U.S. patent application number 11/397900 was filed with the patent office on 2007-10-11 for method for manufacturing high pressure processed food products.
Invention is credited to Robert Love, Peter Macnab, Lawrence R. Wills.
Application Number | 20070237865 11/397900 |
Document ID | / |
Family ID | 38575614 |
Filed Date | 2007-10-11 |
United States Patent
Application |
20070237865 |
Kind Code |
A1 |
Love; Robert ; et
al. |
October 11, 2007 |
Method for manufacturing high pressure processed food products
Abstract
The present invention is directed to the high pressure
processing of food products after packaging in order to extend the
shelf life and eliminate bacteria and microorganisms. Fresh food
products that can be processed according to the present invention
include, for example, beef, chicken, pork, lamb, seafood,
vegetables, sauces and starches. The method for processing food
products involves vacuum sealing a food product within plastic film
to form a vacuum sealed package. The vacuum sealed package is then
placed in a pressurizing apparatus and the pressurizing apparatus
is then loaded with water. The water is then pressurized inside the
pressurizing apparatus to exert hydrostatic pressure on the vacuum
sealed package.
Inventors: |
Love; Robert; (Baltimore,
MD) ; Macnab; Peter; (Bethany Beach, DE) ;
Wills; Lawrence R.; (Parkton, MD) |
Correspondence
Address: |
STERNE, KESSLER, GOLDSTEIN & FOX P.L.L.C.
1100 NEW YORK AVENUE, N.W.
WASHINGTON
DC
20005
US
|
Family ID: |
38575614 |
Appl. No.: |
11/397900 |
Filed: |
April 5, 2006 |
Current U.S.
Class: |
426/129 |
Current CPC
Class: |
B65B 25/06 20130101;
A23L 3/0155 20130101; A23B 4/00 20130101; A23B 7/00 20130101 |
Class at
Publication: |
426/129 |
International
Class: |
B65B 25/06 20060101
B65B025/06 |
Claims
1. A method for processing food products, comprising: (a) vacuum
sealing a food product within plastic material to form a vacuum
sealed package; (b) placing said vacuum sealed package into a
pressurizing apparatus; (c) loading water into said pressurizing
apparatus; and (d) pressurizing said water inside said pressurizing
apparatus to exert hydrostatic pressure on said vacuum sealed
package in a range from 1 minute to 30 minutes at a pressure in a
range from 25,000 psi to 120,000 psi.
2. The method of claim 1, wherein said food product is selected
from the group consisting of beef, chicken, pork, lamb, seafood,
vegetables, sauces and starches.
3. The method of claim 1, wherein said food product is seafood and
said seafood is selected from the group consisting of seafood
cakes, raw fish, sub-par cooked fish, marinated fish, seafood dips,
shellfish, seafood soups, and other food products with seafood
ingredients or stocks.
4. The method of claim 1, wherein at least a portion of said
plastic material has an oxygen transmission rate greater than
10,000 cc/m.sup.2/24 hrs.
5. The method of claim 1, wherein said food product is a plurality
of products.
6. The method of claim 5, wherein said step of vacuum sealing
further comprises: providing a tray with a plurality of cavities;
placing a first plastic film over said tray; filling each of said
plurality of cavities with one of said plurality of products after
placing said first plastic film; placing a second plastic film over
said plurality of products; and vacuum sealing said plurality of
products in said tray between said first and second plastic
films.
7. The method of claim 6, further comprises cutting said vacuum
sealed products into individual vacuum sealed packages.
8. The method of claim 6, wherein said first plastic film is 3 to
12 mil.
9. The method of claim 6, wherein said second plastic film is
oxygen permeable with an oxygen transmission rate greater than
10,000 cc/m.sup.2/24 hrs.
10. The method of claim 6, wherein said second plastic film is
perforated.
11. The method of claim 6, wherein said plurality of food products
comprises seafood cakes.
12. The method of claim 11, wherein said seafood cakes are crab
cakes.
13. The method of claim 1, wherein said plastic material is
flexible and can withstand a compression rate of up to 15%.
14. The method of claim 1, wherein said pressurizing occurs in a
range from 35,000 psi to 87,000 psi.
15. The method of claim 1, wherein said pressurizing occurs for
about 3 minutes.
16. The method of claim 1, wherein said pressurizing occurs at a
temperature in a range from 40.degree. F. to 170.degree. F.
17. The method of claim 1, wherein said plastic material is at
least one barrier film.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is directed to the high pressure
processing of food products after packaging in order to extend the
shelf life and eliminate bacteria and microorganisms.
[0003] 2. Background Art
[0004] There are several competing concerns in the sale and
packaging of food products, particularly seafood: fresh vs. frozen,
extending the shelf life to the maximum extent possible, and the
elimination of bacteria and microorganisms, such as Clostridium
botulinum.
[0005] Fresh seafood is a highly perishable product with a short
shelf life. For instance, fresh seafood bought at a grocery store
should typically be eaten within two to three days. One method for
extending the shelf life of seafood is to freeze the seafood.
However, the energy costs associated with freezing and frozen
storage are high. Also there is a high demand for fresh seafood
products as consumers prefer fresh seafood over frozen seafood, as
the freezing process can change the taste and texture of the
seafood in a negative manner.
[0006] Another concern with the sale of seafood is preventing the
growth of bacteria or microorganisms, such as Clostridium
botulinum, also known as C. botulinum. It is known to package
seafood in reduced oxygen packaging (ROP) including vacuum
packaging and modified or controlled atmospheric packaging (MAP or
CAP) in order to extend the shelf life. ROP also results in
preventing the growth of spoilage bacteria that require normal air
levels of oxygen to grow. However, the reduced oxygen in the
packaging creates an anaerobic environment that can allow for the
growth of C. botulinum.
[0007] Other known methods for eliminating bacteria and
microorganisms, such as C. botulinum, include heating or
irradiation treatments. However, such treatments involve high
temperatures, which can affect the freshness, flavor, texture,
appearance and color of the seafood.
[0008] A new technology that has emerged in recent years is high
pressure processing (HPP). High pressure processing involves
placing a food product in a pressure vessel and surrounding it with
a pressure medium, such as water. The vessel is pressurized to
uniformly apply pressure to all surfaces of the food product. U.S.
Pat. No. 6,537,601 to Voisin discloses a process of treating
shellfish to eliminate bacteria utilizing high pressure processing.
However, this process does not address treating fresh, packaged
food products to eliminate bacteria and extend the shelf life of
the food product.
[0009] Currently there are no available solutions for processing
with high hydrostatic pressure to prevent the growth of C.
botulinum in seafood other than the use of external time
temperature integrators. Therefore, the need exists for a method of
packaging fresh food products, such as seafood, that extends the
shelf life and prevents the growth of bacteria and microorganisms,
such as C. botulinum. To this end, the present invention is
directed to a method of high hydrostatic pressure processing, which
solves the problems of the prior art by processing fresh food
products after they have been vacuum sealed in oxygen permeable
plastic. The process extends the shelf life of the packaged fresh
food products and allows for the retention of the freshness,
flavor, texture, appearance and color of the food product. The high
hydrostatic pressure processing is also quicker and more energy
efficient than other methods known in the prior art.
BRIEF SUMMARY OF THE INVENTION
[0010] It is an object of the present invention to provide a
process for high hydrostatic pressure processing of food products
after packaging in order to extend the shelf life and eliminate
bacteria and microorganisms.
[0011] This objective of the present invention is achieved through
a method for processing food products comprising vacuum sealing a
food product within a plastic material to form a vacuum sealed
package; placing said vacuum sealed package into a pressurizing
apparatus; loading water into said pressurizing apparatus; and
pressurizing said water inside said pressurizing apparatus to exert
hydrostatic pressure on said vacuum sealed package for at least 60
seconds at pressure greater than or equal to 25,000 psi.
[0012] Another object of the present invention is to provide a
process for high hydrostatic pressure processing of food products
that are vulnerable to the growth of C. botulinum by utilizing a
plastic material for the packaging that has an oxygen transmission
rate greater than 10,000 cc/m.sup.2/24 hrs.
BRIEF DESCRIPTION OF THE DRAWINGS/FIGURES
[0013] FIG. 1 is a flow chart showing a process of treating crab
cakes according to the present invention.
[0014] FIG. 2 is a cross-sectional view of the crab cakes in the
tray between two plastic films before vacuum sealing.
[0015] FIG. 3A is a top view of an individual crab cake package
after being treated according to the present invention.
[0016] FIG. 3B is a side view of an individual crab cake package
after being treated according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The present invention is directed to the high pressure
processing of food products after packaging in order to extend the
shelf life and eliminate bacteria and microorganisms.
[0018] Preferred embodiments of the present invention are now
described. While specific configurations and arrangements are
discussed, it should be understood that this is done for
illustrative purposes only. A person skilled in the relevant art
will recognize that other configurations and arrangements can be
used without departing from the spirit and scope of the invention.
It will also be apparent to a person skilled in the relevant art
that this invention can be employed in a variety of other devices
and applications.
[0019] Fresh food products that can be processed according to the
present invention include, for example, protein, vegetables, sauces
and starches. Protein can include beef, chicken, pork, lamb and
seafood. Seafood can include, for example, seafood cakes, raw fish,
sub-par cooked fish, marinated fish, seafood dips, shellfish,
seafood soups, and other food products with seafood ingredients or
stocks. Starches can include, for example, pastas and rice. When a
food product is processed according to the present invention, the
shelf life of a food product is extended if refrigerated, without
having ever frozen the food product. The length of the increase in
shelf life depends on the particular product. Also, safe food
additives may be added to reduce the growth of lactic acid bacteria
and to further extend the shelf life of the food product.
[0020] The process of the present invention involves first
preparing the food item, for example, such as by grilling, baking,
frying, boiling, steaming or marinating. The prepared food product
is then vacuum sealed in a plastic package of suitable plastic
material utilizing settings appropriate to the application. The
plastic material can comprise a plastic bag, a single plastic film
or substrate, or two plastic films or substrates sealed together or
a tray sealed with a plastic lidding material. The vacuum sealing
process comprises surrounding the food product with the plastic
material. A vacuum is created and the plastic is sealed forming a
vacuum sealed food product. For example, the Koch Intact.TM. Vacuum
Skin Packaging Machine, Model RM571 is utilized for the vacuum
sealing process.
[0021] In a preferred embodiment the plastic material is flexible
and can withstand a compression rate of up to 15%. The high
pressure processing can cause an item to shrink by 15% and the
plastic material must be able to withstand such a compression rate
or risk compromising the integrity of the package and/or seal.
[0022] In a preferred embodiment, when the food product being
packaged is vulnerable to the growth of C. botulinum, the plastic
material utilized to form the packaging has an oxygen transmission
rate suitable to allow sufficient amounts of oxygen into the
package to prevent the anaerobic growth of bacteria and
microorganisms, such as C. botulinum. If C. botulinum is not a
concern, the plastic material for packaging the food product may be
a suitable plastic barrier film.
[0023] Seafood products are an example of such a food product that
requires the plastic material of the package to have a suitable
oxygen transmission rate. The vacuum sealing process creates an
anaerobic environment by reducing the amount of oxygen. In order to
prevent the anaerobic growth of bacteria and microorganisms, such
as C. botulinum, the packaging material preferably has an oxygen
transmission rate greater than 10,000 cc/m.sup.2/24 hrs. The
Cryovac.RTM. HP2700 plastic bag, is preferred, as it has a
guaranteed oxygen transmission rate of greater than 10,000 cc/
m.sup.2/24 hrs. The package also must have an appropriate thickness
in order to eliminate the risk of C. botulinum growth.
[0024] The vacuum sealed package is placed in the chamber of a
pressurizing apparatus, such as a pressure vessel and the vessel is
filled with water. The water in the pressure vessel is pressurized
so that it exerts a hydrostatic pressure on the packaged food
product. This process is referred to as hydrostatic high pressure
processing (HPP). U.S. Pat. No. 6,217,435 to Voisin, which is
incorporated by reference in its entirety herein, describes HPP
machinery that can be utilized in the present invention. The HPP
machinery is set for both cycle of time and amount of pressure
according to the specific food product being treated. The
hydrostatic pressure is in a range from 25,000 psi to 120,000 psi,
depending upon the food product being treated, with a preferred
range of 35,000 psi to 87,000 psi. The duration of the pressure is
in a range from one minute to 30 minutes, depending upon the food
product being treated, with a preferred duration of about 3
minutes. The temperature may be adjusted within a range from
40.degree. F. to 170.degree. F., with a preferred range of
40.degree. F. to 70.degree. F., to assist the high pressure and
also to ensure optimal quality.
[0025] The hydrostatic pressure is transmitted through the water to
the packaged food product in equal and uniform amounts
instantaneously to the entire surface of the packaged food product.
These effects are independent of the packaged food product's size
or shape. HPP is beneficial because it reduces and/or destroys
pathogens in the food product, the food product does not need to be
frozen, nothing is added to the food product, it is a non-thermal
process and the food product retains its organoleptic and
nutritional qualities. Another advantage of HPP is that marinated
packaged food products, such as beef, lamb, poultry, pork and
seafood, receive superior marination when subjected to the HPP as
the pressure creates a greater saturation of the food product with
the marinade. Thus this process allows for flavor infusion and
increased food safety.
[0026] In a preferred embodiment, the packaged food product is
loaded into a tube or other machine device, which is subsequently
placed inside the pressure vessel. The packaged food products may
be loaded into the tube or device from the top or side. In
addition, the tube or device may be compartmentalized such that
each packaged food product is separated from the others in order to
fully benefit from the hydrostatic pressure.
[0027] After pressurization the food product is removed from the
HPP machinery and is refrigerated. This process extends the shelf
life of the food product as much as several months depending on the
particular food product.
[0028] Having now generally described the invention, the same will
be more readily understood through reference to the following
examples which are provided by way of illustration, and are not
intended to be limiting of the present invention.
EXAMPLES
Example 1
[0029] FIGS. 1, 2, 3A and 3B describe a process for preparing
seafood cakes, such as crab cakes. The crab cakes 220 are prepared
(STEP 100) and are then pan fried for approximately 3 minutes at
approximately 350.degree. F. (STEP 102). A tray 222 is provided
with a plurality of cavities 224. The tray 222 may be pre-formed or
formed in-line. While pan frying is utilized in this example, the
crab cake may be prepared through other methods, for example, such
as by broiling or baking. A first plastic film 226 is placed over
the tray 222 and each of the cavities 224 is filled with a prepared
crab cake 220 (STEP 104). The first plastic film 226 is preferably
a 3 to 12 mil durable plastic, more preferably a 10 ml durable
plastic, and functions as the top surface 332 of the ultimate
vacuum sealed package 330. A second plastic film 228 is placed over
the crab cakes 220 (STEP 106). The second plastic film 228 can be
either a perforated durable plastic, of preferably 10 mil, or an
oxygen permeable film with an oxygen transmission rate greater than
10,000 cc/m.sup.2/24 hrs, for example one available from Cyrovac.
In a preferred embodiment the second plastic film 228 is thinner
than the first plastic film 226. The second plastic film 228 serves
as the bottom surface 334 of the ultimate vacuum sealed package
330. The crab cakes 220 are then vacuum sealed between the first
and second plastic films 226, 228 utilizing, for example, a Koch
Intact.TM. Vacuum Skin Packaging Machine, Model RM571 (STEP
108).
[0030] After the crab cakes 220 are vacuum sealed, the crab cakes
220 are cut into individual sealed packages 330 (STEP 110). The
individual packages 330 are loaded into a tube (STEP 112) and the
tube is placed into the pressure chamber of a pressurizing
apparatus, such as a high hydrostatic pressure vessel (STEP 114).
The pressure vessel is loaded with water and the water is
pressurized to 60,000 psi for 180 seconds (STEP 116). The
individual packages 330 of crab cakes are then removed from the
tube and the vessel and refrigerated (STEP 118). The treated crab
cakes have a shelf life of up to 70 days.
Example 2
[0031] A salmon steak is steamed for 5 minutes at 165.degree. F.
and then vacuum sealed in a oxygen permeable plastic film with an
oxygen transmission rate greater than 10,000 cc/m.sup.2/24 hrs. The
vacuum sealing process involved pulling a vacuum for 3 seconds and
then sealing for 3 seconds. Afterwards, the packaged salmon steak
was loaded into a pressure vessel for HPP. The water was
pressurized to 45,000 psi for approximately 3 minutes.
Example 3
[0032] A cut of tenderloin was seared and then sauteed for 3
minutes on each side such that the core temperature of the
tenderloin was 45.degree. F. The tenderloin was then vacuum sealed
between two barrier films by applying vacuum for 5 seconds and HPP
was performed for 180 seconds.
Example 4
[0033] A rib lamb chop was sauteed on each side. The tenderloin was
then vacuum sealed between two barrier films by applying vacuum for
3 seconds and then performing HPP for 180 seconds.
[0034] It is to be appreciated that the Detailed Description
section, and not the Summary and Abstract sections, is intended to
be used to interpret the claims. The Summary and Abstract sections
may set forth one or more but not all exemplary embodiments of the
present invention as contemplated by the inventor(s), and thus, are
not intended to limit the present invention and the appended claims
in any way.
* * * * *