BRPI0600533B1 - pressure cooking process of food in air-containing packaging - Google Patents

Abstract

"General food cooking process in air-containing packaging". especially in a multi-step process (e) that allows the use of market-standard equipment and packaging (1) for cooking, preserving and marketing the most varied food products in cold form (oa 4 <198> c), with or boneless, packaged in such flexible (1) air-tight packaging (a), hermetically sealed at any volume, with a longer shelf life than sufficient for worldwide marketing, the new process being It can eliminate viruses such as foot-and-mouth disease and avian fever and considerably decrease the total count of microorganisms. It is quite robust in relation to the maintenance of sensory and microbiological qualities during long term conservation.

Description

“FOOD PRESSURE COOKING PROCESS WITH AIR PACKAGING” [001] This application for an Invention Patent addresses an unprecedented “FOOD PRESSURE COOKING PROCESS WITH AIR PACKAGING”, especially a process for cooking food containing contained in flexible and airtight packaging with the differential of the food in question being cooked in the presence of air by thermal processing in the packaging itself. The present process stands out for introducing a new concept in the technical processing sector of these products, with significant advantages in the extension of the shelf life of cold products, quality of the final product, cost reduction, simplification and flexibility of food cooking processes. , virus elimination and practicality.

[002] The present invention is applicable to the food industry in the cooking, preservation and marketing of chilled foods with a shelf life for a period of time preferably exceeding four months. The cooking process can be used for some types of food products, such as the feijoada, the double, the oxtail in Brazilian cuisine, the cassoulet of French cuisine; the "ossobuco" in Italian cuisine sauce; the “puchero” of Spanish cuisine and other types of concept foods similar to those already mentioned, that is composed of solid and liquid or pasty (brines, broths, sauces, etc.). Said process may also be applied for the cooking, preservation and marketing of foods made from meat, such as whole pork shank or pieces with or without bone; bovine lizard; carcass of chicken or turkey or cuts of these birds with or without bone.

[003] It is well known that the marketing of pre-prepared animal foods is a common practice in the market segment and that with the current way of life has gained an important share of this market.

[004] In the present state of the art, the processes of cooking food in airtight flexible packaging, preserving and marketing in the same package under refrigeration (temperatures above 0 ° C) are generally known as “cook-in” and there are also a variation of this process called “sous-vide”. In these processes there are several variants and applications, such as: [005] In the “cook-in” process, the cooking is performed in flexible packages with very low internal air, which usually requires special equipment to remove the air before cooking. packaging closure. The packages are specific and interact with the product to avoid brine exudation as in cook-in hams. Packaging should also withstand pressure formed internally due to process times and temperatures, typically two to four hours and outside temperatures below 80 ° C. In this process one can place the individual packages in pressed shapes so that the product has a definite shape, as in the case of molded hams. Products are kept under refrigerated temperatures and shelf life is about two to four months.

[006] In the “sous-vide” process, cooking is also performed in flexible packaging, with residual air extraction which requires special high cost equipment that acts before closing the package. This process is best used in smaller portions of food such as: half boneless chicken breast with gravy; rice portion; vegetable portion and etc .. And also in individual or combined form in dishes to serve a meal. The cooking process is less intense than the cook-in and the products are kept refrigerated for three to five weeks.

Therefore, in known state of the art cooking processes, the product is cooked in a package with maximum extraction of the internal air, before closing the latter.

[008] The production process of retortable pouch products can also be cited compared to the process in question. In the “retortable pouch” process, cooking is performed in the flexible packaging itself, but the heat treatment is performed under pressure with sufficient time and temperature to achieve commercial sterility, which allows the product to be stored at room temperature. Like previous processes, this requires extracting air from the package to avoid sensory changes to the product, appearance of stuffed packaging, etc. Special packaging is generally used to withstand pressures and temperatures, and to avoid exchanges with the environment during the storage period. The cooking equipment is also special, because the cooking is done under pressure. In this process, at room temperature of preservation of the product, the presence of air inside the package is extremely undesirable as it may cause oxidation of fats and other nutrients as well as alter the appearance of the packaging, among other drawbacks.

The most noticeable shortcomings of conventional processes with respect to the first two processes mentioned, regarding storage under refrigeration (temperatures above - 0 ° C), are limited to heat treatments which usually have a shelf life of less than four months. ; the high investments required by the specific equipment to remove air before closing the package; high-cost flexible films in addition to the drawbacks listed below: • The inability to cook bone-in meat, because the internal vacuum required by the process makes the packaging more susceptible to perforation by the bone ends, causing loss of the integrity of the food system. / packing; • Formation of internal anaerobic medium which increases the risk of development of pathogenic microorganisms especially Clostridium Botulinum;

[010] The drawback of the “retortable pouch” process that prioritizes microbiological stability, reaching shelf life of over 12 months without the need for refrigeration, is the cost and impairment of the sensory quality of the product due to the intensity of the heat treatment to which it is subjected. subject.

Thinking of these problems, it was that the inventor, after numerous researches, created the process in question for cooking, storing and marketing various food products, with or without bone, which are packed in the presence of air, being cooked. inside the package for a suitable period of time to soften the parts of the meat until an adequate and even texture is obtained for all products accompanying the meat and, without loss of aromatic characteristics and juiciness, restricted within the package.

[012] The claimed process allows the preservation and marketing of the product in the same package in which it was prepared with shelf life above four months for chilled products (0 to 4 ° C), and may exceed 12 months for some types of products.

[013] In the claimed process the ingredients are packaged in flexible packaging in the form of tubes, bags or laminates. After the ingredients have been placed, the packages are hermetically sealed without any special air extraction system, and the air remains inside the package that is hermetically sealed.

[014] The sealed packages are then steamed or otherwise heated. Said cooking may be carried out at atmospheric pressure or under pressure for a time and temperature sufficient to ensure the sensory particularities of softness and juiciness, desired taste as well as microbiological stability to provide adequate food safety for the product during shelf life. pre-established for that type of product. The heat treatment is more than sufficient to destroy any viruses such as foot-and-mouth disease and avian influenza and considerably reduce the total microbiological count.

[015] During the cooking process performed at atmospheric pressure, a small pressure is generated within the package, perfectly bearable by the properties of the flexible film, the closure medium adopted, the interaction of the ingredients with the package and the cooking method adopted.

[016] In the case of pressure cooking, the external pressure may or may not allow expansion of the package's internal air depending on the pressure adopted in the cooking method.

[017] The cooking process promotes sufficient heat treatment and the product has no chance of recontamination. The process is guaranteed and effective enough to ensure long shelf life of more than four months for the product stored at temperatures from 0 to 4 ° C.

[018] The proposed process has as main advantages: • Maintenance of Sensory and Microbiological quality for more than four months in cold products, which may exceed twelve months; • Inserts the concept of air cooking inside the package, breaking a paradigm for this type of technology, since the presence of air does not affect the intrinsic qualities of the product; by way of illustration even fat pigs kept in good palatability after a period of more than twelve months; • Increased microbiological safety of the product due to the presence of air in the packaging, minimizing the anaerobic conditions of the environment, hindering the growth of anaerobic spores, including Clostridium Botulinum. • Total elimination of foot-and-mouth disease or H5N1 virus; • Low initial investment in equipment and packaging; • No special packaging materials required; • Flexibility towards the development of new products; • Possibility of cooking bone products without danger of perforation of the package; • Flexibility of production in small, medium or large scale.

[019] The process is explained with reference to the following illustrative and non-limiting drawings, in which they are shown: Figure 1: Flowchart for the pressure cooking process in air-containing packaging, for products such as Feijoada, “ Puchero ”and the like;

Figure 2: Flowchart for the pressure cooking process of food in air-containing packaging for products in pieces or pieces or carcasses;

Figure 3: Perspective drawing showing any product packed in flexible pouch or sealed bag at ambient pressure cooking stage with internal air detail.

Figure 4: Perspective drawing showing any product packed in tubular flexible packaging, manually closed with knots in the ambient pressure cooking phase with detail of the internal air.

[020] The “air-packed food-pressure cooking process” - the subject of this patent application, consists essentially of a multi-step process (E) allowing equipment and packaging to be used (1) market, for cooking, preserving and marketing in cold form, the most varied food products, with or without bone, packed in said flexible packaging (1) with air (A), hermetically sealed in any volume, being possible obtain longer shelf life, more than enough for worldwide commercialization, the new process being able to eliminate viruses such as foot-and-mouth disease and avian fever, being quite robust in relation to the maintenance of sensory and microbiological qualities during conservation. for long time.

More particularly, the screen process involves raw and / or pre-prepared ingredients packaged in a (1) flexible and tightly sealed package (2) without excluding internal air (A). The required quality of the types of food products that can be cooked in this process allows the presence of internal air (A) in the package (1) closed during cooking, preservation and commercialization, and stands out for not needing specific equipment for removal. before closing said package (1).

[022] Cooking may range in a limited time from two to seven hours at an external temperature above 80 ° C with steam, heated water or other known heating medium.

[023] Lower times can be obtained with pressure cooking.

[024] The basic reference for defining the time-temperature binomial in cooking is the particularities of the cooked parts, in order to reach the appropriate level of palatability, especially softness and juiciness.

[025] In atmospheric pressure cooking, as there is air inside the package, with increasing temperature there is a natural increase in the internal pressure of the package during cooking, which has a desirable effect on the softness and texture of the ingredients ( pieces of boneless meat, beans, pieces of smoked sausages, vegetable pieces, pieces of bone meat, seasonings, broths, sauces, etc.) to the desired point. The aroma and juiciness characteristics are maintained inside the package, with no loss of sensory qualities and weight during cooking, preservation and commercialization.

[026] If cooking takes place under pressure, the cooking time is logically reduced and adjusted to achieve the same desired effects already commented above.

[027] In addition to these positive aspects, the process allows the use of flexible packaging (1) in the form of tubes, bags or laminates, hermetically sealed (2) by means of knots, metal or plastic clips or sealed.

[028] After cooking the package is rapidly lowered to 0 to 1 ° C within less than five hours. Pre-cooling with room temperature water and then water or cold air may be used; then be sent for storage in cold rooms until consumption. During storage and marketing the product should be kept at temperatures between 0 and 4 ° C.

[029] The definitions of the binomial time x temperature in cooling are parameterized by balancing the economics of this process step and the need for microbiological and sensory quality of the final product.

As the intensity of the heat treatment in cooking is relatively high and the process remains airtight during cooking, preservation and commercialization avoids the possibility of recounting inaction by microorganisms, being the product conserved and commercialized at cooling temperatures. Thus, sensory quality and microbiological stability are maintained for periods exceeding four months and may reach more than twelve months, with excellent quality standards at the time of consumption.

[031] The preparation of products such as feijoada, “puchero” and the like (P1) takes place according to the steps described below: 1st stage (E1) - prepare the individual portions of each component according to the unit weight defined in the formulation composition reflecting the total weight of packaging, cleaning, cutting, portioning ingredients as specified by product standards; 2nd stage (E2) - elaboration of the liquid part of the formulation, in which the added broths or sauces are prepared together with the individual portions mentioned above; 3rd step (E3) - Dosage of each component in the package, which deals with the placement of the individual portions in the flexible package, whether in tube, bag or thermoformed films; 4th step (E4) - dosage of the liquid part, deals with incorporating in the packaging the liquid part of the product; 5th step (E5) - weight adjustment, deals with the weighing of the package and adjustment to the preset weight with the additional placement of the liquid part and depending on the difference, with one of the components in the form of pieces; 6th step (E6) - Airtight closing of the package, is nothing more than the act of closing the package, which depends on the type of package chosen. For flexible pipes it can be manually closed with a knot; or by applying metal or plastic clips; For pouches, thermoformed can be sealed and also closed with staples; 7th step (E7) - Baking, is to subject the package to baking at temperatures between 80 and 100 ° C, for a time between two and seven hours, depending on the size of the package and each type of product and its particularities. Temperatures above 100 ° C may be used when cooking under pressure. In this case the binomial time x cooking temperature is adjusted to obtain the desired effects of microbiological and sensory quality of the product during the shelf life; Step 8 (E8) - Cooling, after cooking the temperature is rapidly lowered to 0 to 1 ° C within less than five hours. Pre-cooling with room temperature water and then cold water or air may be used. ; 9th step (E9) - preservation and marketing, the product is stored at a refrigerated temperature of 0 to 4 ° C and marketed in the same package in which it was cooked, obviously the product can be frozen without prejudice to its microbiological qualities; 10th step (E10) - preparation for consumption, at the moment of consumption the package is opened and the product heated in the traditional way according to existing devices for this purpose (pans heated by fire or plate, microwave, water bath in the package itself, etc. .).

[032] The preparation of products in parts or carcasses (P2) such as swine leg, lizard or whole turkeys and the like takes place according to the steps described below: 1st stage (E1 ') - preparing the parts means cleaning, weigh the pieces to be cooked according to specifications with regard to overall appearance, apparent fat, weight of the piece, etc .; 2nd stage (E2 ') - seasoning of the pieces according to the chosen methods, such as: addition of dry seasonings, immersion in solutions or injections of seasoned brines; 3rd stage (E3 ') - placing the parts in the package, which deals with the placement of the parts in the defined flexible packaging, whether in tube, bag or thermoformed films; 4th step (E4 ') - weight adjustment, deals with weighing the package and adjusting to the predefined weight with the additional placement of the liquid part, for example a seasoned brine or sauce; 5th step (E5 ') - hermetic sealing of the package, is nothing more than the act of closing the package, which depends on the type of package chosen. It can be closed manually with a node; or by applying metal or plastic clips; or sealing; Step 6 (E6 ') - Baking, is to subject the package to baking for a minimum of two hours and may reach seven hours, depending on the size of the package and each type of product and its particularities, at temperatures from 80 to 100 ° C. When cooking under pressure, temperatures above 100 ° C may be used, with a significant reduction in cooking time. It is necessary to adjust the time x cooking temperature binomial to obtain the desired effects of microbiological and sensory quality of the product; 7th step (E7 ') - cooling, after cooking the temperature is rapidly lowered to 0 to 1 ° C within less than five hours. Pre-cooling with room temperature water and then water or air may be used. cold; 8th step (E8 ') - preservation and commercialization, the product is stored at a refrigerated temperature of 0 to 4 ° C and marketed in the same package in which it was cooked; 9th step (E9 ') - preparation for consumption, at the moment of consumption the package is opened and the product is usually heated in a traditional oven until the best looking external color and temperature suitable for serving is obtained.

Claims (4)

1) “FOOD-PRESSED COOKING PROCESS IN AIR CONTAINER PACKAGING”, applied to the food industry, in the preparation of raw and / or pre-prepared products takes place in several stages (E) in which food products, with or without bone, are packed in flexible packaging (1) characterized by the presence of air in a 1st stage (E1) - preparing the individual portions of each component; 2nd stage (E2) - elaboration of the liquid part of the formulation; 3rd stage (E3) - dosage of each component in the package; 4th stage (E4) - dosage of the liquid part, 5th stage (E5) - weight adjustment; 6th step (E6) - hermetically sealing the package by hand with a knot by applying metal or plastic clips or heat sealing; 7th step (E7) -submitting the package to pressure cooking using a temperature greater than 100 ° C; 8th step (E8) - cooling, after cooking the temperature is rapidly lowered to 0 to 1 ° C within less than five hours, and may be pre-cooled with water at room temperature and subsequently with water. or cold air at negative temperatures; 9th step (E9) - storage at 0 to 4 ° C and sold in the same package in which it was cooked and frozen; 10th step (E10) - preparation for consumption, open the package the product must be heated in a traditional way. 2) "PRESSURE-COOKING FOOD PROCESS IN AIR CONTAINING PACKAGING" according to claim 1 characterized by the preparation of feijoada, "puchero" and the like (P1). (3) "AIR-CONTAINED FOOD-COOKING PROCESS" according to claim 1, characterized in that the preparation of products in parts or carcasses (P2) takes place in stages whose first stage (E1 ') - prepares the parts; 2nd stage (E2 ') - spice of the pieces; 3rd step (E3 ') - placing the parts in the defined flexible packaging, tube, bag or thermoformed films; 4th step (E4 ') - weight adjustment; 5th step (E5 ') - hermetically sealing the package manually with a knot by applying metal or plastic clips or heat sealing; 6th step (E6 ') -submitting the package to pressure cooking using temperature above 100 ° C; 7th step (E7 ') - cooling, after cooking the temperature is rapidly lowered to 0 to 1 ° C, within less than five hours, and may be pre-cooled with water at room temperature and subsequently with cold water or air at negative temperatures; 8th step (E8 ') - storage at a refrigeration temperature of 0 to 4 ° C and sold in the same package in which it was cooked and frozen; 9th step (E9 ') - preparation for consumption, open the package the product must be heated in a traditional way. 4) "PRESSURE-COOKING FOOD PROCESSING IN CONTAINING AIR" according to claim 3, characterized by the preparation of swine leg, whole lizard or turkey and the like.