WO2008037326A2

WO2008037326A2 - Sanitary food processing, transportation and packaging line to elongate product runs and product shelf life

Info

Publication number: WO2008037326A2
Application number: PCT/EP2007/007354
Authority: WO
Inventors: Joachim Wokurka; Joerg Schmeiser
Original assignee: CFS Bühl GmbH
Priority date: 2006-09-26
Filing date: 2007-07-21
Publication date: 2008-04-03
Also published as: WO2008037326A3

Abstract

The present invention relates to a food transportation-, food processing- and/or food packaging apparatus which is at least partially surrounded by a sterilised or germ reduced zone. The present invention further relates to a process for the transportation, processing and/or packaging of food, which takes place at least partially in a sterilised or germ reduced zone. Additionally, the present invention relates to a food product available with the inventive process.

Description

Sanitary food processing, transportation and packaging line to elongate product runs and product shelf life

Food is nowadays, before its presentation in a shelf, processed, transported and/or packaged. During these process the product is in some cases contaminated with germ or the like, which reduces the shelf life of the food product.

It is therefore the objective of the present invention to provide a food transportation-, food processing- and/or food packaging apparatus and process that does not comprise the deficiencies of the state of the art.

The problem is solved by a food transportation-, food processing- and/or food packaging-apparatus, which is at least partially surrounded by a sterilised or germ reduced zone.

According to the present invention, the inventive apparatus is at least partially surrounded by a sterilised and/or germ reduced zone. Preferably, the inventive apparatus is located under a cover and/or in a room or comprises hoods in which the environment is sterilised and/or germ reduced. Most preferably, the machine is entirely in a sterilised or germ reduced zone. Sterilised or germ reduced zone according to the present invention means, that the apparatus within this zone is sterilised or germ reduced. Furthermore, the air within this zone is germ reduced or sterilised. All products i. e. the food, food additives, packaging materials and/or consumables are preferably sterilised or at least germ reduced. Preferably no person has access to the sterilized or germ reduced zone. Cleaning and sanitation of the machines in the zone is preferably done automatically, without any operator entering the zone.

Around this zone there can be another area with less hygienic requirements.

Preferably, the cover and/or the room comprises inlet-sluice and/or outlet-sluices. Preferably, inlet-sluices have means to sterilise or reduce the germs of the food product, the packaging material, the consumables and/or the air flowing into the cover, the hood and/or the room.

The outlet-sluices preferably sterilise or reduce the germs of the air flowing into the cover and/or the room.

These sluices comprise a radiation source, a pasteurisation unit, a chemical desinfection unit or any other means known by a person skilled in the art for disinfections or germ reduction. The air flowing into the process is preferably sterilised or germ reduced by the radiation source. The food can be sterilised by radiation means, pasteurisation, for example ultra-high pressure pasteurisation and/or the addition of chemicals for example peroxides or ozone. The sluices have the effect, that all the material entering into the zone is sterilised or germ reduced, so that the germ contents in the zone is not increased during production.

In another preferred embodiment of the present invention, the zone, for example the cover, the hood and/or the room, are under a higher pressure than their ambience to assure that there is always a flow away from the zone i.e. the apparatus rather than towards the zone. The air flowing into the zone is sterilised and/or germ reduced.

Preferably, there is a laminar flow of sterilised or germ reduced air around the apparatus under the cover and/or in the room to assure, that there is a constant air exchange and that the food products are constantly surrounded by sterilised air. The laminar flow is important in order to avoid the disburse particles, e. g. germs, bacteria and/or food particles into the air which are then spread within the zone.

In another preferred embodiment the inventive apparatus comprises means for intermediate and/or automatic cleaning and/or sterilisation of the zone and/or the apparatus within the zone. This preferred embodiment of the present invention has the advantage, that the inventive apparatus is cleaned in regular intervals or whenever needed in order to remove food spillages which can be a source for germs or the like and in order to sterilise and/or germ reduce the inventive apparatus and or the zone regularly. Preferably, the inventive machine comprises sensors in order to detect germs in the air and/or on the food product and/or for example to detect spillages of food and the like for example with a camera. As soon as a raised level of germs and/or spillages are identified, the inventive apparatus is cleaned automatically, without an operator, either while the apparatus is still operating or after it has been stopped. If no increased level of germs and/or no spillages are detected, the zone and/or the apparatus are preferably cleaned in regular intervals.

In another preferred embodiment, the inventive apparatus operates without an operator in the zone. Consequently no operator is allowed to enter the zone, in which the inventive apparatus produce, transport and/or package food. In case of a problem, the operator either has to overcome the problem without entering the zone, for example with a robot, repair means from outside the zone or the apparatus has to be stopped, repaired, and sterilised before the apparatus is taken into operation again. Preferably, the inventive apparatus is only re-startable after it has been sterilised. This sterilisation process can be detected by a sensor which is connected to the control unit of the inventive apparatus. This control unit can only start the inventive apparatus after it has received the according signal from the sensor.

As already mentioned above, the product entering the zone should be at least germ reduced or sterilised. If this is not already the case, the sterilisation or germ reduction can be achieved by post-pasteurisation for example ultra-high pasteurisation. Furthermore, chemicals like peroxides, ozone or the like can be spread on the product in order to decontaminate its surface. Alternatively or additionally, radiation can be used to sterilise or germ reduce the product. This radiation can also be used to get information about the product, its volume, its local density, its composition.

In a lot of cases, the product comes within a casing. This casing can be sterilised by the addition of chemicals or a radiation. In case that the casing has already been peeled from the product logs, the peeled product can be sterilised or germ reduced by a radiation, tempering/crusting. In case that the product is for example a sliced product, minces, meat, chunks or the like, the product can be sterilised or germ reduced by radiation.

All other products which enter the zone, for example consumables, packaging materials, labels or the like, can be germ reduced by the addition of chemicals like ozone, peroxide or the like and/or by radiation radiation source, a pasteurisation unit, a chemical desinfection unit or any other processes known by a person skilled in the art for disinfections or germ reduction.

In another preferred embodiment, the products which enter the zone comprise chemicals or other additives which reduce the germ level in the product.

The processes and/or apparatus which are located/carried out within the zone are all processes and apparatus known for the production of food. It can be for example cutters, minzers, batterers, cookers, fryers or the like. To all these apparatus meat, cheese or other food products are added. These food products are then further processed and in some cases additional food products like for example spices and/or bread crumbs are added. All these materials have to be sterilised or germ reduced prior to the processing. In a lot of cases, this food product is then filled into cases. Additionally or alternatively the product is produced under sterile conditions or sterilized after its production.

Before these cased products can be further processed, especially sliced, the casing has to be removed via peeling. Preferably, this peeling takes place in the sterilised zone. More preferably, the peeling is carried out by a machine which is sterilised and not by a operator. Most preferably, even if the peeling is not completed by the apparatus, the logs will not be manually reworked but rejected. Even more preferably, the opening of the casing takes place without tools and is consequently contact free. This can be carried out for example by air pressure or by means of radiation for example with a laser. Due to this contact free peeling, it is assured that the product is not contaminated during the peeling. Even more preferably, the peeler is sterilised or germ reduced in regular intervals and or when needed. This can be carried out with chemicals, radiation source, a pasteurisation unit or any other means known by a person skilled in the art for disinfections or germ reduction.

After the peeling of the logs, these logs are in a lot of cases sliced into a multitude of slices. Preferably, this slicing process also takes place in the sterile or germ reduced zone. Even more preferably, the slicers is sterilised or germ reduced in regular intervals and/or when needed. Especially the slicing blade all beltings, the sheer edge are sanitised for example by a radiation or the addition of chemicals or any other means known by a person skilled in the art for disinfections or germ reduction.

Preferably, the rotor housing is permanently sanitised by the a. m. means.

Preferably, the logs are automatically fed to the slicing machine. Even more preferably, trims and cuts and potential non-conform portions, which e.g. do not have the right weight or which do comprise undesired slices, are rejected automatically and moved out of the zone. Preferably, the feeding of the product is carried out contact free without a gripper. Even more preferred, the portions are directly sliced into sterile trays. This preferred embodiment of the present invention avoids that the slices are contaminated during transportation or during the loading of the complete portion into a tray.

After the slicing has taken place, the portion has to be weighed in order to assure that is comprises the correct weight. The weighing preferably takes place in the sterile zone. The weigher is also cleaned, sterilised or germ reduced in regular intervals or when needed by radiation and/or the addition of chemicals. Portions, which do not have the correct weight, will not be reworked, especially not manually reworked, but discharged automatically.

The entire transporting process within the zone, to the inventive apparatus and/or between two inventive apparatus takes preferably place in the sterile or germ reduced zone. These transportation means are also cleaned, sterilised and/or germ reduced in regular intervals or whenever needed.

After the food portions have been produced, they must be packaged into packaging items. These packaging items can be bags, trays or the like. Normally, these bags or trays are produced from a plane plastic-film-sheet via forming of the plane film material into a bag or the like or by deep-drawing a tray into a film material. This forming of the bags or trays is preferably carried out in the sterilised or germ reduced zone and/or the bags, trays are fed into the sterilised zone. Before the film material or the packaging item enter the sterilised zone, they are preferably sterilised or germ reduced. This can take place by a radiation or the addition of chemicals or any other means known by a person skilled in the art for disinfections or germ reduction. Preferably, the packaging material and/or the bags and/or trays are fed into the zone via a sluice. Thus, the packages are sterile or germ reduced before they are filled with the food product. The person skilled in the art understands that also prefabricated trays or bags can be fed into the zone after sterilization or germ reduction.

These bags and/or trays are subsequently filled with the food product in a so-called loading station. Prior to this loading station the bags or trays have been sterilised and/or are produced by a sterilised and/or germ reduced material. In this loading zone the food product is preferably automatically loaded into the bags or trays. There is preferably no operator present in the zone especially not in the loading area. The loading area is preferably continuously flushed with sterilised air. Especially in the area of the loading zone there is an over pressure so that the sterilised air always moves away from the loading zone and not towards the loading zone in order to avoid the contact of germs with the food to be packaged. Preferably the air flow is laminar.

After the bags and/or trays have been filled with the product, they are sealed. This process takes place in a so-called sealing area, where for example the bags are closed with a longitudinal and/or a cross-seal or wherein the trays are closed with a lid which is sealed to the tray. This process also takes place within the sterile zone in which preferably no operator is allowed. In the entire zone there is an overpressure of a sterilised gas for example air or a gas that inhibits or reduces the oxidisation of the food product for example carbon dioxide and/or nitrogen.

Especially the loading zone but also the sealing zone must also be cleaned, sterilised and/or germ reduced in regular intervals or whenever needed. This cleaning includes preferably the cleaning of all gas tubes, especially the tubes needed for the gas exchange (MAP) in the packages.

After the bags or trays have been sealed they are gas tide. All subsequent processes, for example cutting the trays and/or bags apart and packaging these bags or trays into larger units can be carried out in a zone which with less restrictive sanitary requirements or even under ambient requirements. All waste that is created in the zone like package waste, slicing waste or protions or packages which are rejected are preferably automatically removed from the zone.

Another subject matter of the present invention is a process for the transportation, processing and/or packaging of food, which takes place at least partially in a sterilised or germ reduced zone.

The a.m. disclosure regarding the inventive apparatus is also applicable to the inventive process.

The inventive process allows the production of food products with a significantly increased shelf life and/or an increased product safety.

Preferably, the food product itself, food additives and all materials that come into contact with or in the vicinity of the food product like packaging material, labels and/or consumables, which enter the sterilised or germ reduced zone, are germ reduced or sterilised themselves.

Preferably, the inventive process is operator free in order to avoid, that the operator contaminates the product.

Preferably, a laminar sterilised gas-, especially air-flow, is maintained within the inventive process to assure, that the ambience of the food is also always sterilised and that germs and the like are moved away and not towards the food product. The laminar flow is important in order to avoid that food spillages and/or germs are not steered up and contaminate the food product before the package in which the food product is placed is closed. Preferably, portions of the food products packages or the like are not reworked if they are not as desired but totally rejected.

Another objective of the present invention is a food product available according to the process of the preceding claims. This food product is significantly reduced in germs or the like so that is has an increased shelf life and/or that the product quality is much better than products according to the state of the art.

The inventions are now explained in greater detail according to figures 1 to 4. These explanations do not limit the scope of protection. The explanations apply to all inventions of the present application equally.

Figure 1 shows a thermo-former, a slicer and a transportation means in a sterilised and/or germ reduced zone,

Figure 2 shows the apparatus according to figure 1 but with a tray sealer instead of a thermo-former,

Figure 3 shows an embodiment of the present invention where only the packaging machine is in

a sterilised or germ reduced zone

Figure 4 shows the apparatus according figure 1 as the sterilised and/or germ reduced zone is realised by two covers.

Figure 1 shows the inventive apparatus in a sterilised and/or germ reduced zone 1. In this zone no operator is allowed during the operation of the machine. The apparatus comprise a slicer 3, transportation means 5 and a packaging machine 17. The log 2, in the present example a ham log, has been peeled and is subsequently fed via the sluice 16" into the sterilised and/or germ reduced zone 1. During the passage of the sluice 16" the ham log is sterilised or at least germ reduced via post- pasteurisation, radiation and/or the addition of chemical agents like ozone, peroxides or the like. Afterwards, the log 2 is automatically transported into a slicer 3, which slices the log into slices and forms portions 4 which are transported by the transport means for example endless belt 5 to the packaging machine 17. The packaging machine 17 is a so-called form fill seal machine, which forms in a forming station 13 trays 12 out of a plane plastic film 14 which is rolled from a film roll 15. Prior to the forming the film passes the sluice 16' in which the film is sterilised or at least germ reduced by a radiation and/or the addition of chemicals. The trays are consequently sterile or at least germ reduced. After the trays 12 have been formed, they are filled automatically with the portions 4 in the loading area. Subsequently, the trays are sealed with a cover film in the sealing area 10. The sealed packages 9 are depicted by grey portions instead black portions prior to the sealing. Prior to the sealing the gas in the packages is exchanged by CO₂ or N₂ or the like to avoid perishing of the food. The closed packages have the reference number 9. These closed packages are separated in the cutting station 8 and pass then a sluice 16'". In this sluice 16^'" no sterilisation or germ reduction of the package 9 takes place, but this sluice avoids, that germs enter into the sterilised or germ reduced zone 1. The transportation out of the zone 1 takes place by transportation means 16. The zone outside of zone 1 has the reference number 7. In this zone the requirements regarding sanity are reduced, because in this zone the packages are already closed, so that the food inside the package can not be contaminated anymore. The packaging machine 17 comprises means to identify the amount of germs and spillages and to automatically clean the packaging machine especially in the loading and in the sealing area either in regular intervals or whenever a spillage or an increased amount of germs is identified. Portions or packages which do not meet specified requirements will not be reworked but automatically discharged and not recycled. Zone 1 has a permanent supply of sterilised air and is in comparison to the ambience under a higher pressure so that there is a constant air flow out of zone 1 so that no germs can enter zone 1. Within zone 1 there is a constant laminar flow of sterilised air, especially in the area where the food is not entirely packaged in order to avoid, that germs get into contact with the food product. It is important, that the air flow is only laminar in order to avoid, that spillages or germs are steered up and blown into the packages. Discharge from the slicing, the packaging and/or the portioning is removed from zone 1 automatically. Repair at one of the machines is either done from outside zone 1 through gloves or the like or with a robot.

Figure 2 shows essentially the embodiment according to figure 1. In the present example, the packaging machine 17 is a so-called tray-sealer in which pre-fabricated trays 18 are put on a transportation belt and are subsequently filled and sealed as described in figure 1. The pre-fabricated trays also pass the inlet-sluice 16' in which they are at least germ reduced, preferably sterilised.

Figure 3 shows the embodiment according to figure 1 with the exception, that in the present case slicer 3 is not within zone 1 but outside zone 1. In this case portions 4 are at least germ reduced, preferably sterilised by the inlet-sluice 16".

Figure 4 shows an embodiment in which the slicer 3, the transportation belt 5 and the packaging machine 17 are not in an entire room with zone 1 , but under covers 1', which facilitate a sterilised and/or germ reduced environment.

List of references

1 sterilised, germ reduced zone, room,

1 ' sterilised, germ reduced zone, cover, hood

2 food log, especially ham, sausage, cheese

3 slicer, cutter, minzer, portioner, breader, oven, etc.

4 food portion

5 transportation means, endless belt

6 transportation means, endless belt

7 area reduced requirements in terms of sanity

8 package separation

9 sealed package

10 sealing station

11 loading station

12 tray

13 forming station

14 plastic film

15 plastic film roll 16', 16" inlet sluice

16'" outlet sluice

17 packaging machine

18 trays

Claims

Claims:

1. Food transportation-, Food processing- and/or Food packaging-apparatus (3, 5, 6, 17), characterised in, that it is at least partially surrounded by a sterilised or germ reduced zone.

2. Food transportation-, Food processing- and/or Food packaging-apparatus (3, 5, 6, 17), according to claimi , characterised in, that it is totally surrounded by a sterilised or germ reduced zone.

3. Food transportation-, Food processing- and/or Food packaging-apparatus (3, 5, 6, 17) according to one of the preceding claims, characterised in, that it is located under a sanitised or germ reduced cover (1 ^') and/or in a sanitised or germ reduced room (1 ).

4. Food transportation-, Food processing- and/or Food packaging-apparatus (3, 5, 6, 17), according to claim 3, characterised in, that the cover (1 ^') and/or room (1 ) comprises an inlet-sluice (16^', 16^") and/or an outlet sluice (16^" ).

5. Food transportation-, Food processing- and/or Food packaging-apparatus (3, 5, 6, 17), according to claim 4, characterised in, that the inlet-sluice (16^', 16^") sterilises or reduces the germs of the food product (2, 4), the packaging material (14) and/or the air flowing into the cover (1 ^') and/or into the room (1 ).

6. Food transportation-, Food processing- and/or Food packaging-apparatus (3, 5, 6, 17), according to claim 4, characterised in, that the outlet-sluice (16^'") sterilises or reduces the germs of the air flowing into the cover (1 ^') and/or the room (1 ).

7. Food transportation-, Food processing- and/or Food packaging-apparatus (3, 5, 6, 17), according to claim 5 or 6, characterised in, that the sluice (16^', 16^", 16^'") comprise a radiation source, a pasteurisation unit and/or a chemical desinfection unit or other germ reduction means or processes.

8. Food transportation-, Food processing- and/or Food packaging-apparatus (3, 5, 6, 17), according to one of the preceding claims, characterised in, that the cover (1 ^') and/or the room (1 ) are under higher pressure than their ambience.

9. Food transportation-, Food processing- and/or Food packaging-apparatus (3, 5, 6, 17), according to one of the preceding claims, characterised in, by a laminar flow of sterilised air around the apparatus (3, 5, 6, 17), under the cover (1 ^') and/or in the room (1 ).

10. Food transportation-, Food processing- and/or Food packaging-apparatus (3, 5, 6, 17), according to one of the preceding claims, characterised by means for intermediate, automatic cleaning and/or sterilisation.

11. Food transportation-, Food processing- and/or Food packaging-apparatus (3, 5, 6, 17), according to one of the preceding claims, characterised by operator free operation/production.

12. Food transportation-, Food processing- and/or Food packaging-apparatus (3, 5, 6, 17), according to one of the preceding claims, characterised in, that non conform portions are automatically rejected.

13. Food transportation-, Food processing- and/or Food packaging-apparatus (3, 5, 6, 17), according to one of the preceding claims, characterised by germ detection and spillage means.

14. Process for the transportation, processing and/or packaging of food, characterised in, that it takes place at least partially in a sterilised or germ reduced zone.

15. Process for the transportation, processing and/or packaging of food, according to claim 14, characterised in, that the food, the food additives, the packaging material, and/or the consumables entering the zone are germ reduced or sterilised

16. Process for the transportation, processing and/or packaging of food, according to one of the preceding claims, characterised in, that it is operator free.

17. Process for the transportation, processing and/or packaging of food, according to one of the preceding claims, characterised by a laminar sterilised air flow through the zone.

18. Process for the transportation, processing and/or packaging of food, according to one of the preceding claims, characterised in that no product is reworked.

19. Food product available according to the process of one of the preceding claims.