BAKED FRY PROCESS AND PRODUCT
A method of making a baked, non-fried, frozen potato product, suitable for final bake processing, which has at least the flavor, exterior crispness, and interior texture of a par-fried product, with lower fat content, without par-flying. The process, among other things, combines warm oil deluge and impingement oven baking.
1 . A process for preparing frozen potato pieces comprising,
cutting whole potatoes into pieces,
heating the pieces to remove moisture from the pieces,
contacting the pieces with oil heated to a temperature below the boiling point of water for a time sufficient to absorb oil onto and into the surface of the pieces,
partially baking the pieces,
and freezing the pieces.
2 . The process of claim 1 wherein the oil contact and baking is for a time at a temperature sufficient to achieve the flavor, exterior crispness, and interior texture of par-fried pieces of similar size and shape.
3 . The process of claim 1 wherein,
the pieces are strips, crinkle cuts, wedges, shoestrings, waffle fries, loops or twirls,or steak fries.
4 . The process of claim 1 wherein,
the heating is performed for a time at a temperature to remove about 5% to about 18% by weight moisture from the pieces.
5 . The process of claim 1 wherein,
the heating is performed at about 200° F. to about 400° F. for about 5 to about 20 minutes.
6 . The process of claim 1 wherein,
the oil is at a temperature of about 150° F. to about 211° F.
7 . The process of claim 6 wherein the pieces are contacted with the oil for about 10 seconds to about 60 seconds.
8 . The process of claim 7 wherein the contact is by immersion.
9 . The process of claim 7 wherein the contact is by spraying.
10 . The process of claim 1 wherein,
the baking is performed in an impingement oven.
11 . The process of claim 10 wherein the impingement oven is a hot air impingement oven.
12 . The process of claim 11 wherein the baking is at 350° F. to 550° F. for 1 to 8 minutes.
13 . The process of claim 1 including,
washing the whole potatoes prior to cutting,
blanching the potato pieces prior to heating,
treating the potato pieces with at least one coloring and/or flavoring agent prior to heating,
and removing surface oil from the potato strips prior to baking.
14 . The process of claim 13 wherein the potatoes are peeled before cutting.
15 . The process of claim 14 wherein the potatoes are steam peeled.
16 . The process of claim 14 wherein the peel is removed by scrubbing.
17 . The process of claim 13 wherein defects are removed from the potatoes before cutting.
18 . The process of claim 13 wherein the potatoes are pre-heated before cutting.
19 . The process of claim 18 wherein the pre-heating is performed at 130° F. to 145° F. for 20 to 45 minutes.
20 . The process of claim 1 wherein the cutting is performed mechanically.
21 . The process of claim 1 wherein the cutting is performed with a water knife.
22 . The process of claim 13 wherein the blanching is performed at 150° F. to 185° F. for 5 to 20 minutes.
23 . The process of claim 13 wherein the coloring and/or flavoring agents include at least one of annatto, dextrose, caramel, turmeric and/or paprika.
24 . The process of claim 23 wherein the coloring and/or flavoring agent treatment is performed at 150° F. to 170° F. for 10 to 60 seconds.
25 . The process of claim 1 wherein oil on the surface of the pieces is removed with hot forced air.
26 . The process of claim 1 wherein the freezing is performed in an individual quick frozen freezer, spiral freezer or freezing tunnel.
27 . The process of claim 1 wherein the frozen potato pieces are sorted by size.
28 . The process of claim 1 wherein the frozen potato pieces are treated with additional oil and/or seasoning.
29 . The process of claim 28 wherein the treatment is in a tumble drum.
30 . The frozen, cut potato pieces produced by the process of claim 1 .
31 . Partially baked, non-fried, frozen potato pieces, suitable for final bake processing, having at least the flavor, exterior crispness, and interior texture after baking of a par-fried product of similar size and shape, with lower fat content, without par-frying.
32 . The potato pieces of claim 31 , having a crinkle cut shape and having a fat content 0.5% to 3% less than equivalent par-fried crinkle cut pieces.
33 . The potato pieces of claim 31 wherein,
the oil is absorbed into the surface of the pieces to a depth of not more than 4 millimeters.