METHOD FOR PREPARING A CASING MATERIAL USED IN A CO-EXTRUDING PROCESS OF A FOOD PRODUCT, VISCOUS GELLING AGENT AND A METHOD AND A SYSTEM FOR PREPARING FOOD PRODUCTS

Abstract

The invention relates to a method for preparing a casing material for use in co-extruding food products comprising the steps of providing two or more casing material components; mixing the casing material components and feeding the resulting viscous gelling solution to the co-extrusion process to form an external layer on an extruded strand of food dough. Each of the casing material components in itself is not suitable for co-extrusion as an external layer and the composition of the viscous gelling solution is determined by changing the volumes of the casing material components used dependent on the required food product to be co-extruded and/or the composition of the viscous gelling solution is adjusted by changing the volumes of the casing material components dependent on the information on the properties of the food dough and/or the food product to be co-extruded. The present invention further relates to a method and a system for preparing food products by means of co-extrusion wherein such casing material is used.

Claims

1. Method for preparing a casing material used in a co-extruding process of a food product, comprising the steps of: a) providing two or more casing material components; b) mixing the casing material components provided during processing step a) to a viscous gelling solution; and c) feeding the viscous gelling solution of processing step b) to the co-extrusion process of a food product to be co-extruded as an external layer on a to be extruded strand of food dough, characterized in that each of the casing material components provided during processing step a) in itself is not suitable for co-extrusion as an external layer and wherein: the composition of the viscous gelling solution is determined by changing the volumes of the casing material components provided during processing step a) dependent on the required specification of the food product to be co-extruded; and/or the composition of the viscous gelling solution is adjusted by changing the volumes of the casing material components dependent on the information on the properties of the food dough and/or the food product to be co-extruded.

2. Method according to claim 1, characterized in that one or more of the components provided during processing step a) is chosen from the group consisting of: water, alginate powder, alginate gel, collagen powder, collagen gel, strong acidic solution, weak acidic solution, strong alkaline solution and weak alkaline solution.

3. Method according to claim 1, characterized in that the composition of the viscous gelling solution is determined and/or adjusted during the co-extrusion process of a food product.

4. Method according to claim 1, characterized in that the composition of the viscous gelling solution is determined and/or adjusted between subsequent co-extrusion process runs of different food products.

5. Method according to claim 1, characterized in that the information on the properties of the food dough and/or the food product to be co-extruded is measured automatically.

6. Method according to claim 1, characterized in that the information on the properties of the food dough and/or the food product to be co-extruded is measured manually.

7. Method according to claim 1, characterized in that the viscous gelling solution comprises collagen.

8. Method according to claim 1, characterized in that during processing step b) at least one dry gelling agent is added to at least one aqueous medium.

9. Method according to claim 1, characterized in that during processing step b) at least two semi-manufactured viscous gelling agents are mixed.

10. Method according to claim 1, characterized in that during processing step b) at least two dry gelling agents are mixed, and subsequently the mixed composed dry gelling agent is mixed with the aqueous medium.

11. Method according to claim 1, characterized in that information on the properties of one or more of the casing material components provided during processing step a) is used for steering the proportions of the components provided.

12. Method according to claim 1, characterized in that the casing material components provided during processing step a) comprise an additive that is selected from an emulsifying agent, a buffer solution, a structure improver, a strengthening agent, a thickener agent and/or combinations thereof.

13. Method according to claim 1, characterized in that the viscous gelling solution is composed according to various pre-set recipes.

14. Method according to claim 1, characterized in that the mixing of the casing material components to a viscous gelling solution according to processing step b) comprises plural mixing phases; a first mixing phase wherein a first dry powder gelling agent is added to an aqueous medium wherein the components are mixed at a relative low speed; a second mixing phase wherein the obtained semi-manufactured viscous gelling agent is mixed at a higher speed than the mixing speed during the first mixing phase, which second mixing phase takes place under a gas pressure of less than 0,2 bar, preferably a gas pressure of less than 0,1 bar, during a period of [2, 4] minutes.

15. Method according to claim 14, characterized in that the method in between the first mixing phase and the second mixing phase also comprises an intermediate mixing phase wherein a second dry powder gelling agent is added to the semi-manufactured viscous gelling agent resulting from the first mixing phase and the mixing speed during the intermediate mixing phase is higher than during the first mixing phase but lower than during the second mixing phase.

16. Method according to claim 14, characterized in that the period of mixing the obtained aqueous solution during processing step b) is [2.5, 3.5] minutes.

17. Method according to claim 1, characterized in that the mixing of the casing material components to a viscous gelling solution during step b) comprises mechanical emulsifying of the mixture.

18. Method according to claim 1, characterized in that the average temperature of the casing material components provided during processing step a) is [0, 24] C.

19. Viscous gelling agent obtainable by the method according to claim 1.

20. Method for preparing food products by means of co-extrusion, comprising the steps of: d) providing a food dough; e) providing the viscous gelling solution of claim 19; f) co-extruding a strand of food dough and an external layer of viscous gelling solution, wherein the viscous gelling solution at least partially encloses the strand of food dough; g) treating the exterior of the food strand with an aqueous salt solution; and h) dividing the food strand into separated parts.

21. Method for preparing food products according claim 20, characterized in that the period between finalising processing step e) and the start of processing step f) is less than 1 hour, preferably less than 30 minutes.

22. System for co-extrusion of food products, the system comprising: a co-extrusion unit for extruding a strand of food dough at least partially enclosed by a simultaneously extruded layer of viscous gelling solution, the co-extrusion unit having a food dough inlet and a casing material inlet, characterized in that the system further comprises at least one mixing unit for receiving and mixing a plurality of casing material components, which casing material components in themselves are not suitable for extruding a layer of viscous gelling solution, wherein the mixing unit is provided with at least two casing material component supplies and a viscous gelling solution outlet, and wherein the viscous gelling solution outlet of the mixing unit is connected to the casing material inlet of the co-extrusion unit.

23. System according to claim 22, characterized in that the system further comprises a control unit operably connected to the co-extrusion unit, the mixing unit and the at least two casing material component supplies connecting to the mixing unit to control the flows of casing material components to be mixed in the mixing unit and to control the mixing unit.

24. System according to claim 23, characterized in that the control unit comprises a memory with stored pre-set viscous gelling solution preparation recipes, which viscous gelling solution preparation recipes dictate the casing material component supplies and the operation of the mixing unit, and wherein gel preparation instructions are selectable using an interface to the control unit.

25. System according to claim 24, characterized in that the interface is operable by a human operator.

26. System according to claim 24, characterized in that the system also comprises at least one sensor and the interface receives input from the sensor.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] FIG. 1 shows a schematic view on a system for co-extrusion of food products according the present invention;

[0031] FIG. 2 shows a schematic top view on an alternative embodiment of a system for co-extrusion of food products according the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0032] FIG. 1 shows a system 1 for co-extrusion (P1) of food products 2 (e.g. sausages). The system comprises a co-extrusion unit 3 for extruding a strand of food dough 4 enclosed by a simultaneously extruded layer of viscous gelling solution 5. The co-extrusion unit 3 has a food dough inlet 6 and a casing material inlet 7. The food dough inlet 6 connects to a food dough feeder 8 (e.g. a meat mass hopper) while the casing material inlet 7 connects to a mixing unit 9 for the preparation of the casing material (viscous gelling solution). The mixing unit 9 is fed by a plurality of casing material supplies 10-13, each providing a different type of casing material component. It is however also possible that two (or even more) casing material supplies 10-13 feed an identical casing material component for instance to enable continuous feed of the specific casing material component from holders/drums/packages that require exchange. In the figure shown two material supplies 10, 11 connect to casing material component hoppers 14, 15 that e.g. can feed a dry powder casing material components, a third material supply 12 that connects to a drum 16 for feeding a liquid casing material component and a fourth material supply 13 that connects to a pipe 17 (e.g. a water pipe) to feed a further liquid (e.g. water). In the mixing unit 9 a selected number of the possible casing material components are mixed in a required proportion and with specific process conditions. For operating the system 1 a control unit 18 is provided that connects to the co-extrusion unit 3, food dough feeder 8, mixing unit 9, casing material component hoppers 14, 15, a pump 19 connecting to drum 16 and a valve 20 in the pipe 17. With the control unit 18 the process for co-extrusion of food products 2 can be controlled including control of the composition of the casing material.

[0033] FIG. 2 shows a schematic top view on an alternative embodiment of a system 30 for co-extrusion (P2) of food products 31 wherein the reference signs to parts that correspond with parts of the system 1 as shown in FIG. 1 are referred to with identical reference signs.

[0034] The system 31 comprises a co-extrusion unit 3 for extruding a strand of food dough 4 enclosed by a layer of viscous gelling solution 5. The co-extrusion unit 3 has a food dough inlet 6 and a casing material inlet 7. The food dough inlet 6 connects to a food dough feeder 8 (e.g. a meat mass hopper) while the casing material inlet 7 connects to a second mixing unit 32 for the final preparation of the casing material (viscous gelling solution). The second mixing unit 32 is positioned in-line behind a first mixing unit 33, which first mixing unit 33 is fed by three casing material supplies 34-36, each providing a different type of casing material component. Two of the material supplies 34, 35 connect to casing material component hoppers 37, 38, a third material supply 36 connects to a pipe 39 (e.g. a water pipe) to feed a further liquid (e.g. water).

[0035] In the mixing unit 9 a selected number of the possible casing material components are mixed in a required proportion and with specific process conditions. For operating the system 1 a control unit 18 is provided that connects to the co-extrusion unit 3, food dough feeder 8, mixing unit 9, casing material component hoppers 14, 15, a pump 19 connecting to drum 16 and a valve 20 in the pipe 17. With the control unit 18 the process for co-extrusion of food products 2 can be controlled including control of the composition of the casing material.