JP2022533805A - Protein preparation and packaging methods, systems and related devices - Google Patents

Abstract

The disclosed apparatus, systems and methods relate to preparation, modified atmosphere and autoclaving steps for processing retail raw protein preparations. Proteins are prepared, subsequently packaged in a conditioned atmosphere lacking significant amounts of oxygen, and then exposed to autoclaving. During preparation, the protein may be exposed to aqueous ozone, which further reduces microbial load, extends shelf life, and increases product safety. [Selection drawing] Fig. 1

Description

Related application

[001] This application is a U.S. provisional application entitled "Protein Preparation and Packaging Methods, Systems and Related Devices," filed on September 11, 2019. 62/899,068 priority is claimed. This application claims priority to U.S. patent application Ser. No. 16/419,359, filed February 16, 2018, which is a continuation-in-part, entitled "Methods, Systems, and Related Devices for Protein Preparation Packaging by Modified Atmosphere and Autoclave" (Modified). Atmosphere and High-Pressure Pasteurization Protein Preparation Packaging Methods, Systems and Related Devices”, which is a continuation-in-part of U.S. Patent Application Serial No. 15/932,235, filed February 16, 2017 No. 62/459,888, entitled "Protein Preparation Systems, Devices and Related Methods," filed herein. All of the above applications are hereby incorporated by reference in their entirety under 35 U.S.C. § 119(e).

[002] The present disclosure relates to devices, systems, and methods for protein preparation and storage. Thus, the present disclosure provides a package that enables significant pathogen reduction, extended shelf life, and improved food safety for a variety of proteins, such as raw beef, lamb, pork, poultry, fish, turkey and bison. related to programming systems, devices and methods.

[003] Prior art retail protein display methods and devices often have a number of shortcomings. These disadvantages include meat substitutes for raw meats such as beef, lamb, pork, poultry, fish, turkey, bison, etc., as well as other protein substitutes known in the art (hereinafter generally referred to as "proteins"). pathogens and short shelf life can be mentioned. Lack of worker skills, increased overhead, lack of traceability, and aggressive advertising campaigns in the protein sector also create difficulties, resulting in lost market opportunities.

[004] In prior art approaches, protein suppliers generally make carcasses into so-called "block meats", which are typically packaged in cryobacs or vacuum packaged. . In this block meat state, the protein typically has a shelf life of approximately 40 days for beef/lamb, 15 days for pork and 7 days for chicken. These proteins are also often contaminated with various pathogens that can be harmful to consumers if not cooked properly.

[005] There is a need in the art for improved methods of protein preparation.

[006] Various embodiments of devices, systems and methods for protein processing, packaging and preparation are described herein. Although multiple embodiments including various devices, systems, and methods are described herein as a "system," this is not intended to be limiting or limiting in any way.

[007] In one example, a system for retail protein preparation, comprising a modified atmosphere device configured to seal the protein in a modified atmosphere; and an autoclave configured to sterilize the sealed protein. The above system, including the device. Implementations may include one or more of the following features. The above system, wherein the modified atmosphere comprises carbon monoxide. The above system, wherein the modified atmosphere comprises carbon dioxide. The above system, wherein the modified atmosphere comprises nitrogen. The above system, wherein the modified atmosphere comprises carbon dioxide, carbon monoxide, and nitrogen. The above system, wherein the modified atmosphere does not contain oxygen. Other embodiments include corresponding computer systems, apparatus, and computer programs recorded on one or more computer storage devices configured to perform the actions of each method. Embodiments of the described technology may include hardware, methods or processes, or computer software on computer-accessible media.

[008] Another example is a method for raw retail protein preparation comprising a packaging system including a modified atmosphere device configured to expose the protein to a modified atmosphere and seal the protein in a container. The above method, including manipulating. The method of this example also includes an autoclaving device constructed and arranged to sterilize the sealed protein within the sealed container, the system performing steps including a modified atmosphere step and an autoclaving step. The protein is sealed in a modified atmosphere and exposed to autoclaving.

[009] Implementations in accordance with this and other examples may include one or more of the following features. The above method, wherein the modified atmosphere comprises carbon monoxide. The above method, wherein the modified atmosphere comprises carbon dioxide. The above method, wherein the modified atmosphere comprises nitric oxide. The above method, wherein the modified atmosphere comprises carbon dioxide, carbon monoxide and nitrogen. The above method, wherein the modified atmosphere does not contain oxygen.

[010] Another example is a method for autoclaving a protein comprising at least one modified atmosphere step, wherein the protein is sealed in a modified atmosphere, and at least the autoclaving step is performed in the sealed modified atmosphere. Including the above method, carried out on a protein.

[011] A still further example is a method of packaging a protein in a modified atmosphere for autoclaving, the preparation step comprising multiple steps: a physical preparation substep and a chemical preparation substep; a modified atmosphere step including a modified atmosphere introducing substep and a sealing substep, and an autoclave step including an autoclave substep, wherein the protein comprises carbon monoxide, carbon dioxide, and nitrogen and is substantially free of oxygen. including the above method wherein the container is sealed and autoclaved in a container containing a modified atmosphere.

[012] These example embodiments may include one or more of the following features. The above method, wherein the modified atmosphere step includes a modified atmosphere substep and a sealing substep. The above method, wherein the modified atmosphere comprises carbon monoxide, carbon dioxide, and nitrogen. The above method, wherein the modified atmosphere comprises carbon monoxide, carbon dioxide, and nitrogen. The above method, wherein the modified atmosphere contains about 0.4% carbon monoxide. The above method, wherein the modified atmosphere comprises about 20% carbon dioxide. The above method, wherein the modified atmosphere comprises greater than 79% nitrogen. The above method, wherein the autoclaving step includes a coding/dating substep and a scanning substep. The above method, wherein the high pressure sterilization step includes a high pressure sterilization (“HPP”) substep. The above method, wherein the HPP substep is performed on the conditioned atmosphere protein sealed at about 87,000 psi. The above method, wherein the HPP substep is performed on the sealed conditioned atmosphere protein for about 3 minutes. The above method, wherein the HPP substep is performed on the sealed conditioned atmosphere protein for about 1 second to about 3600 seconds. The above method, wherein the HPP substep is performed on the conditioned atmosphere protein sealed at about 43,500 to about 87,000 psi.

[013] Another example is a method for packaging a protein, comprising a preparation step comprising providing the protein; exposing the protein to an aqueous ozone solution; Including the above method. The method also includes a modified atmosphere step including introducing a modified atmosphere into the container and sealing the container. The method also includes an autoclave step that includes exposing the container to autoclave. The method also includes storing the container.

[014] Embodiments may include one or more of the following features. The above method, wherein the aqueous ozone solution is about 0.5 to about 4 ppm aqueous ozone. The above method, wherein the protein is exposed to the aqueous ozone solution for 1-10 seconds. The above method, further comprising portioning the protein after exposure to the aqueous ozone solution. The above method, further comprising coding and date-stamping the container. The above method, wherein the autoclave is at least about 72,000 psi. The above method, wherein autoclaving is at least about 3 minutes.

[015] Another example is a method for extending the shelf life of a food product, comprising: providing the food product; exposing the food product to an aqueous ozone solution; placing the food product in a package; The above method comprising flushing, sealing the package, and exposing the package to autoclaving.

[016] Embodiments may include one or more of the following features. The above method, wherein the food product is exposed to the aqueous ozone solution for 1-10 seconds. The above method, wherein the aqueous ozone solution comprises 0.5-4 ppm aqueous ozone. The above method, wherein the modified atmosphere is substantially free of oxygen. The above method, wherein the aqueous ozone solution is exposed to the food product through a spray nozzle. The above method, wherein autoclaving is at least 72,000 psi for at least 3 minutes. The above method, wherein the shelf life of the food product is extended by at least 60 days.

[017] In another example, a system for processing a protein includes an aqueous ozone application unit; a packaging device in communication with the aqueous ozone application unit; a modified atmosphere injector in communication with the packaging equipment; sealer; as well as an autoclave tank connected to packaging equipment. In this example, the protein is exposed to aqueous ozone in an aqueous ozone application unit; the protein is packaged by packaging equipment; the package is flushed with a modified atmosphere by a modified atmosphere injector; the package is flushed with a modified atmosphere. The proteins are exposed to autoclaving in autoclaving tanks.

[018] Embodiments may include one or more of the following features. The above system, wherein the aqueous ozone solution is 0.5-4 ppm aqueous ozone. The above system, wherein the protein is exposed to aqueous ozone for 1-10 seconds. The above system, wherein the shelf life of the protein is extended by at least 30 days. The above system, wherein the shelf life of the protein is extended by at least 45 days. The above system, wherein the shelf life of the protein is extended by at least 60 days. The above system, wherein the protein is beef.

[019] In various embodiments featuring automation, a system having one or more components, including a computer, provides software, firmware, hardware, or By attaching combinations of them, they can be designed to perform specific operations or actions. One or more computer programs can be designed to perform specific operations or actions by containing instructions which, when executed by a data processing device, cause the device to perform the actions.

[020] Ranges can be expressed herein as from "about" one particular value, and/or to "about" another particular value. When such a range is expressed, a further aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations by the use of the antecedent “about,” it will be understood that the specific values form a further aspect. It will be further understood that each endpoint of a range is both relative to and independent of the other endpoint. It is also understood that there are a number of values disclosed herein, and each value is also disclosed herein as "about" that particular value, in addition to the value itself. For example, if the value "10" is disclosed, "about 10" is also disclosed. It is also understood that each unit between two particular units is also disclosed. For example, if 10 and 15 are disclosed, 11, 12, 13, and 14 are also disclosed.

[021] While multiple embodiments are disclosed, nonetheless other embodiments of the present disclosure will show and describe exemplary implementations of the disclosed apparatus, systems and methods to those skilled in the art from the following detailed description. would be clear to As will be realized, the disclosed devices, systems and methods can be modified in various obvious forms, all without departing from the spirit and scope of the disclosure. Accordingly, the drawings and detailed description are to be regarded in an illustrative rather than a restrictive sense.

[022] Figure 1 is a schematic flow diagram of a protein packaging process according to an exemplary embodiment. [023] Figure 2A is a perspective view of an aqueous ozone application unit according to one embodiment. [024] Figure 2B is a top view of a facility capable of performing a protein packaging process according to one embodiment. [025] Figure 3 is a perspective view of several components utilized in a process including a weighing device according to one embodiment. [026] Figure 4 is a perspective view of a modified atmosphere device including a conduit and bagging chute according to one embodiment. [027] FIG. 5 is a longitudinal view of the modified atmosphere device of FIG. [028] Figure 6 is a perspective view of a protein bagged and sealed in a conditioned atmosphere on a conveyor belt according to one embodiment. [029] Figure 7 is a perspective view of a conveyor and autoclaving device according to one embodiment. [030] Figure 8 is a further perspective view of an autoclaving device according to one embodiment. [031] Figure 9 is a still further side view of an autoclaving device according to one embodiment.

[032] Various embodiments disclosed or contemplated herein are directed to systems, methods and devices for packaging proteins in airtight bags or other containers, wherein the proteins are , is exposed to a modified atmosphere within the bag, and the bag is exposed to high pressure sterilization (“HPP”). In some embodiments, proteins are additionally exposed to aqueous ozone prior to packaging. In various embodiments, the HPP has an extended decompression time. In various embodiments, various automated or semi-automated components can be used to perform various steps and substeps to prepare such packaged proteins. These embodiments can improve shelf life, visual quality, and other characteristics and properties of the prepared and packaged protein as detailed herein.

[033] Figures 1-9 illustrate a number of exemplary protein packaging processes 1 carried out through operation of a packaging system 10 that includes a number of components that may be automated or semi-automated in part. 1 depicts an embodiment; Various embodiments package proteins, such as meat, sealed in airtight containers containing a modified atmosphere for improved shelf life and other benefits as detailed herein. , HPP (in some embodiments, HPP includes exposing the product to an isostatic pressure of up to about 600 MPa/87,000 psi or higher).

[034] Through the combination of the use of an aqueous ozone solution, a modified atmosphere, and HPP, with or without an extended decompression period, various embodiments provide significant pathogen reduction, extended shelf life, and/or Allows for improved visual quality of the packaged protein. In some of these embodiments, process 1 and system 10 include steps for detecting and tracking the final packaged protein so that it can be traced back to its source, thereby It adds another important food safety element in the supply network. It is understood that these edible proteins are considered to be in the commercial market at one stage or another in the process or route to the end user.

[035] Referring more particularly to the drawings, in the embodiment of Figure 1, Process 1 or Method 1 includes various optional steps and optional sub-steps that can be performed in any order. It is understood that, in various embodiments, packaging system 10 is constructed and arranged to perform this process 1 by utilizing numerous components and associated devices. Various embodiments of this system 10 are depicted in FIGS. 2A-9.

[036] The disclosed embodiments include a number of optional steps that can be performed in any order. Depending on the particular embodiment, additional steps and/or substeps may be included, while other steps and/or substeps may be omitted. As an example, the packaging system 10 shown in FIG. 1 is provided to illustrate optional steps and substeps and is in no way intended to limit implementation to this particular embodiment.

[037] In these embodiments, as shown in Figure 1, the steps in an exemplary embodiment of the process are:
1. optional preparation step 2,
2. Optional Modified Atmosphere Step 4; and 3. Optional autoclaving step 6
including.

Other steps and substeps may be included. In various forms, each of these steps 2, 4, 6 may include various optional sub-steps, as shown in the embodiment of FIG.

[038] In optional preparation step 2, according to various embodiments such as those described in FIG. , can be received, processed and packaged in atmosphere resistant bags, packages or other containers. In an alternative embodiment, the protein may be pre-bagged or otherwise contained in an airtight container for processing in the modified atmosphere step 4 and sterilization step 6. In various embodiments, the protein can be exposed to an aqueous ozone solution during preparation step two.

[039] FIG. 1 illustrates one exemplary embodiment of the disclosed method 1 when implemented in a packaging system 10 during optional preparation step 2. As shown in FIG. Proteins (indicated at 70 in FIG. 6) may enter system 10 via an optional sourcing/receiving substep (box 12). In this procurement/receipt sub-step (box 12), according to a particular embodiment, a procurement order is emanated from, for example, a central processing component or computer (not shown). In these embodiments, the order of procurement is the delivery and receipt of proteins, e.g. can be started.

[040] In various embodiments, the protein for processing may be one or more of raw beef, lamb, pork, poultry, fish, turkey, bison, and the like. In various embodiments, more than one protein may be used, such as a blend of chicken and beef. For example, more than one protein can be used in cooking fajitas, stir-frying, and/or other cooking that would be expected to be understood and appreciated in the art.

[041] In various embodiments, preparation step 2 includes an optional ozone exposure substep (box 13). The protein prior to physical preparation (Box 14), chemical preparation (Box 16) and/or bagging (Step 18) (as further described below) is exposed to an aqueous/liquid ozone solution. good too. In various alternative embodiments, proteins are prepared, including but not limited to procurement (box 12), physical preparation (box 14), chemical preparation (box 16), and weighing/bagging (box 18). After and/or during various other steps and substeps such as the exposure to ozone. In various embodiments, the aqueous ozone solution can kill, eliminate, or otherwise inactivate various microorganisms, such as Lactobacillus and other bacteria. The aqueous ozone exposure substep (box 13) can be useful in targeting bacteria/pathogens that are not affected by HPP, modified atmosphere, and/or other preparation steps.

[042] In the ozone exposure sub-step (box 13), the protein can be sprayed, dipped into, immersed in, or otherwise exposed to an aqueous ozone solution. In various embodiments, the aqueous ozone solution contains from about 0 to about 100 PPM of aqueous/liquid ozone. In some embodiments, the aqueous ozone solution contains about 0.5-4 PPM aqueous/liquid ozone. In various alternative embodiments, the aqueous ozone solution contains about 5 PPM ozone.

[043] In various embodiments, the aqueous ozone solution is between about 0.6°C (about 33°F) and 100°C (212°F). In some embodiments, the temperature of the aqueous ozone solution is ambient or room temperature. The protein may be exposed to the liquid ozone solution for about 1 to about 10 seconds or longer.

[044] In some embodiments, the aqueous ozone solution can be applied to the protein via an aqueous ozone application unit 34. In various of these embodiments, the aqueous ozone application unit 34 has a spray nozzle 36, as shown in Figures 2A and 2B. FIG. 2A depicts one exemplary embodiment of nozzle applicator 34 in which the aqueous ozone solution is applied via multiple spray nozzles 36 arranged on conveyor 38 . In these and other embodiments, proteins are placed on conveyor 38 and passed under nozzle 36 . Of course other embodiments are possible and will be understood by those skilled in the art. In various embodiments, the aqueous ozone solution is applied at a pressure of about 1-50 psi. In some embodiments, the ozone solution is applied at a pressure of about 35 psi.

[045] The use of the aqueous ozone exposure substep (box 13) and packaging system 10 was shown to reduce the bacterial load to zero or near zero over a period of 60 days. Additionally, the use of aqueous ozone exposure has been shown to extend the shelf life of various proteins to at least about 100 days. In one particular example, beef samples were exposed to ozone (as described above) and HPP (87,000 psi for 3 minutes) and then tested for bacterial load after 60 days. In this example, samples were found to have less than 10 cfu/g of E. coli and lactic acid bacteria during testing. In addition, the aerobic plate counts were less than 10 cfu/g and no Listeria monocytogenes was detected for 25 g.

[046] In another example, beef samples were exposed to ozone (as described above) and HPP (72,000 psi for 3 minutes) and then tested for bacterial load after 60 days. In this example, samples were found to have less than 10 cfu/g of E. coli and Lactobacilli during testing. In addition, the aerobic plate counts were less than 10 cfu/g and no Listeria monocytogenes was detected for 25 g.

[047] The results of these studies demonstrate that exposure of proteins to aqueous ozone, as described herein, is useful in reducing the bacterial load of proteins, thus extending shelf life, It is shown to increase the food safety of proteins over time. Further examples and data are presented in the experimental section below.

[048] Referring again to preparation step 2 of the embodiment of FIG. 1, and as further shown in FIG. It's okay. An optional physical preparation substep (box 14) can be performed on the protein in all circumstances. It is understood that during such physical preparation substep (box 14), various preparation techniques can be employed to prepare the protein for processing in subsequent steps and/or substeps of system 10. . These substeps can be used to convert block meat or second grade ingredients to retail condition through well understood techniques such as boning, trimming and portioning. For example, a block of beef chuckeye roll may be cut into loins and trimmed.

[049] As will be further appreciated, in certain embodiments, during preparation step 2, a chemical preparation sub-step (box 16) is performed according to a particular configuration. Marinades, other processing and/or seasoning techniques can be applied to the protein in these forms during the chemical preparation substep (box 16). In various embodiments, the chemical preparation substep (box 16) is performed prior to optional weighing and bagging in the weighing/bagging substep (box 18). In these embodiments, various flavored and/or unflavored marinades are introduced and/or utilized during the chemical preparation substep (box 16) to impart desired flavors and/or flavors to the product. or can be adjusted to color.

[050] In some embodiments, the Weighing/Bagging sub-step (Box 18) completes Preparation Step 2. In a further embodiment, an optional weighing/bagging sub-step (Box 18) is performed at any point in Process 1. Obviously, weighing is generally optional, but in various embodiments, during this weighing/bagging substep (box 18), or generally during preparation step 2, an adjustment The product must be bagged or otherwise inserted into an airtight container to prepare the protein for the atmosphere step 4 and/or the HPP step.

[051] In one illustrative example, the system 10 is constructed and arranged for approximately 16 ounces of pre-packaged protein. In other examples, the protein is about 170 g (about 6 oz), 227 g (8 oz), 283 g (10 oz), 340 g (12 oz) or more. In a further example, the weight of the protein is from about 28 g about 1 oz to 1814 g (64 oz). In additional embodiments, the protein is greater than 64 oz. In still further examples, the protein comprises a variety of individual pieces, such as shrimp and/or fajita fillets, having approximately a specified amount in total. It is understood that various sizes and weights are possible depending on the final retail application.

[052] In certain embodiments, the barrier film or barrier bag (indicated at 69 in FIG. 6) used in the weighing/bagging substep (box 18) may be a nylon bag, a three-layer bag. but other high barrier products are also possible. Other embodiments are also contemplated, including metallic, Saran®, PET, and known materials to provide suitable gas permeability to retain the modified atmosphere introduced. and others well understood by those skilled in the art.

[053] As shown in FIG. 2B, the preparation step 2 and corresponding substeps can be performed, for example, by a method of arranging a table 40, a conveyor 42, a grader 44, a tumbler 46 and/or a weighing device 48. It is understood that numerous arrangements are possible, as would be expected to be understood by those skilled in the art.

[054] In these embodiments, after preparation step 2, a modified atmosphere step 4 is performed. In some embodiments, preparation step 2 is not performed, or is performed concurrently with or after modified atmosphere step 4. Modified atmosphere step 4 generally involves introducing a modified atmosphere (“MA”) to the protein in the bag. In various embodiments, the modified atmosphere is a combination of carbon monoxide, carbon dioxide, and nitrogen. Many additional atmospheric and gaseous compositions are possible, as would be expected to be apparent to those skilled in the art.

[055] In one illustrative example, the prepared, portioned and weighed protein, e.g. , as shown in FIG. 1, exposed to a modified atmosphere via a modified atmosphere introduction substep (box 20), such as the modified atmosphere introduction substep of modified atmosphere step 4, and then packaged during a sealing substep (box 22). sealed or sealed.

[056] As shown in FIG. 2B, the modified atmosphere introduction substep (box 20) and the sealing substep (box 22) can be performed in quick succession via an automatic bagging machine or MA device 50, and further provided for processing. It is understood that the introduction of the modified atmosphere to the protein and the sealing of the package or bag can be accomplished in a variety of alternative ways. In certain embodiments, as shown in FIGS. 3-5, MA device 50 is configured to package proteins/products in barrier films in bagging chute 53, where the bags are Filled with a modified atmosphere via conduit 51 . Other filling and bagging devices, methods and systems can be utilized in alternate embodiments, as will be understood.

[057] In certain embodiments, oxygen is flushed from the protein and the modified atmosphere comprises about 0.4% carbon monoxide, about 20% carbon dioxide, and the balance (79% or greater than about 80% ) is nitrogen. It is understood that in these and other embodiments it may be desirable to exclude oxygen from the conditioned atmosphere.

[058] In further embodiments, the carbon monoxide concentration may be less than or about 0.1% of the atmosphere and may be increased to 0.2%, 0.3% or more. , or 0.5%, greater than 1.0%, or up to 100%.

[059] Similarly, the modified atmosphere may contain carbon dioxide from less than 20% to 0.1% or less. In alternative embodiments, the modified atmosphere may comprise more than 20% carbon dioxide, such as 25%, 30%, 40%, 50% or more, up to 100% carbon dioxide. In all of these embodiments, nitrogen may make up the remainder of the modified atmosphere.

[060] In certain embodiments, a range of about 0% to about 100% nitric oxide and/or carbon dioxide may be introduced into the modified atmosphere mixture. Alternatively, other inert gases may be introduced into the modified atmosphere. However, in exemplary embodiments, the conditioned atmosphere of many embodiments does not contain oxygen, as would be readily appreciated by those skilled in the art.

[061] In some embodiments, one or more gases in the modified atmosphere can be adjusted or modified based on the meat/protein product or cut to be packaged. In one particular example, for raw red meat, the modified atmosphere mixture comprises about 60-80% oxygen and 20-40% carbon dioxide. In another specific example, the modified atmosphere for raw light poultry comprises about 40-100% carbon dioxide and 0-60% nitrogen. In another example, for raw dark poultry, the modified atmosphere comprises 70% oxygen and 30% carbon dioxide. In another example, for sausages, the modified atmosphere comprises 20-30% carbon dioxide and 70-80% nitrogen. In another example, the modified atmosphere for sliced and cooked meat includes 30% carbon dioxide and 70% nitrogen. Of course, other modified atmosphere compositions are possible, as will be understood and anticipated.

[062] With continued reference to the embodiments of FIGS. and via other devices used and well understood in the art, through HPP step 6, which includes one or more post-sealing substeps. In various alternative embodiments, the HPP step is performed before modified atmosphere step 4 or modified atmosphere step 4 is omitted from process 1 .

[063] In certain embodiments, during autoclaving step 6, a sub-step of performing HPP is required, although a number of other optional sub-steps of processing may be performed.

[064] For example, after sealing the protein in a package (with or without a modified atmosphere) (as indicated by box 22 in FIG. 1), the protein is optionally subjected to an encoding/dating substep ( The bag may be dated or coded in box 24). In another optional substep, the protein is scanned or X-rayed in a scanning substep (box 26 and 52 in FIG. 2B). Various of these steps and substeps can ensure quality and/or compliance with, for example, USDA regulations. It is understood that various blank labels and/or other market badges may also be applied to the bag at or during any of these optional Process 1 substeps. Alternate embodiments do not include these dating, encoding, scanning, and X-raying substeps. In further embodiments, Process 1 includes additional packaging, labeling and quality control substeps, as would be understood in the art. These optional dating, encoding, scanning, and x-raying substeps may be performed at any point during process 1, or may be performed at multiple points during the process. further understood.

[065] Referring to Figures 7-9, the protein (whether or not packaged in a modified atmosphere) is packaged in the HPP subfolder, as indicated by box 28 in Figure 1 and 54 in Figures 7-9. Steps are exposed to HPP.

[066] In one embodiment, the HPP sub-step (box 28) is performed at up to about 87,000 psi for a duration of about 3 minutes or longer. Various alternative embodiments are 300-600 MPa/min for durations of less than about 1 minute, greater than about 10 minutes, greater than about 20 minutes, greater than about 30 minutes, greater than about 60 minutes, or longer. HPPs of 43,500 to 87,000 psi or higher pressures are available. The conditions and parameters of the HPP sub-step (box 28) may depend on the environment, conditions and other parameters as expected to be understood. Various embodiments can perform the HPP substep (box 28) from about 1 second to about 3600 seconds or more at pressures between about 43,500 and about 87,000 psi or higher. .

[067] In various embodiments, the HPP (box 28) has process parameters of about 50,000-87,000 psi for 3-5 minutes. In another embodiment, HPP (box 28) is run at 60,000 psi for 4 minutes.

[068] In these and other embodiments, the HPP sub-step (box 28) may include an extended depressurization step (box 29). In various embodiments, after the HPP time has elapsed, the pressure is released and the package/item returned to atmospheric pressure. This depressurization time can last from less than about 1 second to greater than about 10 minutes. In some embodiments, the decompression time is at least about 5 minutes. In some embodiments, the decompression time is at least about 8 minutes or longer.

[069] An extended depressurization step (box 29) can provide additional time for the product/protein to be exposed to pressure above atmospheric pressure. It is understood that exposing the protein to pressure for a longer period of time can increase the amount of bacteria killed. In addition, allowing additional time for decompression after HPP compared to product subjected to HPP where the high pressure was released and the product returned to atmospheric pressure immediately or in a very short period of time, such as seconds. In addition to improving food quality, it has been shown to maintain protein/product aesthetics, eg food color, when used.

[070] In certain embodiments, the temperature for all steps and substeps of Process 1 is maintained below about 10°C (about 50°F), although alternative embodiments range from freezing to room temperature or A change to a higher temperature is possible.

[071] In these embodiments, the HPP substep (box 28) does not cause rupture of the bag because the pressure is uniformly applied to the bag or other gas-tight or sufficiently gas-impermeable container. will be understood by those skilled in the art.

[072] In various embodiments, the autoclaved packages are then dried, packed in cases, and palletized in a storage substep as shown at box 30 in Figure 1 and 56 in Figure 2B.

[073] In certain embodiments, the system 10 may further include a water bath. For example, a water bath at 82°C (180°F (°F)) may be used, or any other bath at a temperature of 0.6°C (about 33°F (°F)) or higher. You may In various of these embodiments, the system 10 can be evacuated with a sealed bag 69 (shown at 58 in FIG. 2B). These embodiments can result in a freezeable product that can be offered to commercial outlets. In some of these embodiments, freezing can affect the color of the protein, in which case the protein turns an undesirable color.

[074] Alternatively, however, as would be appreciated by those skilled in the art, the sealed protein 70 may be exposed to MA or vacuum-packed, rather than frozen, or in addition to freezing. can be either Therefore, in certain embodiments of the system, an alternate route or series of steps and sub-steps are provided so that both the processing for vacuum packaging and the MA processing can be performed at the same facility as Process 1 at substantially the same time. steps can be performed.

[075] In various embodiments, the finished product bags are expected to weigh about 1 pound each and are packaged in 40 pound boxes to provide economically viable shipping methods. May be packaged in 816466 g (1800 lb) pellets. Other arrangements are of course possible, as would be understood by those skilled in the art.

[076] Products treated with Process 1 described herein can remain edible in their raw state and have a shelf life of: approximately 60 days for beef/lamb; is about 45 days, and chicken is about 30 days. In some embodiments, the product remains frozen at -2°C (about 28°F) to 2°C (36°F) during this period. In various embodiments, the product may be stored at about 2-6°C (35-43°F). The use of an aqueous ozone exposure substep (box 13) and/or an extended vacuum substep (box 29) can further extend shelf life.

[077] In various embodiments, the disclosed system 10 and associated devices and methods also provide extended protein shelf life for retailers and safer products for end consumers. Retailers typically purchase advertisements at least one month prior to the actual protein purchase, given the difference in advertising cycles and shelf life in the current retail environment. Typically, these advertisements are deployed based on seasonal trends, with retailers tending to be "bind" to promotions over a given period of time. The system 10 and associated devices and methods disclosed herein enable retailers to postpone and minimize this market decision, thus allowing retailers to spend less money if there is oversupply. Allows selection of less costly cuts of product, thereby maintaining cost reductions and increasing efficiencies. As described herein, proteins purchased from various markets are held for a predetermined period of time, such as about 30-50 days, and then processed using the system 10 and associated methods and devices disclosed herein. be able to. Processing with the disclosed system 10 provides the protein with an additional shelf life of up to about 60 days or longer. These improvements will be appreciated by those skilled in the art in light of the present disclosure.

[078] It is understood that the supply of protein-enhanced products according to various embodiments is expected to provide numerous benefits to end retailers, who require trimming, boning, packaging, etc. If you don't, you'll get a product with a clean extended shelf life. Various of these retailers will therefore enjoy lower overheads while reducing the need for skilled labor. Traceable, in some embodiments informally labeled products can be placed directly on the raw protein counter. These packaged protein units may also be beneficial to the end consumer, utilizing the disclosed system 10, who in turn are safe and of normal visual quality. You will be purchasing a high quality portion of the protein that you have and can trace back to its source facility. Additionally, for retailers, the disclosed system 10 eliminates or minimizes the need for product rework and provides protein and other products with reduced wastage. In this way the total number of preparation steps for the protein performed by the retailer can be reduced. Further, as discussed above, retailers can benefit from avoiding peak times of the year for purchasing certain products and still be able to market in line with seasonal trends.

[079] Various cuts of meat were subjected to various embodiments of the process described above and then subjected to testing for bacterial load. Tests 1-15 were run using the following process parameters: (Box 13) Ozone application at >5 ppm; HPP; (Box 29) HPP with extended vacuum time of 486 seconds; and (Box 20) modified atmosphere packaging with a gas mixture of 80% _N2 , 19.6% _CO2 , and 0.4% CO. Testing was performed before processing, after processing, and at intervals of approximately 10 days thereafter.

[095] Tests AE examined the application of ozone to meat products over time (box 13) and various HPP (box 28) process parameters.

[0100] Tests EL involved applying various process parameters to 1/4 chicken. Test E reflects the microbial value of the chicken prior to any processing via Process 1. Test F reflects the microbial value of the chicken after the ozone application step (box 13). Tests GL reflect microbial values after treatment with HPP (box 28) using the indicated processing parameters.

[0109] Another set of tests was run on beef sirloin flaps using various process parameters and including or omitting various steps and/or substeps. Tests using modified atmosphere packaging ("MAP") used a gas mixture of 80% N, 19.6% _CO2 , and 0.4% CO.

[0110] Although the present disclosure has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the disclosed devices, systems and methods. I guess you are.

1 Packaging Process 2 Preparation Step 4 Modified Atmosphere Step 6 Autoclave Step 10 Packaging System 34 Aqueous Ozone Application Unit, Nozzle Applicator 36 Spray Nozzle 38 Conveyor 40 Table 42 Conveyor 44 Grader 46 Tumbler 48 Weighing Device 50 MA Device 51 Conduit 52 Scanning substep 53 bagging chute 54 HPP substep 58 vacuuming 69 sealed bag 70 protein

Claims (20)

A method of packaging a protein comprising:
a preparation step comprising providing a protein, exposing the protein to an aqueous ozone solution, and placing the protein in a container;
a modified atmosphere step comprising introducing a modified atmosphere into the container and sealing the container;
an autoclave step comprising exposing the container to autoclave and storing the container;
The above method, including 3. The method of claim 1, wherein the liquid ozone solution is from about 0.5 to about 5 PPM. 3. The method of claim 2, wherein said protein is exposed to said aqueous ozone solution for 1-10 seconds. 4. The method of claim 3, further comprising extending the vacuum time after autoclaving. 5. The method of claim 4, wherein the decompression time is about 8 minutes. 2. The method of claim 1, wherein said autoclaving is at least about 60,000 psi. 7. The method of claim 6, wherein said autoclaving is at least about 4 minutes. A method for extending the shelf life of a food product comprising:
providing food;
exposing the food product to an aqueous ozone solution;
placing the food product into a package;
flushing the package with a modified atmosphere;
sealing the package;
exposing the package to autoclaving;
The above method, including 9. The method of claim 8, wherein the food product is exposed to the aqueous ozone solution for 1-10 seconds. 10. The method of claim 9, wherein the aqueous ozone solution comprises 0.5-4 PPM aqueous ozone. 9. The method of claim 8, wherein the modified atmosphere is substantially free of oxygen. 9. The method of claim 8, wherein the aqueous ozone solution is exposed to the food product through a spray nozzle. 9. The method of claim 8, wherein the autoclave has a decompression time of greater than 5 minutes. (a) an aqueous ozone application unit;
(b) a packaging device in communication with said aqueous ozone application unit;
(c) a modified atmosphere injector in communication with the packaging device;
(d) a sealer in communication with the packaging equipment and the modified atmosphere injector; and (e) an autoclave tank in communication with the packaging equipment;
A system for processing proteins, comprising:
a. proteins are exposed to aqueous ozone in said aqueous ozone application unit;
b. the protein is packaged by the packaging device;
c. the package is flushed with a modified atmosphere by the modified atmosphere injector;
d. the package is sealed by the sealer while being flushed with the modified atmosphere;
e. The above system, wherein the protein is exposed to autoclaving in the autoclave tank. 15. The system of claim 14, wherein the aqueous ozone solution is 0.5-4 PPM aqueous ozone. 16. The system of claim 15, wherein said aqueous ozone application unit includes at least one spray nozzle. 17. The system of claim 16, wherein the autoclave has an extended decompression time. 18. The system of claim 17, wherein the decompression time is longer than 8 minutes. 19. The system of claim 18, wherein the shelf life of said protein is extended by at least 60 days. 20. The system of claim 19, wherein said protein is beef.

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