Showing posts with label beetroot pumpkin burger. Show all posts
Showing posts with label beetroot pumpkin burger. Show all posts

Sunday, April 19

RL 150413 & 14: Gold Standard II and Finalising Gold Standard

What a week! Entering week 4 means we're only left three quarters of the semester, and I felt that I just warmed up!

Lesson 8: Whatever does not kill me, makes me stronger

Bad Monday, our group was assigned to collect ingredients. So we're the earliest to reach while the rest arrived later when we're off to collect ingredients. The moment when we re-enter the R&D kitchen, everyone was looking gloomy. I was totally dumbfounded when we're suddenly "blamed" for not 'taking care' of the R&D kitchen. That instance, I really do feel the need to vent all my dissatisfaction, but I suppressed the anger. Now that a week has almost passed, I had done enough reflection to admit that we were at the wrong but still, I don't think we should be treated this way.

Okay, so the incident actually started two weeks ago when Eugene (yes, he's the class rep for FYP) received pictures showing how unorganised the R&D kitchen was, the ingredients were said to not labelled properly and were stored anyhow, and the pots and pans were scattered all over the place. Later on Monday I found out those ingredients have been confiscated. To be frank, I was really unhappy because we were the first group to transfer our ingredients nicely into containers and labelled and kept under our cabinet, more so, I was the one who took the initiative to sort out onions and garlic from the rotten ones and transferred them into clean plastic bags. It just felt like all the work I've done have been put into waste. All the while, we've been carefully following rules, but somehow, the rules were never clearly instructed, how are we supposed to know what to do? Case in point, the flour that is still in the original package. I agree it's our fault not labelling it, but no one has ever told us to transfer it into a new container, even so, there's also no enough containers to keep that much flour. In the end, flour was confiscated. I could ramble on and on but no point crying over spilt milk now. I just sincerely hope for a black and white from the management, clearly stating the SOP of everything in the kitchen, from stock management to equipment usage to code of ethics, etc. Better still conduct a briefing on the do's and don'ts in the kitchen like what they are doing with the science labs. This is to protect both parties, keep us students informed and so we could not argue when the management is performing their authority. 

Fine, enough of complaints. Let's move on to what we did on Monday. We had a sensory test on our patty, bun and sauce to figure out which version had the best sensory acceptance so we could move on assembling and do another sensory test on Tuesday. 

Carrot buns

We did three versions of carrot buns: Bc45 with 45% carrot; Bc70 with 70% carrot; and Bc90 with 90% carrot. As the amount of carrots increased, the texture of the dough became lumpier and thus the buns became softer. Result of sensory test suggested that Bc90 was the spongiest of all, but some found it too soft and could hardly hold its shape. Bc70 was the best among the three buns, as it held its shape while the texture was balanced between sponginess and chewiness. On an extra note was that the buns, despite having high content of carrot, did not taste carrot at all. It was a very welcoming result for us we do not need to find other means to mask the carrot taste. 

Left to right: Bc45; Bc70, Bc90

Patty  no, pictures.. oops

Patty was a tricky one. We did pureed patty, Pp, two kinds of jellied patties, Pj6.5 and Pj13 (with double gelatine), and a control. As we did not managed the time well, the patties were ready right before the sensory test. We didn't have time to properly cool it down, so by the time we cut, it left a hollow space in the patty as some of the filling leaked. As a result, the most accepted patty was Pp, whereby the beetroot and pumpkin puree provided moisture and flavour to the patty, at the same time, gave a variety in texture. We expected Pj13 to have a better acceptance than Pj6.5 but it turned out to be the worst as it was too watery and nothing was left in the patty. 

Sauce

As what we planned previous week, we reduced butter in our sauce (Se100) and compared with the one we got previous week (Se150). Turned out that Se100 is more acceptable as it is less buttery and more balanced. 

Monday ended up to be an exhausting day. We had to immediately analyse the sensory test result so that we could plan for the next day. As we prepared too many samples for the sensory test, it could be a burden for our sensory panels to taste so many different food. Hence, after finalising the sensory results, we decided to pick the best and compare with a control set for the sensory test on Tuesday. 
Top: Control (Sample B) - Bo, Po, So; bottom: Gold standard (Sample A)- Bc70, Pp, Se100 
The preparation on Tuesday went on pretty smoothly as we had already gone through once on Monday. We prepared everything on time, and this time, there were only two samples so the sensory test was done pretty quickly too. 
Gold standard vs control: size is almost similar
Gold standard vs control: bun was thinner in gold standard but patty was thicker.

The results came out as expected, most of the people preferred the gold standard with carrot bun and pureed vegetables filled patty, as it was more moist and flavourful. However, one thing that attracted our attention was that a few of them mentioned the patty looks scary and bloody. Kenley actually named it 'bloody red burger' LOL! what a spot on representation of BRB.. 

More people preferred (18/22) sample A (gold standard)

Sample A (gold standard) had better sensory quality than sample B (control), however it is quite comparable.
The overall comment on our second sensory test was much more welcoming than that on the first day, mainly because the flavours from the sauce, patty, and bun complemented each other and it was too monotonous when consumed separately. However, the patties were still a bit dry, so we are going to improve that on coming Monday. Surprisingly, no one commented on the vibrant colours on the buns and patty except it looked bloody. We treated it as a positive feedback as the colours were meant to attract children's attention. To solve the 'bloody' problem, we were planning to make the filling so solid so it wouldn't smear as much when it is cut. 

Tuesday was a much better day, and we managed to go back early. Yay! What I learnt was practice really does make perfect, and planning helps to keep us on track. Yeah, we're progressing steadily on track so hopefully we could continue doing so.

Looking forward to the next session!

Dong

Saturday, April 11

RL 150406 & 150407: Introduction to Food Product Development 2 & Gold Standard I

Wadup peeps! It's my final semester! but I dunwanna graduate *whines This semester started a bit late because of the RCA conference. We got back on a Tuesday in week 2, and went right back into campus the next day. Since FPD 2 falls on a Tuesday this semester, we only started class in week 3. That's why we are all in rocket mode now. We've got quite some progress to catch up!

Quick recap: our final year project is a School Health Meal Programme whereby we need to develop healthy kids meal through the usage of innovative and functional ingredients. During the last stage in FPD 1, we've came out with 2 beta concepts: Beetroot and Pumpkin burger, and spiral spring roll. We decided to go with Beetroot and pumpkin burger as the idea was more developed.

Lesson 7: Opportunity is for those who are prepared

Yes? No? Maybe? Argh, I don't think I'm ready yet! Not even a second for us to take a deep breath, we're expected to carry out our first trial of gold standard on our first official class. Great We had an introductory class on Monday whereby Dr. Chong briefed us of the structure of the module. 

So this semester, we will be going through 4 phases before we finally launch our product. The first three weeks are to develop a gold standard (GS), followed by 4 weeks of commercial prototype (CP) studies, before moving on to product packaging and marketing study. Along the development, physiochemical properties and storage studies will be carried out. It does look like we had little to do, but there's tonnes of hidden circumstances we have to take into account. So yeah, I better brace myself as it will be my last and toughest semester to go through. 

On Tuesday, we went straight into our first GS trial. Oh, and before I forget, each of us in the team plays a different role to keep our 'company' running. Ernie is the director, responsible for HR management and related stuff. We all agreed for Kenley to be the HACCP manager because he needs some responsibility to correct his messiness. =X I am the product manager whereby I need to plan for the production of both GS and CP, as well as monitoring the quality of our product. That left us with the marketing manager, which is also assigned to Kenley, cause we all know how 'outspoken' he could be. 

Anyway, back to the production on Tuesday, we had tonnes of things to decide. We had three components, the bun, the patty, and the sauce. For bun, we tried the one and only carrot bun (Bc) recipe found on the internet and compared with one without carrots (Bo) as control. Meanwhile, we made 4 versions of patty as we played around with the texture of the patty filling. We had an empty one as control (Po), one with chunk vegetables (Pc), one with pureed vegetables (Pp) and one in jelly (Pj) form. Finally, we also tried two different method to make the spicy honey lemon sauce, one by using thickening agent (corn starch) as the control (So), and the other by emulsification using butter (Se). 

Our production plan

Carrot bun

The carrot bun recipe we found turned out to be too lumpy for a bun, so we added more flour to it. To double check the new formulation works, we made another trial, thus leaving us with three batches of buns.
Left to right: Bo, Bc50 trial 1, Bc50 trial 2

Sensory result

  • Bo: Dense and chewy because of lesser moisture. Irregular shape because did not rest well after reshaping. 
  • Bc50 (1st): Texture was quite compact but soft. Better shape because the dough rested well. Flour was added at the end when the dough was formed to adjust the consistency, hence another trial was conducted to check the texture when all flour were added at the same time.
  • Bc50 (2nd): Texture was fluffier than the 1st Bc50 because a gluten network was formed more properly. Tasted a bit bland.

Next trial

  • To push the carrot content to the limit and determine the possible maximum level of carrot used while maintaining the palatability. 
  • To add some fried shallot to provide more aroma. 

Patty

Top to bottom: Pc, Pp, Pj.

Sensory result:

  • Po: Patty was a bit dry. Overwhelming taste of maggie seasoning, oregano and blackpepper.
  • Pc: Vegetables balanced the taste by a small degree. Beetroot chunk needed too much effort to chew. 
  • Pp: Consistent and easy to form patty. Layer was too thin, could not taste the vegetables. Red colour in the middle looked like uncooked meat.  
  • Pj: Flows out while hot. Best sensory attribute among all variations. Red colour in the middle looked like uncooked meat. 

Next trial

  • To improve on the taste of meat. 
  • To increase the thickness of vegetable filling.
  • To increase amount of gelatin for Pj and compare the sensory profile with the current Pj. 

Spicy Honey Lemon Sauce

Sensory result:

  • So: Cayene was too overpowering
  • Se: Reduced cayenne and added butter. Tasted more balanced and creamy but slightly too buttery. 

Next trial

To reduce amount of butter for Se by 33% and check on the flavour
Appearance of the assembled burger
Cross section of burgers. Top to bottom: Pc, Pp, Pj.

Conclusion

The trials took longer time than expected as we over estimated our capability. However, the outcome showed that we were on the right track as the product came out to be quite appealing. Still a lot of work to be done but so far I'm enjoying the process!.

Looking forward to the coming trial. 

Peace out, 
Dong