NZ250119A - Food product sealed in cook in casing and method of preparation by cooking in a mould with a multifaceted design - Google Patents

Description

2 5 0 119 i Complete Specification Filed: j Ciass: (6) sJoo;,.....

■ : B.V+1.3 J.Hv?;. J^'/ ! - /blication Date: MAR. 1996 ;j'Journal No: N.Z. PATENT ornCE = 7 DEC 1995 RCCF.IVED NEW ZEALAND PATENTS ACT, 1953 No.: Date: \ COMPLETE SPECIFICATION MULTIFACETED PACKAGED PRODUCT AND METHOD OF MAKING SAME We, W R GRACE & CO-CONN, a corporation organized and existing under the laws of the state of Connecticut, USA of 1114 Avenue of the Americas, New York, NY 10036-7794, United States of America hereby declare the invention for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:- - 1 -(followed by page la) 0 1 1 PATENT Case No. 41970 BACKGROUND OF THE INVENTION' 1. Field of the Invention The present invention relates generally to a casing for packaging a meat product during cook-in mold cooking and the cased meat product so produced. More particularly, this invention relates to preprinted thermoplastic food casings for use with cook-in molds having a means of molding a multifaceted design into said cased cook-in meat product and the product so produced. 2. Description of the Related Art Many foods during preprocessing are stuffed into a casing and then placed in a heated medium, such as a hot water bath, for cook-Ln to produce a precooked, encased food product. Generally, a portion of a moldable raw meat, such as sectioned ham or meat emulsion, is pressed into a bag or casing lined smooth wall stainless steel cooking mold having a generally rectangular shape, then cooked while in the mold, and thereafter packaged as a pre-cooked compacted meat product. Alternatively, the moldable raw meat or emulsion can be pressed into the casing without the use of a mold and then cooked or after loading into a casing, the casing can be loaded into a mold for cooking. The term "cook-in" conventionally refers to cooking of a food product while contained in a package. Alternatively, the package may be a heat shrinkable bag which shrinks tightly about a contained food product upon initial exposure to cook-Ln conditions.

The term "cook-in package " is intended to refer to packaging material structurally capable of withstanding exposure to cook-Ln time-temperature conditions while containing a food product. Cook-in time-temperature conditions typically imply a long slow cook, for example by submersion in water at 70°-80° C. for 4-6 hours. Under such conditions, a packaging material properly characterized as cook-in will maintain heat seal integrity and will be de-lamination resistant. The packaging material typically will also be heat shrinkable under these conditions so as to form a neatly fitting package and preferably should have a tendency toward product adhesion to minimize "cook- N.Z. PATENT OFFICE la - 7 DEC 1995 RECEIVED 2 5 0 1 1 9 PATENT Case No. 41970 out" or collection of fluids between the surface of the feed product and the interior surface of the bag.

It is desirable that a cook-in package closely conform to the contained food product to prevent "cook-out". I.e.. exudation of fluids from the food product during cooking. By restricting exudation of fluids from a cook-in contained food product, the yield of the precooked food product is increased, since fluid retention tends to increase product weight. It is also desirable that the cook-in contained food product maintain uniform size over Its full length, and optionally have flattened ends, so as to produce uniform size and weight portions when further processed, thereby further increasing the yield. It is further desirable In the up-scale deli market to produce such a cook-in contained food product having a multifaceted design molded into the cased cook-in product.

U. S. Patent No. 3.765,090 (Roberts et. al.) discloses a method of making cheese including loading the curd into a casing using a tube to help compress the curd and direct the partially compressed curd into the container. Containers contemplated include those of cardboard and of metal as well as plastic bags. There is no cook-in of the cheese product. There is also no appreciation of utilizing the mold to create designs in the molded product.

U. S. Patent No. 4.672.793 fTerlizzi. Jr. et. al.) discloses an improved method of vacuum packaging a molded meat product in a cook-In bag lining a cooking mold. The teaching is directed to an improved vacuum system for use during packing of the meat product. This patent does not appreciate the mold apparatus of the present invention, nor does it suggest forming designs in the molded product.

There Is a continuing market for meat products cased in an "Old World" style casing. This type of casing may be described as having a small mesh stocking-like base with a coarser netting stitched over it. When stuffed tightly and c ooked. the meat product protrudes from each netted "square" in a regular series of "bumps" effecting a very old-fashioned, high quality effect. An example of this type of casing is the Hukki-Hitch casing sold by Vista. This type of casing, because It is air permeable, has a short shelf life and limits the types of meats which can be packaged in it.

N.Z. PATENT OFFICE - 7 DEC 1995 RECEIVED 0 1 1 S PATENT Case No. 41970 OBJECTS AND SUMMARY OF THE INVENTION One object of the present invention is to provide a casing for stuffing and cook-in of cased meat products which produces a cased meat product having a multifaceted design molded therein and produces an "Old World" style casing.

Another object of the present invention is to provide an Old World style casing which increases shelf life, lowers costs, and increases the types of meat products which can be so packaged.

Yet another object of the present invention is to provide improved size uniformity, and reduced waste, of the cased meat product.

A further object is to provide an improved cased meat products molded in a particular desired shape, having a multifaceted design molded therein, and having an Old World style casing.

A still further object of the present invention is tc provide for the use of casing materials which heretofore did not achieve the shape and size uniformity necessary for cook-in cased meat products.

Accordingly, one form of the present invention relates to a process for preparing a cooked meat product, comprising the steps of: A) providing a meat product sealed in a cook-in casing; B) placing the casing, and meat product therein, into an open mold, the mold being tubular, the mold comprising a plurality of shaped body sections and a plurality of holes through the shaped body sections, the holes providing the mold with a multifaceted design; C) closing the mold; D) cooking the meat product in the mold so that a cooked meat product is produced, the meat product expanding into the holes of the mold during cooking, the meat product taking on the multifaceted design of the mold; and E) removing the cooked meat product from the mold.

N.Z. PATENT OFFICE - 7 DEC 1995 0 Another form of the present invention relates to a packaged product, comprising: A) a cooked meat product; and B) a cook-in casing over the cooked meat product; wherein the cooked meat product is sealed in the cook-in casing, and the cooked meat product has a multifaceted design thereon, and the packaged product has convex protrusions thereon, the convex protrusions comprising both the cooked meat product and the cook-in casing. 4 N.2. PATENT OFFICE - 7 DEC 1995 RECEIVED 2" 0 1 9 PATENT Case No. 41970 Preferred forms of the invention, as well as other embodiments, objects, features and advantages of this Invention, will be apparent from the following detailed description which Is to be read In connection with the accompanying drawings.

FIG. 1 shows a plan view of one embodiment of a cook-in mold thermoplastic casing having a preprinted net like pattern thereon.

FIG. 2 shows a schematic side view of a cook-In mold with the casing of Fig. 1 and packaged meat product therein before cooking.

FIG. 3 shows a schematic side view of the cook-In mold of Fig. 2 with a casing ana packaged meat product therein after cooking.

FIG. 4 shows an end view of a two piece cook-in mold of the present Invention using a hinge means to allow opening of the mold and removal of the cased cook-in meat product.

FIG. 5 shows a plan view of one embodiment of the cased product of the present Invention after cook-In and removal from the mold.

DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION The present invention will be better understood from the specification taken in conjunction with the accompanying drawings In which like reference numerals refer to like parts.

In FIG. 1 there is shown a preferred embodiment of the present invention comprising a web of thermoplastic casing material 11 having a net like pattern 12 printed thereon. Additionally, the thermoplastic casing material 11 may be eyed or otherwise have a base color applied to it before, after, or during the process of printing the net like pattern on said casing material.

FIG. 2 shows a cut away view of a preferred cook-in mold 10 with a casing 11 contained meat product 23 Inside the mold before cooking. Further is shown both casing ends having been clipped with clips 21 on neck portions 22. As can be seen pressure plate 5 and spring 6 have caused the meat filled ends of casing 11 to be flattened. This squaring off of the ends of the cased BRIEF DESCRIPTION OF THE DRAWINGS 0 1 1 9 PATENT Case No. 41970 meat product Increase product yield by providing a greater amount of uniform sized meat product per casing length.

In FIG. 3 is shows the cook-in mold 10 of FIG. 2 with a casing 24 contained meat product 23 Inside the mold after cooking. The cook-in procedure causes the cased meat product 23 to swell ana enter the . multifaceted design pattern cutouts 8. producing the desired molded shape in the cooked cased meat product.

FIG. 4 shows an end view of the mold 10 having a hinge means 40 for opening and closing said mold sections 1 and 2 at opining seam 41.

FIG. 5 shows a cased meat product 23 which has be cooked inside the .. casing 11 of the present invention after cooking and removal from a multifaceted mold such as shown in Figs. 2 and 3, having pattern 12 aligned with the molded shapes produced by said mold thereby producing a 3D netting effect on said cased meat product.

In practice the mold sections of the present invention are sealed together by a sealing means, a casing Is introduced into the mold and its preprinted pattern is aligned with the multifaceted design pattern of the mold, and one end cap and pressure plates is put in place on the mold first end. The un- >4 i ^ cooked meat product is introduced into the casing and once the casing is filled the second end cap. with or without a pressure plate, is placed on the second end of the mold. The meat product is then cooked utilizing a cook-in means.

The swelling of the meat product during the cook-in process forces the casing and meat product to enter the multifaceted design cut outs in the mold sections thereby molding the multifaceted design Into the meat product. The cooked, molded meat product is then removed from the heat and chilled following standard industry practice. The mold end plates and pressure plates are removed and the mold sections are separated allowing the cooked meat product with the multifaceted design molded therein and the casing preprinted pattern producing an "Old World" style casing is removed and is ready for shipment and sale.

Any of the well known "cook-In package" meat casing materials may be used with the present Invention. Thus, a packaging material structurally capable of withstanding exposure to cook-in time-temperature conditions while containing a food product is suitable. The use of shrinkable casing material is especially well suited for use with the present invention. Suitable casing ma- 'i 6 250119 PATENT Case No. 41970 terials Include. for example, fibrous casings, moisture proof fibrous casing, cellulosic casings, and casing made from thermoplastics, elastomers, thermoplastic elastomers, polyesters, polyolefins. polyesters copolyesters. polyure-thanes. polystyrenes, polycarbonates, polyvinyl acetate, polyvinyl chloride, PVDC, polyamides. and polyalkaline carbonates. A panicularly preferred packaging material is thermoplastic bi-axially oriented polvolefin film. The casings may be in the form of individual bags, sticks of shirred casings or continuous casing tubing. Further, the casings may be clipped on both ends and the individual bags may have one heat sealed end or one end closed by any other known means. The use of such casing materials and forms is well understood by routineers In the art.

Suitable means of preprinting the desired patterns on the casings of the present invention are well known in the art. PYinting on tubular plastic webs is well understood by those skilled in the art and needs no further discussion herein.

The cook-in mold sections 1 & 2, of the present invention, may be made from stainless steel or from polymeric material.

The use of stainless steel, its composition, forming, and mold construction are well known by those skilled in the art. Likewise, methods and procedures for introducing the multifaceted designs Into the walls of the mold sections is well known and needs no further discussion here. Sufficed to say that known methods of cutting and punching shaped holes into stainless steel sheet Is well known and is not critical to the present invention. The stainless steel cook-in molds of the present Invention may be of any desired length. For example lengths of 15 Inches to 6 feet are easily provided. Further, these stainless steel cook-In molds may be utilized in the stuffing and cooking equipment currently in use. This eliminates the need for the meat processor to install new equipment and the consequent expenses entailed therewith.

Preferably, the mold sections are made from polymeric material which lowers cost, decreases the mold weight and provides safer handling by workers. Polymeric cook-in mold sections 1 & 2 may be made from any semi-rigid to rigid polymeric material which maintains Its shape and dimensions under the temperature and pressure conditions encountered during the cook-in process and subsequent storage. Such conditions are well known and understood in the art. Suitable polymeric materials include, for example, polyolefins such as. 7 7 DEC 1995 RECEIVED 0 1 1 PATENT Case No. 41970 polyvinyl chloride, polyethylene, polypropylene, copolymers thereof, as well as cast aciyiic. and the like. The presently preferred polymeric mold material is a propylene copolymer, because this material is approved for food contact. The mold profile can be of any desired shape and is not restricted to the rectangular shape of stainless steel molds. In addition the cost of the polymeri? cook-in mold of the present invention is substantially less expensive than stainless steel mcids currently used in the cook-in packaged meat industry. Mold shapes such as the highly desirable round shape for luncheon meats. D shape for turkey breast emulsion, tear drop shape, and mar.colin shape for ham products are all easily produced by known extrusion processes of the polymeric mold materials. It Is to be understood that square shapes are also easily accomplished. In addition, almost any other desired irregular shape, for use in upscale celi products for example, may be obtained as '.veil as rectangular shapes where desired. The polymeric cook-in molds of the present invention may be of any desired length. For example lengths of 15 inches to 6 feet are easily provided. Further, these polymeric cook-in molds may be utilized in the stuffing and cooking equipment currently in use. Again, this eliminates the need for the meat processor to Install new equipment and the consequent ex- ^ J penses entailed therewith.

In the case where the polymeric cook-in mold of the present invention is used in machinery having metal molds, the end caps of the metal molds may be utilized thereby eliminating the need for separate er.c caps and pressure plates in the polymeric cook-in molds. Thus, the polymeric cook-in molds of the present invention may be inserted into the preexisting metal molds and then the metal mold end caps and pressure plates put in place.

It is to be appreciated that while two body sections are preferred, a mold comprised of more than two body sections may be utilized without departing for the ir.tent ana scope of the present invention. This may be particularly advantageous for some elaborate mold shapes.

The sealing means for combining the mold body sections may be any suitable sealing means well understood In the art and is not critical to the invention. Suitable means Include hinge and latch, and straps, for example. Methods and means of sealing mold sections together such that they may be separated after processing of the mold contained product are well known and understccd in the art. 8 9MARS994; PATENT Case No. 41970 Suitable design shapes which may be cut into the mold sections walls include, for example, circles, half circles, squares, rectangles, diamonds, and ovals. Other shapes are also suitable and may be utilized and are considered within the scope of the present invention.

The present invention may be used with any suitable casing stuffing or sizing machine. Examples of suitable stuffing, sizing, and vacuum packaging machinery include, for example, the ROBOT 3000 DC available from Robert Reiser & Co., Inc. and Handtmann VF 20 available from TW" Kutter. Inc.. the RS 4201 available from Tipper Tie, the Shirmatic 400 and 600 series available from VIskase and the Mepaco stuffing system and the Cryovac® 8490/8150 vacuuming packaging system. These machines are well known in the art and need no further discussion here.

Although the illustrative embodiments of the present invention have been described herein with reference to the accompanying drawings it Is to be understood that the invention is not limited to those precise embodiments, and that various other changes and modifications may be effected therein by one skilled in the art without departing from the scope of the invention, as defined in the claims.

I J' OFFICE 1 - 7 DEC 1995

Claims (8)

1. WHAT WE CLAIM IS: 1. A process for preparing a cooked meat product, comprising the steps of: A) providing a meat product sealed in a cook-in casing; B) placing the casing, and meat product therein, into an open mold, the mold being tubular, the mold comprising a plurality of shaped body sections and a plurality of holes through the shaped body sections, the holes providing the mold with a multifaceted design; C) closing the mold; D) cooking the meat product in the mold so that a cooked meat product is produced, the meat product expanding into the holes of the mold during cooking, the meat product taking on the multifaceted design of the mold; and E) removing the cooked meat product from the mold.
2. 2. The process according to claim 1, wherein the meat product comprises raw meat emulsion.
3. 3. The process according to claim 1 or 2, wherein the meat is cooked in the mold for a period of from about 4 to 6 hours at a temperature of from about 70 °C to 80 °C.
4. 4. The process according to any one of claims 1 to 3, wherein the casing has two necks and the meat product is sealed in the cook-in casing by clipping at least one of the necks of the casing.
5. 5. The process according to any one of claims 1 to 3, wherein the casing has two necks and the meat product is sealed in the cook-in casing by heat sealing at least one of the necks of the casing.
6. 6. The process according to any one of claims 1 to 5, wherein the meat product is vacuum packaged in the cook-in casing.
7. 7. The process according to any one of claims 1 to 6, wherein the cooked meat product has substantially flat ends.
8. 8. The process according to any one of claims 1 to 7, wherein the mold comprises two mold portions, at least one hinge connecting the mold portions, and a latch. 10 !. PATENT OFFICE - 7 DEC 1995 RECEIVED 9. The process according to any one of claims 1 to 8, wherein the cook-in casing comprises a biaxially-oriented, heat-shrinkable film comprising polyolefin. 10. The process according to any one of claims 1 to 9, wherein the cook-in casing has printing thereon. 11. The process according to any one of claims 1 to 10, wherein the cook-in mold portions are rigid and comprise at least one member selected from the group consisting of stainless steel, polyolefin, polyvinylchloride, and polyacrylonitrile. 12. The process according to claim 11, wherein the cook-in mold portions comprise propylene copolymer. 13. The process according to any one of claims 1 to 12, wherein the multifaceted design on the cooked meat product comprises a multifaceted design of a meat product cooked in an old world style casing. 14. A packaged product, comprising: A) a cooked meat product; and B) a cook-in casing over the cooked meat product; wherein the cooked meat product is sealed in the cook-in casing, and the cooked meat product has a multifaceted design thereon, and the packaged product has convex protrusions thereon, the convex protrusions comprising both the cooked meat product and the cook-in casing. 15. The packaged product according to claim 14, wherein the cooked meat product comprises cooked meat emulsion. 16. The packaged product according to claim 14, wherein the cooked meat product comprises ham. 17. The packaged product according to any one of claims 14 to 16, wherein the cook-in cas ing has two necks, at least one of the necks being heat sealed. 1 ? . The packaged product according to any one of claims 14 to 16, wherein the cook-in cjising has two necks, at least one of the necks being sealed with a clip. 11 N.? : ,.I fICE - 7 DEC 1995 RECEIVED ? !i ft 1 1 9 19. The packaged product according to any one of claims 14 to 18, wherein a volume within the cook-in casing is evacuated, so that the packaged product is in a vacuum package. 20. The packaged product according to any one of claims 14 to 19, wherein the cooked meat product has substantially flat ends. 21. The packaged product according to any one of claims 14 to 20, wherein the cook-in casing comprises a biaxially-oriented, heat-shrinkable film comprising polyolefin. 22. The packaged product according to any one of claims 14 to 21, wherein the cook-in casing has printing thereon. 23. The packaged product according to any one of claims 14 to 22, wherein the multifaceted design on the cooked meat product comprises a multifaceted design of a meat product cooked in an old world style casing. 24. A process for preparing a cooked meat product as claimed in claim 1 substantially as herein described with reference to the accompanying drawings. 25. A packaged product as claimed in claim 14 substantially as herein described with reference to the accompanying drawings. W. R. GRACE & CO. • CONN, By Their Agents AJ PARK & SON 12 N.Z. PATENT C = 7 DEC 1995 RECEIVED