INTRODUCTIONChicken nugget is a chicken product made from either meat slurry or chicken breast cut to shape, breaded or battered. Then deep fried or baked. Fast food restaurant typically fry their nugget in vegetable oil such as coconut oil or palm oil. Inventor of the chicken nugget come from Cornell University professor Robert C. Baker who died in 2006 and the one who proposed a prototype frozen breaded chicken stick in 1963 (McKenna 2012). The invention come in mind of him when he try to help his parents who own a poultry farm. For years chicken were sold as a whole compared to pork and beef, making it inconvenient and inefficient. While he work at Cornell he come up with many processed chicken food such as chicken sausage, chicken patties chicken bologna, chicken hot dog including chicken nugget. More important than the product themselves was what Baker developed to create those product, a method that processed chicken, which allow the meat to be shaped in any way possible.Rumours saying that the popular chicken McNugget from McDonalds which made from processed living chick made people hold themselves away from chicken nugget after that, they have image in their mind saying that all chicken nugget are made through cruel process, till it makes McDonalds itself have to make a video inside their production company to enlighten people what exactly happening in the factory. Also, the fact that nowadays most of chicken nugget we have in restaurant or cold store are not totally chicken meat, only 40% to 50% of a piece of chicken nugget are made from muscle tissue, the rest made from fat, bones, blood vessel and cartilage. (Daily Mail Reporter, 2013).All those bad image on regular chicken nugget are the reason why I want to make a chicken nugget which is healthy and made from more than 50% muscle tissue from chicken. Nowadays people becomes aware of what they eat and consume every day, because they know that everything that get through their mouth eventually will become what they are and effect their health and wellbeing. Especially children, they love chicken nugget because of it taste, softness and also its small portion size which easy to hold for them who have small hand. They do not know what they eat, is it healthy for them or not so their health responsibilities goes to their parents, eating those chicken nugget might get their children obese as eating behavior is one of the factors. The number of obesity increases every year. The percentage of children aged 611 years in the United States who were obese increased from 7% in 1980 to nearly 18% in 2012. Similarly, the percentage of adolescents aged 1219 years who were obese increased from 5% to nearly 21% over the same periodFLOW CHART OF VEGETABLE STUFFED CHICKEN NUGGET PRODUCTIONRaw material (vegetable)

Raw material (chicken breast/fat)Sorting/Grading

Washing/Peeling/ Cutting

Grinder

BlenderBlanching

MixerDrying

Former

Mixer (Batter)

Mixer (Tempura)

Fryer

Freezer

Packaging

EXPLANATION ON UNIT OPERATION INVOLVED IN VEGETABLE STUFFED CHICKEN NUGGETRaw material (vegetable) The vegetable selected will be consist of three different vegetable such as green peas, corn, carrot, cauliflower, long bean and broccoli Those vegetables will be coming from selected farm and chemicals free either from fertiliser nor pesticide. A mixture of four vegetables in which none of the vegetables is less than 8 percent by weight nor more than 35 percent by weight of all the frozen mixed vegetables are selected. Freezing is often considered the simplest and most natural way of preservation for vegetables (Cano, 1996). Frozen vegetables and potatoes form a significant proportion of the market in terms of frozen food consumption (Mallett, 1993). The quality of frozen vegetables depends on the quality of fresh products, since freezing does not improve product quality. Pre-process handling, from the time vegetables are picked until ready to eat, is one of the major concerns in quality retention. The choice of the right cultivar and maturity before the crop is harvested are the two most important factors that affecting raw material quality of the vegetables. Raw material characteristics are usually related to the vegetable cultivar, crop production, crop maturity, harvesting practices, crop storage, transport, and factory reception. The choice of crop cultivars is mostly based on their suitability for frozen preservation in terms of factory yield and product quality (Cano, 1996). Besides practices in the field and factors during growth of crop can also have a significant effect on quality of harvesting vegetables. Those practices include site selection for growth, nutrition of crop, and use of agricultural chemicals to control pests or diseases. The maturity assessment for harvesting is one of the most difficult parts of the production. In addition to conventional methods, new instruments and tests have been developed to predict the maturity of crops that help determining the optimum harvest time, although the maturity assessment differs according to crop variety (Hui et al., 2004).

Sorting/ Grading Performed prior to sizing and grading. This step involves the removal of over mature, too small, severely damaged, deformed or rotting vegetables. This is very important operation unit where it sorting the produce in grades or in categories of its quality. Very small vegetable is usually mechanically removed by mesh screens, pre-sizing belts or chains, desired product will be left behind or maybe past through the indicator. Bruised, rotted, off-shaped units, wilted or yellow leaves are usually removed by hand. Besides for vegetable where water dipping is possible, differential floatation could be used to separate rejects. In addition to this, detergents and brushes can be used to remove soil, latex, insects, pesticides etc. After that those cleaned vegetables should be dried using air dryer. Those rejected vegetables could be disposed as animal feed, sanitary fillings or organic soil amendments.

NEPRO Automatic Food Grading Machine

Washing/ Peeling/ Cutting Washing is normally carried out in basins with recirculating water, or simply with still water that is continuously replaced. Washing consists of eliminating the dirt sticking to the material before it enters the processing line, thus avoiding complications deriving from the possible contamination of the raw material. The washing must be performed using clean water and if necessary should be made potable by adding sodium hypochlorite, 10 ml of 10% solution for every 100 litres of water.

SORMAC vegetable washer type GWM

Peeling is performed on a regular basis. It consists of the removal of the skin of vegetable. It performed by using physical devices like knives or similar instruments, by using heat or chemical methods. Such methods basically aiming to bring about the decomposition of the walls of the external cells of the skin, so that the skin is removed as a result of the tissue's loss of integrity. Peeling is a unit operation that allows for a better presentation of the product, and at the same time enhance sensory quality especially for the material with a firmer and rougher texture is eliminated. Moreover, the skin will presents a colour that will be affected by the thermal processes normally used in processing methods.SORMAC Knife Peeler KP60

Cutting is an operation that makes it possible to achieve different objectives, like an even penetration of heat in thermal processes, uniform drying and make it easier to be mixed with the grinded chicken meat. In the specific case of drying, cutting enhances the surface/volume ratio, which increases the efficiency of the process. When performing the cutting operation, special care must be taken, the cutting tools or devices must produce clean and clear. In other words, they must not cause excessive damage to the tissue, to avoid detrimental effects like a change in colour, and subsequently a change in the product's flavour. Moreover, the cutting must be performed in such a way as to allow for a viable industrial performance. Urschel DiversaCut 2110 Dicer

Blanching and Drying Exposure of the vegetables to boiling water or steam for a brief period of time to inactivate enzymes. Practically every vegetable needs to be blanched and promptly cooled prior to freezing, since heating slows or stops the enzyme action, which causes vegetables to grow and mature. After maturation, enzymes can cause loss in quality, flavour, colour, texture, and nutrients. If vegetables are not heated sufficiently, the enzymes will continue to be active during frozen storage and may cause the vegetables to toughen or develop off-flavours and colours. Blanching also causes wilting or softening of vegetables, making them easier to pack. It destroys some bacteria and helps remove any surface dirt (Desrosier and Tressler, 1977). Blanching in hot water at 70 to 105 C has been associated with the destruction of enzyme activity. Blanching is usually carried out between 75 and 95 C for 1 to 10 minutes, depending on the size of individual vegetable pieces (Holdsworth, 1983). Blanched vegetables should be promptly cooled down to control and minimize the degradation of soluble and heat-labile nutrients (Deitrich et al., 1977). Best to use steam rather than hot water in the blanching process, mainly to avoid the loss of soluble solids, like water-soluble vitamins, which occurs when hot water is used. Right after the blanching process over, the vegetable needed to be dry and let the water drip on a conveyerVapor-Flow Rotary Steam Blancher

Raw Material (Chicken meat) Meat can be defined as the muscle tissue of slaughter animals 80% of the chicken nugget will be consist of muscle tissue and the rest is fat as it will increase the palatability of the chicken nuggets. The part of chicken meat that will be selected in the process is GRADE 1 deboned breast meat which consist of breast and chicken filet and also tight meat. Chicken meat will be supplied by selected slaughterhouse and farm which it hygiene and sanitation practice were applied in the process and the chicken free from disease

Grinding In this unit we try to grind those chicken meat into small coarse particle meat for further processing A meat grinder is a machine used to force meat or meat trimmings by means of a feeding worm (auger) under pressure through a horizontally mounted cylinder (barrel). At the end of the barrel there is a cutting system consisting of star-shaped knives rotating with the feeding worm and stationary perforated discs (grinding plates). The perforations of the grinding plates normally range from 1 to 13mm. The meat is compressed by the rotating feeding auger, pushed through the cutting system and extrudes through the holes in the grinding plates after being cut by the revolving star knives. Simple equipment has only one star knife and grinder plate, but normally a series of plates and rotary knives is used. The degree of mincing is determined by the size of the holes in the last grinding plate. PSS RM 3000 Meat Grinder

Blender Blender or mixer are used to blend meat and spices, or coarse and finely chopped meat. For the production of Vegetable Stuffed Chicken Nugget, a general blender machine will be use. Generally consists of a rectangular or round bottom vessel through which two parallel shafts operate. Various paddles are mounted on those shafts to mix the meat. The mixer is discharged through tilting by 90 degrees. Some blender are designed as vacuum blender, as the blending under vacuum (exclusion of oxygen) has advantages for the development of desirable product colour and texture. Material will be added into the blender during this process is granulated garlic, salt, black pepper and also binder. Phosphates, described in the previous section, act as binding agents by forming a sticky layer of swollen protein on the surface of a fillet. Many other substances, including natural and synthetic gums, have been proposed as binders. The most used are salts of alginic acid, especially the sodium, potassium and propylene glycol salts. Blending process will be taking over 15 minutes till the mixture become even.

Meat Mixers AP300/AP500 Large-Scale Production

Mixing (Vegetables & Blended chicken meat) After the grounded chicken meat done under blending process with other ingredient, mixing process take place including dried vegetables from the left hand side process. The mixing cannot be done for a very long period of time because it will cause excessive damage to the vegetable tissue added into the mixture. The optimum time for mixing is 5 minutes The paddle used in the mixing also have to be taken into consideration

Forming There are various type of forming or moulding machine. There are type where the product is loaded into a self-feeding hopper then it is forced into the forming plates by means of a piston. When they have been filled, the plates are moved forward to the knock-out position and the contents are deposited onto the out feed conveyor. There also type where all the mixture are in a kind of roller and the meat will be press from inside-out through a mould onto a conveyor shaped like the ball, the boots, the bells and the bowtie.

Mixer (Batter) Battering consist of dipping the meat pieces in a semi-liquid mixture of oil, eggs, water and spices. Battering also done as a way for the breading become efficient and easy. Moulded chicken nugget which on a conveyer gut under a light batter machine make the semi-liquid batter evenly covered on a surface of the nugget ready for breading.

Mixer (Tempura) Coating with flour, fat/flour mixes and/or breadcrumb The tempura machine must be able to handle high viscosity of tempura batter Take place by applying tempura over the nugget on a conveyor There is also another type of method to apply tempura such as the nugget will pass onto a conveyer covered in tempura breading then it also will be covered with tempura falling from top

Marel Townsend Tempura Applicator

Fryer The reason we applying heat treatment after chicken nugget done processed is for the enhancement of desirable texture, flavour and colour, in order to make meat products more palatable and appetizing for consumption. Also for the reduction of microbial content thus achieving the necessary preservation effect for an extended shelf life of the product and also for the food safety effect by eliminating potential food poisoning agents. The heating parameters to be applied in meat processing can vary considerably in temperature and time depending on the type of product. Heat treatment methods cause various physical-chemical alterations in meat, which result in the beneficial sensory and hygienic effects on the processed products. Most processed meat products are heat treated during manufacture and cooled down in a next step, as they undergo shorter or longer cold storage periods for distribution and sales. Also heat treatment is applied to stabilize the coatings on the meat surface. This short heat treatment in hot fat/oil (approx. +175C) as part of the processing must be seen as a pre-treatment only and does not cook the product. The final heat treatment is carried out by the consumer right before eating. Vegetable Stuffed Chicken Nugget fall under fresh processed meat product. Generally these products are meat mixes composed of comminute muscle meat with varying quantities of animal fat. Products are salted only, curing is not practiced. Non-meat ingredients are added in smaller quantities for improvement of flavour and binding.

Freezer Chicken meat is a highly perishable products and soon becomes unfit to eat and possibly dangerous to health through microbial growth, chemical change and breakdown by endogenous enzymes even though it already passed through the pre-heat treatment process. Freezing must be used to minimize any physical, biochemical and microbiological changes affecting quality in storage. During freezing most of the water content of the meat, about 80 percent, solidifies into pure ice crystals, accompanied by a separation of dissolved solids. A product can be considered frozen when its centre has a temperature of -12C or less. To reach this temperature the product passes through the temperature range of maximum crystallization (from -1 to -5C). The speed of freezing is a very important factor as frozen meat quality depends mainly on the size of the ice crystal formed: the lower the speed of freezing the larger the size of the crystals. Freezing commercially done at -29C and domestically at -18C. Those temperature is now a standard method of preserving for periods of 1-2 years. Recommended freezer is cryogenic freezer. Cryogenic freezing is a relatively new method of freezing in which the food is exposed to an atmosphere below -60 C through direct contact with liquefied gases such as nitrogen or carbon dioxide (Hung and Kim, 1996). This type of system differs from other freezing systems since it is not connected to a refrigeration plant; the refrigerants used are liquefied in large industrial installations and shipped to the food-freezing factory in pressure vessels. Thus, the small size and mobility of cryogenic freezers allow for flexibility in design and efficiency of the freezing application. Low initial investment and rather high operating costs are typical for cryogenic freezers (Persson and Lohndal, 1993).

CRYOLINE MT Cryogenic Tunnel Freezer

Packaging The basic purpose of packaging is to protect meat and meat products from undesirable impacts on quality including microbiological and physio-chemical alterations. Packaging protects foodstuffs during processing, storage and distribution from contamination by dirt, by micro-organism, by parasite, by toxic substances, influences that affecting colour, smell and taste and also loss or uptake of moisture. A range of synthetic materials suitable for meat packaging are available mainly in the form of plastic films or foils. Packaging must be flexible, mechanical strength, light weight, odourless, hygienic, easy recycling, resistance to oil and fats, good barrier against gases, sealing capability and low-cost. Plastics of interest for cold storage are: polyamide (PA) polyethylene (PE) polyester (polyterephthalic acid ester) (PET/PETP) polyvinylchloride (PVC) polyvinyliden chloride (PVDC)

OTHER HEALTHY PREFERRED NUGGET PRODUCT

TVP (Textured Vegetable Protein) or TSP (Textured Soy Protein) Traditional route of utilization of soybean Extraction with water as in the production of soymilk. Precipitation from water extracts as in the preparation of soybean curd (tofu) Fermentation processes as in the elaboration of soybean paste (miso), soysauce (sho-yu) , tempeh, fermented soybean curd (su-fu) For those who is totally vegetarian they can always go for this TVP Applied to soy protein products, the terms "texturization or texturing" mean the development of a physical structure which will provide, when eaten, a sensation of eating meat. Meat "texture" is a complex concept comprising visual aspect (visible fibres), chewiness, elasticity, tenderness and juiciness. The principal physical elements of meat which create the texture complex are: the muscle fibres and the connective tissue. Defatted soy flour with a high protein solubility index is first conditioned with live steam, before entering the extruder proper. Well controlled conditioning is essential for good texturization and product uniformity. The moisture content of the feed is very important. A moisture level of about 20-25% is used for texturization. The conditioned flour usually assumes the form of small spheres. The flour-water mixture is next fed into the extruder and picked up by the screw. As it advances along the barrel, it is rapidly heated by the action of friction as well as the energy supplied by the heating elements around the barrel. The high pressures attained through the compression mechanism explained above permits heating to 150-180C. This rapid "pressure cooking" process transforms the mass into a thermoplastic "melt", hence the name of "thermoplastic extrusion" by which the process is also known. The directional shear forces causes some alignment of the high molecular weight component while the proteins undergo extensive heat denaturation. The sudden release of pressure causes instant evaporation of some of the water and "puffing". The result is a porous, laminar structure. Puffing and therefore porosity can be controlled by monitoring melt temperature at the die. If a dense product is desired, the melt is cooled at the final section of the barrel, just before entering the die.

Soya Nugget Extruder

The extrudate is cut continuously by a rotating knife as it emerges from the die. It may be dried and sold as a shelf-stable product, or it can be hydrated, flavoured, mixed with other ingredients, shaped and marketed, usually, as a frozen food. While texturizing the soy material, extrusion cooking also provides the heat treatment necessary to reduce the microbial load and to inactivate the trypsin inhibitor. It should be noted that, despite the high temperatures in the extruder, trypsin inhibitor inactivation may be incomplete, due to the relatively short processing time.

Chunks of extrusion texturized soy protein products and spun fibre based preparations are marketed as "imitation meat" or "meat analogs". The market for these products was, at first, limited to the relatively small sector of vegetarians. Recently there is a marked trend to reduce the consumption of red meat, associated with the demand for low-cholesterol foods. At the same time, the industry has been successful in developing more attractive meat analogs made from rehydrated textured soy proteins, alone or in combination with wheat gluten. These products are marketed as flavoured, fully prepared, frozen ready-to eat entres. The present marketing strategy for meat analogs is to present them to the public as new, high quality products, and not as inexpensive substitutes for meat. So far, this strategy seems to be successful. The market for these sophisticated (and by no means inexpensive) products is rapidly expanding.

REFERENCES1. McKenna, M. (2012). The Father of Chicken Nugget. Retrieved from http://www.slate.com/articles/life/food/2012/12/robert_c_baker_the_man_who_invented_chicken_nuggets.html2. Blitx, M. (2012) The Cornell Professor Who Gave Us the Chicken Nugget. Retrieved from http://www.todayifoundout.com/index.php/2014/08/cornell-professor-gave-us-chicken-nugget/ 3. Daily Mail Reporter. (2013). The average chicken nuggets is only HALF meat.. and the rest is fat, bone and nerve endings. Retrieved from http://www.dailymail.co.uk/news/article-2445440/Chicken-nuggets-study-reveals-half-meat.html#ixzz3LCtNgcQl4. Ogden CL, Carroll MD, Kit BK, Flegal KM. Prevalence of childhood and adult obesity in the United States, 2011-2012. Journal of the American Medical Association 2014;311(8):806-814.5. Cano, M.P. 1996. Vegetables, Freezing Effects on Quality, Marcel Deccer, NY.6. Mallett, C.P. 1993. Frozen Food Technology. Chapman and Hall, London, UK.7. Hui, Y.H., Ghanzala, S., Graham, D.E., Murrell, K.D. and Nip, W.K. 2004. Handbook of Vegetable Preservation and Processing. Marcel Dekker, Inc.8. Desrosier, N.W. and Tressler, D.K. 1977. Fundamentals of Food Freezing, AVI Publishing Co. Inc. Wesposrt CT.9. Holdsworth, S.D. 1983. The Preservation of Fruits and Vegetable Food Products, Macmillan Press, London, UK.10. Dietrich, W.C., Olson R. L., Nutting, M.D., Neumann, H.J., and Boggs, M. M. 1959. time-temperature tolerance of frozen food. XVIII. Effect of blanching conditions on color stability of frozen beans, Food Technology, 13:258.11. Hung, Y.C. and Kim, N.K. 1996. Fundamental aspects of freeze-cracking. Food Technol 50:59.12. Persson, P.O. and Lohndal, G. 1993. Freezing Technology, Frozen Food Technology (Mallett CP ed.), Chapman and Hall, London, UK.13. Campbell, M.F. (1981). Processing and Product Characteristics for Textured Soy Flours, Concentrates and Isolates. J. Amer. Oil Chem. Soc. 58: 33614. Gutcho, M.H. (1977). "Textured Protein Processing" Noyes Data Corp. Pea Ridge, N.J.15. Berk, Z. (1992) FAO AGRICULTURAL SERVICES BULLETIN No. 97. Technology Of Production Of Edible Flours And Protein Products From Soybeans. Retrieved from http://www.fao.org/docrep/t0532E/t0532e00.htm#con16. Heinz, G. & Hautzinger, P. (2007). FOOD AND AGRICULTURE ORGANIZATION OF THE UNITED NATIONS. Meat Processing Technology For Small-To Medium-Scale Producers. Retrieved from http://www.fao.org/docrep/010/ai407e/AI407E00.htm#Contents 17. Barbosa-Cnovas, G. V. Altunakar, B. & Meja-Lorio, D. J. (2005) FOOD AND AGRICULTURE ORGANIZATION OF THE UNITED NATIONS. Freezing of Fruits and Vegetables. Retrieved from http://www.fao.org/docrep/008/y5979e/y5979e00.htm#Contents18. 20