One of the main ways poultry processors add value to any product is bread. The two biggest reasons processors add breadcrumbs to poultry are to enhance or add flavor and texture.
“I believe there are two main breading systems in the poultry industry, flat and home applications,” said Robert Nothum Jr., President of Nothum Food Processing Systems in Springfield, Missouri. “In these two products, there are several choices and varieties, but those two products account for the majority. Flats will cover your shaped products, such as nuggets and patties. Homestyle will cover ribbon products, tender meats and Large texture products. Of course, there are many other products in between, but this is the majority.”
Doug Kozenski, Heat and Control Processing Industry Manager in Hayward, California, adds that the breaded poultry products range from very light to very heavy coatings of flour or breadcrumbs. Flour gives poultry a soft crust and mouthfeel, while the crumb crust provides the crunchy texture required by many processors.
Kozenski said: “When most of the flavor and texture comes from the meat itself, a lighter coating is the first choice for the product, and when most of the flavor and texture comes from the coating itself, choose a heavier coating.”
For the processor, to reach one or more ranges in the breadcrumb range, a large number of variables need to be incorporated into the equation.
The coating of poultry should consist of at least three parts: dust, batter and final breadcrumbs. For heavier final coatings, processors and their equipment must go through multiple stages to “stack” the coating. The common process usually includes dust, batter, breadcrumbs, another batter, and then the final breadcrumbs.
Kozenski said: “When heavier paint is needed, it can be extended to a three-pass system.” “It is very important to establish a coating so that the batter and breadcrumbs have time to properly hydrate and adhere to the product. Add a thick coating quickly, as in one step, the coating will not adhere properly and will fall off during frying or handling, resulting in an uncoated product.”
Nothum pointed out that batter plays an important role in bread crumbs, especially in product appearance. He said that the batter and its applicator are often overlooked and only considered as a means of adding pickups to the final product.
Nothum said: “The reality is that the batter plays a huge role in the appearance, taste and feel of the final product.” “The main problem is that the processor can’t really control their batter mixer or spreader.”
Especially for home-style bread, equipment manufacturers and suppliers agree that the final appearance determines the success of home-style bread. The final appearance comes from the ability to make adjustments. The surface of household bread products should have a rough appearance to give it a hand-crafted appearance and distinguish it from a smoother “machined” appearance.
Nothum said: “The best home-style appearance is created by the perfect combination of craftsmanship, coating and equipment.” “One of the advantages we have is not only equipment experience, but also process experience. In doing business In the past 50 years, we have figured out the size adjustments that can be made to the process to help reduce waste and labor, while increasing delivery volume and output.”
For processors, drum crumbs are usually used for the final application of flour crumbs to flip or roll the substrate to create a home-style appearance. The operator will sow the drum crumbs by adding a small amount of water, batter mixture or water to make the crumbs slightly clumpy. The sown breadcrumbs cling to the surface of the poultry, creating a homely style.
“The amount of added moisture and the speed at which the product passes through the drum breadcrumbs will change the strength of the home’s appearance and the amount of paint picked up, allowing manufacturers to fine-tune the appearance and texture of the product. The product,” Kozenski said.
Nothum and Kozenski agree that the improvement of breadcrumb technology comes entirely from the innovation of the equipment used by the processor.
Nothum Food Processing launched FlexDrum and BatterPro in the late 90s, and continued to develop and innovate. FlexDrum became SuperFlex, both of which allow processors to better control the further processing of dust removal, breadcrumbs and batter.
Nothum said: “Processors have real control and understanding of what happens on their further processing lines.”
Another device evolution that has occurred in recent years is the safety concerns of manufacturers and processors. Like all food processing equipment, batter application and bread crumb manufacturing companies have specifically designed and built sanitation and worker safety in recent years. In addition, thermal and control engineers and manufacturers are also committed to the function, durability and reliability of the equipment.
Kozenski said: “The durability of the belt itself has always been a problem for all belt crumbs.” “Due to the working pressure of the bread belt, the belt often breaks. The heat and control department developed a simple and effective method for the main belt. The dynamic tensioning method can reduce the tension, provide a way of damping, and greatly extend the service life of the belt on the bread machine.
Moreover, the preference for processors has begun to shift from traditional hydraulic drives to electric drives on moving parts of coating equipment. The size and technology of the electric drive make the design and construction of the coating easier and more practical, which is the key reason for the change.
Kozenski said: “This allows the integration of coating equipment into a PLC controlled system for automatic speed setting/adjustment and performance feedback.”
Just as the design and construction of processing equipment are changing and evolving, so are the ways in which customers interact with suppliers, manufacturers and end users, and ultimately how they do business. The Nothum Food Processing team does not need to compete with the entire industry to promote innovation and make better changes.
Nothum said: “Now, we work with customers and even different suppliers every day to bring greater technologies to the market.”
He added the history and dedication of Nothum Food Processing’s family business since its establishment.
“Our founder, Bob Nothum Sr., founded our company 50 years ago, and he has taken a great path for us, and for future generations, there will be more power to promote Our industry is moving forward,” Northam said.
Heat and control attach great importance to partnerships. Before providing the processor with equipment for coating and breading poultry meat, the company will meet with potential partners to discuss characteristics such as ingredients and the final product, and spend as much time as possible to fully understand the needs of the processor.
Kozenski said: “It is important to understand whether the meat is boneless or bone, formed muscle or complete muscle, and how to load it on the production line.” “Then discuss the type and amount of coating. It is important to know. The amount of coating to be added to the meat, the texture of the product, and any other specific characteristics. With all this information, it is possible to design the best system to complete the desired final product. A single pass may be sufficient However, for heavier coated products, a double or even triple production line may be required.”
Suppliers and their customers must also consider the type of product before deciding on breadcrumb and batter application equipment. For example, coating equipment using linear processes can better prevent damage to molded products. For de-dusting and final breading applications, full-muscle items with no bones or intact bones may be best or require breading.
Kozenski said: “Knowing all the attributes and characteristics of raw materials and finished products will help design the most suitable and compatible coating system to ensure a complete and stable coating of the product.”
Post time: Sep-01-2020