U.S. patent application number 10/414121 was filed with the patent office on 2003-10-30 for packaged cooked meat and low ph sauce having extended refrigerated shelf life.
Invention is credited to Brown, Keena, Cuccia, Jennifer, Painter, Cory J., Thrasher, Kent, Ticknor, Doris.
Application Number | 20030203079 10/414121 |
Document ID | / |
Family ID | 24564481 |
Filed Date | 2003-10-30 |
United States Patent
Application |
20030203079 |
Kind Code |
A1 |
Thrasher, Kent ; et
al. |
October 30, 2003 |
Packaged cooked meat and low pH sauce having extended refrigerated
shelf life
Abstract
Control of the texture of meat cuts is accomplished so as to
minimize the development of mealy, wet and soft texture of the meat
cut, particularly when used in combination with a sauce having a
relatively low pH of about 4.5 or below. The meat cuts are first
fully cooked and chilled and then inserted, together with a low pH
sauce, into a pouch and hermetically sealed within the pouch and
stored under refrigerated, non-frozen conditions for at least 60
days without deterioration.
Inventors: |
Thrasher, Kent; (Sun
Prairie, WI) ; Painter, Cory J.; (Cottage Grove,
WI) ; Brown, Keena; (Madison, WI) ; Ticknor,
Doris; (Fitchburg, WI) ; Cuccia, Jennifer;
(Waunakee, WI) |
Correspondence
Address: |
COOK, ALEX, MCFARRON, MANZO, CUMMINGS & MEHLER LTD
SUITE 2850
200 WEST ADAMS STREET
CHICAGO
IL
60606
US
|
Family ID: |
24564481 |
Appl. No.: |
10/414121 |
Filed: |
April 15, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10414121 |
Apr 15, 2003 |
|
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|
09639530 |
Aug 16, 2000 |
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6579549 |
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Current U.S.
Class: |
426/124 |
Current CPC
Class: |
A23L 13/72 20160801;
A23B 4/068 20130101; B65D 77/02 20130101; A23L 13/06 20160801; A23L
13/55 20160801 |
Class at
Publication: |
426/124 |
International
Class: |
A23B 004/00 |
Claims
1. A process for preparing a non-frozen packaged meat product
having an extended refrigerated shelf life, comprising: selecting
an uncooked meat cut having an outer surface; treating the uncooked
meat cut with a marinade containing an organic salt, a lactate salt
and a diacetate salt; searing a substantial portion of said outer
surface of the meat cut, and cooking the meat cut to provide a
cooked meat cut having an internal temperature of at least
155.degree. F. (68.degree. C.); cooling said cooked meat product to
below room temperature and without internally freezing the cooked
meat product; placing the thus cooled cooked meat product into a
pouch, and placing a low pH sauce into said pouch, said sauce
having a pH of less than about 4.5; sealing the pouch with the
cooked meat product and the low pH sauce therewithin to provide a
sealed pouch containing the cooked meat and low pH sauce; and
marketing said sealed pouch having a cooked meat and low pH sauce
in a refrigerated, non-frozen condition, said meat and sauce having
an extended refrigerated life.
2. The process in accordance with claim 1, wherein said placing
includes sauce having a pH of 4.2 or lower.
3. The process in accordance with claim 1, wherein said placing
includes sauce having a pH of 4.0 or lower.
4. The process in accordance with claim 1, wherein said placing
includes sauce having a pH of 3.8 or lower.
5. The process in accordance with claim 1, further including adding
a caramel composition to said outer surface of the meat cut before
completion of the cooking operation.
6. The process in accordance with claim 1, wherein said treating
with a marinade includes treating with a phosphate salt.
7. The process in accordance with claim 1, wherein said extended
refrigerated shelf life of said marketing is at least 60 days.
8. The process in accordance with claim 1, wherein said extended
refrigerated shelf life of said marketing is at least 90 days.
9. The process in accordance with claim 1, wherein said selecting
is of uncooked meat cuts having a length no less than one inch
(2.54 cm).
10. The process in accordance with claim 1, wherein said selecting
is of meat cuts of poultry whole muscle.
11. The process in accordance with claim 1, wherein said placing
includes sauce having a water activity of about 0.92 or below.
12. The process in accordance with claim 2, wherein said placing
includes sauce having a water activity of about 0.92 or below.
13. The process in accordance with claim 1, wherein said placing
includes sauce having a water activity of about 0.9 or below.
14. A process for preparing a non-frozen packaged meat product
having an extended refrigerated shelf life, comprising: selecting
an uncooked meat cut having an outer surface; treating the uncooked
meat cut with a marinade containing an organic salt, a lactate salt
and a diacetate salt; searing a substantial portion of said outer
surface of the meat cut, and cooking the meat cut to provide a
cooked meat cut having an internal temperature of at least
155.degree. F. (68.degree. C.); cooling said cooked meat product to
below room temperature and without internally freezing the cooked
meat product; placing the thus cooled cooked meat product into a
pouch, and placing a low pH sauce into said pouch, said sauce
having a pH of 4.5 or lower; sealing the pouch with the cooked meat
product and the low pH sauce therewithin to provide a sealed pouch
containing the cooked meat and low pH sauce; providing a tray sized
to accommodate said sealed pouch having the cooked meat and low pH
sauce, and inserting said sealed pouch into said tray; closing said
tray so as to seal said pouch therewithin to provide a packaged
cooked meat and sauce product; and marketing said packaged cooked
meat and sauce in a refrigerated, non-frozen condition, said
packaged food product having an extended refrigerate shelf
life.
15. The process in accordance with claim 14, further including
adding a sleeve over at least a portion of said packaged cooked
meat and sauce product to provide a sleeved packaged food product
as the packaged food product having an extended refrigerated shelf
life.
16. The process in accordance with claim 14, wherein said tray has
an internal volume which is sized in a manner to provide gas space
between said sealed pouch and said tray.
17. The process in accordance with claim 14, wherein said placing
includes sauce having a pH of 4.0 or lower.
18. The process in accordance with claim 14, further including
adding a caramel composition to said outer surface of the meat cut
before completion of the cooking operation.
19. The process in accordance with claim 14, wherein said extended
refrigerated shelf life of said marketing is at least 60 days.
20. The process in accordance with claim 14, wherein said selecting
is of uncooked meat cuts having a length no less than one inch
(2.54 cm).
21. The process in accordance with claim 14, wherein said selecting
is of meat cuts of poultry whole muscle.
22. A refrigerated packaged food product, comprising: a tray having
a bottom wall, an annular rim and a sidewall joining together said
bottom wall and said annular rim, said tray being made of a
material suitable for heating food therewithin by a microwave oven;
an indent within said annular rim of the tray; a lid removably
secured onto said annular rim of the tray and over said indent; a
releaseably sealed pouch positioned within said tray with said lid
secured onto said annual rim; a food product including cooked meat
and a sauce having a low pH prior to its combination with the
cooked meat, said food product being sealed within said pouch, said
food product being at an unfrozen, refrigerated temperature; free
space between said sealed pouch and said tray sealed with the lid;
and a sleeve position over said tray which has the lid sealed
thereonto.
23. The refrigerated packaged food product in accordance with claim
22, wherein said low pH sauce has a pH of not greater than about
4.5.
24. The refrigerated packaged food product in accordance with claim
22, wherein said low pH sauce has a pH of not greater than about
4.2.
25. The refrigerated packaged food product in accordance with claim
22, wherein said low pH sauce has a pH of not greater than about
4.0.
26. The refrigerated packaged food product in accordance with claim
22, wherein said cooked meat comprises a meat cut having a length
of at least about 1 inch (2.54 cm).
27. The refrigerated packaged food product in accordance with claim
22, wherein said cooked meat is a poultry whole muscle cut.
28. The refrigerated packaged food product in accordance with claim
22, wherein said low pH sauce has a water activity of about 0.92 or
below.
29. The refrigerated packaged food product in accordance with claim
22, wherein said low pH sauce includes an inorganic salt at between
about 2 and about 3 weight percent, based on the total weight of
the low pH sauce.
Description
BACKGROUND OF THE INVENTION
[0001] The invention generally relates to packaged precooked meat
which is able to be stored under refrigerated conditions for
extended time periods without developing a wet and soft texture,
off-flavors, or undesired microbial growth. More particularly, the
present invention relates to cooked meat cuts which are precooked
and sealed into a pouch together with a low-pH sauce to provide a
non-frozen packaged meat product having an extended refrigerated
shelf life.
[0002] Methods and processes for packaging meat products in order
to enhance their shelf stability are generally well-known. One
category of providing shelf-stable packaged meat-containing
products relies upon freezing those products with the objective of
maintaining important flavor qualities and controlling microbial
growth. Other approaches include packaging under aseptic conditions
in the form of canned or retorted products or by using other
technologies which tend to undesirably change the character of the
meat products. There is a tendency for such products to lose their
characteristic texture and to have their taste detrimentally
affected. In general, meat freezing is still a preferred approach
for long-term storage of meats and meat products. Freezing
generally preserves flavor attributes and texture during reasonably
long frozen storage periods.
[0003] In some instances, there is a desire to avoid frozen meat
products for a variety of reasons. One may wish to avoid the time
and inconvenience of having to proceed through a thawing operation.
This is especially important in marketing meat products which are
intended to exhibit a minimum of preparation time or to require
minimal advance planning to allow for adequate defrosting time.
Meat products which are marketed frozen can also give the
impression of having a less fresh quality when compared with meat
products which are available in a refrigerated, non-frozen
state.
[0004] Refrigerated, non-frozen meat products are widely
distributed in refrigerated food cases. Often, such products are in
the nature of butchershop products which are pre-cut or
pre-portioned and typically packaged in a simple manner suitable
for self-serve refrigerated meat cases. These types of refrigerated
meat cases are generally recognized as a fine source of so-called
fresh meat products. The refrigerated shelf life of meat products
marketed in this manner is necessarily relatively short and can
require special handling and maintenance.
[0005] At times, meat products within refrigerated, non-freezing
marketing display cabinets are of the pre-cooked variety. It has
been found that pre-cooked meat products can be especially
problematic in terms of maintaining flavor without developing
characteristic and often unacceptable off-flavors. Refrigerated,
non-frozen meat products likewise can be problematic in terms of
microbial growth control. This is the case for even cooked meat
products. In fact, cooked meat products are especially problematic
when it comes to avoiding the development of off-flavors when
stored under non-freezing refrigeration, even when that storage is
for a relatively short time, for as short as a few days or even
only several hours. Characteristic warmed-over flavors develop
which render precooked meat products undesirable, even after they
are heated during meal preparation.
[0006] Previous approaches recognize the importance of addressing
these general concerns and problems. For example, Brotsky U.S. Pat.
No. 4,788,070 describes meat emulsions including common salt and
other components, which are then shaped and cooked, with attention
being paid to low interior acid levels for meat products of this
general type. This patent indicates the importance of rapid
treatment of the meat particles in the emulsion, which are to be of
a size smaller than meat cubes of intact muscle. Tonner U.S. Pat.
No. 4,262,027 relates to ground meat with an acid source having a
slow release characteristic which will acidify after heating is
initiated. Bernatovicz U.S. Pat. No. 3,985,904 relates to ground
meat products having fillers. The use of citric acid in cooked
ground meat products is discussed.
[0007] Other approaches address meat cuts which are not necessarily
processed as ground products. Szczesniak U.S. Pat. No. 4,075,357
relates to intermediate moisture meats having a preservation system
including a common chloride salt with certain organic salts, while
recognizing that it can be useful to lower the pH of meats from the
near-neutral range of from 5.5 to 8.0 down to a pH of as low as 3.0
by the use of food grade acids. Anders U.S. Pat. No. 4,888,191
recognized that Clostridium botulinum can be addressed in fish and
poultry through the use of lactate salts, either alone or combined
with agents such as sodium chloride or sodium nitrite. Included are
turkey breasts injected with a brine solution, as well as the
lactate salt. Ruzek U.S. Pat. No. 5,780,085 describes treating
fresh pork cuts with a treatment solution having a lactate buffer
salt, a phosphate sequestrate, and a diacetate flavor enhancement
agent.
[0008] Although approaches such as these have been suggested,
satisfactory industrially prepared and packaged cooked meat cuts in
sauces have not been available in a form which achieves extended
shelf life attributes even when stored under refrigerated,
non-frozen conditions. Thus, there is a potentially important
category of food products which are convenient to distribute
industrially and market, while also requiring a minimum amount of
consumer preparation. This potentially important category relates
to meat products which are quick and easy to prepare, typically
being eaten after a brief heating period, such as by microwave
heating close in time to consumption. More particularly, this
category preferably includes precooked, uncured meat cuts. A
primary reason for the rarety of refrigerated, precooked and
uncured meat cuts being available to consumers through retail
markets is the sususptiblity of such meat components to decline in
meat quality during long-term refrigerated storage.
[0009] In this regard, meat quality decline can involve three
principal aspects. Microbial quality typically deteriorates under
refrigeration, especially under conditions at which the cooked cut
is neither frozen nor cured. Psychorotropic bacteria can multiply
during refrigerated storage and reduce acceptable shelf life of the
meat.
[0010] Another aspect of meat quality deterioration, which is of
particular concern when cooked and uncured meat products are
refrigerated, particularly above meat-freezing temperatures, is
flavor quality deterioration. Maintenance of acceptable flavor of
cooked, uncured meat is challenged by the rapid onset of
off-flavors, which can be known in the art as "warmed-over flavor"
(at times referred to herein as "WOF"). The development of these
types of off-flavors typically occurs within hours of cooking.
Consequently, consumer acceptability of precooked, uncured meat
products declines very rapidly with the length of storage time. It
is generally accepted that the WOF phenominum is caused by
autoxidation of meat lipids. WOF characteristics generally are
associated with the characteristics of oxidate we rancidity. At a
minium, unpleasant flavor notes develop in short order when
precooked meat cuts are wrapped and refrigerated.
[0011] A third meat quality deterioration can occur when providing
meat cuts which are flavored or which are otherwise treated with
relatively low pH compositions. It has been found that precooked
products within this general category can be faced with a problem
of excess tenderness or a mealy feel and appearance, thereby
providing a product which is not of a satisfactory texture
characteristic of a freshly cooked meat cut. It is believed that
this disagreeable characteristic is due to a reduction in the water
holding capacity of the cooked meat. This water holding capacity
reduction is believed to lead to water purge and resulting yield
loss, as well as the mealy and soft, tending toward slimy feel and
appearance of such packaged precooked meat cuts. It is generally
believed that cooking with a low pH sauce or component moves the
meat to near or at its isoelectric point. Meat pH reduction which
occurs prior to cooking reduces water holding capacity of the meat,
causes it to lose water and thus yield.
[0012] These detrimental microbial, flavor and texture
characteristics become more problematic during non-freezing
refrigerated storage for extended time periods. To provide
precooked meat products, particularly ones which are flavored, the
avoidance of texture degradation, oxidative rancidity, significant
bacterial count increases, and off-flavor development must be
avoided or substantially retarted so as to provide cooked meat
products or meat-containing products which are both safe and
acceptably flavored.
SUMMARY OF THE INVENTION
[0013] The present invention is directed to a refrigerated packaged
food product and process for preparing the food product. Meat cuts
are processed and packaged with a selection from a variety of
sauces and to provide precooked meat cuts in sauces in a form which
has an extended shelf life of months for meat cuts which exhibit
and maintain control of microbial growth and avoid mealy, wetter
and softer texture characteristics, while maintaining good flavor
attributes and retarding warmed over flavor development. Unfrozen
meat cuts are treated with a marinade, followed by cooking and
chilling. Thereafter, the cooked, uncured cuts are placed into a
pouch, together with a low pH sauce, which pouch is then sealed and
placed into a refrigerated, non-frozen environment. The product is
marketed and sold. In a preferred embodiment, the pouch containing
the food product is placed within a tray which is also sealed and
part of the refrigerated package.
[0014] It is accordingly a general object of the present invention
to preserve precooked meat cuts for long term refrigerated
storage.
[0015] Another aspect of the present invention is to provide
improved precooked and uncured meat products, processes for
preparing and using same, and kits incorporating same, which meat
products retard microbial growth, off-flavor development, and mealy
characteristics.
[0016] Another aspect of this invention is to provide refrigerated,
never frozen, precooked and uncured meat cuts in a form suitable
for sale to consumers through retail markets by imparting microbial
and flavor shelf-stability for lengths of time suitable for retail
markets and channels of trade and without causing water transfer
out of the meat, which would result in mealy, wet texture and yield
loss.
[0017] Another aspect of the present invention is to combine
formulation, processing and packaging features in preparing cooked
meat products having a shelf life of at least 60 days, the
formulation features including treatment with a marinade, and the
processing including full cooking prior to the addition of an
acidic sauce.
[0018] Another aspect of this invention is to provide non-frozen
whole muscle meat cuts or portions which, although unground,
maintain long-term shelf stability and flavor maintenance and
texture maintenance without subjecting same to freezing.
[0019] In another aspect of the invention, a marinade formulation
including a lactate, a phosphate, and a common salt treats an
unfrozen meat cut prior to searing, cooking and chilling, done
prior to the addition of any low pH sauce for contact with the
meat.
[0020] These and other objects, aspects, features and advantages of
the present invention will be apparent from and clearly understood
through a consideration of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] In the course of this description, reference will be made to
the attached drawings, wherein:
[0022] FIG. 1 is a top perspective view of packaged treated meat
cuts and sauce according to an embodiment of the invention;
[0023] FIG. 2 is a cross-sectional view along the line 2-2 of FIG.
1;
[0024] FIG. 3 is a top perspective view of the packaged product as
generally shown in FIG. 1, but with the over sleeve removed and the
tray opened;
[0025] FIG. 4 is a cross-sectional view along the line 4-4 of FIG.
3; and
[0026] FIG. 5 is an end view of the tray illustrated.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Originating meat cuts according to the invention are most
advantageously from poultry sources, including chicken, turkey and
other foul. White meat cuts are especially advantageous meat cut
sources. Examples include breast fillets, strips and portions,
including pre-severed strips and chunks. The invention finds
particularly useful application when the originating meat cuts have
length or width dimensions of at least one inch (2.54 cm).
[0028] When there is a desire to practice the invention with other
originating meat sources, such sources also can be suitable for
use. Other meats include pork, beef and lamb sources. The invention
currently has especially useful commercial application for poultry
originating meat cuts. This being the case, special emphasis is
placed herein on poultry cuts in general and chicken cuts in
particular.
[0029] Another important advantage of the invention is that the
meat cuts can originate from never frozen sources. Typically, the
sources will be whole muscle pieces or portions. To the extent that
unfrozen food supplies are readily available at a commercially
acceptable cost, the meat sources themselves will be of the fresh
variety. Thus, the meat cuts are not cured, either before, during
or after processing according to the invention. The invention is
particularly unique in its ability to improve the shelf stability,
flavor stability and texture maintenance of meat cuts which are not
ground or comminuted sources. Whatever the ultimate origin of the
meat cuts, they will begin the process as unfrozen cuts.
[0030] In proceeding with the processing, these unfrozen meat cuts
are treated with a marinade which has been found to be especially
suitable when used in combination with the other major features of
the process. The marinade treatment is carried out in accordance
with acceptable food-processing procedures. These include tumbling
and contacting the surfaces of the meat cuts with the marinade. The
length of treating or contacting should be adequate such that the
components of the marinade penetrate into and typically through the
external surfaces of the meat cuts. An important objective of this
treatment is to have the marinade components remain with the meat
cuts during subsequent treatment, especially during the cooking
operation.
[0031] A preferred marinade formulation is comprised of one or more
lactate salts, a diacetate salt, and a common inorganic salt. This
is an aqueous composition, and typically the majority of the
marinade is water. Another component which can be included is a
phosphate salt or complex phosphate salt. While not an essential
component, flavoring agents can be included, such as chicken
flavor, as can be binding agents or sweetening agents, an example
of other possible agents being dextrose.
[0032] The lactate salts usually comprise either or both of sodium
lactate and potassium lactate. Because many lactate products are
available as a syrup, this form of lactate addition typically is
practiced. A typical syrup will be a 60 percent solution of the
lactate salt within water. The lactate will be present in the
marinade at levels of between 0.01 weight percent and up to the
legal limit for lactate in meat products, which is 4.8 weight
percent. These percentages are based upon the total weight of the
meat cuts and the marinade. When considered in terms of the
marinade itself, the lactate can be present at a level of between
about 0.06 weight percent and about 28.8 weight percent.
Preferably, the amount of lactate is between about 1.5 and about 3
weight percent, based upon the total weight of the meat and
marinade. This is between about 9 and 18 weight percent, based upon
the total weight of the marinade.
[0033] Diacetate salt levels are between about 0.01 weight percent
and up to the legal limit of a diacetate in meat products, namely
0.25 weight percent. These are based upon the weight of the total
meat and marinade composition. When considered in terms of the
marinade alone, the diacetate component is present at a level of
between about 0.06 weight percent and about 1.5 weight percent. For
a typical diacetate component such as sodium diacetate, the
preferred range for this component is between about 0.05 and about
0.2 weight percent, based upon the total weight of the meat and
marinade. Based upon the total weight of the marinade itself, the
preferred level is between about 0.3 and about 1.2 weight
percent.
[0034] Suitable inorganic salts are typically sodium chloride,
potassium chloride and the like, generally identified herein as
common inorganic salts. The common inorganic salt component is
present at a level of between about 0.01 and about 3 weight
percent, based upon the total weight of the meat and marinade.
Based upon the weight of the marinade alone these levels are
between about 0.06 and about 18 weight percent. Preferably, the
common organic salt component is present at between about 0.75 and
about 1.5 weight percent, based upon the total weight of the meat
and marinade. Based upon the weight of the marinade alone, the
common inorganic salt component is present at between about 4.5 and
about 9 weight percent.
[0035] A typical marinade will have a water content of between
about 8 and 20 weight percent, based upon the total weight of the
meat and marinade. When considered in terms based on the weight of
the marinade only, water is present at between about 50 and about
85 weight percent. It will be appreciated that some of the water
content can be contributed by other components, most notably by the
lactate syrup component. Preferred water ranges are between about
10 and about 15 weight percent, based upon the total weight of the
meat and marinade. Based upon the weight of the marinade only,
water ranges between about 55 and about 80 weight percent.
[0036] The marinade compositions can include a phosphate salt,
often a complex phosphate salt. When this phosphate component is a
compound such as sodium tripolyphosphate, this component will be
present at a level of between about 0.1 and about 2 weight percent.
This is based upon the total weight of the meat and marinade. Based
upon the weight of the marinade alone, this phosphate component
would be present at levels of between about 0.6 and about 12 weight
percent. Preferably, when present, the phosphate component will be
at a level of between about 0.2 and about 1 weight percent, based
upon the total weight of meat and marinade. Based upon the weight
of the marinade alone, this component would be present at between
about 1.2 and about 6 weight percent.
[0037] Other components can be included. A typical flavoring
component or combination of flavoring components can be present at
between about 0.5 and about 3 weight percent, based upon the total
weight of the meat and marinade. When based upon the weight of the
marinade alone, this will be between about 3 and about 18 weight
percent. Other additives, such as humectints, thickeners,
sweetening agents and the like can be present. An example of an
additional ingredient is dextrose. When present, levels are between
about 0.1 and about 2 weight percent, based upon the weight of the
meat and marinade, or between about 0.6 and about 12 weight percent
based upon the weight of the marinade only.
[0038] The marinade will be combined with the meat cuts at suitable
levels so as to achieve the needed marinating function. At this
stage of the process, the marinade will comprise between about 10
and about 25 weight percent, while the meat cuts will comprise
between about 75 and about 90 weight percent of the total meat and
marinade composition within the mixture added to the mixing
container.
[0039] Before cooking the marinated meat cuts, they can be treated
with a caramel component or formulation. A commercially available
formulation which is suitable in this regard is Maillose.RTM., of
Red Arrow Products Co., Inc. This formulation is an aqueous
solution of caramel coloring produced according to food
regulations. Usage levels can vary between about 0.3 and about 3
weight percent, based upon the weight of the marinated meat cuts.
Typically, this component will be applied as a solution (such as
for spraying) having a ratio of 2:1 of Maillose:water.
[0040] Whether or not thus additionally treated, the marinated meat
cuts are cooked. Preferably, the cooking includes an initial
high-heat searing of the meat cuts. Cooking will proceed thereafter
so as to achieve full cook characteristics as required by food
processing regulations. The searing operation is done rapidly and
at high temperature so as to provide a denatured protein skin
barrier. This has been found to assist in reducing water transfer
out of the meat. Full cooking is typically indicated when the
internal temperature of the meat reaches 155.degree. F. or higher
(68.3.degree. C.). Any industrial oven, such as one suitable for
industrial flow-through cooking, can be used.
[0041] The cooked meat cuts are subjected to chilling in accordance
with procedures suitable for industrial handling of meat products.
For example, a spiral freezer will chill fully cooked chicken
fillets down to about 27.degree. F. (-2.8.degree. C.) in about one
half an hour. Cooling is accomplished in accordance with
controlling governmental regulations. The chilling does not freeze
the meat, although a so-called crusting can take place. The
objective of the chilling step is not to freeze the meat cuts, but
to rapidly chill in accordance with good meat handling
practices.
[0042] The precooked and thus chilled meat cuts are next to
combined with a low pH sauce. The sauce provides a variety of
flavors to the meat cuts, depending upon the particular product
being prepared. These can be, for example, barbecue flavored,
teriyaki flavored, garlic flavored, herb flavored, either alone or
combined with other flavorings such as lemon or citrus, pepper,
with the like. A principal feature of the sauce is that it has a
low pH, meaning a pH of below about 4.5, typically of about 4.2 or
below, preferably of about 4.0 or below. This is the pH of the
sauce prior to its addition to the fully cooked meat cuts. This low
pH characteristic is provided by including a food grade acid within
the sauce. Often, this is achieved by having vinegar within the
sauce. A typical vinegar includes acetic acid. An example of a
vinegar which is instrumental in providing an adequately low pH to
such sauces is 120 grain vinegar. Many suitable sauces will have a
pH of 4.1 or below. Other suitable sauces will have a pH of 3.8 or
below. Some can have a pH of 3.5 or below. A typical pH range for
the sauce prior to its addition to the meat cuts is 2.5 to 4.2. A
preferred range is 3 to 4.0. Another preferred range is 3 to 3.5
pH.
[0043] A typical low pH sauce will include between about 40 weight
percent and about 65 weight percent water, based upon the total
weight of the sauce. Typical sauce water activities will be on the
order of about 0.92 or lower. Generally, beneficial effects
according to the invention will be achieved by low pH sauces having
a low water activity. Broadly, sauce water activity will be below
0.92. Some sauce water activities will be at about 0.9 or below. An
advantageous common inorganic salt level is between about 2 and
about 3 weight percent, based on the total weight of the sauce. It
will be especially advantageous to have sauces with a combination
of these pH values, water activities and salt levels.
[0044] Various low pH sauces are available commercially. Examples
include Kraft.RTM. Honey Hickory BBQ sauce, Bulls-Eye.RTM. teriyaki
sauce, McCormick.RTM. Golden Dip teriyaki sauce, sauce formulations
including flavoring from Firmenich.RTM., Bulls-Eye.RTM. garlic herb
grilling sauce, lemon pepper flavored sauces, as well as various
other commercially available sauces or other sauces formulated to
have the desired flavor, while exhibiting the requisite low pH. A
typical sauce formulation will include water, vinegar, starch,
vegetable oil, flavoring, sweetener, gums and other typical sauce
formulation components.
[0045] Adding the low pH sauce to the fully cooked product is an
important feature of the process. Especially suitable in this
regard is adding the low pH sauce to the cooked and chilled meat
cuts shortly before hermetic packaging together of the cooked meat
cuts and low pH sauce. It will be appreciated that the cooked meat
pieces most often will have a pH considerably higher than that of
the sauce with which they are combined. Such combined pH values
will be on the order of about 5 to about 6.3 once a generally
equilibrated condition is reached. To a limited extent, the low pH
value required of the sauce will depend somewhat upon the condition
of the meat cuts prior to the combining step. Examples of relevant
meat condition factors are pH, microbial activity, temperature and
the like. For most meat cuts, the sauce pH values of the sauces
noted herein will be adequate. It is also preferred that the
temperature of the sauce be on the order of that of the cooked and
chilled meat cuts, typically at or below 40.degree. F. (4.degree.
C.).
[0046] It is preferred in that the hermetic sealing together of the
fully cooked meat cuts and the low pH sauce will be under so-called
vacuum conditions. Packaging can be carried out on commercially
available form, fill and seal equipment, or simply within suitable
vacuum packaging commercial equipment. When equipment is used which
incorporates a forming operation, usually both a forming film and a
non-forming film will be used. A suitable forming film is a
Curlon.RTM. forming film available from Curwood, a preferred
example being Curlon 1251. A typically suitable non-forming film is
Curlon 1915G. Preferably, the hermetically sealed pouch has a
peelable seal, such as one provided by an adhesive, by mating
strips, and the like. Typical peel adhesive formulations also are
available from Curwood. In one aspect of the invention, the thus
vacuum packaged fully cooked meat cuts and low pH sauce are ready
for entering commercial distribution channels. The invention
permits the equipment of these distribution channels and the cases
of the marketing and sales channels to be refrigerated and not
frozen. This allows the provision of unfrozen meat cuts which are
ready to use, with or without heating. Typically, however, the meat
cuts will be heated, such as in a consumer microwave oven, prior to
cooking, whether with the sauce or without.
[0047] Another aspect of the packaging which can be used in
connection with the fully cooked meat cuts and low pH sauce is to
provide a protective tray within which the hermetically sealed
pouch is placed. This protective tray physically protects the
hermetically sealed pouch, both from unintentional damage and
potentially intentional tampering. The tray, which itself includes
a sealing lid, also provides assistance in maintaining the
refrigerated temperature in storage. There will be "dead air" or
gas space, often merely air space, between the outside of the pouch
and the interior surface of the tray. Once chilled, this gas
provides an additional buffer or sink for maintaining a desired
refrigerated, non-frozen temperature.
[0048] The tray also can provide the function of a convenient
cooking tray during microwave heating of the food product prior to
consumption. With this approach, the food product, whether only the
cooked meat cuts or the cuts within the low pH sauce, will be
opened, and the contents poured in the tray, while its lid is
peeled back, opened or removed.
[0049] Refrigerated temperatures for the products are consistent
with those provided in wholesale storage and transportation
facilities and vehicles. They also will be in accordance with
temperatures and air flow conditions of refrigerated retail storage
cases. Generally speaking, these refrigerated conditions are such
that the packaged products remain unfrozen. A typical refrigerated
temperature is between about 32.degree. F. (0.degree. C.) and about
44.degree. F. (7.degree. C.), typically on the order of about
40.degree. F. (4.4.degree. C.).
[0050] With particular reference to the food packaging which is
illustrated, FIG. 1 through FIG. 5 generally show at 21 a
refrigerated packaged food product. Included is a tray 22 having an
internal volume defined by a sidewall 23 and a bottom wall 24.
Sidewall 23 can include ridges 36 for added rigidity of the tray.
Sidewall 23 includes an annular rim 25. Closure of the tray in this
illustrated embodiment is accomplished by a lid 26. A typical lid
is a polymeric lidding sheet which is flexible and releaseably
sealed to the annular rim 25. In the illustrated embodiment, a
sleeve 27 provides added mechanical protection and barrier
properties, for example reducing photo-oxidation. Sleeve 27 also
provides a convenient means for packaging graphics. The tray and
sleeve, as well as the sealed lid and the oxygen barrier pouch
reduce oxygen penetration and exposure of the food.
[0051] Positioned within the volume of the tray and between the
tray and the lid is a pouch 31 containing the food product. It will
be noted that, even with the pouch within the tray sealed by the
lid, free space 32 remains. This free space provides an opportunity
for gas, typically, air, to provide a sink or buffer volume as
generally discussed herein.
[0052] Pouch 31 includes fully cooked meat cuts 33 and a low pH
sauce 34. Preferably, the pouch is vacuum sealed and securely
closed by suitable conventional approaches. Sealing may be
accomplished by an adhesive, especially a peelable adhesive, or by
suitable mechanical arrangements. An interlocking seal strip
arrangement 35 is suitable in this regard.
[0053] In use, the combined meat cuts and sauce remain hermetically
sealed and refrigerated within the pouch until such time as heating
and serving are desired. At that time, the seal 35 is broken, the
pouch is opened, and the meat cuts and sauce are removed from the
pouch. They can be placed within a suitable heating container. If
desired, only the meat cuts can be heated for serving, when it is
desired to not utilize the combination of sauce and meat. It has
been found that the sauce flavor is delivered to the meat cuts in
their mutual chilled environment, and the sauce flavor is evident
in the meat cuts even after washed from the surfaces of the cooked
meat cuts which had been refrigerated with the sauce.
[0054] In the illustrated kit embodiment, the tray 22 serves well
as a heating container for heating within a microwave oven, for
example. In that instance, the desired content from the pouch is
emptied into the tray. If desired, the lid 26 can be re-positioned
onto the annular rim 25 for spattering protection and heat
maintenance in accordance with typical microwave heating practice.
In that instance, annular rim 25 includes a depression 37 to
facilitate venting when the lid is secured to the annular rim,
including during reheating.
[0055] When the tray is used as a container for heating the edible
contents, it preferably includes ramped corners 38 to facilitate
movement of the sauce away from the bottom corners of the tray and
towards the center of the tray. These slanted corner ramps also
increase corner strength. When the tray component is provided, it
preferably is made of a high performance polymer which will
withstand household microwave heating, as well as show resistance
to damage during storage, transport, display and general handling.
A suitable material is a blended copolymer and homopolymer of
polypropylene. Polymers of this type are available from
Curwood.
[0056] Exemplary illustrations of the disclosure herein are
provided in the following examples.
EXAMPLE 1
[0057] Chicken breast fillets were treated with a marinade
according to the invention and were seared on both sides. They were
thereafter sprayed with a 2:1 Maillose:water solution. These
fillets were placed in a combination oven which was set on heat
plus steam at 400.degree. F. (204.degree. C.). The fillets reached
an internal temperature of at least 160.degree. F. (71.degree. C.)
and then chilled. The cooked fillets were packaged in vacuum
pouches with three different sauces. Several packages contained
Kraft.RTM. honey hickory barbecue sauce (pH of 3.2). Several other
pouches contained McCormick.RTM. golden dip teriyaki sauce (pH of
4.2). After six days storage under refrigerated, non-frozen
conditions, the fillets were removed from the pouches. In order to
evaluate transfer of flavor from the sauce to the cooked fillets,
all of the sauces were removed from the fillets, and the fillets
were rinsed with tap water. These fillets were heated and tasted.
In each instance, the tasting indicated that each sauce flavor was
delivered to the fully cooked fillet within the refrigerated
environment provided by the pouch under refrigeration. No adverse
texture problems were observed, there being no indication of a
mealy, wet or soft texture or consistency.
EXAMPLE 2
[0058] A marinade was prepared and combined with chicken breast
fillets. The weight percents of the components were as follows,
each percent being based upon the total weight of the chicken
breast fillets and the marinade components: chicken breast fillets
83.33 percent; water 9.92 percent; chicken flavoring 1.25 percent;
sodium lactate 2.45 percent; potassium lactate 1.00 percent; sodium
chloride salt 1.10 percent; dextrose 0.51 percent; sodium
tripolyphosphate 0.334 percent; and sodium diacitate 0.10 percent.
These were 4 ounce fillets, and the marinated fillets were cooked
and chilled. The chilled yield average was observed to be 77.1
weight percent. Cooking of a group of these fillets was done within
a Progrill.RTM. system at 345.degree. F. (174.degree. C.) for 65
seconds, creating a seared protein skin of the fillets. These were
passed to a combination oven for a cook time of about 4 minutes at
500.degree. F. (260.degree. C.), under steam at about 600 pounds
per hour. Grill marks were imparted to the fillets by a charring
device. Average cooked yield was 82.6 weight percent (standard
deviation 0.73 percent). After chilling, the cooked and chilled
fillets had an average yield of 77.08 weight percent (standard
deviation 0.94 percent).
EXAMPLE 3
[0059] Fillets were marinated substantially in accordance with
Example 2, cooked and chilled. These were combined with one of
three different sauces, a Kraft.RTM. honey hickory barbecue sauce
at a pH of 3.2, and a teriyaki sauce at a pH of 4.2. They were
vacuum packaged in pouches and stored under refrigeration for three
months. Other pouches were control products which were identical
except no sauce was added prior to vacuum packaging. The control
fillets showed an increase in microbial activity from 4 weeks
through to 10 weeks of refrigerated, vacuum sealed storage. The
increase was from one Log CFU/gm at 4 weeks, 2.5 Log CFU/gm at 8
weeks, and 3 Log CFU/gm at 10 weeks. The teriyaki sauce treated
fillets were at about one Log CFU/gm at 4 weeks, and remained at
that level, both at 8 weeks and 10 weeks. The low pH barbecue sauce
treated fillets were at about 1 Log CFU/gm at 4 weeks, and were at
about the same value at 8 weeks and at 10 weeks. The three low pH
sauces had less then 10 col. after 10 to 13 weeks.
EXAMPLE 4
[0060] A marinade formulation was prepared as follows: 70.07 weight
percent water, 14.70 weight percent sodium lactate, 6 weight
percent potassium lactate, 6.6 weight percent sodium chloride, 2
weight percent sodium tripolyphosphate, and 0.6 weight percent
sodium diacetate, each being based upon the total weight of the
marinade. This marinade was vacuum tumbled with chicken breast
fillets at a weight ratio of 5:1 of fillets:marinade. These fillets
were seared and cooked until the internal temperature was about
160.degree. F. (71.degree. C.). The fillets were cooled and
packaged with a variety of low pH sauces. These sauces included
Kraft.RTM. honey hickory sauce at a pH of 3.27, Bulls-Eye.RTM.
teriyaki grilling sauce having a pH of 3.8, Bulls-Eye.RTM. garlic
herb grilling sauce, McCormick.RTM. golden dip teriyaki sauce
having a pH of 4.2, and a formulated lemon pepper sauce having a pH
of 3.3. After sauce and cooked fillet composites were vacuum
packaged together, the following pH readings were noted: Kraft.RTM.
honey hickory barbecue sauce and cooked fillets, 5.47 pH;
Bulls-Eye.RTM. garlic herb grilling sauce and cooked fillets, 6 pH;
and McCormick.RTM. golden dip teriyaki sauce with cooked fillets,
5.5 pH. The fillets were observed to be devoid of any visible
mealy, wet or soft texture.
EXAMPLE 5
[0061] Uncooked chicken strips were treated with a marinade
together with a teriyaki flavor, such being a low pH treatment
prior to cooking. After cooking and chilling, the chicken cuts were
observed to have a mealy, wetter and softer texture than before
cooking. Removing the low pH teriyaki prior to cooking, and moving
it to addition promptly after cooking and chilling avoided these
negative developments. Chicken cuts having the low pH sauce added
after cooking resulted in little, if any detrimental affects to the
texture.
[0062] It will be understand that the embodiments of the present
invention which have been described are illustrative of some of the
applications of the principles of the present invention. Numerous
modifications may be made by those skilled in the art without
departing from the true spirit and scope of the invention.
* * * * *