Agricultural scientist Robert Baker invented chicken nuggets at Cornell University in 1963. His intent was to find a home for the often unused sections of the bird by grinding them into a bite-sized mass and coating them in a breading that could withstand the rigors of frozen distribution followed by industrial frying. He was successful. Since, his process paved the way for all types of proteins to become crispy, crunchy finger foods.

The one thing most of these innovations have relied on is wheat flour breadcrumbs, a rather inexpensive industrial ingredient (compared to the protein cost). Unfortunately, the inclusion of wheat introduces an allergen to the protein. For the approximate 8.5% of the world’s population who have a gluten-related disorder such as celiac disease or gluten intolerance, that means they have to miss out on all the deliciousness, including the ongoing restaurant chain chicken sandwich wars.

US Foods, Rosemont, Ill., is one of a number of foodservice distributors making it possible to keep breaded foods in a gluten-avoidance diet. The company uses a rice and yellow corn flour blend seasoned with black pepper, garlic, onion, thyme, sage and celery seed to make its gluten-free breaded chicken breast filets and whole-muscle chicken breast chunks. They come par-fried and sold frozen and may be prepared in either a fryer or oven.

Recently, the company developed a crunchy coating made with amaranth, quinoa and chia seeds, which is blended with rice and navy bean flours. It made its debut on gluten-free breaded sole.

These are two very different gluten-free coatings. There’s a myriad of combinations formulators may explore for the breaded protein space.

Adding value to meat

Breadings and batters help food manufacturers add value to meat and poultry products by creating unique textures and flavors. They can assist with economics as well, since coatings increase finished product yield.

“They also act as a barrier to help retain moisture in meat or poultry during cooking, resulting in a juicier product,” said Conor Sullivan, senior technical services specialist for convenience foods, Cargill. “At the same time, brands can use breadings and batters to support flavor innovation, adding seasonings, spices and herbs to create spicy, bold profiles or ethnically inspired creations.”

Amr Shaheed, technical services and application development manager, Innophos, Cranbury, NJ, added, “Breadings and batters can extend shelf life by protecting against oxidation and contaminants, ensuring a uniform appearance and increasing product value. In addition to these benefits, coated meat and poultry products offer convenience as ready-to-cook options for consumers.”

The good news is that unlike commercial bread and baked goods, gluten is not a necessary component of breadings and batters. Wheat flour tends to be easier to work with, and again, quite economical, but the function of gluten is not required.

“Gluten is the protein found in wheat-based breads that promotes dough elasticity and gives bread a soft, chewy structure,” said Brenda Zavala-Livengood, senior marketing specialist, Kemin Food Technologies NA, Des Moines, Iowa. “This bread becomes the ‘starting point’ to making breadcrumbs, which ultimately impacts the texture the breading will have on a meat or poultry product. However, this doesn’t necessarily mean gluten is absolutely required. Gluten-free bread has increasingly seen more innovation in this space to make breadcrumbs that can still provide a pleasing texture without including the allergen. Additional ingredients may be needed to match gluten-free breading to the appearance and functionality of wheat-based options but will depend on the substrate it is being used on.”

Some of the more common gluten-free options for batters and breading are almond flour, chickpea flour, cornmeal, corn starch, rice flour and potato starch. Blends of these ingredients tend to work best.

“If formulators move from a wheat-flour-based batter or breading to a gluten-free formulation, they’ll need to watch for viscosity differences, as that will affect major parameters like pick up, cook time and texture,” said Sullivan. “They’ll also want to be on the lookout for any changes that might not meet a product’s quality specifications, such as differences in color, blistering or yield.”

In basic formulations, the goal is to replace wheat flour with a flour that provides a similar texture, processing and eating experience. It should be comparable to the traditional product.

Formulators can use other gluten-free ingredients such as cornstarch or xanthan gum to help with viscosity, cling, binding and crispiness characteristics. Added water levels may require adjustments, too.

“Working with gluten-free breadings and batters on meat and poultry presents challenges such as achieving a cohesive texture, managing moisture levels and ensuring proper adhesion,” said Shaheed. “These coatings can be prone to dryness, have variable flavor profiles, and may require specialized handling and processing techniques.”

Shaheed suggests using phosphate in the batter or breading recipe to improve texture, adhesion and moisture retention of the final product. And, before the coating is applied, ensure that the protein’s surface is dry.

“A pre-dust can help improve the functional properties of coating systems and bring additional flavor,” said Sullivan. “It serves three primary functions: helping with adhesion of both breadings and batters, providing a film layer that helps prevent blow outs and serving as a flavor carrier.”

“Think of the pre-dust as the initial phase of the coating system,” Sullivan added. “It’s used to add ingredients like starches or flours, which help dry the surface of the substrate, thus allowing the batter to stick better, and subsequently, the breading. They also serve as the first film layer, helping keep moisture in the meat product. You’ll also see developers incorporate flavors and seasonings in the pre-dust, so they don’t get lost in the fryer.”

Whatever the coating system, Zavala-Livengood suggests adding an antioxidant to it to assist with shelf life. If there are mold concerns, an antimicrobial/anti-mold agent will help.

Next-generation options

One of the more interesting areas in this space is the use of high-protein, gluten-free ingredient systems to add nutrition with nominal carbohydrates in order to appeal to the growing number of carb avoiders. The ingredients that achieve this will likely be more expensive, but their inclusion will also command a higher price on menus or at retail.

“In a nod toward today’s health-conscious consumer, some brands are exploring the use of gluten-free ancient grains and flours in the breading and batter space,” said Sullivan. “Incorporating these trendy ingredients is one way to add more value to the end product and appeal to consumer desire for products they perceive as better-for-you.”

With “everything old being new again,” ancient grains are a growing go-to for gluten-free everything, including breadings and batters. While there is no official definition of what qualifies as an ancient grain, the Whole Grains Council describes ancient grains as those that have been largely unchanged since the beginning of time. This definition suggests modern varieties of corn, rice and wheat, which are products of years of selective breeding, are not ancient grains.

Most ancient grains are available individually as whole grain flours, as well as in whole grain multi-grain blends. Ancient grains can also be milled to desired granulations, or not milled at all.

Like all grains, ancient grains start out as whole grains. They remain whole grain ingredients, meaning they are the entire seed of a plant. This kernel contains three nutrient-dense components — the bran, germ and endosperm — and when ground into a granulated format such as flour, is defined as whole grain. Refining removes the bran and the germ, leaving only the endosperm. Without the bran and germ, about one-fourth of the protein is lost, as are many important nutrients, including fiber. These nutrients are present in ancient grains.

“Ancient grains cover a wide array of cereals (grasses) and pseudo cereals (non-grasses used the same way as grass-derived grains),” said Colleen Zammer, vice president of varietal solutions growth and innovation, Bay State Milling Co., Quincy, Mass. “Amaranth, buckwheat, millet, oat, quinoa, sorghum and teff are gluten-free ancient grains. They offer a range of flavors and textures that provide some excitement to consumers beyond the typical rice and corn typically found in gluten-free foods. They can be used as the base ingredients in the flour form, or inclusions and toppings in the whole grain form.”

Some categorize chia and flax as ancient grains because of their nutrient density and superfood status. They are, however, true seeds, albeit also gluten free.

These grains and seeds vary in nutrition and sensory profiles. Teff, for example, has been a staple of traditional Ethiopian cooking for thousands of years. It has a mild, nutty flavor and is a good source of iron, calcium, magnesium and zinc.

Quinoa varies from a mild flavored white quinoa to slightly nutty in earthy, darker shades. White quinoa is typically used in its intact whole seed form or as flour and flakes.

“White, red and black tri-colored quinoa may add texture and visual appeal as an inclusion in foods,” said Jessica Strouse, senior product marketing manager at Ardent Mills, Denver. “Quinoa is also a good source of fiber, iron, thiamine, riboflavin and an excellent source of folate.”

Buckwheat has a nutty and mildly earthy flavor. While wheat is in its name, it is wheat free.

“It has been described to have a slightly bitter, yet pleasant taste,” said Strouse. “Buckwheat is a good source of fiber, riboflavin and niacin.”

Sorghum is gaining traction in all types of applications due to its neutral flavor profile that pairs well with other flavors, both sweet and savory. Chicago-based ADM recently added sorghum flour to its ingredient portfolio. It is processed in the company’s verified net carbon-neutral mill in Dodge City, Kan. It is made from a special white variety of sorghum flour that has a light color and sweet, nutty flavor.

“Millet is a hardy grain, similar to sorghum,” said Paula LaBine, marketing director-milling and baking solutions at ADM. “It has a mild, corn-like flavor profile and is often used in multi-grain systems.”

Amaranth is grown all over the world, including the United States. It is a small, light-colored grain with a peppery, earthy flavor.

“It is rich in lysine, an essential amino acid that is often limited in other grains,” said Tarrand Fiesel, vice president of sales and marketing, DakotaMB, Fargo, ND. “Amaranth also has emulsifying properties that improve the stability and texture of food products.”

Vegetable flours are finding their way into breadings, with cauliflower leading the way. Highlighting their addition contributes to a better-for-you positioning.

Edible glitter and extrudates can add visual interest to products or can serve as visual cues for flavor notes. It is possible to color them with vegetable-based extracts and use them as substitutes for vegetable pieces that might not hold up during frying or baking.

Crespel & Deiters, Ibbenbüren, Germany, offers a number of extrudates that provide unique appearance and crunch. Native and modified starches ensure optimum adhesion and crispness in batters, tempura coatings and dustings. The gluten-free options are made with corn, rice or potato flours.