Method and device for producing shaped meat portions from whole natural meat pieces
A device for producing shaped meat portions, the device including a sorting device for sorting meat into a first set of pieces having a weight which is below a desired weight, a second set of pieces having a weight which corresponds to a desired weight, and a third set of pieces having a weight which is above a desired weight. The device further includes a cutting device which cuts each of the third set of pieces to a desired weight so that the cut pieces having a desired weight define a set of selected meat pieces. A transport device transports the set of selected meat pieces and a freezing facility through which the transport device conveys the set of selected meat pieces and which freezes the set of selected meat pieces. The device further including a shaping device which presses or presses and punches the frozen set of selected meat pieces in a mold and thus transforms the frozen set of selected meat pieces into a final shape or a plurality of final shapes, wherein the shaping device produces in a controlled manner meat portions having a predefined weight and a predefined three-dimensional shape.
1. A method for producing shaped meat portions, the method comprising the steps of sequentially:
introducing pieces of whole natural meat into a processing line;
determining respective weights of said introduced pieces;
combining a first set of those introduced pieces which do not reach said desired weight into a cluster of meat pieces that has said desired weight;
selecting a second set of those introduced pieces each having a weight which corresponds to said desired weight;
cutting down at least one piece of a third set of those introduced pieces having a weight which exceeds said desired weight such that the pieces of said third set each have said desired weight;
freezing said cluster of the first set of meat pieces, one piece of said second set of meat pieces having said desired weight, or one piece of said third set of meat pieces having cut down to said desired weight to form a frozen meat portion having said desired weight;
preshaping said frozen meat portion in a freezing mold such that it can be set in a cavity of a shaping device without extending past edges of the cavity;
deep freezing said preshaped frozen meat portion;
inserting said preshaped deep-frozen meat portin into the cavity of the shaping device; and
shaping by the shaping device in the shaping cavity by either pressing or punching said preshaped deep frozen meat portion in a controlled manner and under action of pressure so as to form a shaped deep-frozen meat portion having a three-dimensional shape like that of the shaping cavity; and
removing from said shaping cavity said shaped deep-frozen meat portion having a predefined weight and the predefined three-dimensional shape.
2. The method according to claim 1 , wherein said third set of those introduced pieces are sorted so as to cut therefrom as many whole multiples of said desired weight as possible, wherein said whole multiples of said desired weight have said freezing, preshaping, deep freezing, shaping and removing processes performed thereon.
3. The method according to claim 1 , wherein those ones of said third set of those introduced pieces having a weight such that at least when a foreseeable off cut of such a piece will again exceed said desired weight and thus a further meat piece can be produced therefrom, are divided in such a way that said meat portion and said off-cut come substantially to a shape of said shaping cavity.
4. The method according to claim 1 , wherein in the case of said third set of those introduced pieces and prior to said cutting, said preshaping comprises rolling said third set of those introduced pieces into a shallow mold.
5. The method according to claim 1 , wherein said preshaping comprises overlapping portions of one of said cluster of meat pieces, said second set of those introduced pieces having said desired weight or said third set of those introduced pieces having said desired weight within a mold prior to said freezing.
6. The method according to claim 1 , wherein said frozen meat portion is removed from said mold and then separated and supplied to a shaping device comprising a plurality of shaping cavities.
7. The method according to claim 1 , wherein said frozen meat portion is heated by a heating system or a warm water bath so as to improve removal of said frozen meat portion from said mold.
8. The method according to claim 1 , wherein said mold is one of a plurality of molds in a transport belt which supplies said meat to a freezing station.
9. The method according to claim 1 , wherein said shaping cavity is one of a plurality of shaping cavities, and said shaping comprises pressing and punching said frozen meat portion so as to form said shaped frozen meat portion.
10. The method according to claim 1 , wherein said removed shaped frozen meat portion is reshaped to a different thickness, wherein to this end said removed shaped frozen meat portion is cut in a targeted manner such that a different degree of deformation occurs in said shaping cavity.
11. The method according to claim 1 , wherein said shaped frozen meat portion is coated with breadcrumbs.