RU2850829C1 - Zrazy with chickpeas - Google Patents

Abstract

FIELD: food industry.

SUBSTANCE: chickpea patties containing poultry meat, chicken by-products, onions, table salt, ground black pepper, as well as a protein-fat emulsion, maltodextrin, ground nutmeg, ground coriander, dried basil, and dried garlic. The filling consists of chickpea purée, pre-sprouted in a sodium selenite solution with a selenium content of 0.1 g/l. To make 10 kg of protein-fat emulsion, 4 kg of chicken skins, 4 kg of extruded chickpea flour, 1 kg of refined sunflower oil, and 1 kg of ice-water mixture are used.

EFFECT: increased nutritional value.

1 cl, 3 tbl

Description

The invention relates to the food and meat industry, namely to the production of chopped semi-finished products from meat and edible by-products of poultry such as zrazy with an increased protein content enriched with a bioavailable form of selenium using a protein-fat emulsion.

A method for producing chopped semi-finished meat products is known [RU Patent No. 2613281, IPC A23L 13/60, published 03/15/2017], containing beef, lard, mechanically deboned poultry meat, a hydrated cake mixture, chicken eggs (melange), fried mushrooms, fried onions, fried carrots, edible sea salt, and ground black pepper.

The disadvantage of this method is the use of mechanically separated poultry. Firstly, this type of meat contains more fat than protein, which reduces its nutritional value. Secondly, mechanically separated poultry has a shorter shelf life than regular poultry, which can affect the shelf life of the finished product. Furthermore, these minced meat products are higher in calories due to the use of lard.

A method for producing semi-finished meat products is known [RU Patent No. 2477968, IPC A23L 1/314, published 03/27/2013], containing pork, beef, lupine paste concentrate, canned mushrooms, onions, spices (salt, ground black pepper).

The disadvantage of this production method is the use of pork and beef as raw meat. Pork is not a dietary meat, and beef is expensive.

A known method for producing chopped semi-finished products with a protein-fat emulsion [RU Patent No. 2776010, IPC A23L 13/50, published July 12, 2022] contains broiler chicken meat, a protein-fat emulsion, chicken eggs, potato starch, and ground allspice. The composition is characterized in that the composition contains chicken eggs, potato starch, and ground allspice. The protein-fat emulsion is made from chicken thigh fillet with skin, chicken liver, chicken gizzards, chicken hearts, whey protein concentrate, chickpea extrudate, and ice water.

A disadvantage of this production method is the use of raw chicken eggs, which increases waste and necessitates the use of larger warehouses. Another drawback is the multi-component nature of the protein-fat emulsion, the preparation of which requires extensive additional equipment, increasing the company's energy and resource consumption. This prototype is developing a minced meat intended for unfilled minced semi-finished products (cutlets). This minced meat cannot be used for filled semi-finished products due to its insufficient physical and mechanical properties (cohesion, stickiness, viscosity, etc.).

A method for producing meat zrazy with mushrooms is known [RU Patent No. 2525630, IPC IPC A23L 1/314, 1/317, published 08/20/201], which includes adding a hydrated mixture of wheat germ cake, amaranth seeds and pumpkin seeds to prepared minced meat (beef + pork), adding spices, and forming the filling from canned mushrooms and onions with subsequent frying in vegetable oil.

The disadvantages of this method include an unbalanced composition, low nutritional value of the finished products, the complexity of the technology associated with the need to first obtain a paste-like concentrate from amaranth, and the relatively low physical, mechanical, and functional-technological properties of the filling made from canned mushrooms and onions.

The closest technical solution chosen as a prototype is the recipe composition of chicken zrazy with giblets [Chicken zrazy with giblets: website. – URL: https://www.russianfood.com/recipes/recipe.php?rid=124938 ; access date: 11/19/24]. – Electronic text.], containing the following ingredients: chicken breasts or minced meat, salt, ground black pepper, eggs, large onions, breadcrumbs, chicken hearts, chicken gizzards, chicken liver, carrots, butter.

The disadvantages include the product's insufficient protein content due to the lack of high-protein plant ingredients in the recipe, as well as high losses during heat treatment. The use of poultry by-products as a filling results in an excessively dense and tough consistency of the semi-finished product filling, and also reduces its functional and technological properties (water- and fat-retaining capacity).

The objective of the invention is to develop semi-finished products made from minced meat and poultry by-products with improved functional and technological properties, having an increased protein content enriched with a bioavailable form of selenium, and to reduce losses during heat treatment of the semi-finished product.

The technical result is an increase in the nutritional value of the semi-finished chopped product.

The stated technical result is achieved in chickpea zrazy containing poultry meat, chicken by-products, onions, edible salt, ground black pepper, additionally containing protein-fat emulsion, maltodextrin, ground nutmeg, ground coriander, dried basil, dried garlic, and as a filling - chickpea puree, pre-sprouted in a sodium selenite solution with a selenium content of 0.1 g/l, with the following ratio of the original components, wt.%:

broiler chicken meat 42,

protein-fat emulsion 10,

by-products of broiler chickens, liver, stomachs, hearts 15,

fresh chopped onion 2.8,

maltodextrin 0.5,

table salt 2.2,

ground black pepper 0.1,

ground nutmeg 0.1,

ground coriander 0.1,

dried basil 0.1,

dried garlic 0.1,

chickpeas sprouted in a solution of sodium selenite 6.75,

water 20.25,

In this case, to produce 10 kg of protein-fat emulsion, 4 kg of chicken skins, 4 kg of extruded chickpea flour, 1 kg of refined sunflower oil, and 1 kg of ice-water mixture are used.

Using chickpea puree as a filling increases the nutritional value of the finished product. The protein content of chickpea seeds ranges from 20.1 to 32.4%. Chickpeas surpass other legumes in the amount of essential acids—methionine and tryptophan. Chickpea seeds are rich in phosphorus, potassium, and magnesium. Chickpeas are a good source of lecithin, riboflavin (vitamin _B2 ), thiamine (vitamin _B1 ), niacin, pantothenic acid, and choline.

It is worth noting that pre-sprouting chickpeas before blanching allows for a significant reduction in heat treatment time by softening the spatial structure of the legume and saturating the chickpeas with a salt solution (sodium selenite).

Depending on the production method (manual or on an automatic line), the technological modes for processing chickpeas are selected, with the decisive factor being the consistency and stability of the finished product during heat treatment.

Broiler chicken meat is a rich source of high-quality protein and contains important nutrients such as essential amino acids, vitamins _B6 and _B12 , iron, zinc, and selenium, which are essential for the growth, repair, and maintenance of body tissues. Broiler chicken is widely available and relatively more affordable than other types of meat.

Chicken by-products have a specific chemical composition and contribute to the increased nutritional value of semi-finished products (zrazy) when processed using a comprehensive set of raw materials. Chicken by-products contain significant amounts of phospholipids, which are an important component of cell membranes and also serve as a source of phosphoric acid, essential for human life. By-products are rich in vitamins _B2 , _B12 , and A. The liver is the most valuable by-product, as it contains a large amount of iron (2.5 times more than the meat itself).

The spices and herbs used in the proposed recipe impart the required organoleptic properties to the finished product (taste, aroma, and smell of the product after heat treatment).

The use of maltodextrin (any maltodextrin produced in accordance with GOST 34274-2017 can be used, for example, DE20 (NewBio. Deep grain processing/Maltodextrin: [website]. - URL: https://newbio.ru/maltodextrin; accessed: 16.10.24), which is a product of bioconversion of corn starch, consisting of a mixture of carbohydrates of different molecular weights (glucose, maltose and polysaccharides), allows you to bind moisture, stabilize the aroma, and also has a positive effect on the consistency and appearance of the finished product.

The use of protein-fat compositions using chicken skin in the production of poultry products will ensure the inclusion of collagen-containing associated raw materials in production.

The use of chicken skin emulsion as a fat component allows for the achievement of an optimal consistency of minced meat, the binding of its components together, and the provision of the necessary functional and technological properties of the protein-fat emulsion (PFE), and, consequently, of the chopped semi-finished product with chickpea filling.

Extruded chickpea flour is a suitable protein component in protein-fat emulsions. This additive is produced in an extruder at 160°C and 50 atm. Extrusion eliminates the specific odor and flavor of legumes, which subsequently manifests itself in finished products. The pressure and high temperature also destroy pathogenic microflora and improve protein digestibility and starch assimilation. For better distribution within the product, the chickpea additive is ground into flour. Unlike other types of chickpea flour, extruded chickpea flour contains virtually no protein-based anti-nutritional compounds that can reduce the nutritional value of protein products and food items (such compounds include gastrointestinal protease inhibitors and lectins). Overall, chickpea flour proteins possess high nutritional value due to their amino acid composition. In terms of lysine content, an essential amino acid that limits the amount of varietal wheat flour, chickpea protein is close to proteins of animal origin.

The additional use of refined vegetable oil as a component of the protein-fat emulsion allows for the optimization of the fatty acid composition of the chopped semi-finished product with chickpea filling.

The composition of the protein-fat emulsion allows for a uniform consistency of minced meat and improves its structure, since a stable homogeneous dispersed system is formed by a combination of proteins and fats of plant and animal origin in a close to optimal ratio of protein: fat: water (1: 1.25: 0.25).

To activate the proteins and dissolve them, it is necessary to add salt at the very beginning of the cutting process so that its effect lasts as long as possible and thus, the best consistency of the minced meat is achieved.

Adding an ice-water mixture at the beginning of cutting allows you to reduce the viscosity and temperature of the mixture, which quickly heats up at the beginning of processing and can lose plasticity without a sufficient amount of liquid fraction.

The introduction of extruded chickpea flour as a vegetable protein allows the strength characteristics of the emulsion to be preserved during heat treatment and freezing, and then of the semi-finished products.

Disruption of the structure of animal and vegetable protein solutions facilitates effective emulsion stabilization, as fat is partially retained by adsorption on the surfaces of protein particles. Due to the high surface structural and mechanical properties (adhesion and cohesion) developed during fine grinding, strong interactions occur within the fat-protein system, resulting in the emulsion's spatial structural network being stable for a considerable period of time. Thus, a protein-fat emulsion significantly enhances the functional and technological properties of minced meat and poultry by-products, reducing losses after heat treatment of the minced semi-finished product.

To assess the quality of the chickpea zrazy, they were subjected to heat treatment, namely, frying at a temperature of 120°C until cooked (to a temperature of at least 72°C in the center of the product).

Organoleptic indicators before and after heat treatment, as well as losses during roasting of zrazy are presented in Table 1.

Table 1

Name of the indicator Characteristics of the indicator For the stated sample Prepared according to the prototype Organoleptic properties of frozen semi-finished products Smell characteristic of raw meat and poultry by-products characteristic of raw meat and poultry by-products Consistency solid,
when stored for 30 days and then defrosted to +1°C, they did not lose their shape solid
when stored for 30 days and then defrosted to +1°C, they partially lost their shape Color The minced meat is light pink, with red inclusions of offal particles, the filling is light yellow the mince is light pink, the filling is brown Organoleptic properties of fried products Taste and smell typical of fried chicken and high-quality offal with a spicy flavor and aroma; moderately spicy, moderately salty; the filling has a pleasant bean flavor (chickpea, similar to pea, but less pronounced), without any foreign flavor or smell typical of fried chicken and good-quality offal with a spicy taste and smell; moderately spicy, moderately salty Consistency elastic, dense, juicy, for filling – tender, slight looseness is acceptable elastic, juicy, not crumbly, for filling - very dense, quite tough Color gray, with brown offal particles and a yellow chickpea filling visible on the cut White to light yellow, it has a crispy golden crust and a brown offal filling. Losses during roasting, %, no more than 4.5 6.5

Physicochemical properties of zrazy with chickpeas are presented in Table 2.

Table 2

Name of the indicator Value of the indicator For the stated sample Prepared according to the prototype Mass fraction of fat, %, no more than 9.0 9.0 Mass fraction of protein, %, not less than 14.5 13.0 Mass fraction of dietary fiber, % not less than 12.0 1.5 Mass content of sodium chloride, %, not more than 2.2 1.8 Mass fraction of selenium, μg%, not less than 40 traces Total acidity, ˚T, no more than 4.0 4.0 Mass fraction of filling, %, of the minced meat mass, no more than 30.0 30.0 Mass fraction of breading, %, no more than of the product mass not used 3.0

The table shows that the declared chickpea zrazy are distinguished by a high protein content – at least 14.5%, as well as a high selenium content – at least 100 mcg%.

Table 3 presents the functional and technological properties of minced meat and edible by-products.

Table 3

Name of the indicator Value of the indicator For the stated sample Prepared according to the prototype pH of the stuffing system 6.11±0.2 6.10±0.2 Moisture-holding capacity (MHC) of minced meat, % of total moisture 91.8±0.1 80.9±0.1 Fat-retaining capacity (FRC) of minced meat, % 93.9±0.2 88.0±0.2 Stability of minced meat emulsion, % 90.0±4.0 86.0±4.0

The samples of zrazy produced according to the stated recipe had high functional and technological indicators (the moisture-holding capacity of minced meat (MHC) was at the level of 91.8%, the stability of the minced meat emulsion was 90.0%), which will allow the mass to be preserved during freezing and thawing of semi-finished products, as well as reduce mass loss during heat treatment (frying).

The proposed recipe composition for zrazy with chickpeas allows you to obtain a chopped semi-finished product using a non-traditional type of plant material – chickpea puree – with a delicate consistency and a balanced composition of nutritional components.

Zrazy with chickpeas are prepared as follows.

First, chickpeas are sprouted in a solution containing 0.1 g/L of selenium. 6.0 kg of chickpeas are rinsed in running water at 25°C, then soaked in a container at 22°C for 4 days in a 0.1 g/L sodium selenite solution. The chickpeas are then transferred to a baking sheet and placed in a single layer between two layers of linen or cotton fabric, well-soaked in a 0.1 g/L sodium selenite solution, and sprouted at 22°C. The top fabric is moistened twice a day (morning and evening) with the same solution until sprouts emerge (pierce) (no more than 3 days). The sprouts should be at least 2 mm long. Next, the sprouted chickpeas are carefully and thoroughly rinsed in running water.

Blanching of sprouted chickpeas (6.75 kg) is carried out in vats at a temperature of 100°C. The chickpea-to-water ratio is 1:4. The process lasts 30 minutes.

Chickpea puree is prepared by finely grinding the chickpeas until they reach a visually uniform consistency. Add 1 kg of salt during the grinding process.

Before forming the products, the chickpea puree is cooled to a temperature of 10-12°C.

For the production of chopped semi-finished products, broiler chicken meat – 42 kg and chicken by-products – 15 kg are used as raw meat.

The meat of broiler chickens and offal are ground using a grinder with a grid diameter of 2-3 mm.

To make 10 kg of protein-fat emulsion (PFE), you'll need 4 kg of chicken skin, 4 kg of extruded chickpea flour, 1 kg of refined sunflower oil, and 1 kg of ice-water mixture. Place the chicken skin and 1/3 of the required amount of ice in a cutter or emulsifier. Once the skin is completely ground, add the chickpea flour and sunflower oil and grind for 10 minutes, adding the remaining ice-water mixture. The process should be carried out at a temperature no higher than 12°C. The protein-fat emulsion is then maintained at a temperature no higher than 12°C for 15-30 minutes.

Fresh onions are minced using a grinder with a 3 mm diameter grate. The result is 2.8 kg of chopped onions.

The minced meat is prepared in a minced meat mixer. The ingredients are added in the following order while continuously mixing: first, 42 kg of chopped broiler chicken meat, 15 kg of chopped offal, and 1.2 kg of edible salt. Then, 10 kg of protein-fat emulsion are added and mixed until evenly distributed. Next, the remaining ingredients are added: 0.5 kg of maltodextrin, 2.8 kg of fresh chopped onion, 0.1 kg of ground black pepper, 0.1 kg of ground nutmeg, 0.1 kg of ground coriander, 0.1 kg of dried basil, and 0.1 kg of dried garlic. The total duration of the minced meat mixing process is no more than 10 minutes. The amount of cold water to be added is 20.25 kg; it is added throughout the mixing stage in accordance with a visual assessment of the viscosity and stickiness of the consistency. The temperature of the finished minced meat should not exceed 12°C.

Next, the minced meat and chickpea puree are used to form the pastry. Pre-prepared and cooled chickpea puree is used as the filling. The minced meat (covering) to filling ratio is 2.5:1. Each pastry weighs 100 g. The pastry is then frozen in quick-freezers at -35°C until the center temperature reaches no higher than -18°C.

An example of preparing zrazy with chickpeas.

First, chickpeas are sprouted in a solution containing 0.1 g/l of selenium. 6.0 kg of chickpeas are rinsed in running water at 25°C, then soaked in a container at 22°C for 4 days in a 0.1 g/l sodium selenite solution. The chickpeas are then transferred to a baking sheet and placed in a single layer between two layers of linen or cotton fabric, well soaked in a 0.1 g/l sodium selenite solution, and sprouted at 22°C. The top fabric is moistened twice a day (morning and evening) with the same solution until sprouts appear (pierce) (no more than 3 days). Sprouts should be at least 2 mm long. Chickpeas are carefully rinsed in running water. Thus, the mass of washed sprouted chickpeas should be 6.75 kg.

Sprouted chickpeas are blanched in vats at 100°C. The chickpea-to-water ratio is 1:4. The process lasts 30 minutes.

Chickpea puree is prepared by finely grinding the chickpeas until they reach a visually uniform consistency. Add 1 kg of salt during the grinding process.

Before forming the products, the chickpea puree is cooled to a temperature of 10-12°C.

The quantity of chickpea puree, taking into account losses during cooking and cooling, should be at least 30 kg.

For the production of chopped semi-finished products, broiler chicken meat – 42 kg and chicken by-products – 15 kg are used as raw meat.

The offal is removed from the semi-eviscerated broiler carcasses, and the neck and breast portion, along with the keel, are removed with knives. Before deboning, the skin is removed from the breasts, which are then used for emulsion preparation. The deboning is performed with knives, removing the keel and breastbones. The offal is rinsed under running water at 25°C, removing any membranes. The stomachs should be thoroughly rinsed to remove any remaining bile.

The meat of broiler chickens and offal are ground using a grinder with a grid diameter of 2-3 mm.

To make 10 kg of protein-fat emulsion (PFE), you will need 4 kg of chicken skin, 4 kg of extruded chickpea flour, 1 kg of refined sunflower oil, and 1 kg of ice-water mixture. Place the chicken skin and 1/3 of the required amount of ice in a cutter or emulsifier. Once the skin is completely ground, add the chickpea flour and sunflower oil and process for 10 minutes, adding the remaining ice-water mixture. The process should be carried out at a temperature no higher than 12°C. The protein-fat emulsion is then maintained at a temperature no higher than 12°C for 15-30 minutes. The PFE should be stored for no more than 24 hours at 0-4°C.

Fresh onions are peeled and thawed, then rinsed under running water at 25°C. Grind the onions using a 3mm grinder. This yields 2.8 kg of chopped onions.

The minced meat is prepared in a minced meat mixer. The ingredients are added in the following order while continuously mixing: first, 42 kg of chopped broiler chicken meat, 15 kg of chopped offal, and 1.2 kg of edible salt. Then, 10 kg of protein-fat emulsion are added and mixed until evenly distributed. Next, the remaining ingredients are added: 0.5 kg of maltodextrin, 2.8 kg of fresh chopped onion, 0.1 kg of ground black pepper, 0.1 kg of ground nutmeg, 0.1 kg of ground coriander, 0.1 kg of dried basil, and 0.1 kg of dried garlic. The total duration of the minced meat mixing process is no more than 10 minutes. The amount of cold water to be added is 20.25 kg; it is added throughout the mixing stage in accordance with a visual assessment of the viscosity and stickiness of the consistency. The temperature of the finished minced meat should not exceed 12°C.

Next, the minced meat and chickpea puree are formed into products using an automatic extrusion-molding machine. Pre-prepared and cooled chickpea puree is used as the filling. The minced meat (coating) to filling ratio is 2.5:1. Each product weighs 100 g. The products are then frozen in quick-freezers at -35°C until the core temperature reaches no higher than -18°C.

Thus, the use of chickpea zrazy containing poultry meat, chicken by-products, onions, edible salt, ground black pepper, protein-fat emulsion, maltodextrin, ground nutmeg, ground coriander, dried basil, dried garlic, and as a filling - chickpea puree, pre-sprouted in a sodium selenite solution with a selenium content of 0.1 g / l, allows to increase the nutritional value of the chopped semi-finished product.

Claims (15)

Zrazy with chickpeas, containing poultry meat, chicken by-products, onions, edible salt, ground black pepper, characterized in that they additionally contain protein-fat emulsion, maltodextrin, ground nutmeg, ground coriander, dried basil, dried garlic, and as a filling - puree of chickpeas, pre-sprouted in a solution of sodium selenite with a selenium content of 0.1 g / l, with the following ratio of the original components, wt.%: broiler chicken meat 42, protein-fat emulsion 10, by-products of broiler chickens, liver, stomachs, hearts 15, fresh chopped onion 2.8, maltodextrin 0.5, table salt 2.2, ground black pepper 0.1, ground nutmeg 0.1, ground coriander 0.1, dried basil 0.1, dried garlic 0.1, chickpeas sprouted in a solution of sodium selenite 6.75, water 20.25, In this case, to produce 10 kg of protein-fat emulsion, 4 kg of chicken skins, 4 kg of extruded chickpea flour, 1 kg of refined sunflower oil, and 1 kg of ice-water mixture are used.