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Method for continuously processing meat substrates using a marinade with increased viscosityRelated Patent Categories: Food Or Edible Material: Processes, Compositions, And Products, Processes, Packaging Or Treatment Of Packaged ProductMethod for continuously processing meat substrates using a marinade with increased viscosity description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070184156, Method for continuously processing meat substrates using a marinade with increased viscosity. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application is a continuation-in-part of U.S. patent application Ser. No. 11/204,080, filed on Dec. 6, 2005. FIELD OF INVENTION [0002] The present invention relates to methods for continuously processing meat substrates. More specifically, the present invention relates to continuously marinating and packaging meat substrates, such as portions of poultry. BACKGROUND OF THE INVENTION [0003] Meat processors often utilize various techniques to enhance and add value to their food products, such as by applying marinade to meat substrates. The procedure for applying marinade to meat substrates may take one or multiple steps based on the size of the substrate, the marinade composition, and the desired level of marination. In the food processing industry, there are various approaches to marinating meat substrates and the processes are selected according to the type of product desired and the composition of the marinade. Such processes include massaging, tumbling, vacuum tumbling, injecting, or a combination of these techniques. [0004] One of the more commonly-used methods of marination is tumbling. Marination by tumbling typically involves a batch process in which large quantities of meat substrates are combined with a marinade in a mechanical tumbler. As the tumbler is agitated, the marinade and meat substrates are mixed, and the marinade is absorbed by the meat substrates. The method of marination by vacuum tumbling uses a sealed chamber in which the marinade and meat substrates are placed. Air is partially evacuated, and the chamber is agitated to increase the rate of marinade absorption by the meat substrates. [0005] Another commonly-used method of marination is injection. Marination by injection uses needles to Inject a predetermined volume of marinade directly into the meat substrates. Regardless of the method used, all known currently utilized processes substantially complete marination of the meat substrates prior to placing and sealing the substrates into packages. [0006] Currently utilized marination techniques often result in inconsistently marinated, non-aesthetically pleasing products and may contribute to significant waste of marinade. Furthermore, these processes often require multiple pieces of equipment for marinating and packaging the meat substrates. Moreover, the prior art processes often require binders, such as phosphates, to ensure that a sufficient amount of marinade is retained in the meat substrate. The use of binders is increasingly being viewed as a negative and can adversely affect the sales of the product. [0007] Accordingly, there is a need in the art for a method to efficiently marinate and package meat substrates. There is also a need for a marination method which provides consistently-marinated products. It is also desirable to reduce the number of pieces of equipment used in current marination and packaging processes. Moreover, it is also desirable to provide a method which can be used to adequately marinate a meat substrate without the use of binders. SUMMARY OF THE INVENTION [0008] In view of the shortcomings of the prior art processes, an embodiment of the present invention relates to a method for continuously processing meat substrates including the step of placing a meat substrate in a package which is sized to contain the meat substrate and a predetermined amount of marinade, which comprises at least a solute and water, and optionally a thickening agent. The predetermined amount of marinade is selected to be substantially absorbed by the meat substrate. The method includes the step of adding the predetermined amount of marinade to the package, which is then sealed to allow the marinade to be substantially absorbed by the meat substrate while the package is sealed. [0009] According to a second embodiment of the present invention, the method includes the step of placing a meat substrate into a package which is sized to contain the meat substrate and a predetermined amount of marinade, which consists essentially of a solute, a thickening agent, water, and, optionally, a soluble seasoning. The predetermined amount of marinade is selected to be substantially absorbed by the meat substrate. The method includes the step of adding the predetermined amount of marinade to the package, which is then sealed to allow the marinade to be substantially absorbed by the meat substrate while the package is sealed. [0010] According to a third embodiment of the present invention, the method includes the step of placing a fraction of a predetermined amount of marinade in a package which is sized to contain a meat substrate and a predetermined amount of marinade, which comprises at least a solute, a thickening agent, and water and, optionally, has an insoluble seasoning dispersed therein. The predetermined amount of marinade is selected to be substantially absorbed by the meat substrate. The meat substrate is then added to the partially filled package to provide a meat-containing package. Then, the remainder of the predetermined amount of marinade is added into the package, which is sealed to allow the marinade to be substantially absorbed by the meat substrate while the package is sealed. [0011] According to a fourth embodiment of the present invention, the method includes the step of placing a fraction of a predetermined amount of marinate in a package which is sized to contain a meat substrate and a predetermined amount of marinade, which consists essentially of a solute, a thickening agent, water, and, optionally a soluble seasoning and has an insoluble seasoning dispersed therein. The predetermined amount of marinade is selected to be substantially absorbed by the meat substrate. The meat substrate is then added to the partially filled package and the remainder of the predetermined amount of marinade is added into the package, which is sealed to allow the marinade to be substantially absorbed by the meat substrate while the package is sealed. BRIEF DESCRIPTION OF THE DRAWINGS [0012] The features of the invention and the elements characteristic of the invention are set forth with particularity in the appended claims. The invention itself, however, may best be understood by reference to the detailed description which follows when taken in conjunction with the accompanying drawings in which: [0013] FIG. 1 is a flow-chart describing a method for continuously processing meat substrates according to an embodiment of the present invention; and [0014] FIG. 2 is a flow-chart describing a method for continuously processing meat substrates according to another embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION [0015] The present invention is directed to a method for continuously processing meat substrates. As used herein, the term "processing" primarily means marinating and packaging, but can also encompass other process steps, including additional, optional steps done before and after the marinating and packaging steps. Such preliminary steps include macerating, scoring, or tenderizing the meat substrate; cutting the meat substrate; trimming the meat substrate, among others. Post-packaging steps include tumbling the package to facilitate marination and freezing or cooking the meat substrate, including freezing and/or cooking it while it is still contained within the package. In addition, while the process is primarily directed to effecting marination without the use of injection or tumbling, the inventive process of the present invention can be used in conjunction with an injection, tumbling, or other marination process. [0016] Any edible meat substrate can be processed in accordance with the present invention. Examples of such meat substrates include portions of poultry, beef, pork, lamb, veal, or seafood and may be a single cut of meat or portions thereof. Poultry includes chicken, turkey, and Cornish hens, among others. In addition, it is provided that the meat substrate can be a bone-in or boneless meat substrate. The meat substrate may be skinless or skin-on. It is primarily envisioned that the present invention be used to process whole muscle meat, but the method can also be used to process other types of meat substrates. In one embodiment of the invention, the method is used to process a portion of poultry, such as chicken, and in a more specific embodiment of the invention, the method is used to process a chicken breast. [0017] The method is a continuous process as opposed to a batch process, such as many known tumbling marination processes. The various steps of the method are carried out as part of a continuous process. For example, the method can be carried out using any suitable rollstock machine preferably having a conveyor belt, such as commercially available rollstock machines manufactured by Multivac Inc. of Kansas City, Mo.; Rapid Pak of Lodi, Wis.; and Reiser of Canton, Mass. In an embodiment for processing chicken breasts, an R530 rollstock machine, manufactured by Multivac, is used. [0018] The marinade used can be any known marinade used to tenderize, moisten, and/or flavor the meat substrate. In its most general sense, the marinade includes a solute, such as salt (which typically is sodium chloride but could also be or include potassium chloride, among others), and water. Such a marinade serves primarily to tenderize the meat and increase the water-holding capacity of the meat, thereby allowing for a cooked product having increased moistness. The marinade may also include one or more soluble seasonings primarily for imparting flavor to the meat. For example, soluble seasonings can be used to impart any of a wide variety of flavors to the meat substrate, such as barbecue, Italian, honey-mustard, teriyaki, tomato basil, and lemon pepper, among others. Seasonings include ingredients such as sweeteners, starches, soy proteins, and hydrocolloids. While the term "soluble seasoning" is used, such seasonings encompass seasonings which are typically added to water either as a dry powder or as a liquid. While binders, such as phosphates, can also be included in the marinade, it is generally preferable to provide a marinade which consists of a solute, water, and optionally a soluble seasoning, to the exclusion of any binders. It has been found that the method of the present invention can achieve a significant degree of marinade absorption without the use of binders, thereby minimizing the waste of marinade while avoiding the negative attributes associated with using binders. Continue reading about Method for continuously processing meat substrates using a marinade with increased viscosity... 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