Title of Invention

A PROCESS FOR THE PREPARATION OF READY TO EAT AND SHELF STABLE FRIED CHICKEN LEG PIECES

Abstract

This invention relates to a process for the preparation of ready to eat and shelf stable fried chicken leg pieces comprising in the steps of deskinning and cutting the clean chicken legs, pricking the cut chicken legs, soaking the pricked chicken legs in a solution containing 0.5-1% of citric acid and 6-8% salt, mixing the chicken legs in a masala mix as herein described and which is then allowed to marinate, frying the marinated legs in a frying medium, wiping off the excess frying medium from the surface of said fried legs.

Full Text

FIELD OF INVENTION This invention relates to the process for the preparation of a fried, ready-to-eat and shelf stable chicken leg pieces with good quality characteristics in terms of microbiological standards, chemical stability and sensory attributes. The chicken leg pieces prepared by the process of the present invention was stable under ambient, refrigerated and freezing temperature conditions. PRIOR ART Today, a variety of ready-to-eat foods are available in the market. Most of these foods are based on cereals and pulses. There is a paucity of shelf stable meat based products in the market. The meat-based products currently available in the market are of foreign origin. These are generally expensive and do not match the Indian culinary and taste. Patent search revealed that a few patents have been granted for development of shelf stable boneless chicken roll, oven roasted shelf stable meat products, shelf stable meat protein and meat products based on common ingredients. A boneless chicken roll has been prepared from chicken meat placed in elastic net, vacuum packed with/without spices or smoked (Brajkovic, 2003) against US patent no. WO2004/000039A2. Purser (1999) developed a method for producing fully cooked semi moist shelf stable meat product based on common ingredients (US Patent no. 5945152). Shull (2004) prepared a fully cooked oven roasted shelf stable meat product (US Patent no. 2004/0247763A1). Shelf stable, dehydrated, heat treated meat protein product has been discussed by Diebel and Gordon (2004) involving heating and dehydrating to reduce it to 30-65% of its original weight (US Patent no. 2004/0146613A1). Cormarais (2002) have also explained a new food product based on chicken meat. The process involved addition of flavoring and functional ingredients and then frying the meat pieces, cooling and packaging (US Patent no. FR2820615A1). Sada et al (2002) invented a method for production of Chinese fried meat dumplings which included loading of meat dumplings on a conveyor, steaming and frying the meat dumplings by raising the temperature from 50°C to 200-280°C in 1-8 min (US patent no. 192513). Some patents have also been granted for development of process for battering and frying for meat products while certain others have been filed on frying process with additives. A method of producing fully cooked bone-in poultry product has been explained by Afman et al (1996), which involved the steps like pre-dusting, battering, breading and pan frying before final cooking in vapor cooker ( US patent no. 734812). A process for deep fat frying of chicken patented by Kaufman (1972) contemplated the use of unique mixture of batter so that said chicken parts have a particular batter coating consistency ensuring taste, texture and appearance (US patent no. 241451). Clatfelter (1980) has patented a method of cooking chicken parts. Fresh chicken parts with batter were fried in hot oil at a temperature of 300- 400°F for 3-8 min and then subjected to high intensity microwave oven at 10-25 KW for a short period ( US patent No. 205357 described a process for preparing a batter-coated, barrier layer-coated porous inner food structure containing macerated beef or chicken (Stypula, 1998). A process has been patented by Rao and Gross (1993) for preparing a batter free breaded product by adhering high gluten flour to the pieces. Hydrating the dust sufficiently to render the dust tacky and then adhering dust to the hydrated dust (US patent No. 012553). Another US patent no. 845735, which gave details for fried chicken parts involved predusting, battering, breading and frying followed by oven-cooking (Babkaetal, 1992). Marine products like shrimps have also been developed and patented. Teijeiro (1975) gave a new shrimp product against his patent US patent no. 593479. Small shrimps were decapitated with lemon juice, sodium phosphate and monosodium glutamate and then prepared by flaking, blending, extruding and battering, partially frying and quick freezing.Ready-to-eat products like samosa, kachori, cutlet, pakoras, vada etc. are more popular among the consumers. This is because of the moist feel imparted to the palate and the characteristic taste and flavour of the fried products. Therefore, these moist fried foods are preferred over the others prepared through methods like roasting, baking, steaming etc. Moist meat based shelf stable food products are not available in India market because meat is highly perishable owing to its high nutritious composition, favourable water activity and pH. OBJETS OF THE INVENTION An object of the present invention is to propose a process for the preparation of ready to eat fried chicken leg pieces. Another object of this invention is to propose an additive formulation for the development of the fried chicken legs. Yet another object of the present invention is to propose a process for the preparation of ready to eat fried chicken leg pieces, which has shelf stability of product at ambient, refrigerated and freezing temperature conditions. A further object of the present invention is to propose a process for the preparation of ready to eat fried chicken leg pieces, which is efficient. The process provides ready to eat, fried chicken product that has a shelf life of up to 5 days at room temperature, 2 months at 5°C, and 4 months at-18°C. DESCRIPTION OF INVENTION According to this invention there is provided a process for the preparation of ready to eat and shelf stable fried chicken leg pieces comprising in the steps of: a) deskinning and cutting the clean chicken legs, b) pricking the cut chicken legs, c) soaking the pricked chicken legs in a solution containing 0.5-1% of citric acid and 6-8% salt, d) mixing the chicken legs in a masala mix as herein described and which is then allowed to marinate, e) frying the marinated legs in a frying medium, f) wiping off the excess frying medium from the surface of said fried legs. The steps of the process comprises :- 1. Processing of raw material (a) Deskinned, fresh, clean chicken legs from 5-7 weeks old broiler chickens weighing around 120-150g were procured from the local market. The leg pieces were cut into 2-3 smaller portions (40-50 g). The pieces were thoroughly cleaned with potable water 3-4 times and the surface fat removed manually. (b) The pieces were pricked with fork all over to facilitate the absorption of salt, citric acid and other ingredients. 2. Solution containing 0.5-1% citric acid and 6-8% salt was prepared using potable water and chicken leg pieces were immersed in it for 2 hrs. 3. Turmeric, chilli and chicken masala powders as well as cornstarch were autoclaved at 121 °C for 15 min prior to preparation of the product. 4. After 2 hours of soaking the citric acid and salt solution was completely drained off and the pieces were then mixed with masala mix (turmeric @ 0.1-0.2%, chilli powder @ 0.6-0.7%, chicken masala @ 0.6-0.7%, corn starch @ 2.0 to 2.5% TBHQ @0.02%) and allowed to marinate for half an hour 5. Mini Master Fryer with open surface area 34 x 19 sqcm and 6 liters capacity, procured from M/S. Continental India, Bangalore was used for frying chicken legs at 160-180°C for 8-10 min. Hydrogenated vegetable fat (vanaspati) procured locally was used as frying medium. 6. Surface oil was drained on a tissue paper while cooling. (7) The product was then packed in. paper-foil-polyethylene pouches (PFP), (45 GSM paper/20 microns aluminium foil, 37.5u LDPE), measuring 20 x 20 sqcm (8) The product was hermetically sealed and then subjected to storage studies under ambient (25 ± 2°C, RH 60-70%), refrigerated (5 ± 2°C, RH 80%), and freezing temperature (-18°C ±2°C, RH 60-80%) conditions. (9) In order to determine shelf stability, the product was kept for 1, 10 and 18 weeks under ambient, refrigerated and freezing temperature conditions respectively. WORKING EXAMPLE FOR THE PREPARATION OF 2 Kg FRIED CHICKEN LEGS (1) Fresh deskinned 3.5 Kg of chicken legs were procured locally and surface fat (250g) removed and cleaned with potable water and then cut into 65 pieces of 50g each. (2) A solution was prepared by dissolving 32.5 g citric acid and 390 g salt in 6.5 liters of clean potable water. (3) 65 pieces of chicken legs were immersed in the solution for 2 h. (4) Turmeric 6.5 g, chilli powder 22.75 g, chicken niasala 22.75g and com starch 81.25 g were taken in separate conical flasks and autoclaved. (5) The chicken pieces were taken out from the solution and mixed with autoclaved spices and 0.65 g TBHQ. (6) 3.5 liters of hydrogenated vegetable fat was taken in fryer and the pieces were fried for 8 min at 180°C with a minimum product to oil ratio of 1: 10. (7) The pieces were taken out from the fryer with a perforated ladle and surface fat removed by keeping the pieces on tissue papers till it was cooled to room temperature. (8) Sixty five PFP pouches measuring 20 x 20 sq cms were made and cleaned by wiping with 70% alcohol. (9) Fried chicken leg pieces were hermetically packed in clean paper-foil- polyethylene pouches for storage evaluation under ambient, refrigerated and freezing temperature conditions. The flow chart of the process is described hereinabove. FLOW CHART Procurement of deskinned chicken less, additive and other materials Cutting of leg m to pieces weighing 50 to 60 g and thorough cleaning Preparation of PFP pouches and cleaning AutocUn ing of spice mix and corn starch Soaking of pieces in 0.5 to 6% citric acid and 6 to 8 % salt solution for 2h Draining the solution Mixing of corn starch, spices. TBHQ with chicken pieces and leaving for 30 nun Frying at 180°C for 8 nun with product to oil ratio of 1:10 Removal of surface fat and conditioning/tempering at room temperature Hermetic Packaging Storage WE CLAIM: 1. A process for the preparation of ready to eat and shelf stable fried chicken leg pieces comprising in the steps of: a) deskinning and cutting the clean chicken legs, b) pricking the cut chicken legs, c) soaking the pricked chicken legs in a solution containing 0.5-1% of citric acid and 6-8% salt, d) mixing the chicken legs in a masala mix as herein described and which is then allowed to marinate, e) frying the marinated legs in a frying medium, f) wiping off the excess frying medium from the surface of said fried legs. 2. A process as claimed in claim 1 wherein the pricked chicken legs were soaked in the solution of citric acid and salt for approximately 2 hours. 3. A process as claimed in claim 1 wherein the masala mix comprises turmeric, chilli powder, chicken masala and corn starch. 4. A process for the preparation of ready to eat shelf stable fried chicken leg pieces substantially as herein described.

Documents:

113-DEL-2006-Abstract-(05-05-2010).pdf

113-del-2006-abstract.pdf

113-DEL-2006-Claims-(05-05-2010).pdf

113-del-2006-claims.pdf

113-DEL-2006-Correspondence-Others-(05-05-2010).pdf

113-del-2006-correspondence-others-1.pdf

113-del-2006-correspondence-others.pdf

113-del-2006-correspondence-po.pdf

113-DEL-2006-Description (Complete)-(05-05-2010).pdf

113-del-2006-description (complete).pdf

113-del-2006-form-1.pdf

113-del-2006-form-18.pdf

113-del-2006-form-2.pdf

113-DEL-2006-Form-3-(05-05-2010).pdf

113-DEL-2006-GPA-(05-05-2010).pdf