This invention relates to a method for making portions of food products stuffed with a filling, formed of a main material containing pieces of animal meat, in particular raw minced meat, surrounding a filling material, as well as devices for implementing said method.
It is known in particular through patent document EP 1 509 089 a method and device for producing portions of minced meat stuffed with a filling, such as stuffed minced meat steaks. The device includes a mincer provided at the output with two distribution spouts in order to form a lower layer of minced meat and an upper layer of minced meat deposited respectively on a main conveyor and a secondary conveyor. Doses of filling are deposited at regular intervals on the lower layer, and the upper layer is then brought to cover the lower layer and the filling deposited on the latter in order to form a vein of stuffed minced meat, which then passes into a device for cutting and shaping. The device for cutting and shaping comprises means for cutting the vein of minced meat into portions, lateral shaping means acting simultaneously of each side of the vein of minced meat in order to shape the contours of the portions and the vertical shaping means cooperating with said lateral shaping means in order to confer the desired thickness to said portions.
The device requires a perfect synchronisation between the system for depositing doses of filling, the conveyor and the device for portioning in order to carry out the cuts in the middle of the intervals between the doses of filling. Moreover, such a device has a speed in manufacturing portions that is limited.
The purpose of this invention is to propose a solution that aims to overcome the aforementioned disadvantages.
To this effect, this invention has for object a method for making portions of food products stuffed with a filling, formed of a main material containing animal meat in pieces, such as raw minced meat of beef, veal, pork or poultry, or fish flesh, surrounding a filling material, characterised in that said method comprises
According to the invention, the filling material is continuously extruded in the form of a continuous inner layer in a main continuous vein further comprising an outer layer of main material surrounding said inner layer, and the portioning is carried out by nipping the main continuous vein in order to expel the filling. In order to allow for its extrusion and its displacement during the operation of nipping, the filling material is a liquid, semi-liquid or pasty material, for example a sauce with cheese and/or vegetables, such as process cheese or tomato sauce. In order to expel the filling during the operation of nipping of the main vein, substantially without leakage through the outer layer formed of pieces of animal meat, said pieces of animal meat are processed in such a way as to obtain an outer layer sufficiently tight and resistant to expel the material, while maintaining a flexibility that is sufficient to become deformed during the nipping. The main vein is then cut on nipped areas. The method according to the invention allows for the manufacture of stuffed portions, at high speeds, with the portions able to be of diverse shapes and sizes.
In the field of producing food products, fresh products, such as animal meat, are conventionally kept at a temperature between 0° C. and 6° C., typically of about 4° C. Surprisingly, the applicant discovered that a simple cooling of the animal meat to a temperature less than or equal to 0° C., but greater than the freezing point of the animal meat made it possible to obtain a main continuous layer having a flexibility sufficient to be crushed without breaking as well as a cohesion between the pieces sufficient to expel the filling, substantially without leakages. According to an embodiment, said step of processing therefore comprises the cooling of the main material, to a temperature less than or equal to 0° C., and greater than the freezing point of the main material.
The processing temperature is defined according to the freezing temperature of the meat, which depends on the nature of the meat, in particular of its water and salt content. By way of example, for a main ingredient formed of chicken and/or turkey minced meat, with a freezing point of about −4° C., the meat is processed at a temperature of about −3° C. In the case of minced beef meat, such as used in the production of minced meat steaks, the meat is processed at a temperature of about −1° C.
According to an embodiment, the cooling is carried out before the extrusion of said main material in a continuous outer layer. The main material, such as meat in pieces, is minced, then cooled, for example by mixing with nitrogen or carbon dioxide, and/or by passage or storage in a refrigerated enclosure. The cooled minced meat is then extruded. Alternatively, the minced meat is cooled after extrusion.
According to another embodiment, the step of processing is carried out by agglomeration of at least one portion of the pieces of animal meat by means of a gelling agent. The minced meat can be gelled before extrusion, by mixing a gelling agent and a mass of pieces of meat. Advantageously, the meat in pieces, for example minced meat is gelled by adding a composition that can be gelled comprising for example one or several hydrocolloids such as sodium pectate or alginate, pectin, carrageenates, or others, then by gelling said composition. By way of example a solution of sodium alginate is added to the minced meat then a calcium gelling of the alginate is carried out by adding a solution of calcium salt. According to an alternative, the calcium gelling, and possibly the adding of alginate beforehand, are carried out after extrusion of the minced meat, for example by spraying, only a portion on the surface of the outer layer of the vein then being agglomerated.
According to a particularity, said inner layer of filling material constitutes at most 50% of the thickness of the main continuous vein as a transversal section, more preferably at most one-third of the thickness of the main continuous vein.
According to another particularity, said outer layer is carried out by extrusion of animal meat minced into fibrous pieces of lengths less than or equal to 10 mm, more preferably 3 to 4 mm, and/or of transversal section less than or equal to 20 mm2.
According to an embodiment, said main continuous vein is obtained by co-extrusion of an annular layer of main material and of the inner layer of filling material. The vein can have a substantially circular outer transversal section. The portioning is then carried out more preferably by means of nippers acting substantially symmetrically on either side of the main vein. The main vein can also have a substantially rectangular transversal section.
According to another embodiment, said main continuous vein is obtained by
said upper secondary layer resting on either side of the inner layer on the lower secondary layer, and forming with the latter the outer layer of the main continuous vein.
This invention further also has for object a device for producing portions of filled food products for the implementation of the method described previously, characterised in that it comprises:
and a system for portioning comprising
According to another embodiment, the device is characterised in that it comprises
a co-extrusion head for forming a main continuous vein comprising a continuous outer layer of a main material surrounding a continuous inner layer of a filling material, said co-extrusion head comprising
a first duct defining a main passage intended to be supplied with a main material, and presenting a substantially circular output orifice, and
a second duct arranged at least partially concentrically inside main passage defining a secondary passage intended to be supplied with a filling material and having an output orifice, more preferably substantially circular, the diameter of the output orifice of the second duct being substantially less than or equal to half of the diameter of the output orifice of the first duct, and
a system for portioning comprising
means for nipping comprising at least one pair of opposite nippers able to be displaced towards one another by first means of actuating from an open position to a closed position for nipping the main vein, said first means of actuating being able to move closer and move away according to a back-and-forth movement in the orthogonal direction as well as in the direction parallel to the transport direction of the main vein, the speed of displacement of the nippers being substantially equal to the speed of transport of the bead when the nippers are in contact with the bead for the operations of nipping and cutting, and variable outside of the operations of nipping and cutting,
each nippers of said pair comprising at least two main plates provided at the end with a front nipping edge and arranged in such a way that, during the displacement of the nippers towards their closed position, the main plates of the nippers are positioned in alternation, with two adjacent plates not belonging to the same nippers, and form by their front nipping edge passages or diaphragms of which the section decreases progressively,
The invention shall be better understood, and other purposes, details, characteristics and advantages shall appear more clearly in the detailed explanatory description which shall follow of two currently preferred particular embodiments of the invention, in reference to the annexed diagrammatical drawings, wherein:
Considering first
The device comprises an extrusion system 1 making it possible to continuously extrude a main continuous vein V1 formed of a continuous outer layer C1 of minced meat surrounding an inner layer G1 of a filling material, such as a paste of process cheese, and a device for portioning 3.
Said extrusion system comprises a first extrusion head 10 comprising two extrusion spouts 11a, 11b, offset vertically from each other, each comprising an extrusion orifice 12a, 12b of substantially rectangular section in order to form a lower secondary layer C′1 and an upper secondary layer C″1 of minced meat. This first extrusion head is mounted at the output of a device for regulating flow (not shown), of the stuffer type, such as a piston pump or a vane pump, supplied via a hopper with a material referred to as the main material, constituted of minced meat. Such as shown in
In reference to
The extrusion head system comprises a second extrusion head 20 arranged downstream of the first extrusion head, between the two secondary conveyor belts, for the extrusion on the lower layer C′1 of a continuous inner layer G1 of filling material, of width less than that of the lower layer, and substantially in the centre of the latter. This second extrusion head is also connected to a device for regulating flow (not shown), and has a distribution spout 21 provided with a substantially rectangular distribution orifice having a width less than that of the distribution orifices pour the secondary layers of minced meat.
The lower layer C′1 covered with the layer of filling G1 is taken on the upper strand 31a of a conveyor belt, referred to as the main conveyor belt 31, of the portioning system.
The downstream return wheels of the secondary conveyor belts are positioned substantially to the vertical of each other, in such a way that the upper layer C″1 is deposited at the output of the upper secondary conveyor belt on the lower layer C′1 and the inner layer of filling coming to be deposited, in order to form the main continuous vein V1. On either side of the inner layer of filling, the upper secondary layer C″1 rests on the lower secondary layer C′1 and forms with the latter the outer layer C1 of the main continuous vein. Alternatively the lower secondary conveyor belt 13 is confounded with the main conveyor belt 31.
The thicknesses of the secondary layers are substantially identical. In this embodiment, the thickness of each of the lower and upper secondary layers C′1, C″1 is more than two times greater than that of the layer of filling G1.
The portioning system, shown partially and diagrammatically in the figures, comprises said main conveyor belt 31 and, arranged successively above said conveyor belt, from upstream to downstream in relation to the forward direction F1 of the main vein, a nipping wheel 32, of the vaned-wheel type, then a cutting wheel 33.
In reference to the
During this operation of nipping, the filling of the inner layer G1 is expelled substantially perpendicularly to the transversal bar, in such a way that the nipped area is substantially devoid of filling. For this, according to the invention, the minced meat constituting the outer layer of the main vein was cooled beforehand to a processing temperature less than 0° C., but greater than the freezing temperature of the minced meat. According to an embodiment, before extrusion, the minced meat is mixed with nitrogen in order to be cooled down to a processing temperature, for example of about −3° C. for turkey or chicken minced meat. The cooled minced meat is loaded into the hopper of the pump and is then extruded into two secondary layers, such as described previously, in order to form a main vein with a cooled outer layer which is transferred as it is formed towards the nipping wheel and the cutting wheel. Alternatively, as a replacement for the aforementioned heat treatment, the minced meat is gelled before extrusion by mixing with a solution of sodium alginate, then by mixing with a solution of calcium acetate in order to gel the alginate. The minced meat is then extruded at a conventional temperature of about of 4° C.
The cutting wheel 33 has an axis 331, arranged transversally in the forward direction F1, carrying two plates 332. Between these plates, is mounted a plurality of transversal flat blades 333, arranged with regular angular spacing, parallel to the axis, and extending radially towards the exterior. The wheel is arranged above the main conveyor belt in such a way that each flat blade is able to come cut the main vein V1 across its entire thickness, substantially in the middle of a nipped area, via its transversal cutting edge 333a. As can be seen better in
The nipping wheel and the cutting wheel are driven in iso-speed by a common drive system 34, and in synchronism with the main conveyor belt.
According to alternative embodiments, the nipping wheel and the cutting wheel are adapted to crush and section longitudinally the vein in order to form at least two portions in the width of the main vein and/or to form identical portions with curved or triangular contours for example, without loss of material.
In an alternative embodiment shown in
In reference to
The co-extrusion head 110 is for example arranged directly over the upper strand 31a of the main conveyor belt 31 of a device for portioning such as described previously in order to form portions P2. At the output of the co-extrusion head, the upper secondary layer C″2 rests on the lower secondary layer C′2 on either side of the inner layer of filling in order to form the outer layer C2 of a main vein V2.
Alternatively, the aforementioned co-extrusion head can be adapted to directly extrude a main vein generally of rectangular section, comprising an annular outer layer of minced meat surrounding a central layer of filling, the head then comprising a single annular distribution orifice in order to extrude the minced meat.
The device comprises a co-extrusion head 201 making it possible to continuously extrude a main vein V3 formed of an annular outer layer C3 of minced meat surrounding an inner layer G3 of filling material, such as shown in particular in
In reference to
The co-extrusion head comprises a second duct 222 defining a secondary passage, for example of substantially circular transversal section, with an input orifice 227a and an output orifice 227b. This second duct, intended to be supplied with filling material, comprises a straight portion which is arranged coaxially in the main passage, and of which the free end, arranged withdrawn in relation to the output orifice 217 of the first duct, defines the output end 227b of the secondary passage. This first portion is extended by an elbow-shaped portion extending through the wall of the first duct and delimited by the input orifice 227a. The input orifice is provided with a connector 226 for the connection of the secondary passage to a conventional device of the “stuffer” type in order to supply said passage with filling material.
In this embodiment the diameter of the output orifice of the secondary passage for the extrusion of the filling is substantially equal to half of the diameter of the output orifice of the main passage.
The device comprises a system for portioning comprising a pair of opposite nippers able to be displaced towards one another by means of actuating from an open position to a closed position in order to nip the main vein exiting from the co-extrusion head. The two nippers are arranged and displaced in such a way that a passage subsists in the closed position. The portioning system further comprises means for cutting comprising a blade associated to the pair of nippers, able to be actuated by means of actuating in order to cut the main vein on the nipped area when the nippers are in closed position.
The device for portioning is for example of the type described in French patent application 07 03162. The nippers of each pair are mounted rotatingly on rotating discs in order to be displaced according to a back-and-forth movement by circular translation. In reference in particular to
In reference to
The discs are driven in rotation around their axis A and A′ in inverse directions, in such a way that the nippers are displaced in the forward direction F3 of the vein when they are in contact with the latter, and at the same speed as that of the main vein, and the nippers are driven in rotation on the discs around their axis C and C′ in such a way as to remain arranged constantly perpendicular to the transport direction F3 of the vein, and parallel to one another, with their front edge opposite.
During the displacement of the nippers towards the closed position shown in
As can be seen in
The cutting system comprises a flat blade 81, diagrammatically shown in
Such as shown in the figures, the rotating discs can include a second pair of nippers. On each disc, the nippers are arranged symmetrically on either side of the axis of rotation of the disc.
Although the invention has been described in liaison with various particular embodiments, it is of course obvious that is in no way limited to this and that it comprises all of the equivalent techniques of the means described as well as their combinations if the latter enter within the scope of the invention.
Number | Date | Country | Kind |
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0854187 | Jun 2008 | FR | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP2009/057808 | 6/23/2009 | WO | 00 | 3/1/2011 |