CA2262547C - Method of preparing fully cooked bacon derived from pork bellies - Google Patents
Method of preparing fully cooked bacon derived from pork bellies Download PDFInfo
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- CA2262547C CA2262547C CA002262547A CA2262547A CA2262547C CA 2262547 C CA2262547 C CA 2262547C CA 002262547 A CA002262547 A CA 002262547A CA 2262547 A CA2262547 A CA 2262547A CA 2262547 C CA2262547 C CA 2262547C
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- Prior art keywords
- pork bellies
- slices
- weight
- pork
- bellies
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Links
- 235000015277 pork Nutrition 0.000 title claims abstract description 94
- 210000001015 abdomen Anatomy 0.000 title claims abstract description 93
- 235000015241 bacon Nutrition 0.000 title claims abstract description 53
- 238000000034 method Methods 0.000 title claims abstract description 42
- 238000010411 cooking Methods 0.000 claims abstract description 37
- 235000021110 pickles Nutrition 0.000 claims abstract description 37
- 238000012545 processing Methods 0.000 claims abstract description 14
- 239000000796 flavoring agent Substances 0.000 claims description 9
- 239000000779 smoke Substances 0.000 claims description 9
- 239000007788 liquid Substances 0.000 claims description 8
- 239000007787 solid Substances 0.000 claims description 6
- 235000013355 food flavoring agent Nutrition 0.000 claims description 5
- 238000010438 heat treatment Methods 0.000 claims 8
- 238000005096 rolling process Methods 0.000 claims 1
- 230000001105 regulatory effect Effects 0.000 abstract description 8
- 239000013585 weight reducing agent Substances 0.000 abstract description 7
- 239000000243 solution Substances 0.000 description 25
- 238000001723 curing Methods 0.000 description 9
- 235000013372 meat Nutrition 0.000 description 7
- 238000004519 manufacturing process Methods 0.000 description 5
- 235000019634 flavors Nutrition 0.000 description 4
- 230000000694 effects Effects 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 239000012267 brine Substances 0.000 description 2
- 238000001802 infusion Methods 0.000 description 2
- 238000009877 rendering Methods 0.000 description 2
- HPALAKNZSZLMCH-UHFFFAOYSA-M sodium;chloride;hydrate Chemical compound O.[Na+].[Cl-] HPALAKNZSZLMCH-UHFFFAOYSA-M 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 238000005303 weighing Methods 0.000 description 2
- NGZXDRGWBULKFA-NSOVKSMOSA-N (+)-Bebeerine Chemical compound C([C@@H]1N(C)CCC=2C=C(C(=C(OC3=CC=C(C=C3)C[C@H]3C=4C=C(C(=CC=4CCN3C)OC)O3)C=21)O)OC)C1=CC=C(O)C3=C1 NGZXDRGWBULKFA-NSOVKSMOSA-N 0.000 description 1
- 108010089254 Cholesterol oxidase Proteins 0.000 description 1
- 101100010163 Mus musculus Dok2 gene Proteins 0.000 description 1
- 239000012080 ambient air Substances 0.000 description 1
- 238000010420 art technique Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 235000011194 food seasoning agent Nutrition 0.000 description 1
- 230000035876 healing Effects 0.000 description 1
- 230000002706 hydrostatic effect Effects 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 210000003205 muscle Anatomy 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 125000002924 primary amino group Chemical group [H]N([H])* 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 230000000391 smoking effect Effects 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 230000004580 weight loss Effects 0.000 description 1
Classifications
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23B—PRESERVATION OF FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES; CHEMICAL RIPENING OF FRUIT OR VEGETABLES
- A23B4/00—Preservation of meat, sausages, fish or fish products
- A23B4/26—Apparatus for preserving using liquids ; Processes therefor
- A23B4/28—Apparatus for preserving using liquids ; Processes therefor by injection of liquids
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23B—PRESERVATION OF FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES; CHEMICAL RIPENING OF FRUIT OR VEGETABLES
- A23B4/00—Preservation of meat, sausages, fish or fish products
- A23B4/02—Preserving by means of inorganic salts
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23B—PRESERVATION OF FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES; CHEMICAL RIPENING OF FRUIT OR VEGETABLES
- A23B4/00—Preservation of meat, sausages, fish or fish products
- A23B4/06—Freezing; Subsequent thawing; Cooling
- A23B4/08—Freezing; Subsequent thawing; Cooling with addition of chemicals or treatment with chemicals before or during cooling, e.g. in the form of an ice coating or frozen block
Landscapes
- Life Sciences & Earth Sciences (AREA)
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Wood Science & Technology (AREA)
- Zoology (AREA)
- Food Science & Technology (AREA)
- Polymers & Plastics (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Meat, Egg Or Seafood Products (AREA)
Abstract
Methods of curing and processing pork bellies into fully coked bacon have be en developed that eliminates the need for smokehouse treatment with a dramatic reduction in processing time and cost. The methods of the present invention employ a single cooking step that both fully cooks a pickle solution infused pork belly and achieves the necessary weight reduction to meet the regulatory product definition for fully cooked bacon. The methods of the present invention may be employed for either strip form or circular form bacon.
Description
M>E'CHOD OF PIZ.I:YARING FULLY COUKED
BACON DERIVED FROM PORK BELL.CES
DESCRIPTION
Technical Field The present invention generally relates to curing and processing pork bellies to produce bacon and, in particular, to a novel method of processing pork bellies into fully conked bacon without the need for smokehouse trcatmcm.
AMENDED SHEET
BACON DERIVED FROM PORK BELL.CES
DESCRIPTION
Technical Field The present invention generally relates to curing and processing pork bellies to produce bacon and, in particular, to a novel method of processing pork bellies into fully conked bacon without the need for smokehouse trcatmcm.
AMENDED SHEET
Background Cl,~The Invention The term "bacon" broadly defines a cace;gory of cured and processed pork bc;llics, Most commonly, pork bellies arc cured and processed into strip form bacon or circular fi~rrn. Tlc weight and yi~;(d of bacon is precisely dviincd by federal regulation. For example, for cured perk bellies to he labelled as "~rcsh"
bacon, l.c., uncooked, the cured pork bellies must have a w~:igltt not v,ccccding the weight ofuncured pork bellies. Similarly, for cured pork bellies to be labelled as "cooked" or ''precooked'' bacon, the cured pork bellies must have a yield not more than 4U'% the weight of uncured pcxk bellies, l.c., 6e)% shrinkage from thr initial 1 O weight of the pork belly, also known as the "green weight," is required.
The traditional process of curing pork bellies t.o create a bacon procluct entails the infusion of a liquid pickle solution into the pork bellies l.nfusion of the pickle solution creates an inCusioo weiu~ht that exceeds been weight. Depending on manufacturing capabilities and eustocner preference, 1 S infusion weight may be anywhere 1T'c)TCl 1 t15'% to 115°/u of green weight. To meet the regulatory product delitlitions o f either fresh or cooked bacon, a degree of weight loss must occur equal to or greater than the added weight of the injoctcd pickle solution, l.c., the finished weight must be equal to or less than the maat portion prior to the injection of the pickle solution. Hence, to obtain the nccess'-try ?p weight reduction to rnevt the regulatory proiluct definitions for bacon, the prior art leas subjected the infused pork bellies to a prolonged low temperature cook cycle.
ITistorically, this slow cc,oking took place in smokehouses which achieved the necessary weight reduction and also imparted a smoke flavor characteristic of bacon. vlodern techniques employ cooking ovens which heat the 25 product to a core temperature of G(l °C (144"I=) during a 4 to 5 hour cook cycle.
This slow, low temperature healing produces a l0% - 15% 1055 of injected weight without reaching temperatures to Iully cook the pork bellies. The "smokehouse"
trcatm~~nt cooks-off the liquid portion of the pickle solution leaving behind the seasoning carried in the liquicl thus curing the pork bellies and imparting the AMENOE~ SN~ET
bacon, l.c., uncooked, the cured pork bellies must have a w~:igltt not v,ccccding the weight ofuncured pork bellies. Similarly, for cured pork bellies to be labelled as "cooked" or ''precooked'' bacon, the cured pork bellies must have a yield not more than 4U'% the weight of uncured pcxk bellies, l.c., 6e)% shrinkage from thr initial 1 O weight of the pork belly, also known as the "green weight," is required.
The traditional process of curing pork bellies t.o create a bacon procluct entails the infusion of a liquid pickle solution into the pork bellies l.nfusion of the pickle solution creates an inCusioo weiu~ht that exceeds been weight. Depending on manufacturing capabilities and eustocner preference, 1 S infusion weight may be anywhere 1T'c)TCl 1 t15'% to 115°/u of green weight. To meet the regulatory product delitlitions o f either fresh or cooked bacon, a degree of weight loss must occur equal to or greater than the added weight of the injoctcd pickle solution, l.c., the finished weight must be equal to or less than the maat portion prior to the injection of the pickle solution. Hence, to obtain the nccess'-try ?p weight reduction to rnevt the regulatory proiluct definitions for bacon, the prior art leas subjected the infused pork bellies to a prolonged low temperature cook cycle.
ITistorically, this slow cc,oking took place in smokehouses which achieved the necessary weight reduction and also imparted a smoke flavor characteristic of bacon. vlodern techniques employ cooking ovens which heat the 25 product to a core temperature of G(l °C (144"I=) during a 4 to 5 hour cook cycle.
This slow, low temperature healing produces a l0% - 15% 1055 of injected weight without reaching temperatures to Iully cook the pork bellies. The "smokehouse"
trcatm~~nt cooks-off the liquid portion of the pickle solution leaving behind the seasoning carried in the liquicl thus curing the pork bellies and imparting the AMENOE~ SN~ET
characteristic bacon taste. After the smokehouse trc;stment, the cured pork bellies arc: substantially fluid free.
Because o1 the use of modetz~ slow cooking ovens, the smoke flavor is now produced in difl~;rent ways. For circular bacon, created by two individual pork bellies cold formed together and encased within a sausage-style ca.Sing, a smoke flavoring agent is added to the pickle suiuliun. With strip bacon, lltc;
vttlir~
pork belly n,ay also he subject to an atotuized spray oC smoke flavoring ay nt within the cooking chamber of the oven.
For fresh bacon, the "smokehouse" treatment causes ;tdequale I U weight reduction to return the cured perk belly to green weight and therefore within the regulatory product definition fbr fresh bacon. After the smokehouse treatment, cured pork bellies intended to be sold as Fresh bacon arc weighed to assure the necessary loss of 10% weight from infused weight. Next, the internal temperatures of the cured pork bellies are chilled from 60''C (14f)°F) to -1 '/~°C
(30°F) to facilitate slicing. The product is sliced and then packaged.
However, for litlly cooked bacon, additional weight reduction of at least another 60°,a from green weight is necessary to bring the product within the regulatory definition for "cooked" bacon. ARer completion of the smokehouse treatment, cured pork bellies intended to be sold as cooked arc weighed to assure loss of at least 10% weight t°rom infused weight. Whether in circular form or strip form, the internal temperatures of the cured pork bellies are chilled 1?om about (it)°C (140'F) to -1 ~h°C: (30°h). Again, such chilling is done to facilitate slicing.
The bellies are sliced and then further cooked, typically in microwave ovens for abouC 1 '/~ to 2 minutes depending on microwave amperage, conveyor heft speed tluough the microwave ovens and, the number of nucrowave cooking cavities being employed. Such further cooking causes the necessary 60% shrinkage to bring the cured and now fully cooked pork bellies within the regulatury doliriitiou for fully cooked baccm_ Improvements upon conventional methods oh manufacturing cooked 3U ham are disclosed in DE 37 1321 1 A1 and EP 0 683 98fi Al. Specifically, DIr 37 AM~N~E~ SH~E~
13'_' 1 1 A1 is directed to a process tar manufacturing cooked barn with an improved cooking yield without negatively atfecttng the texture. '1'hv process includes a step of treating pieces of pig muscles with a hydrostatic preasure of fiom 300 to _'Uc)U
bar betor~; injecting brine into thCtll. EP C7 (j83 98G A l is directed to a method for manufacturing cooked barn to obtain a product that is as uniformly dense and solid a.; possible. 'Ihe method includes massaging the meat prior to the introduction of brine, or pounding the meat after the brim has been injected while the tncat is being eoolvd.
As discussed above, curing pork bellies intended ats "fresh" bacon l U uses single step cooking ctnploying solely the smokehouse treatment while curing pork bellies intended as "cooked" bacon uses a two step cooking ernployin' both stookehousc treatment and a second cooking step, typically microwave caoktng.
The Prior art teaches that smokehouse treatment was necessary for curing pork he!lies whether tltcy were intended to be sold as fresh or Cully cooked bacon.
~.5. Yatent No. 4,957,751> discloses a method of preparing cooked haccm where the conventional smoking step ot~low heat (:or long time periods is eliminated. The method includes the step of holding a pork belly injected with pickle solution for a time period sufficient for the pickle solution to disperse in the pork belly. Specifically, U.S. latent No. 4,957,756 requires a holding period of at 2() least 3? hours, otherwise the method yields precooked bacon having a water activity higher than 0.85, which is generally accepted as the maximum ruicrobiologically safe level of water activity.
1t is apparent from the above d isclosure th at smokehouse treatment is both time and ~tergy intensive and contributes greatly to the cost of producing bacon. But with the market fvr fully cooked bacon product );amino in consumer popularity, prior to the development ~f the present invention, a need existed for methods to cure and process pork bellies into fully cooked bacon by reducing the costs and time associated with a two step cooking cycle and paaticularly with the smokehouse treatment.
~M~NpED SHEE?
Summary Of 'fhc Ct3,.vcnt~n According to the present invention, novel methods of ouring and proc;tssing pork bellies into fully cooked bacon have been developccl thst eliminate;
the need for smokehouse treatment with a dramatic reduction in processing tune S and cast. Essentially, the methods of the present invention employ a single cooking step flat both fully cooks a pickle solution infused pork belly and achieves the necessary weight reduction to meet the regulatory tleftnition for fully cooked bacon. The methods of the present invention may he employed for either strip Form or circular l'om~ bacon.
1 () Generally, the methods of the present invention folloGV traditions( curing methods by infusing the pork bellies with pickle solution t« I05%-115%
of green weight. But instead of then subjecting the infused park bellies to smokehouse treatment to achieve at least a 1()% weight reduction, the methods of the present invention eliminate smokehouse treatment. In complete deviation from 1 ~ the prior art, the infused pork bellies are rapidly chilled to tcmpcraturc;s below tt~.ose commonly used to facilitate slicing. Specifically, the pickle solution infused pork bellies axe chilled to between -5 ~J,,°C (22'F) and -3 ~/,~°C (25°F). In either strip form or circular form, the reduced temperatures render the pickle solution within the pork bellies into a semi-solid. "this retains pickle solution within the 20 pork bellies, preserves the compositional integrity of the product, and facilitates handling of individual pork belly slices prior t0 cooking. Such reduced chilling ternpr;ratures also lave the effect of cold setting the individual pork bellies that comprise circular form bacon. Reduced temperaritre chilling of the pickle solution infused pork bellies also permits thinner slicinb of the product.
25 Also, in deviation from prior ate techniques, the present invention reduces the thickness of the slices by about 5%. Reduced slicing allows for cooking cycles that unexpectedly are only slightly longer than the prior art second step cooking cycles which employ smokehouse treatment.
Further, even though the methods of the present invention eliminate 30 smokehouse treatment and employ only a slightly longer singly step cooking, a aMENQED SHEET
more than 60% shrinkage from infused Weight results sufficient to meet the regulatory definition Ce~r E'ully cooked bacon. Yet, the rrxethods of the presc;nt itlventi.on re~ull in Fully conkecl Prncluct having the aroma, flavnr, te~chtrc and appearmce of fully cooked bacon produced by smokehouse treatment, while rcducinb caring and processing time by an estimates 3~-35 hours, resulting in clr.unatic savings.
Other adv:irttages and aspects of the present invention will become apparent Crorn the following detailed dcscr~iption of the invention.
~1,~~plpEp SHEET
pctailcd 1)e,criptioa Of The Preferred >;mbodiment While this invention is suscelatible of etnbodirntnt itt many different forms, there is herein described in detail preferred embodiments of the I11VC;ILlIUII
with the understanding that the present disclosure is to be cc~nsiciered as an S exemplification of the principles of the invention and is not intended l0 limit the broad aspect ofthe invention to the embodiments illustrated.
T'he methods of the present invention arc directed to curing and processing pork bellies to produce sliced fully cooked bacon in either strip form or circular Norm. By utilizing lower temperatures to chill pickle solution infused pork 1 O beI lies, the liquid pickle solutiotl is rendered a semi-solid and retained within th v pork bellies. 'T'lus both maintains the compositional integrity of the product and permits slicing of the pork bellies into slices having a reduced thickness, thus allowing for single step cooking.
The single step cooking cycle employed by the rnethocis of the 1.5 present invention ore generally no more tl~.arl about 15% longer than the second step cookin' cycles known in the alt for producing Cully cooked bacon. Yet, unexpectedly the single step cooking cycle of the present invention results in substantial shrinkage From infused weight to product a fully cooked produce meeting the regulatory definition for "cooked" bacon. Further, single step 20 cooking, preterably by microwave or surface conduction cooking such as by heated conveyor belt surfaces, produces a fully cooked bacon proiiuct having all of the color, texture, aroma and flavor characteristic of fully cooked bacon. Hence, the methods of the present invention eliminate (I) smokehouse trcattncnt, (2) post-s~ziokehousc weighing of product, and (3) the need to dull smokehouse treated 25 pork bellies from high internal meat temperatures of 60°C
(l4Q°F) to slicing temperatures of-1 'h°C (3U°F). The elinunation of these steps rGSUlts in dramatic savings in processing times and costs.
~a:'E~DED S~iEE~
i3 The following Examples describe in more detail the tncthucls of the present invention with reference; to a preferred cotntnercial processin;
operation for both sliced circular form and sliced strip form, fully cooked bacon.
S E~CAMPLE 1 CUUItED CIRCULAR E:'OIZNI SLICfiD BACON
Pork bellies of a selected 4veibht and size arc trimmed in the manner known in the 'ut. Next, a seasoned pickle solution is injected into the trimmed pork bellies to preferably 110°/, of green weight using a mufti-needle Formaco injector or such other injector known in tlae art. 'the seasoned pickle solution may have any composition known in the meat curing aut. To impart a stnokcd flavor to the bacon, a smoke flavoring agent must be added to the pickle solution composition. The infected pork bellies are tumbled in a vacuum meat massager for a time period sufl7cient to enhance the adhesion and bonding together of the pork bellies. Two pork bellies arc rolled together and stuffed into a round, perforatul casing. After. using, the product is often referred to ;as "bacon log."
At this point, prior art techniques teach smokehouse treatment of the encased pork bellies- Instead, in accordance with the present invention, the encased pork bellies are chilled from temperatures of 1 ZIP ° C (35 ° r) to 4 ''h' C:
(~0°r) (approx.imately ambient air temperature within a commercial packing plant) to no more than -3 ah"C (25 "F) and, preferably, within the range of -5 5/9 ° C (22 ° F) to -3 Ah°C (25°1~. It has been discovered that this tcmpcratme ranbe both cold-sets together the individual pork bellies within the casings and cold-sets the pickle solution to thus retain the solution within the pork betties by rendering the pickle solution a semi-solid.
AN1E.N4ED SH~.~~
The encased chilled pork bellies are then sliced to a thickness cal' generally ~-5% thinner than is used in most commercial embodiments. 1~ur example, with reference to the commercial processing operation herein described, bacon logs that have been subjected to smokehouse treartnent arc sliced to a thickness of 2.18410.025 mm (().(jA6 t ().001 inch). By eliminating smokehouse trcatmont, original bacon log diameter is maintained and therefore slices can be achieved having an average thickness of ?.10$ f U.025mm (U.U8:3 t 0.001 inch) and yet meet customer spcciC,catiorts. Such reduced thickness oFthe slices facilitates the necessary slu-inkage and complete cooking of the product.
I0 The slices are then immediately translerred to a cooking device.
This device may include a conveyor belt hzving a heat conductive surface (also known as "belt shilling") or, as preferauly practiced, by passing the slices on a conveyor belt through one or more microwave cooking chambers. With reference to the preferred commercial operation herein described, a five cavity FerriteThc LS microwave unit was ernployed. Each cavity is serviced by two transmitters and each set at maximum amperage setting levels of 4.20. This amperage setting achieves a temperature within each microwave cavtty o.f about 1 t)4 °I9°C (?2U°F).
Conveyor belt speeds had to be decreased from 124 cm/minute (<;UO incheslminute) for sliced product that was subject to smokehouse treatment, 2U to 13)7 cnllrninute (550 incheslmintrte) for sliced product processed according to the present invention. necreased belt speed increased total dwell time within a1I
microwave cooking cavities from approximately 1 minute, 10 seconds to 1 minute, 20 seconds, or about a 15% increase in dwell time.
Sliced product emerging from the microwave cooking chambers 25 possessed the appearance, aroma, taste and texture ofproduct processed according to the prier art two step cooking cycle.
~,~,4ENOED SHEET
C.tAMPLF 2 COOKEL) S'fRIP F()RM SLfCF.D E3ACON
As disclosed above, pork bellies oFu selected weight and stzc ;tre:
trimmed in the manner known in the art. Next, a seasoned pickle solution is injected into the trimmed pork bellies to preferably 1 IO% of green weight using a mufti-needle rormaco injector or such usher injector known in the art. The sessoncd pickle solution may havo any composition known in the meat curin; art. Again a smoke tlavoring agem trust be added to the pickle solution.
The pork bellies are then chilled from temperatures of 1 ~/~"G (35''F) to 41h"C (40°F) to no more than -3 ~/,,°C (25 °F) and preferably within the range of -5'/,"C (22°F) to -3 ~h"C (?5"r) to cold-set arid thereby retain the pickle solution within the pork bellies by rendering the pickle solution a semi-solid.
As described above, the chilled pork bellies are then sliced to a thickness of 4-5% less than the thickness for pork bellies that have been subjected to LS srnuk~huus~ trcattncnt. Such reduced lhicknesof the slices facilitates the necessary shrinkage and complete cooking of the product.
As with sliced circular product, the slices are then immediately transferred to a cooking device. This device may include a conveyor belt having a heat conductive surface (also known as "heft grilling") or as preferably practiced, by passing the slices on a conveyor belt through one or more microwave cooking chambers and using the preferred amperage setting sand dwell time as described above for sliced circular product. Sliced product emerging from the microwave cooking chambers possesses the appearance, aroma, taste and texture of product processed according to the prior art two step cooking cycle.
By eliminating the steps of (1) stnokehousc treatment, (2) post-smokehou-se weighing of product, and (3) the recd to chill smokehouse treated pork bellies from internal meat temperatures ot~~U''C (14U'1~) to slicing temperatures of-1 ply°C (30°Fh the present invention achieves substantial re:ctuctions in cost attd processing tithe fur producing fully cUUkcd bacon pruducls.
For example by eliminating the 4 to 5 hours necessary far smokehouse treatment, it =1~~ENbED SHEET
has lJeCtl l;$tLIItiltl:ll that substantial savings could he achieved in commercial scale production of hilly cooked bacon products.
While tile specific embo~limcnts have heert illustratc~i and described with reference to a preferred commercial c~peTalaUn, numerous nwdifications come to S mind depending on the vu-iahles presented by other commercial operations, all without significantly departing li-om the spirit and intent of the invention.
The .scope of protection is only limited by the scope of the accompanying Claims with reference to this specification.
~rAENDED SHEET
Because o1 the use of modetz~ slow cooking ovens, the smoke flavor is now produced in difl~;rent ways. For circular bacon, created by two individual pork bellies cold formed together and encased within a sausage-style ca.Sing, a smoke flavoring agent is added to the pickle suiuliun. With strip bacon, lltc;
vttlir~
pork belly n,ay also he subject to an atotuized spray oC smoke flavoring ay nt within the cooking chamber of the oven.
For fresh bacon, the "smokehouse" treatment causes ;tdequale I U weight reduction to return the cured perk belly to green weight and therefore within the regulatory product definition fbr fresh bacon. After the smokehouse treatment, cured pork bellies intended to be sold as Fresh bacon arc weighed to assure the necessary loss of 10% weight from infused weight. Next, the internal temperatures of the cured pork bellies are chilled from 60''C (14f)°F) to -1 '/~°C
(30°F) to facilitate slicing. The product is sliced and then packaged.
However, for litlly cooked bacon, additional weight reduction of at least another 60°,a from green weight is necessary to bring the product within the regulatory definition for "cooked" bacon. ARer completion of the smokehouse treatment, cured pork bellies intended to be sold as cooked arc weighed to assure loss of at least 10% weight t°rom infused weight. Whether in circular form or strip form, the internal temperatures of the cured pork bellies are chilled 1?om about (it)°C (140'F) to -1 ~h°C: (30°h). Again, such chilling is done to facilitate slicing.
The bellies are sliced and then further cooked, typically in microwave ovens for abouC 1 '/~ to 2 minutes depending on microwave amperage, conveyor heft speed tluough the microwave ovens and, the number of nucrowave cooking cavities being employed. Such further cooking causes the necessary 60% shrinkage to bring the cured and now fully cooked pork bellies within the regulatury doliriitiou for fully cooked baccm_ Improvements upon conventional methods oh manufacturing cooked 3U ham are disclosed in DE 37 1321 1 A1 and EP 0 683 98fi Al. Specifically, DIr 37 AM~N~E~ SH~E~
13'_' 1 1 A1 is directed to a process tar manufacturing cooked barn with an improved cooking yield without negatively atfecttng the texture. '1'hv process includes a step of treating pieces of pig muscles with a hydrostatic preasure of fiom 300 to _'Uc)U
bar betor~; injecting brine into thCtll. EP C7 (j83 98G A l is directed to a method for manufacturing cooked barn to obtain a product that is as uniformly dense and solid a.; possible. 'Ihe method includes massaging the meat prior to the introduction of brine, or pounding the meat after the brim has been injected while the tncat is being eoolvd.
As discussed above, curing pork bellies intended ats "fresh" bacon l U uses single step cooking ctnploying solely the smokehouse treatment while curing pork bellies intended as "cooked" bacon uses a two step cooking ernployin' both stookehousc treatment and a second cooking step, typically microwave caoktng.
The Prior art teaches that smokehouse treatment was necessary for curing pork he!lies whether tltcy were intended to be sold as fresh or Cully cooked bacon.
~.5. Yatent No. 4,957,751> discloses a method of preparing cooked haccm where the conventional smoking step ot~low heat (:or long time periods is eliminated. The method includes the step of holding a pork belly injected with pickle solution for a time period sufficient for the pickle solution to disperse in the pork belly. Specifically, U.S. latent No. 4,957,756 requires a holding period of at 2() least 3? hours, otherwise the method yields precooked bacon having a water activity higher than 0.85, which is generally accepted as the maximum ruicrobiologically safe level of water activity.
1t is apparent from the above d isclosure th at smokehouse treatment is both time and ~tergy intensive and contributes greatly to the cost of producing bacon. But with the market fvr fully cooked bacon product );amino in consumer popularity, prior to the development ~f the present invention, a need existed for methods to cure and process pork bellies into fully cooked bacon by reducing the costs and time associated with a two step cooking cycle and paaticularly with the smokehouse treatment.
~M~NpED SHEE?
Summary Of 'fhc Ct3,.vcnt~n According to the present invention, novel methods of ouring and proc;tssing pork bellies into fully cooked bacon have been developccl thst eliminate;
the need for smokehouse treatment with a dramatic reduction in processing tune S and cast. Essentially, the methods of the present invention employ a single cooking step flat both fully cooks a pickle solution infused pork belly and achieves the necessary weight reduction to meet the regulatory tleftnition for fully cooked bacon. The methods of the present invention may he employed for either strip Form or circular l'om~ bacon.
1 () Generally, the methods of the present invention folloGV traditions( curing methods by infusing the pork bellies with pickle solution t« I05%-115%
of green weight. But instead of then subjecting the infused park bellies to smokehouse treatment to achieve at least a 1()% weight reduction, the methods of the present invention eliminate smokehouse treatment. In complete deviation from 1 ~ the prior art, the infused pork bellies are rapidly chilled to tcmpcraturc;s below tt~.ose commonly used to facilitate slicing. Specifically, the pickle solution infused pork bellies axe chilled to between -5 ~J,,°C (22'F) and -3 ~/,~°C (25°F). In either strip form or circular form, the reduced temperatures render the pickle solution within the pork bellies into a semi-solid. "this retains pickle solution within the 20 pork bellies, preserves the compositional integrity of the product, and facilitates handling of individual pork belly slices prior t0 cooking. Such reduced chilling ternpr;ratures also lave the effect of cold setting the individual pork bellies that comprise circular form bacon. Reduced temperaritre chilling of the pickle solution infused pork bellies also permits thinner slicinb of the product.
25 Also, in deviation from prior ate techniques, the present invention reduces the thickness of the slices by about 5%. Reduced slicing allows for cooking cycles that unexpectedly are only slightly longer than the prior art second step cooking cycles which employ smokehouse treatment.
Further, even though the methods of the present invention eliminate 30 smokehouse treatment and employ only a slightly longer singly step cooking, a aMENQED SHEET
more than 60% shrinkage from infused Weight results sufficient to meet the regulatory definition Ce~r E'ully cooked bacon. Yet, the rrxethods of the presc;nt itlventi.on re~ull in Fully conkecl Prncluct having the aroma, flavnr, te~chtrc and appearmce of fully cooked bacon produced by smokehouse treatment, while rcducinb caring and processing time by an estimates 3~-35 hours, resulting in clr.unatic savings.
Other adv:irttages and aspects of the present invention will become apparent Crorn the following detailed dcscr~iption of the invention.
~1,~~plpEp SHEET
pctailcd 1)e,criptioa Of The Preferred >;mbodiment While this invention is suscelatible of etnbodirntnt itt many different forms, there is herein described in detail preferred embodiments of the I11VC;ILlIUII
with the understanding that the present disclosure is to be cc~nsiciered as an S exemplification of the principles of the invention and is not intended l0 limit the broad aspect ofthe invention to the embodiments illustrated.
T'he methods of the present invention arc directed to curing and processing pork bellies to produce sliced fully cooked bacon in either strip form or circular Norm. By utilizing lower temperatures to chill pickle solution infused pork 1 O beI lies, the liquid pickle solutiotl is rendered a semi-solid and retained within th v pork bellies. 'T'lus both maintains the compositional integrity of the product and permits slicing of the pork bellies into slices having a reduced thickness, thus allowing for single step cooking.
The single step cooking cycle employed by the rnethocis of the 1.5 present invention ore generally no more tl~.arl about 15% longer than the second step cookin' cycles known in the alt for producing Cully cooked bacon. Yet, unexpectedly the single step cooking cycle of the present invention results in substantial shrinkage From infused weight to product a fully cooked produce meeting the regulatory definition for "cooked" bacon. Further, single step 20 cooking, preterably by microwave or surface conduction cooking such as by heated conveyor belt surfaces, produces a fully cooked bacon proiiuct having all of the color, texture, aroma and flavor characteristic of fully cooked bacon. Hence, the methods of the present invention eliminate (I) smokehouse trcattncnt, (2) post-s~ziokehousc weighing of product, and (3) the need to dull smokehouse treated 25 pork bellies from high internal meat temperatures of 60°C
(l4Q°F) to slicing temperatures of-1 'h°C (3U°F). The elinunation of these steps rGSUlts in dramatic savings in processing times and costs.
~a:'E~DED S~iEE~
i3 The following Examples describe in more detail the tncthucls of the present invention with reference; to a preferred cotntnercial processin;
operation for both sliced circular form and sliced strip form, fully cooked bacon.
S E~CAMPLE 1 CUUItED CIRCULAR E:'OIZNI SLICfiD BACON
Pork bellies of a selected 4veibht and size arc trimmed in the manner known in the 'ut. Next, a seasoned pickle solution is injected into the trimmed pork bellies to preferably 110°/, of green weight using a mufti-needle Formaco injector or such other injector known in tlae art. 'the seasoned pickle solution may have any composition known in the meat curing aut. To impart a stnokcd flavor to the bacon, a smoke flavoring agent must be added to the pickle solution composition. The infected pork bellies are tumbled in a vacuum meat massager for a time period sufl7cient to enhance the adhesion and bonding together of the pork bellies. Two pork bellies arc rolled together and stuffed into a round, perforatul casing. After. using, the product is often referred to ;as "bacon log."
At this point, prior art techniques teach smokehouse treatment of the encased pork bellies- Instead, in accordance with the present invention, the encased pork bellies are chilled from temperatures of 1 ZIP ° C (35 ° r) to 4 ''h' C:
(~0°r) (approx.imately ambient air temperature within a commercial packing plant) to no more than -3 ah"C (25 "F) and, preferably, within the range of -5 5/9 ° C (22 ° F) to -3 Ah°C (25°1~. It has been discovered that this tcmpcratme ranbe both cold-sets together the individual pork bellies within the casings and cold-sets the pickle solution to thus retain the solution within the pork betties by rendering the pickle solution a semi-solid.
AN1E.N4ED SH~.~~
The encased chilled pork bellies are then sliced to a thickness cal' generally ~-5% thinner than is used in most commercial embodiments. 1~ur example, with reference to the commercial processing operation herein described, bacon logs that have been subjected to smokehouse treartnent arc sliced to a thickness of 2.18410.025 mm (().(jA6 t ().001 inch). By eliminating smokehouse trcatmont, original bacon log diameter is maintained and therefore slices can be achieved having an average thickness of ?.10$ f U.025mm (U.U8:3 t 0.001 inch) and yet meet customer spcciC,catiorts. Such reduced thickness oFthe slices facilitates the necessary slu-inkage and complete cooking of the product.
I0 The slices are then immediately translerred to a cooking device.
This device may include a conveyor belt hzving a heat conductive surface (also known as "belt shilling") or, as preferauly practiced, by passing the slices on a conveyor belt through one or more microwave cooking chambers. With reference to the preferred commercial operation herein described, a five cavity FerriteThc LS microwave unit was ernployed. Each cavity is serviced by two transmitters and each set at maximum amperage setting levels of 4.20. This amperage setting achieves a temperature within each microwave cavtty o.f about 1 t)4 °I9°C (?2U°F).
Conveyor belt speeds had to be decreased from 124 cm/minute (<;UO incheslminute) for sliced product that was subject to smokehouse treatment, 2U to 13)7 cnllrninute (550 incheslmintrte) for sliced product processed according to the present invention. necreased belt speed increased total dwell time within a1I
microwave cooking cavities from approximately 1 minute, 10 seconds to 1 minute, 20 seconds, or about a 15% increase in dwell time.
Sliced product emerging from the microwave cooking chambers 25 possessed the appearance, aroma, taste and texture ofproduct processed according to the prier art two step cooking cycle.
~,~,4ENOED SHEET
C.tAMPLF 2 COOKEL) S'fRIP F()RM SLfCF.D E3ACON
As disclosed above, pork bellies oFu selected weight and stzc ;tre:
trimmed in the manner known in the art. Next, a seasoned pickle solution is injected into the trimmed pork bellies to preferably 1 IO% of green weight using a mufti-needle rormaco injector or such usher injector known in the art. The sessoncd pickle solution may havo any composition known in the meat curin; art. Again a smoke tlavoring agem trust be added to the pickle solution.
The pork bellies are then chilled from temperatures of 1 ~/~"G (35''F) to 41h"C (40°F) to no more than -3 ~/,,°C (25 °F) and preferably within the range of -5'/,"C (22°F) to -3 ~h"C (?5"r) to cold-set arid thereby retain the pickle solution within the pork bellies by rendering the pickle solution a semi-solid.
As described above, the chilled pork bellies are then sliced to a thickness of 4-5% less than the thickness for pork bellies that have been subjected to LS srnuk~huus~ trcattncnt. Such reduced lhicknesof the slices facilitates the necessary shrinkage and complete cooking of the product.
As with sliced circular product, the slices are then immediately transferred to a cooking device. This device may include a conveyor belt having a heat conductive surface (also known as "heft grilling") or as preferably practiced, by passing the slices on a conveyor belt through one or more microwave cooking chambers and using the preferred amperage setting sand dwell time as described above for sliced circular product. Sliced product emerging from the microwave cooking chambers possesses the appearance, aroma, taste and texture of product processed according to the prior art two step cooking cycle.
By eliminating the steps of (1) stnokehousc treatment, (2) post-smokehou-se weighing of product, and (3) the recd to chill smokehouse treated pork bellies from internal meat temperatures ot~~U''C (14U'1~) to slicing temperatures of-1 ply°C (30°Fh the present invention achieves substantial re:ctuctions in cost attd processing tithe fur producing fully cUUkcd bacon pruducls.
For example by eliminating the 4 to 5 hours necessary far smokehouse treatment, it =1~~ENbED SHEET
has lJeCtl l;$tLIItiltl:ll that substantial savings could he achieved in commercial scale production of hilly cooked bacon products.
While tile specific embo~limcnts have heert illustratc~i and described with reference to a preferred commercial c~peTalaUn, numerous nwdifications come to S mind depending on the vu-iahles presented by other commercial operations, all without significantly departing li-om the spirit and intent of the invention.
The .scope of protection is only limited by the scope of the accompanying Claims with reference to this specification.
~rAENDED SHEET
Claims
What t claim is:
1. A method occuring and processing pork bellies to produce fully cooked sliced hacon using a single heating, step and omitting any smokehouse treatment, consisting essentially of the steps of:
providing pork bellies having a preselected weight;
iufusing the pork bellies with a seasoned liquid pickle solution;
chilling rapidly the pork bellies sufficient to render the seasoned pickle solution a semi-solid;
slicing the chilled pork bellies into a plurality of individual slices;
heating rapidly the chilled slices with a heat source to a finished weight no more than 40% of the preselected weight; and continuing hcaticts with said heat source until the slices are fully cooked.
2. The method of claim 1 wherein the step of infusing further includva:
infusing the pork bellies with a seasoned liquid pickle solution to obtain an injected weight exceeding the preselected weight.
3. The method of Claim 2 wherein the injected weight is within the range 105% to 115% of the preselected weight.
4. The method of Claim t wherein the step of chilling includes chilling the pork bellies to between -5 5/9°C (22°F) to no more than about -3%°C (25°F).
5. The method of Claim 1 wherein the pickle solution includes a flavoring agent for imparting a smoke taste to the pork bellies.
6. the method of Claim 1 wherein the slices are of circular form or strip form.
7. The method of Claim 1 wherein the steps of heating the slices includes:
passing the slices through a microwave cooking chamber.
8. A method of curing and processing pork bellies to produce circular sliced fully cooked bacon using a single heating step and omitting any smokehouse treatment, consisting essentially of the steps of:
providing pork bellies of a preselected weight;
infusing the pork bellies with a seasoned liquid pickle solution to obtain an injected weight exceeding the preselected weight;
tumbling the pork bellies to promote adhesion;
rolling together two pork bellies;
encasing the rolled pork bellies;
chilling rapidly the encased pork bellies to a temperature less than -38/9°C (25°F);
slicing the chilled pork bellies into a plurality of individual circular slices;
exposing the chilled slices to a heat source to rapidly eliminate at least 60% of injected weight; and cooking the slices with said heat source until the slices are fully cooked.
The method of Claim 8 wherein the step of chilling includes chilling the pork bellies to between -5 5/9°C(22°F) to no more than about -3 8/9°C: (25°F).
l0. The method of Claim 8 wherein the pickle solution includes a flavoring agent for imparting a smoke taste to the pork bellies.
11. The method of Claim 8 wherein the heating source includes a plurality of tandem arranged microwave cooking chambers.
l2. A method of curing and processing pork bellies to produce strip sliced fully cooked bacon using s single heating step and omitting any smokehouse treatment, consisting essentially of the steps of:
providing pork bellies of a preselected weight;
infusing the pork bellies with a seasoned liquid pickle solution to obtain an injected weight exceeding the preselected weight;
chilling rapidly the pork bellies to a temperature less than -3 8/9°C
(25°F);
slicing the chilled pork bellies into a plurality individual strip slices;
exposing the chilled slices to a heat source to rapidly eliminate at least 60% of injected weight; and cooking the slices with said heat source until the slices are fully cooked.
13. The method of Claim 12 wherein the step of chilling includes chilling the pork bellies to between -5 5/9°C (22°F) to no more than about -3 8/9°C (25°F).
14. The method of Claim 12 wherein the pickle solution includes a flavoring agent for imparting a smoke taste to the pork bellies.
15. The method of Claim 12 wherein the heating source includes a plurality of tandem arranged microwave cooking chambers.
16. In a method of curing and processing pork bellies to produce fully cooked, slice, circular form bacon; the method including providing pork bellies having a preselected weight, and infusing the pork bellies with a seasoned liquid pickle solution, the improvement consisting essentially of the steps of:
cold setting the seasoned pickle solution within the pork bellies;
slicing the pork bellies into a plurality of individual slices;
heat reducing the slices with a heat source to a finished weight no more than 40% of the preselected weight; and continuing heating of the slices with said heat source until the slices are fully cooked.
1. A method occuring and processing pork bellies to produce fully cooked sliced hacon using a single heating, step and omitting any smokehouse treatment, consisting essentially of the steps of:
providing pork bellies having a preselected weight;
iufusing the pork bellies with a seasoned liquid pickle solution;
chilling rapidly the pork bellies sufficient to render the seasoned pickle solution a semi-solid;
slicing the chilled pork bellies into a plurality of individual slices;
heating rapidly the chilled slices with a heat source to a finished weight no more than 40% of the preselected weight; and continuing hcaticts with said heat source until the slices are fully cooked.
2. The method of claim 1 wherein the step of infusing further includva:
infusing the pork bellies with a seasoned liquid pickle solution to obtain an injected weight exceeding the preselected weight.
3. The method of Claim 2 wherein the injected weight is within the range 105% to 115% of the preselected weight.
4. The method of Claim t wherein the step of chilling includes chilling the pork bellies to between -5 5/9°C (22°F) to no more than about -3%°C (25°F).
5. The method of Claim 1 wherein the pickle solution includes a flavoring agent for imparting a smoke taste to the pork bellies.
6. the method of Claim 1 wherein the slices are of circular form or strip form.
7. The method of Claim 1 wherein the steps of heating the slices includes:
passing the slices through a microwave cooking chamber.
8. A method of curing and processing pork bellies to produce circular sliced fully cooked bacon using a single heating step and omitting any smokehouse treatment, consisting essentially of the steps of:
providing pork bellies of a preselected weight;
infusing the pork bellies with a seasoned liquid pickle solution to obtain an injected weight exceeding the preselected weight;
tumbling the pork bellies to promote adhesion;
rolling together two pork bellies;
encasing the rolled pork bellies;
chilling rapidly the encased pork bellies to a temperature less than -38/9°C (25°F);
slicing the chilled pork bellies into a plurality of individual circular slices;
exposing the chilled slices to a heat source to rapidly eliminate at least 60% of injected weight; and cooking the slices with said heat source until the slices are fully cooked.
The method of Claim 8 wherein the step of chilling includes chilling the pork bellies to between -5 5/9°C(22°F) to no more than about -3 8/9°C: (25°F).
l0. The method of Claim 8 wherein the pickle solution includes a flavoring agent for imparting a smoke taste to the pork bellies.
11. The method of Claim 8 wherein the heating source includes a plurality of tandem arranged microwave cooking chambers.
l2. A method of curing and processing pork bellies to produce strip sliced fully cooked bacon using s single heating step and omitting any smokehouse treatment, consisting essentially of the steps of:
providing pork bellies of a preselected weight;
infusing the pork bellies with a seasoned liquid pickle solution to obtain an injected weight exceeding the preselected weight;
chilling rapidly the pork bellies to a temperature less than -3 8/9°C
(25°F);
slicing the chilled pork bellies into a plurality individual strip slices;
exposing the chilled slices to a heat source to rapidly eliminate at least 60% of injected weight; and cooking the slices with said heat source until the slices are fully cooked.
13. The method of Claim 12 wherein the step of chilling includes chilling the pork bellies to between -5 5/9°C (22°F) to no more than about -3 8/9°C (25°F).
14. The method of Claim 12 wherein the pickle solution includes a flavoring agent for imparting a smoke taste to the pork bellies.
15. The method of Claim 12 wherein the heating source includes a plurality of tandem arranged microwave cooking chambers.
16. In a method of curing and processing pork bellies to produce fully cooked, slice, circular form bacon; the method including providing pork bellies having a preselected weight, and infusing the pork bellies with a seasoned liquid pickle solution, the improvement consisting essentially of the steps of:
cold setting the seasoned pickle solution within the pork bellies;
slicing the pork bellies into a plurality of individual slices;
heat reducing the slices with a heat source to a finished weight no more than 40% of the preselected weight; and continuing heating of the slices with said heat source until the slices are fully cooked.
Priority Applications (7)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE19681761T DE19681761T1 (en) | 1996-07-29 | 1996-07-29 | Process for making fully cooked bacon bacon |
| BR9612718-0A BR9612718A (en) | 1996-07-29 | 1996-07-29 | Process of preparing fully cooked bacon derived from pork bellies. |
| PCT/US1996/012397 WO1998004142A1 (en) | 1996-07-29 | 1996-07-29 | Method of preparing fully cooked bacon derived from pork bellies |
| CA002262547A CA2262547C (en) | 1996-07-29 | 1996-07-29 | Method of preparing fully cooked bacon derived from pork bellies |
| AU66822/96A AU724232B2 (en) | 1996-07-29 | 1996-07-29 | Method of preparing fully cooked bacon derived from pork bellies |
| JP50875098A JP3647882B2 (en) | 1996-07-29 | 1996-07-29 | How to cook fully cooked bacon from pork bellies |
| DK199900113A DK199900113A (en) | 1996-07-29 | 1999-01-29 | Process for preparing fully cooked bacon from pork belly |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/US1996/012397 WO1998004142A1 (en) | 1996-07-29 | 1996-07-29 | Method of preparing fully cooked bacon derived from pork bellies |
| CA002262547A CA2262547C (en) | 1996-07-29 | 1996-07-29 | Method of preparing fully cooked bacon derived from pork bellies |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2262547A1 CA2262547A1 (en) | 1998-02-05 |
| CA2262547C true CA2262547C (en) | 2004-05-25 |
Family
ID=4163323
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002262547A Expired - Fee Related CA2262547C (en) | 1996-07-29 | 1996-07-29 | Method of preparing fully cooked bacon derived from pork bellies |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2262547C (en) |
-
1996
- 1996-07-29 CA CA002262547A patent/CA2262547C/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| CA2262547A1 (en) | 1998-02-05 |
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