seconds.

[0070] Base conveyor 14 runs along the base of fryer 10 from a point adjacent to the end of in-feed conveyor 12. As shown in FIG. 2, towards the end of the fryer, base conveyor 14 and frying out conveyor 18 are inclined upwards. This assists the batter coated fish substrate to leave fryer 10.

[0071] Referring now to FIGS. 7-10, after exiting fryer 10, fish substrate 32 (with fried batter coating 34) continues to travel in direction 43 and passes from base conveyor 14 to spraying conveyor 46. Fish substrate 32 then enters spraying area 45. The distance 54 between the fryer exit and spraying area 45 is optimised such that the time taken for fish substrate 32 to travel distance 54 is between 5 and 9 seconds.

[0072] As fish substrate 32 passes underneath spray hood 48, batter coating 34 is coated by a spray 44 of water droplets created by passing pressured potable water through two rows of nozzles 42 arranged perpendicular to direction of travel 43. Spray 44 is generated at nozzles 44 by mixing pressured potable water from fluid inlet pipe 47 with air from air inlet pipe 49. Hood 48 is designed to keep the spray 44 within spraying area 45. The spacing and arrangement of nozzles 42, and the direction of atomised spray 44 is such that a full width of conveyor belt 46 is covered by atomised spray 44, and the spray 44 coats substantially the entirety of the patterned upper face 33 and side faces 39 of fried batter 34. The amount of water applied to the external face 41 of the batter coating is sufficient to increase the mass of fish product 30 by between 1% and 3% (by weight). The temperature of the water at the point of atomisation is between 6° C. and 9° C.

[0073] Once aqueous protective layer 37 has been applied to external face 41 of the fried batter coating 34, fish substrate 32 continues to be carried by conveyor belt 46 in direction 43 out of spraying area 45. The protected batter coated fish substrate then enters freezer 50 after a post-spray time period of between 1 and 5 seconds, and remains in the freezer for a period of 120 minutes until it is completely frozen. After freezing, product 30 exits the freezer on conveyor 68 and is packaged into packaging 66.

[0074] Referring now to FIGS. 12-14, a battered fish product 30 produced using the apparatus and process described herein is provided with a pattern of ridges 36 and troughs 38 on upper face 33. A separation distance 57 between external surface 31 of fish substrate 32 and external surface 41 in a ridge region 36 is greater than a separation distance 55 in a trough region 38. This pattern corresponded to the arrangement of ridges 26 and recesses 24 on the surface of first submerger conveyor 16. The colour of the external face 41 of fried batter coating 34 is generally uniform across upper face 33, side faces 39 and underside face 35. A frozen aqueous protective layer 37 is disposed over the upper face 33 and side faces 39 of fish product 30, including over the pattern of ridges 36 and troughs 38 on upper face 33. Subsequent frozen transportation of a packaged fish product 30 showed considerably reduced damage to the pattern of ridges 36 on the upper face compared to products without aqueous protective layer 37. Additionally, subsequent cooking in an oven of the frozen battered fish product 30 with protective layer 37 resulted in a product with a crispy batter relative to products prepared with high saturated fat content by conventional methods without an aqueous protective layer.