- 1 -

APPARATUS AND METHOD FOR PRODUCING A SKINLESS MEAT PRODUCT

This application is a Continuation-In-Part of Application Serial No. 099,418 filed July 30, 1993 which is a Continuation-In-Part Application of Application Serial No. 852,785 filed March 17, 1992, now U.S. Patent No. 5,235,903, issued August 17, 1993.

BACKGROUND OF THE INVENTION

TECHNICAL FIELD

The present invention relates to an apparatus and method of producing a skinless meat product and in particular to the skinless meat product itself.

BACKGROUND ART

Traditionally, boneless meat products, such as hams, have been cooked in large smoke houses to provide additional flavor to die ham. The meats are usually placed in porous bags which allow the smoke flavor in me smoke house to penetrate through the bag and into the meat product itself. During the cooking operation, the high temperature in the smoke house causes the fiber in the meat to shrink inducing the juices in the meat to purge to the surface of the meat. The juice in the meat generally consists of water, animal protein, and salt. The water contained in the

juice on the surface of the meat evaporates away during the cooking process, which leaves behind a residue of protein and salt. The protein and salt residue is exposed to the high temperatures of the smoke house which cause the residue to coagulate, thus forming a skin on the surface of the meat.

The resulting skin on the surface of the meat is usually harder than the rest of the cooked meat product. Such a hardened skin is generally undesirable in taste and appearance to most consumers, especially when the meat product is used as a sandwich meat. U.S. Patent No. 4,721 ,623 to Coffey et al. discloses cooking a meat product in an environment sufficiendy humid to reduce the evaporation of water contained in a coloring spray which is used within the environment. However, this process is to be used in conjunction with a meat product having a skin on its surface. Therefore, the process allows some evaporation within the environment and does not disclose an environment having 100% humidity which prevents any evaporation of water.

The use of steam as a heat transfer medium is well known in the prior art. Such steam cooking devices may employ the steam at atmospheric pressure as in U.S. Patent No. 4,011,805 with convection heat transfer. Steam as the heat transfer medium at substantially atmospheric pressure witii forced convection heat transfer is also known from U.S. Patent No. 4,173,215. In tiiis last patented arrangement, water is introduced into the bottom of a steam chamber and a heat source outside that chamber heats the water to produce steam. The chamber is vented so as to maintain the pressure within the cooking vessel at substantially atmospheric pressure. Such steam cooking devices may also employ the steam at an elevated pressure as in the common "pressure cooker." U.S.

Patent No. 3,800,778 discloses a steam cooker witii a valve and pump arrangement so that the pressure within the cooking vessel can be maintained either above or below atmospheric pressure. However, these references do not disclose steam cooking food products at 100% humidity, which, if prepared in such manner, would ensure mat a skin will not develop on me outer surface of die food product during d e cooking process.

Accordingly, as can be seen from me foregoing, tiiere is a need for a method of cooking a meat product without forming a skin on the outer surface tiiereof, wherein me meat product is placed in an environment which prevents the evaporation of water from the surface of the meat product.

SUMMARY OF THE TNVENTION

It is a primary object of the present invention to overcome die aforementioned shortcomings associated witii me prior art.

Another object of me present invention is to provide a meat product, and an apparatus and method of producing the same, wherein the meat product is cooked without forming a skin around its outer surface.

Yet anodier object of me present invention is to provide a skinless meat product, and an apparatus and method of producing d e same where e meat product is cooked within a chamber in which the amount of water evaporation from the meat product can be regulated.

These as well as additional objects and advantages of d e present invention are achieved by preparing a meat product wherein die meat product is heat treated to have no outer skin about its surface. The meat

9771 PCI7US95/11662

- 4 -

product is placed inside of an air-tight chamber, in which d e meat product is to be cooked. Steam is generated from a source of water and is introduced into die cooking chamber, wherein die steam heats d e inside of me cooking chamber and serves as a heat transfer media to heat me meat product. The steam and pressure witiiin die cooking chamber are regulated so as to create an atmospheric humidity of 100% witiiin the chamber, so any water present within me meat is prevented from evaporating into die atmosphere of said cooking chamber.

The pressure witiiin the cooking chamber can be reduced so as to produce a controlled temperature steam from 160° to 212° F to cook the meat product. Cooking the meat with a low temperature steam assists in preventing the outer surface of the meat from cooking faster than the inside portion of d e meat. Additionally, a flavored ingredient, such a liquid smoke, may be added to d e water utilized in generating die steam in order to flavor the meat product being cooked.

In die case where a thin skin on d e surface of the meat product is desired, the pressure witiiin die cooking chamber can be further reduced after die steam has been heat treating the meat product for a predetermined time period. The reduction in pressure causes the boiling temperature within the cooking chamber to drop, which allows any moisture present on the surface of the meat product to boil off leaving behind a protein and salt residue. The protein and salt residue, being exposed to the heat within the cooking chamber, coagulates so that a thin layer of skin will develop on die surface of die meat product. The above noted method is carried out using an apparatus for cooking d e meat product including an air-tight cooking chamber, a meat product support for supporting the meat product witiiin the chamber, a

source of steam and a control unit for maintaining a humidity level of 100% within die chamber. The apparatus further includes one of many devices for reducing die pressure witiiin die chamber so as to control die cooking temperature witiiin die chamber. These as well as additional advantages of the present invention will become apparent from the following detailed description of die invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a sectional view of the steam cooker of the present invention. Figure 2 is a sectional view of a second embodiment of die steam cooker of the present invention.

Figure 3 is a sectional view of a tiiird embodiment of die steam cooker of die present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention provides for a new method of cooking a skinless meat product. The meat product of die present invention may be any meat which tends to obtain a skin thereon during conventional cooking, including pork, beef, and poultry. The process of preparing the meat product without a skin formed thereon comprises the steps of placing a meat product into a steam cooker, circulating steam witiiin die steam cooker to heat die meat product, and creating an atmospheric humidity of 100% witiiin die steam cooker.

Once placed witiiin die steam cooker, die meat product is exposed to steam, which adds heat to the meat product in order to cook such

product. The steam cooker may be a conventional steam pressure cooker, in which a single meat product, such as a ham, may be placed tiierein and may be used in d e consumer's home. Alternatively, die steam cooker may include a large-scale cooking chamber wherein a plurality of meat products may be placed, such as a smoke house. An air-tight chamber is formed witiiin die steam cooker, so that die atmospheric environment within d e chamber may be controlled.

The amount of steam which is introduced into die chamber is regulated to maintain d e level of atmospheric humidity within die chamber at 100%. In addition to providing a humid environment within die chamber, me steam is also used to cook die meat product by serving as a heat transfer media to heat die meat product. As the temperature of d e meat product rises, some of the juice witiiin die meat product is purged to die surface. The juice, comprising water, animal protein, and salt, builds up on d e surface during cooking and runs off of die meat product taking die salt and protein with it. The water present in die juice cannot evaporate and thus leave die protein and salt behind, because d e steam environment of 100% humidity will not permit water to evaporate witiiin the steam cooker. Unlike previous cooking methods where water is evaporated from the juices leaving a residual of protein and salt behind to form a crust-like skin about the meat product, die meat product formed in accordance witii the present invention does not leave me protein and salt behind to be cooked and thus forms a skinless meat product. Therefore, cooking die meat product in atmospheric humidity of 100% ensures that a skin will not develop on die surface of die meat product.

When exposing the meat product within the steam cooker to die high temperatures associated witii steam, namely 212° F, the outer surface of

die meat product tends to cook quicker than the inner portion of die meat product. In order to ensure that die inner portion of die meat product is adequately cooked, d e outer surface of die meat product is often overcooked. Therefore, die process of cooking die meat product of die present invention may further include the step of placing d e meat product into a reduced pressure steam cooker, wherein the meat product is subjected to a low temperature steam. Through lowering the pressure witiiin die steam cooker, it is possible to obtain a steam having a lower temperature. Subjecting the meat product to a low temperature steam ensures that die meat product is more evenly cooked from its inner portion to its outer surface. This results in a higher quality meat product which is not cooked to different degrees witiiin die meat product.

The pressure may be reduced witiiin die steam cooker to regulate die temperature therein within a range from 160° F to 180° F. The pressure within d e steam cooker is adjusted to provide d e adequate cooking temperature for die particular meat product being cooked. For instance, a low temperature steam of 165° F is die optimal temperature when cooking a boneless ham. Depending upon the texture and thickness of d e meat product being cooked, the temperature of the steam can be adjusted accordingly.

Another step in die process of preparing die skinless meat product may include the addition of a flavoring ingredient to die water which is used for generating die steam. Thereupon, the flavoring ingredient will be carried by die steam in d e steam cooker, such that, as d e steam is heating die meat product, die flavoring ingredient will be disseminated tiiroughout die steam and absorbed by die meat product. Therefore, die meat product can be flavored as it is being cooked. Any flavoring ingredient which may

suitably be added to die water and carried by die steam may be used, such as liquid smoke, garlic, or onion flavoring.

In die instances when it is desirous to have a small amount of skin on the meat product, such as witii hotdogs and the like, a further step may be added to die cooking process which creates a slight skin on die meat product. A small amount of skin could be formed by stopping the steam supply and reducing die internal pressure witiiin die chamber after the meat product is fully cooked, in order to cause the water contained in die juice on die surface of die meat product to boil off leaving a protein and salt residual behind. Therefore, after die meat product is cooked in an atmospheric humidity of 100% until it is fully cooked, die pressure witiiin d e chamber is reduced which, in turn, reduces die boiling temperature of water witiiin the chamber. As the boiling temperature drops witiiin die chamber, me water present in the juice of the meat product is now capable of evaporating.

The pressure in die steam cooker could be reduced to produce a slight skin on the meat product through d e use of vacuum pump. The introduction of a cold surface into d e cooking chamber would also reduce die pressure tiierein. The cold surface could comprise a pipe coil extending through the cooking chamber, wherein cold water or a refrigerant is circulated through die pipe coil when a reduction in pressure is desired. The cold surface would cause die steam within the cooking chamber to condense and thereby reduce the pressure, resulting in the water on the surface of die meat product boiling off. Alternatively, a spray of cold water into die cooking chamber would also achieve a similar result to die addition of a cold surface herein described.

While d e above embodiments for reducing die pressure witiiin die cooking chamber are described above, it is understood that any method of reducing die pressure within die cooking chamber would suffice in allowing die moisture from the meat product to evaporate. Referring to Figure 1 , the apparatus of die present invention will now be set forth. The meat product may be positioned witiiin steam cooker 2 onto a cooking rack 4. The cooking rack 4 is supported on its ends by protrusions 6 extending from die inner walls 8 of cooking chamber 10. When it is desirous to cook a plurality of meat products witiiin cooking chamber 10, a series of cooking racks 4 may be positioned witiiin die cooking chamber 10, while being spaced apart from each other a distance at least equivalent to die size of die meat product being cooked. In an alternative arrangement, die meat product could be hung witiiin cooking chamber 10, such as by a hook or die like or placed on carts and manipulated witiiin a large smoke house or oven.

The steam used for transferring heat to die meat product is generated by heating die water 12 witiiin cooking chamber 10 to its boiling point. The water 12 is introduced into the cooking chamber 10 through a valve 14, which connects the inner cooking chamber 10 to a source of water. The steam used for cooking may alternatively be generated outside of die cooking chamber 10 and introduced into die cooking chamber 10 through valve 14. The amount of steam to be generated or introduced into cooking chamber 10 is controlled by tiiermostat 16 which determines die temperature within cooking chamber 10. A vacuum pump 18 is provided for selectively removing air from witiiin cooking chamber 10 and reducing die pressure tiierein. Reducing die pressure witiiin die cooking chamber 10 tiius reduces die temperature

of the steam and eliminates overcooking which causes die meat product to become tough. The ideal temperature for cooking beef is approximately 155° Fahrenheit while the ideal temperature for chicken and pork is approximately 170° Fahrenheit. Consequently it is desirable to maintain die cooking temperature witiiin the cooking chamber 10 in the range of 150° to 180° Fahrenheit. This can be accomplished by controlling the pressure witiiin the cooking chamber 10.

The vacuum pump 18 may also be utilized for instantaneously reducing die internal pressure within die cooking chamber 10 enough to cause d e water on die surface of the meat product to boil off leaving a skin behind. The small amount of skin is formed by stopping die steam supply and reducing die internal pressure within die chamber using vacuum pump 18 after the meat product is cooked. This results in die lowering die boiling temperature witiiin cooking chamber 10 to below die boiling temperature of water on die surface of the meat product. Thus, die water contained in die juice on the surface of d e meat product will boil off leaving a protein and salt residual behind.

Referring now to Figure 2, an alternative embodiment of the present invention is illustrated, wherein a piping tube 20 is positioned witiiin cooking chamber 10 in order to reduce die pressure therein. The piping tube 20 has a refrigerant, such as freon or cold water, circulated tiieretiirough by a circulating pump 22. When die refrigerant or cold water is circulated through piping tube 20, a cold surface witiiin die cooking chamber 10 is created which causes d e steam witiiin die cooking chamber 10 to condense, tiiereby reducing die pressure within the cooking chamber 10. When the supply of steam into cooking chamber 10 has ceased and die refrigerant is introduced into piping tube 20, the further reduction in

pressure will result in a drop in die boiling temperature causing die moisture to boil off the surface of d e meat product which then forms a skin thereon. Therefore, piping tube 20 may used to achieve d e same result as vacuum pump 18 in controlling the pressure within die cooking chamber 10.

Referring now to Figure 3, the pressure witiiin cooking chamber 10 may also be instantaneously reduced by a spray of cold water into d e chamber through injection valve 24. Towards die end of die cooking cycle for die meat product, die cold water spray is introduced into die cooking chamber which causes die steam to condense. Thus, die boiling temperature witiiin die cooking chamber 10 will fall and die moisture on die surface of die meat product will boil off leaving die protein and salt residue behind.

As can be seen from the foregoing, a meat product prepared in accordance witii die present invention will provide a product which is cooked without forming a skin about an outer periphery tiiereof. Moreover, by regulating die pressure witiiin die steam cooking chamber, die temperature of die steam in die cooking chamber may be controlled which, in turn, allows die amount of water evaporation from the surface of die meat product to be controlled, tiius allowing die formation of a skin on me surface of die meat product to be regulated to its desired level.

While die present invention has been described witii reference to die preferred embodiment, it will be appreciated by tiiose skilled in die art that the invention may be practiced otherwise tiien as specifically described herein witiiout departing from the spirit and scope of die invention. It is, dierefore, to be understood that die spirit and scope of die invention be limited only by die appended claims.