U.S. patent application number 12/747062 was filed with the patent office on 2010-12-23 for high-temperature packaging of bone in meat product.
This patent application is currently assigned to M&Q PACKAGING CORPORATION. Invention is credited to Curtis Rubinstein.
Application Number | 20100323069 12/747062 |
Document ID | / |
Family ID | 40755857 |
Filed Date | 2010-12-23 |
United States Patent
Application |
20100323069 |
Kind Code |
A1 |
Rubinstein; Curtis |
December 23, 2010 |
HIGH-TEMPERATURE PACKAGING OF BONE IN MEAT PRODUCT
Abstract
Methods and apparatuses for preparing a ribbed meat product in a
reduced cook cycle. The methods may comprise placing a ribbed meat
product into a high-temperature cook-in bag suitable for
high-temperature cooking processes that occur at temperatures
greater than about 350.degree. F. and sealing the high-temperature
cook-in bag to create a package. The high-temperature cook-in bag
containing the ribbed meat product may be placed directly into an
oven and exposed to a temperature greater than about 350.degree.
F., reducing the cook time necessary to render or rethermalize the
ribbed meat product by a factor of about 3 as compared to
conventional low temperature cooking processes. The benefits of the
disclosed methods include reduced cook times to render or
rethermalize ribbed meat products, enhanced flavor of the ribbed
meat products, reduced risk of contamination, and improved
cleanliness. Both cooked and uncooked ribbed meat products may be
prepared in these methods.
Inventors: |
Rubinstein; Curtis;
(Anderson, SC) |
Correspondence
Address: |
Pepper Hamilton LLP
400 Berwyn Park, 899 Cassatt Road
Berwyn
PA
19312-1183
US
|
Assignee: |
M&Q PACKAGING
CORPORATION
Schuylkill Haven
PA
|
Family ID: |
40755857 |
Appl. No.: |
12/747062 |
Filed: |
December 10, 2008 |
PCT Filed: |
December 10, 2008 |
PCT NO: |
PCT/US2008/086173 |
371 Date: |
June 9, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61007226 |
Dec 11, 2007 |
|
|
|
Current U.S.
Class: |
426/113 ;
426/393; 426/415 |
Current CPC
Class: |
B32B 27/08 20130101;
B65B 25/22 20130101; B65D 2581/3416 20130101; B32B 2307/54
20130101; B32B 7/12 20130101; B32B 2270/00 20130101; B65D 81/343
20130101; B65B 31/00 20130101; B32B 2439/70 20130101; B32B 2307/31
20130101; B65D 81/2023 20130101; B32B 25/08 20130101; B65B 25/067
20130101; B32B 27/34 20130101; B32B 27/36 20130101; B32B 2439/40
20130101; B32B 2307/736 20130101; B32B 2307/7244 20130101; B32B
2307/5825 20130101; B32B 2307/7265 20130101; B32B 2250/24
20130101 |
Class at
Publication: |
426/113 ;
426/393; 426/415 |
International
Class: |
B65D 81/34 20060101
B65D081/34; B65B 25/06 20060101 B65B025/06 |
Claims
1. A method for preparing a bone in meat product for a cook cycle,
the method comprising: placing the bone in meat product into a
high-temperature cook-in bag comprising a film, wherein the film is
configured to be exposed to a temperature of at least 350.degree.
F. during the cook cycle; and sealing the high-temperature cook-in
bag to form a package that includes the bone in meat product,
wherein the film includes an oxygen barrier for maintaining a
vacuum seal within the package.
2. The method of claim 1, wherein the film is a blended monolayer
film comprising at least 75% nylon blended with at least one of a
polyester, a polyamide elastomer, or a polyester elastomer.
3. The method of claim 1, wherein film is a blended monolayer film
comprising about 60% to 80% nylon 6 and about 20% to 40%
heat-stabilized nylon 6,6.
4. The method of claim 1, wherein the film is a multilayer film
comprising an outer layer and an inner layer, wherein the outer
layer includes at least 75% nylon or polyester blended with a
polyester elastomer or a polyamide elastomer, and wherein the inner
layer includes a polyester elastomer or polyamide elastomer.
5. The method of claim 1, wherein the film is a multilayer film
comprising an outer layer, an inner layer and a tie layer disposed
between the outer and inner layers, wherein the outer layer
includes a polyester elastomer, a polyamide elastomer, or a nylon,
wherein the inner layer includes a polyester elastomer or a
polyamide elastomer, and wherein the tie layer includes at least
75% nylon or polyester blended with a polyester elastomer or a
polyamide elastomer.
6. The method of claim 1, wherein the film has a thickness in a
range of about 1 mil to 6 mils.
7. The method of claim 1, wherein the film has an oxygen barrier
transmission coefficient approximately equal to, or less than, 30
cc/24 hr/100 in.sup.2/mil and a water vapor barrier transmission
coefficient approximately equal to, or less than, 40 g/24 hr/100
in.sup.2/mil.
8. The method of claim 1, wherein the film has a tear strength
greater than about 50 g/mil and a tensile yield strength of greater
than approximately 2,000 psi.
9. The method of claim 1, further comprising cooking or rendering
the bone in meat product prior to placing the bone-in meat product
in the high-temperature cook-in bag.
10. The method of claim 1, further comprising tenderizing,
seasoning, or marinating the bone in meat product prior to placing
the bone in meat product into the high-temperature cook-in bag.
11. The method of claim 1, wherein sealing the high-temperature
cook-in bag includes evacuating air from the high-temperature
cook-in bag and hermetically sealing the high-temperature cook-in
bag.
12. The method of claim 1, wherein the package is configured to be
placed directly into a high-temperature cooking apparatus.
13. The method of claim 1, further comprising refrigerating or
freezing the package, wherein the refrigerated or frozen package is
configured to be placed directly into a high-temperature
apparatus.
14. The method of claim 1, wherein the package is configured to
facilitate a reduced cook cycle that is about one-hour or less.
15. A contained package for preparing a ribbed meat product in a
reduced cook cycle, the contained package comprising: a
high-temperature cook-in bag comprising a film configured to be
exposed to a temperature of at least 350.degree. F. during the
reduced cook cycle, wherein the film has an oxygen barrier
transmission coefficient approximately equal to, or less than, 30
cc/24 hr/100 in.sup.2/mil and a water vapor barrier transmission
coefficient approximately equal to, or less than, 40 g/24 hr/100
in.sup.2/mil; and a ribbed meat product sealed within the
high-temperature cook-in bag.
16. The contained package of claim 15, wherein the film is a
blended monolayer film comprising at least 75% nylon blended with
at least one of a polyester, a polyamide elastomer, or a polyester
elastomer.
17. The contained package of claim 15, wherein film is a blended
monolayer film comprising about 60% to 80% nylon 6 and about 20% to
40% heat-stabilized nylon 6,6.
18. The contained package of claim 15, wherein the film is a
multilayer film comprising an outer layer and an inner layer,
wherein the outer layer includes at least 75% nylon or polyester
blended with a polyester elastomer or a polyamide elastomer, and
wherein the inner layer includes a polyester elastomer or polyamide
elastomer.
19. The contained package of claim 15, wherein the film is a
multilayer film comprising an outer layer, an inner layer and a tie
layer disposed between the outer and inner layers, wherein the tie
layer includes at least a portion of the materials in the inner and
outer layers.
20. The contained package of claim 15, wherein the film has a
thickness in a range of about 1 mil to 6 mils, a tear strength
greater than about 50 g/mil, and a tensile yield strength of
greater than approximately 2,000 psi.
21. The contained package of claim 15, wherein the ribbed meat
product is pre-cooked or pre-rendered.
22. The contained package of claim 15, wherein the ribbed meat
product is hermetically sealed within the high-temperature cook-in
bag.
23. The contained package of claim 15, wherein the contained
package is configured to be placed directly into a high-temperature
cooking apparatus.
24. The contained package of claim 15, wherein the contained
package is configured to be refrigerated or frozen the package.
25. The contained package of claim 24, wherein the refrigerated or
frozen package is configured to be placed directly into a
high-temperature apparatus.
26. The contained package of claim 15, wherein the reduced cook
cycle is less than the cook cycle of conventional rendering methods
by at least a factor of three.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit under 35 U.S.C. .sctn.119(e)
of provisional U.S. Patent Application No. 61/007,226, filed Dec.
11, 2007 and entitled "HIGH-TEMPERATURE PACKAGING OF BONE IN MEAT
PRODUCT," the disclosure of which is incorporated herein by
reference in its entirety.
TECHNOLOGY FIELD
[0002] The present invention relates generally to methods for
preparing bone in meat products in a reduced cook cycle using
high-temperature cook-in bags. This technology is particularly well
suited, but by no means limited, for preparing ribbed meat products
in a reduced cook cycle.
BACKGROUND
[0003] Bone in meat products, including, for example, ribbed meat
products, are traditionally cooked in a two step process. First,
the bone in meat is rendered to loosen the meat from the bone and
to melt away portions of the fat. Following rendering, the bone in
meat is put onto a grill, or some other cooking appliance, to
enhance the appearance and flavor of the meat, and to optionally
caramelize a sauce on top of the bone in meat.
[0004] Rendering is usually performed by boiling or roasting the
bone in meat product. Various problems are associated with these
traditional techniques. These problems exist on both a consumer
level, such as a single end user or a food service facility
including restaurants, schools, institutions, etc., and a producer
level. On the consumer level, the consumer is forced to choose
between a flavorful meat or a short cook time. For example, if the
consumer decides to choose a flavorful meat, the meat must be
rendered by slow roasting in an oven at a low temperature. The
rendering process is extremely time consuming because very low
temperatures must be employed (i.e. 200.degree. F. to 250.degree.
F.) to ensure that the ribs remain moist and tender. If a higher
temperature is used to decrease the process time, the meat becomes
dry, tough, and sticks to the bone. As such, rendering ribs by
roasting in an oven at 200.degree. to 250.degree. F. usually takes
between about 3 and 4 hours.
[0005] If the consumer chooses a quicker method, such as boiling
the bone in meat products, flavor must be sacrificed. In the
boiling method, the bone in meat is submerged into a pot of boiling
water until the bone in meat is sufficiently rendered. Although
this technique is considerably quicker than slow roasting, much of
the flavor of the meat is lost in the boiling water, resulting is a
less flavorful end product.
[0006] These consumer problems lead further to market disadvantages
for meat producers. For example, because few consumers have the
time to properly prepare ribbed meat products, the market for these
products is small. As such, meat producers usually view ribbed meat
products as waste products. Producers usually package and sell only
a portion of the ribbed meat products and the remaining supply is
discarded once all easily boned meat is removed. Accordingly, a
method to prepare bone in meat products, for example ribbed meat
products, in a way that reduces the cook time, and that does not
diminish taste, would be desirable to both consumers and
producers.
SUMMARY
[0007] One aspect of the present invention concerns methods for
preparing a ribbed meat product in a reduced cook cycle comprising:
placing, at a processor facility, an uncooked ribbed meat product
into a high-temperature cook-in bag suitable for high-temperature
cooking processes that occur at temperatures greater than about
350.degree. F.; evacuating air from an inside of the cook-in bag;
providing an oxygen barrier to maintain shelf life of the uncooked
ribbed meat product contained within the cook-in bag; and
hermetically and vacuum sealing the high-temperature cook-in bag to
create a contained package containing the uncooked ribbed meat
product. The high-temperature cook-in bag containing the uncooked
ribbed meat product may be placed directly into an oven. The
contained package may be exposed to a temperature greater than
about 350.degree. F. thus reducing the cook time necessary to
render the ribbed meat product by a factor of about 3 as compared
to conventional low temperature cooking processes. In certain
embodiments, the cook cycle may comprise a time period of about 1
hour.
[0008] The methods may further comprise freezing the contained
package to produce a frozen contained package, wherein the frozen
contained package is suitable for direct placement into a
high-temperature cooking apparatus. The cooking apparatus may be an
oven having a temperature setting of greater than about 350.degree.
F.
[0009] The high-temperature cook-in bag may comprise a blended
monolayer film comprising nylon 6 and heat stabilized nylon 6,6. A
suitable blended monolayer comprises from about 60% to about 80%
nylon 6 and from about 20% to about 40% heat stabilized nylon 6,6.
Preferably, the blended monolayer comprises about 80% nylon 6 and
about 20% heat stabilized nylon 6,6. In another embodiment, the
high-temperature cook-in bag may comprise a multi-layer film,
wherein the multi-layered film comprises an outer layer and an
inner layer. The multi-layer may further comprise a tie layer
between the outer layer and inner layer.
[0010] Methods of the present invention may further comprise
preparing the uncooked ribbed meat product prior to placing the
uncooked ribbed product into the high-temperature cook-in bag.
Preparing may comprise tenderizing, seasoning, marinating and/or a
combination thereof.
[0011] Methods may further comprise reducing the likelihood of
contamination of the ribbed meat product and/or transfer of
bacteria from the ribbed meat product to humans by fully containing
the ribbed meat product within the high-temperature cook-in bag
from placement of the ribbed meat product in the cook-in bag at the
processor facility until after rendering of the ribbed meat product
in a high-temperature apparatus. In one embodiment, the methods may
comprise retaining moisture and flavor of the ribbed meat product
by containing the juices from the ribbed meat product within the
contained package.
[0012] In one embodiment, the methods may comprise venting of the
high-temperature cook-in bag. The methods may further comprise
hermetically sealing the contained package under vacuum. The
high-temperature cooking bags utilized in the methods of the
present invention may have a tear resistance of greater than about
50 g/mil to reduce tearing or puncturing of the cook-in bag by the
ribbed meat product during transportation of the contained
package.
[0013] Another aspect of the present invention concerns methods for
preparing a ribbed food product in a reduced cook cycle comprising:
placing, at a processor facility, a substantially fully cooked
ribbed meat product into a high-temperature cook-in bag suitable
for high-temperature processes that occur at temperatures greater
than about 350.degree. F.; providing an oxygen barrier to maintain
shelf life; and hermetically sealing the high-temperature cook-in
bag to create a contained package containing the substantially
fully cooked ribbed meat product. The contained package may be
exposed to a temperature greater than about 350.degree. F., thus
reducing the cook time necessary to rethermalize the ribbed meat
product. The cooked ribbed meat product may be prepared prior to
placing the cooked ribbed product into the high-temperature cook-in
bag. The methods may further comprise freezing the contained
package to produce a frozen contained package, wherein the frozen
contained package is suitable for direct placement into a
high-temperature cooking source. The contained package of the
current methods may be hermetically sealed under vacuum. Further,
methods may comprise transporting the contained package.
[0014] Another aspect of the present invention may comprise methods
for preparing a ribbed food product in a reduced cook cycle
comprising: placing an uncooked ribbed food product into a
high-temperature cook-in bag; closing the high-temperature cook-in
bag to create a sealed package comprising the uncooked ribbed food
product; and reducing the cook time to render the ribbed food
product by exposing the sealed package to a temperature greater
than about 350.degree. F. The cook cycle may comprise about 1 hour.
Further, the cook cycle may be reduced by a factor of three over
conventional rendering methods. The current methods may provide for
the juices from the ribbed meat product to remain within the sealed
package, thereby retaining moisture and flavor of the ribbed meat
product.
[0015] Methods of the present invention may convert the rendering
of bone in meat products from a low temperature, long cook cycle
process into a high-temperature short cook cycle process,
essentially turning bone in meat products into a convenience
food.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The foregoing and other aspects of the present invention
will become apparent from the following detailed description of the
invention when considered in conjunction with the accompanying
drawings. For the purpose of illustrating the invention, there is
shown in the drawings embodiments that are presently preferred, it
being understood, however, that the invention is not limited to the
specific instrumentalities disclosed. In the drawings:
[0017] FIGS. 1A and 1B are top and side views, respectively, of an
exemplary contained package comprising a high-temperature cook-in
bag and a ribbed meat product;
[0018] FIG. 1C is a side view of an exemplary contained package
comprising a high-temperature cook-in bag and a ribbed meat
product, under vacuum;
[0019] FIGS. 2A and 2B are top and side views, respectively, of an
exemplary high-temperature cook-in bag used to prepare a ribbed
meat product;
[0020] FIGS. 3A and 3B are top and side views, respectively, of an
exemplary high-temperature cook-in bag with a ribbed meat placed
within;
[0021] FIG. 4 is a cross section view of an exemplary blended
monolayer film that may be used in the formation of a
high-temperature cook-in bag for preparing ribbed meat products in
a reduced cooking cycle;
[0022] FIG. 5 is a cross sectional view of an exemplary multilayer
film comprising two layers that may be used in the formation of a
high-temperature cook-in bag for preparing ribbed meat products in
a reduced cooking cycle;
[0023] FIG. 6 is a cross sectional view of an exemplary multilayer
film comprising three layers that may be used in the formation of a
high-temperature cook-in bag for preparing ribbed meat products in
a reduced cooking cycle;
[0024] FIGS. 7A and 7B are top and side views, respectively, of an
exemplary method for packaging and preparing a ribbed meat product;
and
[0025] FIG. 8 is a side view schematic of an exemplary process for
making high-temperature cook-in bags that may be used in the
methods of the present invention.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0026] The present invention is directed to methods for the
preparation of bone in meat products in a reduced cook cycle. Bone
in meats, may include for example, fowl, fish, lamb, pork, beef,
among others. Suitable bone in meat products may include hams, pork
shoulders, etc. The present invention is particularly well-suited
for preparing ribbed meat products. Suitable ribbed meat products
can include, for example, pork and beef products including rib
roasts, pork chops, spareribs, baby back ribs, St. Louis style
spareribs, country style spareribs, Kansas City style ribs,
riblets, rib tips, and the like.
[0027] As used herein, a cook cycle may be defined as the period of
time required to at least substantially cook a bone in meat
product, render a bone in meat product, or reheat a bone in meat
product. The methods of the present invention provide several
advantages over current methods to prepare bone in meat products.
For example, cooking cycles required to render ribbed meat products
using the methods of the present invention are dramatically
reduced. In some embodiments, the cooking cycle to render the
ribbed meat product is reduced by a factor of three. In other
embodiments, the cooking cycle to render the ribbed meat product is
less than about one hour. The reduced cook cycle afforded by the
high-temperature cook-in bag provides a marked advantage over
conventional low temperature methods of cooking ribbed meat
products, which typically take place at 200.degree. F. to
250.degree. F. and take as long as 3-4 hours or more.
[0028] Other benefits of the present invention include increased
flavor associated with the cooked bone in meat product, retained
moisture during the cooking process, lower risk of
cross-contamination between the bone in meat product and humans,
and easier cleanup after the cooking process is complete. These
benefits are afforded through the placement of bone in meat
products, such as ribbed meat products, into high-temperature
cook-in bags and subsequently sealing the high-temperature cook-in
bags to form a contained package. The high-temperature cook-in bags
may be any type of enclosure, container, package, pouch, rollstock,
tube, form-fill-seal films, etc., suitable for receiving bone in
meat products.
[0029] FIGS. 1A and 1B are top and side views, respectively, of a
contained package 10A having an exemplary high-temperature cook-in
bag 10. As shown in FIGS. 1A and 1B, the contained package 10A may
include the high-temperature cook-in bag 10 with a ribbed meat
product 300 disposed therein. The high-temperature cook-in bag 10
may include ends 13, 14, which may be closed or sealed after the
ribbed meat product is disposed in the high-temperature cook-in bag
10. FIG. 1C is a side view of the contained packaged 10A sealed
under vacuum, which may improve the shelf-life of the ribbed meat
product 300.
[0030] FIGS. 2A and 2B are top and side views, respectively, of the
high-temperature cook-in bag 10 prior to insertion of the ribbed
meat product 300. The high-temperature cook-in bag 10 may be
comprised of a high-temperature film 100, and may include at least
one side wall 11 and the ends 13, 14. The high-temperature cook-in
bag 10 may define a cavity 12. As shown in FIG. 2B, the end 13 of
the high-temperature cook-in bag 10 may be closed and the end 14 of
the high-temperature cook-in bag 10 may define an opening 15 into
the cavity 12 for receiving the ribbed meat product 300.
[0031] FIGS. 3A and 3B are top and side views, respectively, of the
high-temperature cook-in bag 10 with the ribbed meat product 300
inserted in the cavity 12 through the opening 15. After the ribbed
meat product 300 is inserted into the cavity 12, the end 14 may be
closed to form a contained package 10A that includes the ribbed
meat product 300. For example, opening 15 may be closed using a
seal 17, such as a heat seal. In certain embodiments, the air
inside the bag may be evacuated during the sealing process, as
shown in FIG. 1C for example.
[0032] As used herein, high-temperature may refer to temperatures
greater than about 350.degree. F. The high-temperature cook-in bag
10 utilized in the present invention may comprise a blended
monolayer film or may comprise multilayer films comprising
materials that can withstand high-temperatures and may also have
other beneficial properties such as the ability to be readily heat
sealed, durability, good moisture barrier properties, and/or good
gas barrier properties. Suitable films for use with embodiments of
the present invention are described in U.S. Provisional Patent
Application No. 60/973,961, filed on Sep. 20, 2007, and U.S. patent
application Ser. No. 12/233,319, filed on Sep. 18, 2008, the
disclosures of which are incorporated herein by reference in their
entireties. Furthermore, high-temperature thermoformed webs may
also be utilized in the methods of the present invention. Suitable
thermoformed webs and suitable films comprised in suitable
thermoformed webs are described in U.S. Provisional Patent
Application No. 60/973,963, filed on Sep. 20, 2007, and U.S. patent
application Ser. No. 12/233,204, filed on Sep. 18, 2008, the
disclosures of which are incorporated herein by reference in their
entireties.
[0033] The high-temperature cook-in bag 10 utilized in certain
embodiments of the present invention may also be readily heat
sealed on conventional heat seal equipment that exists in meat
packing plants. Furthermore, the high-temperature cook-in bag 10
may have better tear strength and puncture resistance than the
traditional cook-in bags, and may be frozen and shipped with
improved tear strength and puncture resistance. The
high-temperature cook-in bag 10 may also have improved gas and/or
moisture barrier properties over conventional cook-in bags.
[0034] The film for the high-temperature cook-in bag 10 may be
produced using any technology known to one skilled in the art of
high-temperature cook-in bag production. Suitable technologies
include blown film technology (both mono-layer and co-extrusion),
cast film technology (both mono-layer and co-extrusion), or biaxial
orientation (double-bubble or tenter frame, mono-layer or
co-extrusion). The film can be either shrink or non-shrink. Typical
film thickness may be from about 1 mil to about 6 mils. Preferably,
film thickness may be from about 3 mils to about 4 mils.
[0035] The high-temperature films employed in the present invention
may have an interior surface and an exterior surface. The interior
surface is the portion of the high-temperature film that is in
contact with the ribbed meat product. The exterior surface is the
outside of the high-temperature film. Preferably the interior
surface is comprised of a composition that does not stick to
meat.
[0036] Several materials may be used to construct high-temperature
films for use in high-temperature cook-in bag 10 for rending ribbed
meat products in reduced cooking cycles. Suitable materials may
have one, if not more, of the following characteristics. These
characteristics include: high melting point, can be readily heat
sealed, good tear strength/puncture resistance, can withstand being
frozen, shipped, etc., and good barrier properties, such as gas
and/or moisture barrier properties. Suitable materials include
polyester elastomer, polyamide elastomer, nylon, polyester, and
polypropylene.
[0037] One characteristic for a suitable material is good barrier
properties such as gas and moisture. As used herein, a material
with a suitable gas barrier property has an oxygen barrier
transmission coefficient of approximately 30 cc/24 hr/100 in2/mil.
Preferably, the oxygen barrier transmission coefficient is at least
approximately 10 cc/24 hr/100 in2/mil. As used herein, a material
with a suitable moisture barrier property has a water vapor barrier
transmission coefficient of approximately 40 g/24 hr/100 in2/mil.
Preferably, the water vapor barrier transmission coefficient is
approximately 10 g/24 hr/100 in2/mil.
[0038] Another characteristic for a suitable material is good tear
strength. As used herein, a material with good tear strength has a
tear strength greater than about 50 g/mil. In a more preferred
embodiment, a material with a good tear strength has a tear
strength of greater than about 75 g/mil. A suitable material may
also have a good tensile yield strength. As used herein, a material
with a good tensile yield strength has a tensile yield strength of
greater than approximately 2,000 psi. Preferably, the tensile yield
strength is greater than approximately 2,500 psi. In certain
embodiments, the tear strength, puncture resistance, and tensile
yield strengths of the film are improved through the combination of
multiple layers in a multi-layer film.
[0039] A further characteristic for a suitable material is one that
substantially does not adhere to ribbed meat products during or
after the cooking of ribbed meat products. As used herein,
substantially does not adhere to ribbed meat products may be
defined as less than about 5% weight of the ribbed meat product
sticking to the package.
[0040] Homopolymer nylon is a suitable material for a layer within
a high-temperature multilayer film. Nylon has exceptional oxygen,
carbon dioxide and nitrogen barrier properties. Accordingly, it can
be used as a barrier layer in a film structure that will maintain a
vacuum or could be used in a gas flush package.
[0041] Nylon can be used as a layer by itself, or can be blended
with other materials to form a layer. Suitable materials that can
be blended with nylon include, polyester, polyamide elastomer, and
polyester elastomer. Suitable nylon includes AKULON.RTM.,
AKULON.RTM. F136 C1 which is a nylon 6, ULTRAMID.RTM., ULTRAMID B40
LN01 which is a nylon 6, BASF B40LN01, which is a nylon 6,
ASCEND.RTM., SOLUTIA 66J, which is a nylon 6,6 containing a heat
stabilizer, and UTRAMID C33, which is a nylon 6,6/6 co-polymer.
Further, various nylons may be blended together to form a blended
monolayer. For example, nylon 6 may be blended with a heat
stabilized nylon 6,6.
[0042] In certain embodiments, heat stabilizers may be added to the
nylon to improve its heat stability. Although nylon has a
relatively high melt point, approximately 423.degree. F., without
the addition of a heat stabilizer, nylon may become brown and
brittle at temperatures higher than approximately 325.degree. F.
Suitable heat stabilizers may include copper salts such as copper
iodide, copper bromide, and copper acetate.
[0043] When producing multi-layers films, it may be desirable to
combine layers using a method that does not decrease the bags
ability to be used for high-temperature cooking. A suitable method
to accomplish this is through the use of a tie layer. A tie layer
may be an intermediate layer between two layers of dissimilar
materials. The tie layer may be comprised of materials of the
layers in which it is between. This composition facilitates good
adhesion of the layers because each layer is attached to a layer
comprised, at least in part, of like materials. For example, to
join a polyester layer with a nylon layer, a tie layer comprising a
polyester elastomer blended with nylon would be suitable.
[0044] In certain embodiments, layers comprise a blend of a base
material, such as polyester or nylon, with an elastomeric material
such as polyester elastomer or polyamide elastomer. Preferably, the
percentage of base material in a layer is at least about 75% (by
weight). In other embodiments, the percentage of base material in a
layer is at least about 80% (by weight). In other embodiments, the
percentage of base material in a layer is at least about 90% (by
weight).
[0045] FIG. 4 is a cross-sectional view of an exemplary
high-temperature film 100a used in embodiments of the
high-temperature cook-in bag 10 of the present invention. As shown,
the film 100a may include a blended monolayer 1a with an exterior
20a and an interior 30a. The blended monolayer film 100a may
comprise a blend of nylon 6 and heat stabilized nylon 6,6. In
certain embodiments, the blended monolayer film 100a may comprise
from between about 60% and about 80% nylon 6 and from about 20% to
about 40% heat stabilized nylon 6,6. Preferably, the blended
monolayer film 100a may comprise about 80% nylon 6 and about 20%
heat stabilized nylon 6,6. The blended monolayer film 100a has
several advantages over traditional monolayer films. For example,
the nylon blend has superior oxygen barrier properties providing
improved shelf life of the ribbed meat product 300. Further, the
blended monolayer film 100a is very durable and has suitable tear
and puncture resistance to withstand shipping/storing applications.
Most notably, however, is the ability of the blended monolayer film
100a to withstand high-temperatures. For example, the blended
monolayer film 100a may withstand temperatures greater than about
350.degree. F., and for example, temperatures greater than about
400.degree. F.
[0046] FIG. 5 is a cross-sectional view of an exemplary multilayer
film 100b that may be used in the formation of the high-temperature
cook-in bag 10. The multilayer film 100b may comprise an exterior
20b and an interior 30b. FIG. 5 shows a two layer structure, i.e.,
an outer layer 1b and an inner layer 2b. The outer layer 1b of the
film 100b (outside of the bag) may be a blend of two materials.
Suitable materials for the outer layer 1b include a polyester
blended with either polyester elastomer or polyamide elastomer.
Suitable materials for the inner layer 2b (inside of the bag)
include a polyester elastomer or polyamide elastomer.
[0047] There are several advantages to the film structure shown in
FIG. 5. First, because the inner layer 2b of the bag 10 may be a
polyester or polyamide elastomer, it will not stick or have reduced
adhesion to meat proteins during cooking. Also, the elastomer
content provides good puncture resistance. Furthermore, the
polyester provides suitable moisture barrier properties. Finally,
the polyester may be oriented. Orientation provides additional
benefits including increased tear resistance and puncture
resistance along with the ability for the bag to be shrinkable.
[0048] Other suitable materials for the outer layer 1b include
nylon blended with a polyester elastomer or polyamide elastomer.
The benefits of this type of layer is that the outer layer 1b
possesses some of the beneficial characteristics of a nylon layer,
e.g., good gas barrier properties, and some of the beneficial
characteristics of a polyester elastomer or polyamide elastomer
layer, e.g., good flexibility. Furthermore, the polyester elastomer
in the polyester elastomer/nylon blend of the outer layer 1b has an
affinity for the polyester elastomer inner layer 2b. Suitable
amounts of polyester elastomer in the outer layer are less than
about 25% (by weight). Preferably, the amount of polyester
elastomer is less than about 20% (by weight).
[0049] FIG. 6 is a cross-sectional view of an exemplary multilayer
film 100c that may be used in the formation of the high-temperature
cook-in bag 10. The multilayer film 100c may comprise an exterior
20c and an interior 30c. FIG. 6 shows a three layer structure
comprising an outer layer 1c, an inner layer 2c, and a middle layer
3c. Suitable materials for the outer layer 1c include polyester
elastomer, polyamide elastomer, or nylon. Suitable materials for
the inner layer 2c include polyester elastomer or polyamide
elastomer. Suitable materials for the middle layer 3c include a
polyester blended with a polyester elastomer or a polyamide
elastomer; or a nylon blended with a polyester elastomer or
polyamide elastomer.
[0050] In one embodiment, the high-temperature cook-in bag 10 may
be comprised of the film 100c wherein the outer layer 1c comprises
a polyester elastomer or polyamide elastomer, the inner layer 2c
comprises a polyester elastomer or polyamide elastomer, and the
middle 3c layer comprises a polyester blended with a polyester
elastomer or polyamide elastomer. The middle layer 3c in this
embodiment may serve as a tie layer between the outer layer 1c and
inner layer 2c. Benefits include good moisture barrier properties
due to the presence of polyester in the film 100c, reduced adhesion
of meat products to the bag 10 due to polyester elastomer or
polyamide elastomer as an inner layer, and increased flexibility
and durability because of the polyester elastomer layers.
[0051] In another embodiment, the high-temperature cook-in bag 10
may be comprised of the film 100c wherein the outer layer 1e
comprises nylon, the inner layer 2c comprises a polyester elastomer
or polyamide elastomer, and the middle layer 3c comprises a nylon
blended with a polyester elastomer or polyamide elastomer. The
middle layer 3c in this embodiment may serve as a tie layer between
the outer layer 1c and inner layer 2c. The benefits of this
structure include superior gas barrier properties due to the 100%
nylon outer layer 1c, improved heat seal qualities due to polyester
elastomer or polyamide elastomer as the inner layer 2c, reduced
adhesion of meat products to the bag due to polyester elastomer or
polyamide elastomer as the inner layer 2c, and improved bone
puncture resistance due to the presence of polyester elastomer and
polyamide elastomer in the film 100c.
[0052] FIGS. 7A and 7B are top and side views, respectively, of an
exemplary process for preparing a ribbed meat product. As shown in
FIGS. 7A and 7B, the high-temperature cook-in bag 10 may be
manufactured from a sheet of film tube 200--Step 1. The film tube
200 may be in the form of a roll that can be unrolled across a bag
machine 800 (see FIG. 8.) to produce high-temperature cook-in bags
10 utilized in the present invention. The film tube 200 may be
unrolled on an unwind stand 805. The film tube 200 may be
subsequently rolled through dancer rolls 810 to control the tension
of the film tube roll as it moves along the bag machine 800.
Individual compartments 130 may be formed from the film tube roll
200 using various methods to produce the seal 17--Step 2. Suitable
methods to seal the film tube roll 200 are known to one skilled in
the art and may include heat sealing, and ultrasonic welding, among
others. In this embodiment, the seals 17 are formed by heat sealing
using a heated seal bar 820. The heat seal bar 820 melts the tubing
by pressing the film tube against a rubber roller 830. As the film
tube progresses down the bag machine via nip rolls 840, the film
tube 200 with the seals is subsequently cut 850 in a manner where
the seal is only at the bottom of the bag 10 and the top portion of
the bag 10 contains an opening. The resultant high-temperature bag
10 for rending ribbed meat products 300 in a reduced cook cycle can
be seen in FIGS. 2A and 2B.
[0053] Once the bags 10 are formed, the ribbed meat product 300 may
be placed into the cook-in bag 10--Step 4 (see also FIGS. 3A and
3B). Suitable ribbed meat products 300 are described herein and may
be either cooked or uncooked when they are insert into the cook-in
bag 10. Further, the ribbed meat products 300 may be prepared prior
to placement into the bag 10. For example, the meat products 300
may be tenderized, seasoned, sauced, or any combination thereof.
Also, various amounts of meat products 300 may be included into one
bag 10. Depending upon the application, one or more ribbed meat
products 300 may be placed into the bag 10. In one embodiment, two
ribbed meat products 300 are placed within the bag 10. In another
embodiment, three ribbed meat products 300 are placed within the
bag 10. As such, the size of the bag 10 may vary depending upon the
application.
[0054] For example, to prepare a single riblet, a suitable
high-temperature cooking bag 10 may have a size of approximately 2
inches by 8 inches. To prepare a bone in pork shoulder or ham, a
suitable high-temperature cooking bag 10 may have a size of
approximately 16 inches by 30 inches. In one embodiment, a short
rack of baby back ribs may be prepared in a high-temperature
cook-in bag 10 with an approximate size of about 6 inches by 20
inches. In other embodiments, the size of the bag 10 is about 7
inches by 24 inches, or for example, about 9 inches by 28 inches.
Preferably, the size of the bag 10 is suitable to contain at least
one rack of ribs. In some embodiments, the bag 10 is suitable to
contain at least two racks of ribs. In another embodiment, the size
of the bag 10 is suitable to contain at least three racks of
ribs.
[0055] After the ribbed meat product 300 is placed inside the bag
10, air may optionally be evacuated 400 from the cook-in bag 10 and
the bag 10 may be closed by, for example sealing the bag
closed--Step 5 (see seal 17). Air may be evacuated from the
interior of cook-in bag 10 using conventional methods known to one
skilled in the art (e.g., a vacuum). Further, the cook-in bag 10
may be sealed using conventional methods known to one skilled in
the art. For example, the cook-in bag 10 may be sealed using a heat
sealing technique. The resultant product is a contained package 10A
(see FIGS. 1A-1C). Preferably, the bag 10 is hermetically and/or
vacuum sealed to increase the shelf-life of the ribbed meat product
300. Maintaining a vacuum within the sealed cook-in bag 10 helps
ensure that there is none or only a negligible amount of free
oxygen in the cook-in bag 10 and a hermetic seal helps ensure that
no or a negligible amount of oxygen may enter the cook-in bag 10
during shipping and storage. Further, the films utilized to produce
the high-temperature cook-in bags 10 of the present invention have
very low oxygen transmission coefficients. Thus, an oxygen barrier
is provided with this contained package 10A to increase shelf life
of the ribbed meat product 300.
[0056] In one embodiment, formation of the contained package 10A
occurs at a processing facility. Once the contained package 10A is
formed, the package 10A may subsequently be transported to another
facility, such as a retail market. The films used to produce the
bags 10 of the present invention provide for a durable bag with
increased puncture/tear resistance. These durable bags 10 are able
to withstand the rigor of transport. Further, the contained package
10A containing the ribbed meat product 300 may be frozen or
refrigerated in a freezer/refrigerator 500--Step 6. This may occur
either before or after transport. The frozen/refrigerated contained
package 10A may subsequently be placed directly into a
high-temperature heating apparatus 600--Step 7. Suitable
high-temperature heating apparatuses 600 include ovens, microwaves,
convection ovens, steam and pressure cookers, slow cookers, smoke
houses, and vessels containing heat water, among others.
Alternatively, the frozen/refrigerated contained package 10A may be
removed from the freezer or refrigerator and may be defrosted in a
microwave prior to being placed into a high-temperature heating
apparatus 600. Advantageously, embodiments of the present invention
allow for the ribbed meat product 300 to be sealed in a
high-temperature cook-in bag 10 to form a contained package 10A,
frozen or refrigerated 500 in that same contained package 10A, and
placed into a high-temperature heating apparatus 600 in that same
contained package 10A.
[0057] If the ribbed meat product 300 is cooked prior to placement
into the high-temperature cook-in bag 10, the various benefits of
the present invention still apply, however, rather than the ribbed
meat product 300 being cooked within the contained package 10A, the
cooked ribbed meat product 300 may be rethermalized within the
contained package 10A. Rethermalizing the ribbed meat product 300
according the methods of the present invention reduces the time
required to accomplish the rethermalizing due to the ability to
apply a high-temperature, i.e., greater than 350.degree. F.
Further, because the ribbed meat product 300 is contained within
the cook-in bag 10, the ribbed meat product 300 stays moist and
will not dry out. Further, the high-temperature cook-in bags 10 of
the present invention provide for an oxygen barrier, a hermetic
seal, a vacuum seal or a combination thereof which improves the
shelf-life of the ribbed meat product 300 as discussed herein.
[0058] In another embodiment of the present invention, the
placement of the ribbed meat product 300 into the high-temperature
cook-in bag 10 is performed after the ribbed meat product 300 has
been shipped by the meat processor. This placement may be
performed, for example, in a residential kitchen, in a restaurant,
in a cafeteria, etc. In this embodiment, high-temperature cook-in
bags 10 may be prepared using methods as discussed above. The
ribbed meat product 300 may be placed into the high-temperature
cook-in bag 10 prior to being placed directly into the
high-temperature heating apparatus 600. Suitable high-temperature
heating apparatuses 600 include ovens, microwaves, convection
ovens, steam and pressure cookers, slow cookers, smoke houses, and
vessels containing heat water, among others. The ribbed meat
product 300 may also be placed into the high-temperature cook-in
bag 10 and may subsequently be frozen/refrigerated. Following the
freezing/refrigeration process, the high-temperature cook-in bags
10 containing the ribbed meat product 300 may be placed directly
into a high-temperature heating apparatus 600.
[0059] The high-temperature cook-in bag 10 may include a closure
system to provide for a sufficient seal to contain the juices of
the ribbed meat product 300 within the cook-in bag. The closure
system is preferably suitable for high-temperature applications.
For example, the closure system may include a flap portion combined
with an adhesive wherein the flap portion may be folded over the
opening 15 in the bag 10 and the adhesive closes and seals the bag
opening. The adhesive may be disposed on the flap portion and/or
the portion of the bag opposite the flap where the flap portion
folds over. The adhesive may be covered by a non-adhesive covering
(e.g. tape) that covers and protects the adhesive prior to use.
[0060] Alternatively, the oven bag closure system may include a
high-temperature zip lock closure or "slider" closure substantially
near the top open end of the bag 10. Such a closure may be made out
of a material such as nylon or polyester. In another example, the
closure bag system may include high-temperature snap fasteners
substantially near the top open end 15 of the bag 10. Such snap
fasteners may be welded on to a lip of the bag 10. The snaps may be
made using well-known techniques in the art, such as injection
molding the snaps out of nylon or polyester, for example.
[0061] There are several advantages to this embodiment over the
current art. For example, this embodiment allows for ribbed meat
products 300 to be cooked in situations that were not possible
prior to this invention. Previously, cooking ribbed meat products
300 at large functions was impractical due to the slow cook times.
This invention, however, allows for consumers such as cafeterias,
banquet facilities, and catering facilities, to prepare large
quantities of ribbed meat products 300. This is provided, in part,
because of the shorter cook times provided by the present
invention. The consumer may simply purchase the ribbed meat
products 300, place the ribbed meat products 300 into the
high-temperature cooking bags 10, and render the ribbed meat
products 300 in a reduced cook cycle.
[0062] Those skilled in the art will appreciate that numerous
changes and modifications may be made to the preferred embodiments
of the invention and that such changes and modifications may be
made without departing from the spirit of the invention. It is
therefore intended that the appended claims cover all such
equivalent variations as fall within the true spirit of the
invention.
* * * * *