IE20100324A1 - A food production process - Google Patents

Abstract

A method of manufacturing meat products includes de-boning (2) and cutting (3) a carcass to provide meat cuts and by-products, and a vacuum packing (4) the meat cuts and dipping (6) the packages in a water bath at an elevated temperature to cause shrinkage of the package. The packaged and dipped meat packages are placed into a rigid plastics tray (7), and transported (8) in the tray to a destination. The trays (T) are returned after delivery to a wash system (60) which operates by supporting the tray (T) in a support bracket (61), and moving the tray (T) through a plurality of cycles, each cycle including elevating and decending the tray through a spray from spray bars (64). Waste water is removed from at least one of the cycles and re-used for a cycle of the next operation. The by-products are placed (20) in a lined tray, which is placed in a freezer (22), and when the by-products are frozen the liner containing the frozen by-products is removed for delivery, and the empty trays are returned to the wash system (60). The brackets (61) have only point contact with the trays (T). A first wash cycle uses recovered water from a second cycle of a previous wash operation, a second cycle uses recovered water from a third cycle of previous wash operation, and a third wash cycle uses fresh water. Used wash water flows via a sump under the brackets (61) into a tank selected by a valve (71) under the sump, there being a tank (A,B,C) associated with each cycle for complete washing of a tray.

Description

“A Food Production Process” (Ms nhwuc isspccnoi SB0B 2* Λ&0 SOLE 25 ΐ isl Μ) Introduction The invention relates to production of meat products.

In a typical manufacturing process an animal carcass is processed by boning and cutting to provide individual cuts for supply either customer-ready or for further cutting by butchers. The cuts are vacuum sealed and packed into cardboard cartons for delivery.

An object of the invention is to simplify the manufacturing process and to reduce manufacturing costs. Another object is to achieve improved consistency in presentation of the food product.

Summary of the Invention manufacturing' meat products, the According to the invention, there is provided a method o method comprising the steps of: de-boning and cutting a carcass to provide meat cuts and by-products; vacuum packing the meat cuts and dipping the packages in a liquid bath at an elevated temperature to cause shrinkage of the packages; placing the packaged and dipped meat packages into a rigid plastics tray, and transporting the packages in the tray to a destination, returning the tray after delivery to a wash system and the wash system washing the tray by: supporting the tray in a support bracket, moving the tray through a plurality of cycles, each cycle including moving the tray in a cycle through a spray delivered by spray bars, and recovering waste water from at least one of the cycles and re-using the recovered waste water for a cycle of the next waste operation, placing the by-products in a lined tray, placing the tray in a freezer, and when the byproducts are frozen, removing the liner containing the frozen by-products for delivery, and returning the empty tray to the wash system.

In one embodiment, the bracket has only substantially point contact with the tray. fE 1 Ο Ο 3 2 4 -2In one embodiment, a first cycle uses recovered water from a second cycle of a previous wash operation. In one embodiment, a second cycle uses recovered water from a third cycle of a previous wash operation. In one embodiment, a third wash cycle uses fresh water.

In one embodiment, used wash water flows via a sump under the brackets into a tank selected by a valve under the sump, there being a tank associated with each cycle for complete washing of a tray. In another embodiment, the flows from the tanks to the nozzles are via an in-line filter. In one embodiment, the tanks are insulated.

In one embodiment, the gauge of plastics film used for vacuum packaging the meat cuts is in the range of 3 5 μιη to 45 pm. In one embodiment, the gauge is approximately 40pm.

In one embodiment, an inspection is performed before dipping of the packed meat cuts.

In one embodiment, the tray-supporting brackets are suspended from a substantially horizontal bar, and a drive mechanism moves the bar up and down in a vertical plane for wash each cycle.

In one embodiment, the bar is movable at both ends in a groove or rail of a housing of the wash 20 system.

In one embodiment, the drive mechanism comprises a single drive element which is linked to both ends of the bar. Preferably, the drive element is linked to the bar ends via flexible links running over pulleys or sprokets. Preferably, the flexible links are belts and the belts run over pulleys mounted at a higher level than the drive element. Preferably, the bar has a carriage at each end, each carriage having a set of rollers engaging the rail.

In one embodiment, the bar is driven to rotate at the end of a final cycle so that the trays are tilted to drain off excess water. Preferably, the tilting movement is caused by a ram engaging an arm extending radially from the bar.

In another aspect, the invention provides a wash system comprising: a housing, a plurality of juxtaposed support brackets suspended from a support, IE 1 00324 -3a plurality of spray bars having spray nozzles mounted in the housing in a manner to leave a free path for the support brackets to move up and down in a vertical plane in wash cycles, a drive mechanism for the bracket support, arranged to lift and drop the support in each of 5 a plurality of cycles, a pump means for pumping wash liquid through the spray nozzles, a sump beneath the brackets, a valve means, a plurality of tanks linked with the valve means, a controller adapted to operate the spray bars and the support drive in a plurality of cycles each with up and down movement of the brackets through the spray bars, and in each cycle to route waste water to a selected tank, and to draw water from one of said tanks for at least one wash cycle.

In one embodiment, the housing is closed on all but one side, which side is for access of trays to be washed.

In one embodiment, the bracket has only substantially point contact with the tray.

In one embodiment, the controller is adapted to, in a first cycle, use recovered water from a second cycle of a previous wash operation. In one embodiment, the controller is adapted to, in a second cycle, use recovered water from a third cycle of a previous wash operation. Preferably, the controller is adapted to, in a third wash cycle, use fresh water. Preferably, there is a tank associated with each cycle.

In one embodiment, flow lines between the tanks and the spray bars include in-line filters of the T type, with cylindrical filter elements. In one embodiment, the tanks are insulated.

In one embodiment, the fray-supporting brackets are suspended from a substantially horizontal bar, and a drive mechanism moves the bar up and down in a vertical plane.

In one embodiment, the bar is movable at both ends in a groove or rail of the housing of the wash system.

IE 1 0 032 4 4 In one embodiment, the drive mechanism comprises a single drive element which is linked to both ends of the bar. Preferably, the drive element is linked to the bar ends via flexible links running over pulleys or sprokets. Preferably, the flexible links are belts and the belts run over pulleys mounted at a higher level than the drive element. Preferably, the system comprises a ram arranged to engage an arm extending radially from the bar to cause the bar to tilt at the end of at least one cycle, so that the trays are tilted to drain off excess water.

Detailed Description of the Invention The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only with reference to the accompanying drawings in which:Fig. 1 is a flow diagram illustrating a meat product manufacturing process of the invention; Fig. 2 is a flow diagram illustrating a process for washing trays as part of the manufacturing process, the trays being for internal handling of by-products and for packing of meat cuts; Figs. 3 to 6 are plan, side, front, and perspective views respectively of a tray wash system used in the process, in which housing panels are not shown for clarity; Fig. 7 is a pair of perspective views showing insertion of a tray for washing; Figs. 8 and 9 show a wash cycle; and Fig. 10 is a diagram illustrating management of water used by the washing system and also a final part of a wash cycle.

Referring to Fig. 1, a manufacturing process 1 for meat products has a step 2 of carcass boning followed by cutting 3 to provide a variety of meat cuts as desired from a production run. There can be a wide variety in the shapes and sizes of the cuts, and the process of the invention provides for efficient handling while allowing this flexibility.

IE 1 0 0324 -5In step 4 the meat cuts are inserted into a plastics package, a vacuum is applied, and the package is sealed. It has been found that a plastics film gauge of about 40μηα (and more generally in the range of 35pm to 45μηι) is sufficient, rather than the more typical gauge of 60pm - 70pm.

The packaged meat products are inspected in step 5, both visually and automatically with a metal detection system.

After inspection, in step 6, the packages are dipped in water heated to a temperature in the range of 81 °C to 83°C. This causes the packaging film to contract around the meat, thus reducing the volume and making the package more robust for subsequent handling.

In step 7 the dipped packages are placed directly into a rigid plastics tray (T, shown in Fig. 7). Because a rigid plastics tray is used to hold multiple products, rather than a cardboard carton, the products can be placed directly without need for drying. Also, because the container is relatively rigid, the products can be packed more tightly, giving better transport efficiency and reduced risk of product damage. The full trays are lifted directly into a transport vehicle or stored and are delivered in this manner. At the customer premises the individual products are removed and the trays are returned, steps 8 and 9.

Also, within the manufacturing facility, by-products such as pieces with high fat content are internally processed using trays T. By-products arising from the boning and cutting operations are placed in a tray T which had previously been lined with a plastics liner having excess overhanging at the sides. This excess is folded over in step 21 and in step 22 the tray is placed in a freezer.

At a later stage, after the by-products are frozen, the tray is removed from the freezer and the products are removed by lifting out the liner containing the frozen by-products. These byproducts are then transported in a suitable container to a by-product customer.

The ffeed-up tray T is moved to a wash system, as are those returned after delivery of the main meat products to customers. Thus, the trays T are used for both production of the main meat products and their delivery to the customer, and also for internal handling of the by-products. Irrespective of their use the trays T are washed in a step 31 in a very efficient manner both in -6IE 1 0 03 2 4 terms of time taken and in terms of use of water and energy. In step 32 the washed trays are returned to the work stations in the manufacturing line.

Referring to Figs. 2 to 10 the washing step 31 is performed by a wash system 60 having in this 5 embodiment four tray support brackets 61 suspended from a support bar 62. An electronic controller (not shown) is linked with all moving parts of the system 60 to control their operations. The support bar 62 is mounted to move in a vertical plane to move the brackets 61 through spray bars 64 having nozzles for tray washing in three cycles. Each cycle has an upward movement followed by a downward movement to a lower home position. The movement is caused by movement of a piston 65 located outside the frame 63 and linked to the support bar 62 at both of its ends by belts 66 running over pulleys 67, The drive is reliable because the main moving parts are located outside of the cabinet 63 and the links to the ends of the support bar 62 are simple - giving little chance of failure. Also, in the event of failure of the drive both ends of the support bar 62 are equally affected. On the other hand, if there were a separate drive at each end of the support bar 32, failure of one drive could damage the bar and possibly other parts of the system as the bar would continue to move at one end and not the other.

It will be noted that the brackets 61 are configured to have a very small contact area with the trays T, little more than point contact. This allows comprehensive washing and fast drying. As shown in Fig. 10 the wash system 60 has a valve 70 for directing used wash water from a sump into one of three tanks, Tank A, Tank B and Tank C. There are in-line “T” filters 71 with cylindrical filter elements in these lines, secured in place by quick-release couplers. Liquid flow is axially through the centre and back through the filter element, which is cylindrical in configuration.

Fig. 10 also illustrates a tilting action at the end of the third cycle, caused by pivoting of the support bar 62. This helps to ensure run-off of excess water at the end of washing.

The bar 62 runs in the vertical plane in a rail 80 at each end, four rollers 81 on a carriage at each end engaging the rain internal surfaces. This helps to ensure a smooth and reliable movement of the bar in the corrosive environment of the inside of the wash system 60. There is a vertical pneumatic ram 82 having a piston 85 which pushes against an arm 83 extending radially from the bar 62 in order to cause the rotation of the bar and hence tilting of the supports 61 as shown in Fig. 10.

IE 1 0 0324 -7Referring again to Fig. 2 in step 40 four trays T are placed in the brackets 61 when they are at their (lower) home position. In step 41 there is a first cycle of up and down movement of the trays, in which a pump delivers under a pressure of 5 to 7 bar a flow comprising water drawn from Tank B and a detergent. This liquid is heated to 60 to 70°C in the tank. Because the water is drawn from the Tank B, water intake from the mains supply 7 is minimised. Waste water from this cycle is delivered to Tank A.

In step 42 is a second wash cycle the trays T are again lifted up through a spray and back down 10 to the home position (Figs. 8 and 9). The spray bars 64 spray water heated to 30 to 40°C and drawn from Tank C. The waste from this cycle is delivered to the Tank B.

In a third wash cycle the trays T are brought up and down through a spray of rinse water drawn from mains supply. The waste from this cycle is delivered to the Tank C.

It will be appreciated that the first and second cycles use water which was previously used for the second and third cycles of previous batches. This minimises consumption of water, and as this water retains some of the heat from the previous cycles only top-up heating is required. Also, because the trays are lifted up and dropped down for each cycle there is only a small wash machine footprint, and a simple and reliable mechanism can be used. This is in contrast to conveyor wash systems. This allows feasible washing of trays for even small production facilities. Also, the wash system is very simple, requiring very few moving parts, and is therefore inexpensive to install and to maintain. Further, because there is only point contact between the brackets and trays there is very comprehensive washing and drying in a reliable manner.

The above advantageous features allow comprehensive use of rigid plastics trays for both internal by-product handling and also for final stages of main product manufacture and delivery to customers. The expense and time required by carton assembly and use is avoided. Also, the packaged and dipped meat products can be immediately packed rather than needing to be dried for a period beforehand.

It will also be appreciated that the process allows use of lighter gauge plastics film for vacuum packing, about 40pm instead of the more typical όΟμιη to 70μιη. This is because the packages are placed with close packing in a rigid plastics tray rather than in a cardboard carton. Use of IE 1 0 03 2 4 -8these trays for by-product handling provides for efficient freezing of the by-products as the tray provides little thermal insulation, unlike cartons. They also allow simple and effective handling of the by-products in the factory.

Another major advantage is that the meat products can be packed directly into the trays immediately after dipping because there is no need to dry them after dipping. This avoids need for storage space and drying equipment and attendant energy consumption. By performing QC inspection before dipping the risk of dipping a product with a faulty seal and consequent contamination is avoided.

The invention is not limited to the embodiments described but may be varied in construction and detail.

Claims (25)

Claims

1. A method of manufacturing meat products, the method comprising the steps of: de-boning and cutting a carcass to provide meat cuts and by-products; 5 vacuum packing the meat cuts and dipping the packages in a liquid bath at an elevated temperature to cause shrinkage of the packages; placing the packaged and dipped meat packages into a rigid plastics tray, and transporting the packages in the tray to a destination, returning the tray after delivery to a wash system and the wash system washing the tray 10 by: supporting the tray in a support bracket, moving the tray through a plurality of cycles, each cycle including moving the tray in a cycle through a spray delivered by spray bars, and recovering waste water from at least one of the cycles and re-using the recovered 15 waste water for a cycle of the next waste operation, placing the by-products in a lined tray, placing the tray in a freezer, and when the byproducts are frozen, removing the liner containing the frozen by-products for delivery, and returning the empty tray to the wash system. 20

2. A method as claimed in claim 1, wherein the bracket has only substantially point contact with the tray.

3. A method as claimed in claims 1 or 2, wherein a first cycle uses recovered water from a second cycle of a previous wash operation.

4. A method as claimed in claim 3, wherein a second cycle uses recovered water from a third cycle of a previous wash operation.

5. A method as claimed in claims 2 or 3, wherein a third wash cycle uses fresh water.

6. A method as claimed in any preceding claim, wherein used wash water flows via a sump under the brackets into a tank selected by a valve under the sump, there being a tank associated with each cycle for complete washing of a tray. IE 1 0 03 2 4 - 107. A method as claimed in claim 6, wherein the flows from the tanks to the nozzles are via an in-line filter.

7. 8. A method as claimed in claims 6 or 7, wherein the tanks are insulated.

8. 9. A method as claimed in any preceding claim, wherein the gauge of plastics film used for vacuum packaging the meat cuts is in the range of 35pm to 45pm.

9. 10. A method as claimed in claim 9, wherein the gauge is approximately 40pm.

10. 11. A method as claimed in any preceding claim, wherein an inspection is performed before dipping of the packed meat cuts.

11. 12. A method as claimed in any preceding claim, wherein the tray-supporting brackets are 15 suspended from a substantially horizontal bar, and a drive mechanism moves the bar up and down in a vertical plane for wash each cycle.

12. 13. A method as claimed in claim 12, wherein the bar is movable at both ends in a groove or rail of a housing of the wash system.

13. 14. A method as claimed in claims 12 or 13, wherein the drive mechanism comprises a single drive element which is linked to both ends ofthe bar.

14. 15. A method as claimed in claim 14, wherein the drive element is linked to the bar ends via 25 flexible links running over pulleys or sprokets.

15. 16. A method as claimed in claim 15, wherein the flexible links are belts and the belts run over pulleys mounted at a higher level than the drive element. 30

16. 17. A method as claimed in any of claims 13 to 16, wherein the bar has a carriage at each end, each carriage having a set of rollers engaging the rail.

17. 18. A method as claimed in any of claims 12 to 17, wherein the bar is driven to rotate at the end of a final cycle so that the trays are tilted to drain off excess water. IE 1 0 0324 -11 30

18. 19. A method as claimed in claim 18, wherein the tilting movement is caused by a ram engaging an arm extending radially from the bar. 5 20. A wash system comprising: a housing, a plurality of juxtaposed support brackets suspended from a support, a plurality of spray bars having spray nozzles mounted in the housing in a manner to leave a free path for the support brackets to move up and down in a vertical plane in wash 10 cycles, a drive mechanism for the bracket support, arranged to lift and drop the support in each of a plurality of cycles, a pump means for pumping wash liquid through the spray nozzles, a sump beneath the brackets, 15 a valve means, a plurality of tanks linked with the valve means, a controller adapted to operate the spray bars and the support drive in a plurality of cycles each with up and down movement of the brackets through the spray bars, and in each cycle to route waste water to a selected tank, and to draw water from one of said tanks for

19. 20 at least one wash cycle.

20. 21. A wash system as claimed in claim 20, wherein the housing is closed on all but one side, which side is for access of trays to be washed. 25

21. 22. A wash system as claimed in claims 20 or 21, wherein the bracket has only substantially point contact with the tray.

22. 23. A wash system as claimed in any of claims 20 to 22, wherein the controller is adapted to, in a first cycle, use recovered water from a second cycle of a previous wash operation.

23. 24. A wash system as claimed in claim 23, wherein the controller is adapted to, in a second cycle, use recovered water from a third cycle of a previous wash operation. IE 1 0 03 2 4 -1225. A wash system as claimed in claims 23 or 24, wherein the controller is adapted to, in a third wash cycle, use fresh water. 26. A wash system as claimed in any of claims 20 to 25, wherein there is a tank associated 5 with each cycle. 27. A wash system as claimed in claim 26, wherein flow lines between the tanks and the spray bars include in-line filters of the T type, with cylindrical filter elements. 10 28. A wash system as claimed in claims 26 or 27, wherein the tanks are insulated. 29. A wash system as claimed in any of claims 20 to 28, wherein the tray-supporting brackets are suspended from a substantially horizontal bar, and a drive mechanism moves the bar up and down in a vertical plane. 30. A wash system as claimed in claim 29, wherein the bar is movable at both ends in a groove or rail of the housing of the wash system. 31. A wash system as claimed in claims 29 or 30, wherein the drive mechanism comprises a 20 single drive element which is linked to both ends of the bar. 32. A wash system as claimed in claim 31, wherein the drive element is linked to the bar ends via flexible links running over pulleys or sprokets.

24. 25 33. A wash system as claimed in claim 32, wherein the flexible links are belts and the belts run over pulleys mounted at a higher level than the drive element. 34. A wash system as claimed in any of claims 29 to 33, wherein the system comprises a ram arranged to engage an arm extending radially from the bar to cause the bar to tilt at the

25. 30 end of at least one cycle, so that the trays are tilted to drain off excess water.