BE1027291B1 - PROCESS FOR INDUSTRIAL PREPARATION OF FOOD - Google Patents

Abstract

The present invention relates to a method for industrial preparation of meals, wherein one or more meal components are prepared by means of a sous-vide pasteurization process, wherein the sous-vide pasteurization process takes place in stackable plastic containers.

Description

PROCESS FOR INDUSTRIAL PREPARATION OF FOOD

TECHNICAL FIELD The invention relates to a method for industrial preparation of meals, wherein one or more meal components are prepared by means of a sous-vide pasteurization process, and wherein the sous-vide pasteurization process takes place in stackable plastic containers.

STATE OF THE ART Sous-video pasteurization, also called sous-vide cooking or vacuum cooking, is a well-known method for preparing food in the food industry, and is a variant of low-temperature cooking. Meat, fish and vegetables can be cooked at a relatively low temperature in a bag or casing specially intended for this purpose, usually made of a type of plastic such as plastic, polyamides and / or polyethylene. For this, the food is placed in the plastic bag, which is (partially) vacuumed and sealed. Subsequently, it is placed in a hot water bath, also called au bain-marie, or in a steam oven, and heated to a temperature usually between about 50 and 90 ° C under a certain pressure. The temperature used for cooking meat is usually around 55-60 ° C. This is higher on average for vegetables. In conventional high temperature cooking, such as roasting or grilling in the oven, the food product is exposed to a much higher temperature than the desired internal core temperature, and the product must be removed from the high heat before the optimum temperature is reached. If the product is removed too soon or too late, the product will be undercooked or overcooked respectively. Due to precise temperature control during sous-vide cooking, whereby the ambient temperature of eg. the hot water bath is equal to the desired core temperature, very precise control can be maintained and an even temperature is achieved over the entire product. With vacuum cooking, all flavors, aromas and moisture remain in the plastic bag, so that these flavors and aromas remain more intense and the product does not dry out. Vitamins are also better preserved and the product retains its color. The final result is a product that is cooked evenly on the inside and outside. However, as discussed in US 2016/0220059, the Maillard reaction occurs much less through this method. This reaction, also called non-enzymatic browning, is a collective name for a series of chemical reactions that occur between reducing sugars and amino acids, under the influence of heat, for example, during the baking of food products. Since this reaction occurs much less with sous-vide pasteurization, however, the product does not develop a brown crust as is the case with baking or deep-frying.

This browning or reaction between reducing sugars and amino acids also results in an altered, often more pronounced, taste. In order to still get this flavor into the product, the food can be seared briefly after vacuum cooking before serving. In addition, the product can also be seared briefly before vacuum cooking, so that the more pronounced taste will be preserved during cooking.

Another known advantage of baking the food product for the sous-vide process is the reduction of the risk of bacteria. For this, the food product is briefly baked or seared in an oven, on a pan or with a gas burner, and at very high temperatures, which will kill a large part of the bacteria on the surface of the product.

BE1201964B1 describes a method for preparing food with a sous-vide process. Food components are placed in relatively rigid plastic containers in portions of a size for the consumption of at least one person, which containers are then closed with a vacuum skin packaging film to be applied over the food component and the containers thus packed are subjected to heating according to a sous-vide. process. In the method according to the invention, the raw food, such as meat, chicken, potatoes or vegetables, is first placed in or on the container and the container is sealed in a vacuum-tight manner with the skin packaging foil.

With this method, the taste is well preserved and the shelf life of the food to be consumed increases. The vacuum skin packaging film is preferably a plastic based on polyethylene.

During the sous-vide process, the trays with food are heated according to the Delta-T principle. When cooking in an autoclave, the heating temperature of the food is continuously maintained at a slight difference of only a few degrees from the core temperature of the food for a certain period of time. There will then be virtually no cooking damage. According to the Delta T principle, the longer the cooking time the lower the core temperature. The choice of the heating period and the associated temperature depends on the relevant food component. Meat is first seared on the outside and then placed in the tray, after which the method according to the invention is carried out. Several appliances are known for pasteurizing food products. US 2011/0085947 describes some of these devices. The first is a static autoclave with a basket in which the products to be autoclaved, pasteurized or sterilized are stacked. This is then enclosed in the autoclave where it undergoes a rise in temperature and pressure. Preferably, superheated water can drip over the products to promote heat transfer. This system has the advantage that it is possible to handle industrial quantities of product (from 100 kg to 10 tons). In addition, it partially retains the organoleptic properties of products, it is reliable and reproducible. This system requires a relatively long treatment time (2 to 3 hours). In addition, its implementation also leads to the cooking of the products. To shorten the treatment time, a rotation system has been proposed in which the basket is rotated in the autoclave during the heat treatment. This system shortens the treatment time because it promotes forced convection. In addition, other autoclaves are known with optimized shaking systems that allow rapid heat treatment of food or pharmaceutical products in industrial quantities.

Food products packaged for industrial pasteurization, sterilization, or autoclaving in an autoclave are loaded on trays, also called trays or plates. These plates fit stacked in special autoclave baskets, also called baskets or carts. These carts are often on wheels so that they can easily be driven into the autoclave. Before the autoclaving process, these plates are filled on the carts, and after the autoclaving process, they are unloaded again by transferring the packaged food products one by one into bins for transport, eg. back to the cooling unit. However, this is very labor-intensive work, which increases the cost. The present invention aims to solve at least some of the above-mentioned problems or drawbacks. The object of the invention is to provide a method which obviates these drawbacks.

SUMMARY OF THE INVENTION In a first aspect, the present invention relates to a method according to claim 1. Performing the pasteurization process in stackable plastic bins ensures that the food products no longer have to be transferred one by one to the plates that are stacked on the carts before they are loaded into an autoclave. This also makes unloading after autoclaving much faster, which results in a profit in time, and associated reduced costs. Preferred forms of the method are set out in claims 2 to 10.

A specific preferred form relates to the invention of a method according to claim 2. In this preferred form the bottom of the stackable plastic container is perforated. This allows the formed condensation water to drain from the tray, and it is also guaranteed that the irrigation water flows from one tray to the other tray. As a result, all containers are irrigated and thus efficiently pasteurized.

Another specific preferred form relates to the invention of a method according to claim 3. Not only the bottom, but also the side walls of the stackable plastic container are perforated therein. This further improves the flow of condensation water and irrigation water through the tanks.

According to the preferred shapes according to claims 4, 5 and 6, the preferred dimensions, material and characteristic of the stackable plastic trays are discussed, thereby optimizing them for use in a sous-vide pasteurization process according to the invention.

Preferred shapes according to claims 7 and 8 discuss the manner of stacking the food products in the stackable plastic trays and the size of the prepackaged portions of the food products. These preferred shapes optimize the sous-vide pasteurization process in stackable plastic containers. Another specific preferred form concerns the invention of a method according to claim 9. In this preferred form the sous-vide pasteurization process is preceded by a process of undercutting, which entails a more pronounced taste of the meal components.

In another preferred form according to claim 10, the meal component is heated to a core temperature of at least 2 minutes at 72 ° C, to guarantee a good microbiological quality of the meal component.

DETAILED DESCRIPTION Unless otherwise defined, all terms used in the description of the invention, including technical and scientific terms, have the meaning as commonly understood by those skilled in the art of the invention. For a better assessment of the description of the invention, the following terms are explicitly explained. “A”, “the” and “the” in this document refer to both singular and plural unless the context clearly suggests otherwise. For example, “a segment” means one or more than one segment. When “about” or “around” is used in this document for a measurable quantity, parameter, time or moment, and the like, it means variations of +/- 20% or less, preferably +/- 10% or less, more preferably +/- 5% or less, even more preferably +/- 1% or less, and even more preferably +/- 0.1% or less than and of the quoted value, to the extent that such variations of are applicable in the described invention. However, this should be understood to mean that the value of the quantity using the term “approximately” or “round” is itself specifically disclosed. The terms “comprise”, “comprising”, “consist of”, “consisting of”, “incorporating”, “containing”, “containing”, “containing”, “containing” are synonyms and are inclusive or open terms that define the indicate the presence of the following, and which do not exclude or prevent the presence of other components, features, elements, members, steps known from or described in the prior art. Quoting numeric intervals through the endpoints includes all integers, fractions, and / or real numbers between the endpoints, including these endpoints.

In a first aspect, the invention relates to a method for industrial preparation of meals, wherein one or more meal components are prepared by means of a sous-vide pasteurization process, and wherein the sous-vide pasteurization process takes place in stackable plastic containers. In the present invention, the term “pasteurization” refers to a process in which water and certain packaged and / or unpackaged foods are treated with a mild heat treatment, usually to less than 100 ° C (212 ° F)

for a suitable period of time to remove pathogens such as yeasts, fungi and bacteria and to extend shelf life.

The process is intended to destroy or inactivate organisms and enzymes that contribute to spoilage or the risk of disease, including vegetative bacteria, but not bacterial spores.

This improves the microbiological quality of the product.

The choice of the period of exposure to a particular temperature depends on the product concerned.

Due to the mild heat, there are only minor changes in the nutritional quality and sensory properties of the treated food.

The “microbiological quality” is expressed in the form of the bacterial count.

This is the number of germs (ie micro-organisms and traces thereof) per unit of product and can be determined by means of a measurement method known per se, for example by taking a representative sample of the product, possibly diluting it, and plating it on a suitable medium under suitable environmental parameters.

The number of colonies of microorganisms can then be counted.

There are also automatic systems in which the number of micro-organisms is counted and measuring systems in which the number of germs is determined by means of a coloring agent which reacts to the amount of micro-organisms.

By the term "sous-vide pasteurization", also referred to as "sous-vide cooking", "vacuum cooking" or "low temperature long time cooking (LTLT)" is meant in the present invention pasteurization as described above under a partial vacuum. or partial negative pressure.

Much, but not all, air is discharged from the receptacles, for example a plastic bag or glass jar, in which the product is contained.

Subsequently, it is heated, for example in a hot water bath, also called au bain-marie, or in a steam oven, to a temperature usually less than 100 ° C, usually between about 50 and 90 ° C.

By way of illustration but not limitative, the average temperature for cooking meat is around 55-60 ° C.

This is higher on average for vegetables.

Cooking times are longer than with conventional cooking, usually 1-7 hours, in some cases up to 48 hours or more and at a precisely controlled temperature, of course also depending on the portion size.

The term “meal” can be understood in this text as any prepared food product that can be used for human consumption.

Non-limiting examples of meals are spicy meatballs with spaghetti, vol au vent with wild mushrooms and carrot stew with sausage.

The term “meal components” can be understood in this text as a constituent part of a meal, as prepared foodstuffs that can be used as parts of one or more meals suitable for human consumption. Non-limiting examples of meal items are puree, tomato sauce, carrot stew, and prepared ground beef. An advantage of performing the sous-vide pasteurization process for industrial preparation of meals in "stackable plastic containers" of this invention, also referred to as "stackable plastic crates", is that the prepackaged food products or meal components no longer have to be transferred one by one. from the transport units to plates or trays that are stacked on the carts before being loaded into an autoclave where the pasteurization process is carried out. The trays with prepackaged meal components can be loaded directly onto the carts. This also makes unloading after autoclaving much faster, which results in a gain in time and associated reduced costs.

The stackable plastic bins used in the method of the invention, in a preferred embodiment have a perforated bottom, and more preferably a perforated bottom and perforated side walls. This allows the formed condensation water to drain out of the tray, and it is also guaranteed that the irrigation water from the autoclave flows from one tray to the other tray. As a result, all containers are irrigated and thus efficiently pasteurized.

In another preferred embodiment, the stackable plastic trays used in the present process have dimensions that are standard for food industry trays. These are preferably bins that meet the Euro standard for stacking bins. Euronorm is based on the basic size 600 x 400 mm (length x width) and is accepted as a standard throughout Europe. Various other soil sizes have been derived from this basic size. Manufacturers, (wholesalers) and transporters throughout Europe realize the most efficient method of transport and storage with the Euronorm format. The Euronorm dimensions of bins and crates are intended for efficient use in combination with Euro pallets 1200 x 800 mm, ISO pallets 1200 x 1000 mm and roll containers 800 x 600 mm. The dimensions of these load carriers are again tailored to the dimensions of the transport by trucks. Standard dimensions of Euronorm bins are for example 200 x 150 mm, 300 x 200 mm, 400 x 300 mm, 600 x 400 mm and 800 x 600 mm. The height can differ. Even more preferably, the trays of the present process have dimensions of 600 x 400, most preferably the dimensions are 600 x 400 x 75 mm. In another preferred embodiment, the stackable plastic containers used in the present method are made of polypropylene, also called polypropylene or PP. Polypropylene can be used in the food industry and is very resistant to chemicals. This is a hard but relatively flexible product, so it does not break too quickly.

In another preferred embodiment, the stackable plastic trays used in the present method can withstand temperatures up to 98 ° C. This is necessary as a pasteurization process is carried out at temperatures up to 98 ° C, as mentioned earlier. If the stackable plastic containers can withstand this temperature, the containers will not deform from the heat. The drawing in of the side walls and the bending of the bottom due to the heat should be strongly avoided, as this prevents the stackability and thus the stability of the trays.

In another preferred embodiment packaged food products are stacked obliquely or upright in said stackable plastic containers. As a result, the irrigation water runs down towards containers that may be stacked lower, and the irrigation water does not run through the side walls of containers with perforated side walls. As a result, all containers are irrigated and thus efficiently pasteurized.

In yet another preferred embodiment of the method of this invention, the meal components are packaged in portions of maximum 2 kg. The smaller the components, the easier the heat will penetrate into the core of the portion and the faster it will be pasteurized.

In a preferred embodiment of the method of the present invention, the sous-vide pasteurization process is preceded by an undercutting process. The term "undercutting" of the present invention means any form of pre-cooking, for the sous-vide pasteurization process. This may, for example, be briefly searing, searing or searing the meal component in an oven, on a pan or with the aid of a gas burner, but is not limited to these methods or appliances.

As mentioned earlier, the Maillard reaction occurs much less via the sous-vide pasteurization process. This chemical reaction produces a brown crust, as is the case with baking or deep-frying. This browning or reaction between reducing sugars and amino acids also results in an altered, often more pronounced, taste. In order to still get this flavor into the product, the meal component can be seared briefly before or after vacuum cooking before serving, if desired. If this is done before the sous-vide pasteurization process, it can be referred to as “undercooking”, and the more pronounced taste and the browner color will be retained during cooking.

Another known benefit of undercutting for the sous-vide process is the reduction of the risk of bacteria. By briefly exposing the meal component to high temperatures, much of the bacteria on the surface of the product will be killed.

In another preferred embodiment, the meal component is heated to a core temperature of at least 2 minutes at 72 ° C. This guarantees a good microbiological quality of the meal component.

In what follows, the invention is described by means of non-limiting examples illustrating the invention, and which are not intended or should be construed to limit the scope of the invention.

EXAMPLES The invention will now be further elucidated by means of the following example, without otherwise being limited thereto. EXAMPLE 1 Example 1 concerns the industrial preparation of baked potatoes with rosemary by means of a sous-vide pasteurization process in stackable plastic containers. A 400 g portion of baked potatoes with rosemary is vacuum packed, in a package suitable for a sous-vide pasteurization process. Twenty servings of 400 g vacuum packed baking potatoes with rosemary are stacked upright per polypropylene tray with perforated bottom of 600 x 400 x 75 mm. Five times 12 trays of 20 portions are stacked in five stacks and transported to an autoclave suitable for pasteurizing food for the food industry. 12 bins are loaded into each of the autoclave's 5 carts and the autoclave door is closed. The baked potatoes are sous-vide pasteurized for 60 min at 90 ° C and afterwards cooled in the autoclave. Once cooled, the carts are moved out of the autoclave and the bins are stacked on a pallet for transport to the cooling zone for storage.

EXAMPLE 2 This example concerns the industrial preparation of duck legs in elderberries by means of a sous-vide pasteurization process in stackable plastic containers, the duck legs undergoing undercutting for the sous-vide pasteurization process.

Duck legs are briefly seared in an oven to obtain a brown coloring and improved flavor. Portions of 0.220 kg duck leg with elderberry are vacuum packed in packaging suitable for a sous-vide pasteurization process. Thirty servings of these packaged meals are stacked upright per polypropylene container with perforated bottom and side walls. Each tray measures 600 x 400 x 75mm. Five stacks of 12 trays each are made and thus transported to an autoclave suitable for pasteurizing food for the food industry. 12 bins are loaded into each of the autoclave's 5 carts and the autoclave door is closed. The duck legs with elderberries are pasteurized sous-vide for 120 min at 95 ° C and afterwards cooled in the autoclave. Once cooled, the carts are moved out of the autoclave and the bins are stacked on a pallet for transport to the cooling zone for storage.

EXAMPLE 3 Example 3 relates to the industrial preparation of chicken soup by means of a sous-vide pasteurization process in stackable plastic containers.

280 ml portions of chicken soup are vacuum packed in a package suitable for a sous-vide pasteurization process. Thirty servings of these packaged meals are stacked upright per polypropylene container with perforated bottom and side walls. Each tray measures 600 x 400 x 75mm. Five stacks of 12 trays each are made and thus transported to an autoclave suitable for pasteurizing food for the food industry. 12 bins are loaded into each of the autoclave's 5 carts and the autoclave door is closed. The chicken soup is sous vide pasteurized for 60 min at 90 ° C and afterwards cooled in the autoclave. Once cooled, the carts are moved out of the autoclave and the bins are stacked on a pallet for transport to the cooling zone for storage.

Claims (10)

CONCLUSIONS A method for the industrial preparation of meals, wherein one or more meal components are prepared by means of a sous-vide pasteurization process, characterized in that the sous-vide pasteurization process takes place in stackable plastic containers. Method according to the preceding claim, characterized in that the sous-vide pasteurization process takes place in stackable plastic containers, at least the bottom of which is perforated. A method according to preceding claims 1-2, characterized in that the sous-vide pasteurization process takes place in stackable plastic containers, the bottom and side walls of which are perforated. Method according to preceding claims 1-3, characterized in that said stackable plastic bins measure 600 x 400 x 75 mm. A method according to preceding claims 1-4, characterized in that said stackable plastic containers are made of polypropylene. A method according to any of the preceding claims 1-5, characterized in that said stackable plastic containers can withstand a temperature of up to 98 ° C. Method according to preceding claims 1-6, characterized in that packaged food products are stacked obliquely or upright in said stackable plastic containers. 8. A method according to preceding claims 1-7, characterized in that the food is packaged in portions of maximum 2 kg. Method according to preceding claims 1-8, characterized in that the sous-vide pasteurization process is preceded by a process of undercutting. A method according to preceding claims 1-9, characterized in that the meal component is heated to a core temperature of at least 2 minutes at 72 ° C.