WO2020019088A1 - Process for producing cooked and roasted chicken with a shelf life of at least 25 days for use in large-scale production processes in retail chains - Google Patents

Process for producing cooked and roasted chicken with a shelf life of at least 25 days for use in large-scale production processes in retail chains Download PDF

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Publication number
WO2020019088A1
WO2020019088A1 PCT/CL2018/050057 CL2018050057W WO2020019088A1 WO 2020019088 A1 WO2020019088 A1 WO 2020019088A1 CL 2018050057 W CL2018050057 W CL 2018050057W WO 2020019088 A1 WO2020019088 A1 WO 2020019088A1
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Prior art keywords
product
chicken
temperature
retail
raw material
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PCT/CL2018/050057
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Spanish (es)
French (fr)
Inventor
Javier Andrés LUCK URBAN
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Alimentos Pacífico Limitada
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Application filed by Alimentos Pacífico Limitada filed Critical Alimentos Pacífico Limitada
Priority to PCT/CL2018/050057 priority Critical patent/WO2020019088A1/en
Priority to ARP190102099A priority patent/AR123402A1/en
Publication of WO2020019088A1 publication Critical patent/WO2020019088A1/en

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Classifications

    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23B—PRESERVING, e.g. BY CANNING, MEAT, FISH, EGGS, FRUIT, VEGETABLES, EDIBLE SEEDS; CHEMICAL RIPENING OF FRUIT OR VEGETABLES; THE PRESERVED, RIPENED, OR CANNED PRODUCTS
    • A23B4/00—General methods for preserving meat, sausages, fish or fish products
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23B—PRESERVING, e.g. BY CANNING, MEAT, FISH, EGGS, FRUIT, VEGETABLES, EDIBLE SEEDS; CHEMICAL RIPENING OF FRUIT OR VEGETABLES; THE PRESERVED, RIPENED, OR CANNED PRODUCTS
    • A23B4/00—General methods for preserving meat, sausages, fish or fish products
    • A23B4/005—Preserving by heating
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L13/00—Meat products; Meat meal; Preparation or treatment thereof
    • A23L13/50—Poultry products, e.g. poultry sausages
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L5/00—Preparation or treatment of foods or foodstuffs, in general; Food or foodstuffs obtained thereby; Materials therefor
    • A23L5/10—General methods of cooking foods, e.g. by roasting or frying

Definitions

  • the present invention is related to the food industry, specifically refers to a process for cooking poultry meat, particularly for the preparation of cooked and roasted chicken that allows the centralization of large-scale production processes applied to retail chains, the which achieves a duration of at least 25 days, which significantly decreases production times and costs in the public service premises. Also the invention is applicable to turkeys, which follows the same process as chickens as raw material.
  • roast chicken which are made during the day and placed in gondolas so that users can take them out of said retail areas and take a product that has been roasted in the day.
  • the invention aims to provide a process for preparing a roast chicken designed to allow the centralization of production plants geographically distributed in a dispersed area with a particular application to the needs of retail chains. This elaboration process allows to centralize the preparation of chicken in productive plants and then take them to retail, for which the product is required to have a duration of at least 25 days.
  • the invention is developed so that a process adapts to the requirements of retail chains in terms of which the product must give the perception that it has been freshly prepared for consumption and achieve a homogeneous quality and characteristics of a freshly chicken roast. With this process, production times and costs are reduced significantly in the customer service premises, which additionally improves the availability of the product in a self-service gondola and therefore the sales of this product, which It presents peak hourly demand that are difficult to meet at a reasonable cost by companies.
  • the roast chicken that is sold in retail chains is made from refrigerated or frozen raw material, which once roasted is marketed within the day it was produced.
  • Retail chains offer their customers the roast chicken product in the freshly roasted condition, with characteristics defined and recognized by consumers for immediate consumption.
  • the product is sold in each of the premises where raw material storage rooms, dressing section, production rooms and packaging and labeling section are sold. This requires having defined physical spaces, dedicated personnel and infrastructure and equipment for each stage of the process. Additionally, the current state of the process means that the required production times prevent compliance with consumer demand at a cost that makes this line of business profitable, especially during peak hours, with the consequent impact on consumer satisfaction .
  • the present invention solves the problem of large-scale retail chains, allowing frozen or fresh raw material to be commercialize as freshly prepared roast chicken, simplifying and reducing the times and costs of the elaboration process.
  • patent document LV 14095 discloses an invention that relates to the food industry, particularly to the production of "ready-to-eat foods".
  • the object of said invention is a method for chicken fillet preparations using a Sous vide package.
  • the process includes marinating in fruit and berry sauce rich in organic acids and semi-dry white wine at refrigerated temperature in individual polymeric containers - thermoformed bags or containers, of which substantially all the air must be removed giving vacuum. Then follow the final heat sealing of the containers and the packages are placed in a refrigerator for a specific time of 20 to 24 hours.
  • EP 2901870 discloses a procedure for preparing and packaging roast chicken for later distribution, which uses raw chicken raw material from a slaughterhouse and is already properly cleaned and at a suitable temperature, characterized by the fact that it comprises the following stages : a) injection of a basic brine in the chicken raw material; b) marinated chicken raw material; c) baking or roasting the raw material; d) temperature abatement; e) chicken raw material packaging in a container; f) pasteurization of chicken raw material; g) weighing and labeling of the container; h) abatement at a suitable temperature; i) packaging of the chicken raw material container; and j) storage at adequate temperature.
  • Cooking US 2015/1 89906 discloses a method of preparation of roast chicken, and more specifically, it refers to a method of preparation of roast chicken in which a raw chicken is pre-seasoned by rubbing, putting preconditioning ingredients such as garlic and the salt of red pepper powder, then the smell of chicken meat is eliminated by a process of softening the meat by means of maturation refrigerated at low temperature, then a batter is applied with flour with overflow obtained by mixing wheat flour and starch of corn with salt, pepper, garlic powder, whole peppers, ginger powder, chili powder or similar, then perform the frying step which is done in a mixed oil, and then remove the oil and toast using a direct fire grill, so that roast chicken is one in which the fat has been removed by submitting a chicken from a fried chicken step to a direct flame roasting
  • the invention is useful because fat is removed from common fried chickens, the risk of ingesting large volumes of cholesterol is exceeded, storage properties are improved after preparation and a crispy taste is achieved, even if the interior is moist and smooth, as well as the fraction of water in meat juices is preserved.
  • This document also does not disclose the stages of cooking of a chicken in a centralized area, then send it to the retail premises for its roasting stage and subsequent sale nor that the chicken has a duration of 25 days from its reception in the centralized area Cooking
  • Document FR 2946839 discloses a process that consists of cutting two pieces of raw chicken, macerating the two pieces cut by marinating it with liquid for a specific period of time, boiling the chicken meat with steam for a specific period of time, placing the Boiled chicken meat between two pieces of marinated raw chicken, boiling the set of pieces to obtain a part of crispy chicken, and adhering the ends of the two pieces of boiled chicken.
  • the liquid to marinate it consists of mustard and butter of the same amount, and is filled with spices.
  • the chicken piece is cut in a circular manner.
  • Cooking DE 2747213 discloses the preparation of roast chicken which comprises the steps of (a) dividing the chicken into sections, (b) roasting the sections in a microwave oven, preferably in 10-1 1 minutes (c) surrounding with a mixture of pre-prepared dough of flour, eggs, honey, milk, oil and spices, and add partially crushed corn flakes, and (c) roast the pieces in the form of “crumbs” in a pan, while floating in hot fat, preferably in 3 minutes at 175-190 ° C, until the dough is golden brown.
  • Excess roasting can be done in a different place from that for the first microwave oven.
  • the process is particularly suitable for restaurants, ready-to-eat or frozen meals. Loss of juices is prevented.
  • the chicken pieces have a characteristic, sweet, new and attractive appearance and a crispy and attractive appearance.
  • This document also does not disclose the stages of cooking of a chicken in a centralized area, then send it to the retail premises for its roasting stage and subsequent sale nor that the chicken has a duration of 25 days from its reception in the centralized area Cooking
  • the present invention is a large-scale roast chicken production process, particularly for retail chains, in which different stages of the processing process have been segmented in order to meet the expectations of The final consumers.
  • the process of the present invention considers the following steps:
  • a central production plant receives fresh or frozen chicken raw material of a certain weight range, defined in order to ensure homogeneity in behavior at each stage of the subsequent process.
  • the bag containing the raw raw material and its respective dressings is introduced into a high temperature water bath for a definite time exactly to achieve that a certain temperature is reached in the thermal center of the product.
  • the chicken is cooked inside the bag with its dressings enhancing the flavors and achieving a unique juiciness by not losing liquids by evaporation or dehydration in the container.
  • the retail chain distributes at a defined temperature specifically for the proper conservation of the product to the points where it has a geographical presence.
  • the product is received and stored in cameras at a defined temperature.
  • the previously cooked chickens are taken out of their bag and they are introduced into a convection oven for a reduced time in order to give a dorado that allows the characteristic presentation of roast chicken in terms of color, temperature and smell.
  • This final process in store implies a reduction of production time and cost in the premises of 75% which translates into a greater capacity of rotation of the necessary equipment for cooking and therefore in greater product availability to meet the demand of customers
  • the final gilding process is carried out with a specific program of time, temperatures and humidity.
  • the packaging procedure is carried out in individual packages in order to ensure an adequate treatment of the product without suffering mechanical damage and, on the other hand, to administer the quantity in production avoiding losses of roasted product by better adjusting supply and demand.
  • the present invention it is possible to transform raw raw material into a product that has the characteristics of a freshly prepared, homogeneous product with high flexibility for the development of different recipes, achieving a final golden in store sought by customers.
  • the benefits in decreasing investments, reduction of physical space for production, cooking times and costs for the retail chain are significant, as well as the improvements in food safety attributed to the process detailed above.
  • Figure 1 shows a diagram of the physical places where the flow of cooked chickens to roast chickens occurs.
  • Figure 2 shows a flow chart of the process of preparing cooked and roasted chickens.
  • Figure 3 shows a graph of the mesophilic aerobic count.
  • Figure 4 shows a graph of growth curve of Escherichia coli.
  • Figure 5 shows a graph of growth curve of Staphylococcus aureus.
  • Figure 6 shows a growth curve plot of Clostridium perfringens.
  • Figure 7 shows a graph describing the total quality of cooked whole chickens.
  • the present invention relates to a process for the preparation of cooked and roasted chicken that allows the centralization of large-scale production processes applied to retail chains, which achieves a duration of at least 25 days, which significantly reduces the times and production costs in customer service premises. Also the invention is applicable to turkeys, which follows the same process as chickens as raw material.
  • roast chicken which are made during the day and placed in gondolas so that users can take them out of said retail areas and take a product that has been roasted during the day. If the roast chicken is not sold during the day, losses occur in the retail premises because of having to eliminate that amount of chickens that have not been sold.
  • the invention aims to provide a process for preparing a roast chicken designed to allow the centralization of production plants geographically distributed in a dispersed area with a particular application to the needs of retail chains. This elaboration process allows to centralize the preparation of chicken in productive plants and then take them to retail, for which the product is required to have a duration of at least 25 days.
  • Figure 1 shows a flow chart of the chickens from the slaughterhouse to the sale as roast chicken to retail customers.
  • these are killed and subjected to refrigeration, either for distribution as fresh or frozen chickens.
  • fresh or frozen chickens are sent to a centralized place where they are cooked in airtight plastic bags.
  • the chickens in their plastic bags are sent to the retail distribution center where they are conditioned to send them to the specific retail location where they will be roasted and marketed to their customers.
  • the objective of this invention is to deliver to the retail customers a chicken that has the characteristics of freshly roasted, mixing two processes: 1) cooking in sealed plastic bags; and 2) roast chicken at the retail store.
  • a) receive in a central production plant the raw material of chicken in a fresh or frozen state of a weight range of between 1.0 and 2.5 Kg in order to ensure homogeneity in behavior at each stage of the process later. Also, in the case of turkeys the weight caliber is between 2.5 to 5.0 Kg.
  • the raw material in the case that is required, arranged in an environment, space and temperatures that allow to give the defined times for an adequate process that ensures the required texture and juiciness characteristics in the protein.
  • the raw material is at least -18 ° C and defrosts until it reaches between -2 and 0 ° C. This is done in an environment that is maintained between 0 and 5 ° C. Depending on the defrosting technique, the time may vary between 2 hours (accelerated process) to 24 hours (normal process).
  • the roast chicken is required to last at least 25 days.
  • the product under test was cooked whole chicken, to determine if its shelf life is 25 days, stored at refrigeration temperature (4 ° C ⁇ 1 ° C).
  • Lot chicken number 3929 to 3933 cooked whole chicken (or to ns)
  • Lot chicken number 3934 to 3938 cooked whole chicken (or to ns)
  • Lot chicken number 3939 to 3943 cooked whole chicken (or to ns)
  • Lot chicken number 3944 to 3948 cooked whole chicken (or to ns)
  • Lot chicken number 3949 to 3953 cooked whole chicken (or to ns)
  • Lot chicken number 3954 to 3958 cooked whole chicken (or to ns)
  • microbiological and physicochemical parameters evaluated were:
  • T o, 5 and 20 Mesophilic Aerobic Count, Escher ⁇ chia coli Count,
  • T 10, 15, 25 Mesophil Aerobic Count and pH Determination, as indicators of deterioration.
  • the sensory evaluation study was carried out through a trained panel and based on the "Quality Assessment Test" with scale by parameter according to Düsseldorf's scheme.
  • the parameters analyzed were: Color, Appearance, Odor, Taste and Texture.
  • each sensory parameter was made based on the different components of the “Cooked whole chicken” matrix.
  • the scale used allowed to discriminate on the intensity in which the components are presented, in such a way that all the typical components were described in section 7-9 (quality grade 1: typical characteristics).
  • sample units corresponding to the product “Cooked whole chicken, stored at 4 ° C ⁇ 1 ° C” comply with the microbiological parameters established in Article 173 point 15.1 and Article 174 point 2 of the current Food Sanitary Regulation DS 977/96 and with requirement for parameter "Mesophilic aerobic count" as an indicator of deterioration.
  • sample units corresponding to the product “Cooked whole chicken, stored at 4 ° C ⁇ 1 ° C” comply with the microbiological parameters established in Article 173 point 15.1 and Article 174 point 2 of the current Food Sanitary Regulation DS 977/96 and with requirement for parameter "Mesophilic aerobic count" as an indicator of deterioration.
  • sample units corresponding to the product “Cooked whole chicken, stored at 4 ° C ⁇ 1 ° C” comply with the requirement for “Mesophilic aerobic count” parameter as an indicator of deterioration.
  • sample units corresponding to the product “Cooked whole chicken, stored at 4 ° C ⁇ 1 ° C” comply with the requirement for “Mesophilic aerobic count” parameter as an indicator of deterioration.
  • sample units corresponding to the product “Cooked whole chicken, stored at 4 ° C ⁇ 1 ° C” comply with the microbiological parameters established in Article 173 point 15.1 and Article 174 point 2 of the current Food Sanitary Regulation DS 977/96 and with requirement for parameter "Mesophilic aerobic count" as an indicator of deterioration.
  • sample units corresponding to the product “Cooked whole chicken, stored at 4 ° C ⁇ 1 ° C” comply with the requirement for “Mesophilic aerobic count” parameter as an indicator of deterioration.
  • Figure 3 shows a graph of the mesophilic aerobic count, where the limits of the colony forming unit (ufe) per gram were established by the inventor. The growth curve was made based on an average value of m to ns (ufe / g).
  • Figure 4 shows a graph of the Escherichia coli growth curve, where the limits of pfu per gram are those established in the current Food Sanitary Regulations DS 977/96, Article 173.
  • the growth curve was made based on average value of n1 to n5 based on the colony forming unit per gram (ufe / g).
  • Figure 5 shows a graph of the growth curve of Staphylococcus aureus, where the limits of pfu per gram are those established in the current Food Sanitary Regulations DS 977/96, Article 173.
  • the growth curve was made based on average value from n1 to n5 (ufe / g).
  • Figure 6 shows a graph of the growth curve of Clostr ⁇ dium perfringens, where the limits of pfu per gram are those established in the current Food Sanitary Regulations DS 977/96, Article 173.
  • the growth curve was based on value average from n1 to n5 (ufe / g).
  • the mode of preparation was retermalized, reaching temperatures above 65 ° C.
  • the process of the present invention meets one of the established requirements that is a duration of at least 25 days, in order to achieve a cooking preparation in a centralized place and a preparation of roast chicken in the retail premises for the It was sold to consumers.

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Abstract

The invention relates to a process for producing cooked and roasted chicken, which allows large-scale production processes to be centralised, can be used in retail chains and achieves a shelf life of at least 25 days. The process comprises receiving, in a central production plant, fresh or frozen raw chicken matter, in a size range, expressed in weight, between 1.0 and 2.5 kg, to ensure uniform behaviour in each subsequent stage of the process, and putting the raw material in its raw state into a highly thermally resistant multilayer bag, together with seasoning, and introducing same into a water bath at a high temperature between 85 and 97ºC for 1.0 to 2.5 hours to reach a temperature between 80 and 85ºC in the thermal centre of the product. Subsequently, the product is rapidly cooled until reaching a temperature greater than 0ºC and less than 5ºC in the thermal centre of the product, and is then packaged, transported and distributed to retail chains, under refrigeration conditions suitable for its preservation, so that the product is received and stored in refrigeration chambers at a temperature between 0 and 5ºC. The product, now in the store, is then put in a convection oven for between 15 and 30 minutes to brown, giving the appearance of a roast chicken in relation to colour, temperature and odour. The product is subsequently packaged individually to ensure suitable treatment of the final product, without it suffering mechanical damage, and to administer the quantity during production.

Description

PROCESO PARA LA ELABORACIÓN DE POLLO COCIDO Y ASADO CON UNA VIDA ÚTIL DE AL MENOS 25 DÍAS, APLICADO A PROCESOS PRODUCTIVOS A  PROCESS FOR THE ELABORATION OF COOKED AND ROASTED CHICKEN WITH A USEFUL LIFE OF AT LEAST 25 DAYS, APPLIED TO PRODUCTIVE PROCESSES A
GRAN ESCALA EN CADENAS DE RETAIL  GREAT SCALE IN RETAIL CHAINS
CAMPO TÉCNICO DE LA INVENCIÓN TECHNICAL FIELD OF THE INVENTION
La presente invención está relacionada con la industria alimentaria, específicamente se refiere un proceso para la cocción de carnes de aves, particularmente, para la elaboración de pollo cocido y asado que permite la centralización de procesos productivos a gran escala aplicado a cadenas de retail, el cual logra una duración de al menos 25 días, lo que permite disminuir significativamente los tiempos y costos de producción en los locales de atención al público. También la invención es aplicable a pavos, el cual sigue el mismo proceso que los pollos como materia prima.  The present invention is related to the food industry, specifically refers to a process for cooking poultry meat, particularly for the preparation of cooked and roasted chicken that allows the centralization of large-scale production processes applied to retail chains, the which achieves a duration of at least 25 days, which significantly decreases production times and costs in the public service premises. Also the invention is applicable to turkeys, which follows the same process as chickens as raw material.
ANTECEDENTES DE LA INVENCIÓN BACKGROUND OF THE INVENTION
En la industria del retail uno de los productos de mayor venta es el pollo asado, los cuales son elaborados durante el día y puestos en góndolas para que los usuarios los saquen de dichas zonas de expendio y se lleven un producto que ha sido asado en el día.  In the retail industry, one of the best-selling products is roast chicken, which are made during the day and placed in gondolas so that users can take them out of said retail areas and take a product that has been roasted in the day.
La invención tiene por objeto proveer de un proceso de elaboración de un pollo asado diseñado para permitir la centralización de plantas productivas distribuidas geográficamente en un área dispersa con una aplicación particular a las necesidades de las cadenas de retail. Este proceso de elaboración permite centralizar la preparación de pollo en plantas productivas y luego llevarlas a los retail, para lo cual se requiere que el producto tenga una duración de al menos 25 días.  The invention aims to provide a process for preparing a roast chicken designed to allow the centralization of production plants geographically distributed in a dispersed area with a particular application to the needs of retail chains. This elaboration process allows to centralize the preparation of chicken in productive plants and then take them to retail, for which the product is required to have a duration of at least 25 days.
La invención está desarrollada para que un proceso se adapte a los requerimientos de las cadenas de retail en términos de que el producto debe dar la percepción de que ha sido recién elaborado para el consumo y lograr una calidad homogénea y de características propias de un pollo recién asado. Con este proceso se disminuyen significativamente los tiempos y costos de producción en los locales de atención al público, lo que adicionalmente mejora la disponibilidad del producto en góndola de autoatención y por consiguiente las ventas de este producto, el cual presenta peak de demanda horaria que son difíciles de cumplir a un costo razonable por las empresas. The invention is developed so that a process adapts to the requirements of retail chains in terms of which the product must give the perception that it has been freshly prepared for consumption and achieve a homogeneous quality and characteristics of a freshly chicken roast. With this process, production times and costs are reduced significantly in the customer service premises, which additionally improves the availability of the product in a self-service gondola and therefore the sales of this product, which It presents peak hourly demand that are difficult to meet at a reasonable cost by companies.
Se han tenido en consideración las necesidades de incremento de la vida útil de los pollos con la finalidad de permitir la centralización de procesos productivos, obtención de economías de escala en una planta productiva centralizada y las mejoras en la inocuidad de los procesos que se realizan en locales manteniendo la calidad del producto final.  The needs to increase the useful life of the chickens have been taken into account in order to allow the centralization of production processes, obtaining economies of scale in a centralized production plant and improvements in the safety of the processes carried out in premises maintaining the quality of the final product.
Existen en el estado actual de la técnica diferentes procedimientos para la preparación y envasado de pollo asado.  There are different procedures for the preparation and packaging of roast chicken in the current state of the art.
El pollo asado que se comercializa en las cadenas de retail se elabora desde materia prima refrigerada o congelada, el cual una vez asado se comercializa dentro del día en el que fue producido.  The roast chicken that is sold in retail chains is made from refrigerated or frozen raw material, which once roasted is marketed within the day it was produced.
Las cadenas de retail ofrecen a sus clientes el producto pollo asado en la condición de recién asado, con características definidas y reconocidas por los consumidores para su consumo inmediato. Para tal efecto se disponen en cada uno de los locales donde se comercializa el producto salas de almacenaje de materias primas, sección de adobado, salas de producción y sección de envasado y rotulado. Esto requiere disponer de espacios físicos definidos, personal dedicado y de infraestructura y equipamiento para cada etapa del proceso. Adicionalmente, el estado actual del proceso hace que los tiempos de producción requeridos impidan cumplir con la demanda de los consumidores a un costo que haga rentable esta línea de negocio, lo anterior especialmente en horas peak, con el consiguiente impacto en la satisfacción de los consumidores.  Retail chains offer their customers the roast chicken product in the freshly roasted condition, with characteristics defined and recognized by consumers for immediate consumption. For this purpose, the product is sold in each of the premises where raw material storage rooms, dressing section, production rooms and packaging and labeling section are sold. This requires having defined physical spaces, dedicated personnel and infrastructure and equipment for each stage of the process. Additionally, the current state of the process means that the required production times prevent compliance with consumer demand at a cost that makes this line of business profitable, especially during peak hours, with the consequent impact on consumer satisfaction .
Para resolver esta problemática existen una serie de procedimientos y técnicas de producción que permiten incrementar la vida útil o estado de conservación hasta su consumo final.  To solve this problem there are a series of production procedures and techniques that allow to increase the useful life or state of conservation until its final consumption.
Estos procedimientos hasta el momento no han logrado resolver la problemática que las cadenas de retail tienen en términos de ofrecer un producto que los consumidores consideren como recién elaborado.  These procedures have so far failed to solve the problem that retail chains have in terms of offering a product that consumers consider as freshly made.
La presente invención soluciona la problemática de las cadenas de retail a gran escala, permitiendo que desde la materia prima congelada o fresca se comercialice como pollo asado recién elaborado, simplificando y disminuyendo los tiempos y costos del proceso de elaboración. The present invention solves the problem of large-scale retail chains, allowing frozen or fresh raw material to be commercialize as freshly prepared roast chicken, simplifying and reducing the times and costs of the elaboration process.
En el estado del arte han existido intentos por proveer de un proceso que proporcione una larga vida útil a un pollo cocido, para evitar las mermas de los productos que no han sido vendidos en el día. Así por ejemplo el documento de patente LV 14095 divulga una invención que se refiere a la industria alimentaria, particularmente a la producción de“alimentos listos para el consumo”. El objetivo de dicha invención es un método para preparaciones de filete de pollo usando un envase Sous vide. El proceso incluye marinar en salsa de frutas y bayas ricas en ácidos orgánicos y vino blanco semiseco a temperatura refrigerada en envases poliméricos individuales - bolsas o recipientes termoformados, de los cuales sustancialmente todo el aire debe eliminarse dando vacío. Luego sigue el termosellado final de los envases y los paquetes se colocan en un refrigerador durante un tiempo determinado de 20 a 24 horas. Después de marinar el producto envasado al vacío sigue el tratamiento térmico (pasteurización) del mismo de acuerdo con los requisitos de la tecnología Sous vide. Este documento no divulga una zona centralizada de preparación de pollo cocido para luego despacharlo a una cadena de retail para su posterior etapa de asado y venta ni tampoco que el pollo tenga una duración de 25 días desde su recepción como materia prima en la zona centralizada de cocción.  In the state of the art there have been attempts to provide a process that provides a long shelf life for a cooked chicken, to avoid the loss of products that have not been sold on the day. Thus, for example, patent document LV 14095 discloses an invention that relates to the food industry, particularly to the production of "ready-to-eat foods". The object of said invention is a method for chicken fillet preparations using a Sous vide package. The process includes marinating in fruit and berry sauce rich in organic acids and semi-dry white wine at refrigerated temperature in individual polymeric containers - thermoformed bags or containers, of which substantially all the air must be removed giving vacuum. Then follow the final heat sealing of the containers and the packages are placed in a refrigerator for a specific time of 20 to 24 hours. After marinating the vacuum-packed product, the heat treatment (pasteurization) of the product is followed in accordance with the requirements of Sous vide technology. This document does not disclose a centralized cooked chicken preparation area and then dispatches it to a retail chain for its subsequent roasting and sale stage, nor does the chicken have a duration of 25 days from its receipt as raw material in the centralized area of cooking.
En el documento EP 2901870 divulga un procedimiento de preparación y envasado de pollo asado para su distribución posterior, que utiliza materia prima de pollo fresco procedente de un matadero y ya adecuadamente limpia y a una temperatura adecuada, caracterizado por el hecho de que comprende las siguientes etapas: a) inyección de una salmuera básica en la materia prima de pollo; b) marinado de la materia prima de pollo; c) horneado o asado de la materia prima; d) abatimiento de temperatura; e) envasado de la materia prima de pollo en un envase; f) pasterización de la materia prima de pollo; g) pesado y etiquetado del envase; h) abatimiento a una temperatura adecuada; i) embalaje del envase de la materia prima de pollo; y j) almacenamiento a temperatura adecuada. Este documento no divulga las etapas de cocción de un pollo en una zona centralizada, para luego enviarlo a los locales de retail para su etapa de asado y posterior venta ni tampoco que el pollo tenga una duración de 25 días desde su recepción en la zona centralizada de cocción. El documento US 2015/1 89906 divulga un método de preparación de pollo asado, y más específicamente, se refiere a un método de preparación de pollo asado en el que se pre-condimenta un pollo crudo frotando, poniendo ingredientes de preacondicionamiento como el ajo y la sal en polvo de pimienta roja, luego el olor a carne de pollo se elimina mediante un proceso de ablandamiento de la carne mediante maduración refrigerada a baja temperatura, luego se aplica un rebozado con harina con rebosamiento obtenido mediante el mezclando harina de trigo y almidón de maíz con sal, pimienta, ajo en polvo, pimientos enteros, jengibre en polvo, ají en polvo o similar, para luego realizar el paso de freír el cual se realiza en un aceite mezclado, y luego se quita el aceite y se tuesta usando una parrilla fuego directo, de modo que el pollo asado es uno en el que la grasa se ha eliminado al someter un pollo desde un paso de pollo frito hasta un paso de tostado de llama directa. La invención es útil porque se elimina la grasa respecto de los pollos fritos comunes, se supera el riesgo de ingerir grandes volúmenes de colesterol, se mejoran las propiedades de almacenamiento después de la preparación y se logra un sabor crujiente, aunque el interior esté húmedo y suave, así como la fracción de agua en los jugos de carne se conserva. Este documento tampoco divulga las etapas de cocción de un pollo en una zona centralizada, para luego enviarlo a los locales de retail para su etapa de asado y posterior venta ni tampoco que el pollo tenga una duración de 25 días desde su recepción en la zona centralizada de cocción. In EP 2901870 it discloses a procedure for preparing and packaging roast chicken for later distribution, which uses raw chicken raw material from a slaughterhouse and is already properly cleaned and at a suitable temperature, characterized by the fact that it comprises the following stages : a) injection of a basic brine in the chicken raw material; b) marinated chicken raw material; c) baking or roasting the raw material; d) temperature abatement; e) chicken raw material packaging in a container; f) pasteurization of chicken raw material; g) weighing and labeling of the container; h) abatement at a suitable temperature; i) packaging of the chicken raw material container; and j) storage at adequate temperature. This document does not disclose the stages of cooking a chicken in a centralized area, then send it to the retail premises for its roasting stage and subsequent sale, nor does the chicken have a duration of 25 days from its reception in the centralized area. Cooking US 2015/1 89906 discloses a method of preparation of roast chicken, and more specifically, it refers to a method of preparation of roast chicken in which a raw chicken is pre-seasoned by rubbing, putting preconditioning ingredients such as garlic and the salt of red pepper powder, then the smell of chicken meat is eliminated by a process of softening the meat by means of maturation refrigerated at low temperature, then a batter is applied with flour with overflow obtained by mixing wheat flour and starch of corn with salt, pepper, garlic powder, whole peppers, ginger powder, chili powder or similar, then perform the frying step which is done in a mixed oil, and then remove the oil and toast using a direct fire grill, so that roast chicken is one in which the fat has been removed by submitting a chicken from a fried chicken step to a direct flame roasting step. The invention is useful because fat is removed from common fried chickens, the risk of ingesting large volumes of cholesterol is exceeded, storage properties are improved after preparation and a crispy taste is achieved, even if the interior is moist and smooth, as well as the fraction of water in meat juices is preserved. This document also does not disclose the stages of cooking of a chicken in a centralized area, then send it to the retail premises for its roasting stage and subsequent sale nor that the chicken has a duration of 25 days from its reception in the centralized area Cooking
El documento FR 2946839 divulga un proceso que consiste en cortar dos trozos de pollo crudo, macerando las dos piezas cortadas adobándolo mediante líquido durante un período específico de tiempo, hirviendo la carne de pollo con vapor de agua durante un período específico de tiempo, colocando la carne de pollo hervida entre dos piezas de pollo crudo marinado, hirviendo el conjunto de piezas para obtener una parte de pollo crujiente, y adhiriendo los extremos de las dos piezas de pollo hervidas. El líquido para adobarlo se compone de mostaza y mantequilla de la misma cantidad, y se llena con especias. El corte de la pieza de pollo se lleva a cabo en forma circular. Este documento tampoco divulga las etapas de cocción de un pollo en una zona centralizada, para luego enviarlo a los locales de retail para su etapa de asado y posterior venta ni tampoco que el pollo tenga una duración de 25 días desde su recepción en la zona centralizada de cocción. El documento DE 2747213 divulga la preparación de pollo asado que comprende las etapas de (a) dividir el pollo en secciones, (b) asar las secciones en un horno de microondas, preferentemente en 10-1 1 minutos (c) rodeando con una mezcla de masa pre-preparada de harina, huevos, miel, leche, aceite y especias, y agregar copos de maíz parcialmente triturados, y (c) asar las piezas en forma de“migajadas” en una sartén, mientras flota en grasa caliente, preferentemente en 3 minutos a 175- 190°C, hasta que la masa se dore. El exceso de tostado puede efectuarse en un lugar diferente de aquel para el primer asado en horno de microondas. El proceso es particularmente adecuado para restaurantes, comidas preparadas ultracongeladas o para llevar. La pérdida de jugos se previene. Las piezas de pollo tienen un sabor atractivo característico, dulce, nuevo y una apariencia crujiente y atractiva. Este documento tampoco divulga las etapas de cocción de un pollo en una zona centralizada, para luego enviarlo a los locales de retail para su etapa de asado y posterior venta ni tampoco que el pollo tenga una duración de 25 días desde su recepción en la zona centralizada de cocción. Document FR 2946839 discloses a process that consists of cutting two pieces of raw chicken, macerating the two pieces cut by marinating it with liquid for a specific period of time, boiling the chicken meat with steam for a specific period of time, placing the Boiled chicken meat between two pieces of marinated raw chicken, boiling the set of pieces to obtain a part of crispy chicken, and adhering the ends of the two pieces of boiled chicken. The liquid to marinate it consists of mustard and butter of the same amount, and is filled with spices. The chicken piece is cut in a circular manner. This document also does not disclose the stages of cooking of a chicken in a centralized area, then send it to the retail premises for its roasting stage and subsequent sale nor that the chicken has a duration of 25 days from its reception in the centralized area Cooking DE 2747213 discloses the preparation of roast chicken which comprises the steps of (a) dividing the chicken into sections, (b) roasting the sections in a microwave oven, preferably in 10-1 1 minutes (c) surrounding with a mixture of pre-prepared dough of flour, eggs, honey, milk, oil and spices, and add partially crushed corn flakes, and (c) roast the pieces in the form of “crumbs” in a pan, while floating in hot fat, preferably in 3 minutes at 175-190 ° C, until the dough is golden brown. Excess roasting can be done in a different place from that for the first microwave oven. The process is particularly suitable for restaurants, ready-to-eat or frozen meals. Loss of juices is prevented. The chicken pieces have a characteristic, sweet, new and attractive appearance and a crispy and attractive appearance. This document also does not disclose the stages of cooking of a chicken in a centralized area, then send it to the retail premises for its roasting stage and subsequent sale nor that the chicken has a duration of 25 days from its reception in the centralized area Cooking
Ninguno de los documentos anteriormente descritos divulga las etapas de cocción de un pollo en una zona centralizada, para luego enviarlo a los locales de retail para su etapa de asado y posterior venta ni tampoco que el pollo tenga una duración de 25 días desde su recepción en la zona centralizada de cocción. Tampoco divulgan procedimientos que logren resolver la problemática que las cadenas de retail tienen en términos de ofrecer un producto que los consumidores consideren como recién elaborado. Es por ello, que la presente invención soluciona la problemática de las cadenas de retail a gran escala, permitiendo que desde la materia prima congelada o fresca se comercialice como pollo asado recién elaborado, simplificando y disminuyendo los tiempos y costos del proceso de elaboración.  None of the documents described above disclose the stages of cooking a chicken in a centralized area, then send it to the retail premises for its roasting stage and subsequent sale nor that the chicken has a duration of 25 days from its reception in the centralized cooking zone. Nor do they disclose procedures that manage to solve the problem that retail chains have in terms of offering a product that consumers consider as freshly made. That is why, the present invention solves the problem of large-scale retail chains, allowing frozen or fresh raw material to be marketed as freshly prepared roast chicken, simplifying and reducing the times and costs of the manufacturing process.
RESEÑA DE LA INVENCIÓN SUMMARY OF THE INVENTION
La presente invención a un proceso de elaboración de pollo asado a gran escala, particularmente para cadenas de retail, en el que se ha segmentado diferentes etapas del proceso de elaboración con la finalidad de cumplir con las expectativas de los consumidores finales. En general el proceso de la presente invención considera las siguientes etapas: The present invention is a large-scale roast chicken production process, particularly for retail chains, in which different stages of the processing process have been segmented in order to meet the expectations of The final consumers. In general, the process of the present invention considers the following steps:
a) Una planta productiva central recibe materia prima pollo en estado fresco o congelado de un cierto rango de calibre en peso, definido con la finalidad de asegurar la homogeneidad en el comportamiento en cada etapa del proceso posterior.  a) A central production plant receives fresh or frozen chicken raw material of a certain weight range, defined in order to ensure homogeneity in behavior at each stage of the subsequent process.
b) Descongelado de la materia prima en caso de que sea requerido, dispuesto en un ambiente, espacio y temperaturas que permiten dar los tiempos definidos para un adecuado proceso que asegure las características requeridas de textura y jugosidad en la proteína.  b) Defrosting of the raw material if required, arranged in an environment, space and temperatures that allow to give the defined times for an adequate process that ensures the required texture and juiciness characteristics in the protein.
c) Se procede a introducir el pollo en su estado crudo en el interior de una bolsa multicapa de alta resistencia térmica e introducir los aliños característicos de la preparación que se está elaborando. De este modo se asegura una estandarización en el sabor del producto final. La bolsa se sella herméticamente.  c) Proceed to introduce the chicken in its raw state inside a multilayer bag of high thermal resistance and introduce the dressings characteristic of the preparation being prepared. This ensures a standardization in the taste of the final product. The bag is sealed tightly.
d) La bolsa que contiene la materia prima cruda y sus respectivos aliños se procede a introducir en un baño de agua a alta temperatura por un tiempo definido exactamente para lograr que se alcance cierta temperatura en el centro térmico del producto. El pollo se cocina en el interior de la bolsa con sus aliños realzando los sabores y logrando una jugosidad única al no perder líquidos por evaporación o deshidratación en el recipiente.  d) The bag containing the raw raw material and its respective dressings is introduced into a high temperature water bath for a definite time exactly to achieve that a certain temperature is reached in the thermal center of the product. The chicken is cooked inside the bag with its dressings enhancing the flavors and achieving a unique juiciness by not losing liquids by evaporation or dehydration in the container.
e) Se procede a enfriar el producto de manera acelerada hasta alcanzar la temperatura adecuada.  e) The product is cooled in an accelerated manner until the appropriate temperature is reached.
f) Una vez que se han cumplido los procesos de tiempo y temperatura adecuados en el abatimiento del producto se introduce en cajas para su entrega. Estas se transportan a temperaturas controladas y definidas, se entregan en un centro de distribución que posea la cadena de retail, simplificando de esta manera la recepción de la materia prima por parte de la cadena.  f) Once the appropriate time and temperature processes have been fulfilled in the despondency of the product, it is placed in boxes for delivery. These are transported at controlled and defined temperatures, delivered to a distribution center that has the retail chain, thus simplifying the reception of the raw material by the chain.
g) La cadena de retail distribuye a temperatura definida específicamente para la adecuada conservación del producto a los puntos donde tenga presencia geográfica.  g) The retail chain distributes at a defined temperature specifically for the proper conservation of the product to the points where it has a geographical presence.
h) En las tiendas se recibe el producto y se procede a almacenar en cámaras a temperatura definida. i) En el local se procede a sacar los pollos previamente cocidos de su bolsa y se introducen en un horno de convección por un tiempo reducido con la finalidad de dar un dorado que permita la característica presentación del pollo asado en cuanto a su color, temperatura y olor. Este proceso final en tienda implica una reducción de tiempo de producción y costo en el local de un 75% lo que se traduce en una mayor capacidad de rotación del equipamiento necesario para la cocción y por lo tanto en mayor disponibilidad de producto para satisfacer la demanda de los clientes. El proceso de dorado final se realiza con un programa específico de tiempo, temperaturas y humedad. h) In stores, the product is received and stored in cameras at a defined temperature. i) In the premises, the previously cooked chickens are taken out of their bag and they are introduced into a convection oven for a reduced time in order to give a dorado that allows the characteristic presentation of roast chicken in terms of color, temperature and smell. This final process in store implies a reduction of production time and cost in the premises of 75% which translates into a greater capacity of rotation of the necessary equipment for cooking and therefore in greater product availability to meet the demand of customers The final gilding process is carried out with a specific program of time, temperatures and humidity.
j) El procedimiento de envasado se realiza en envases individuales de modo de asegurar un adecuado tratamiento del producto sin que sufra daños mecánicos y por otro lado administrar la cantidad en producción evitando mermas de producto asado al ajustar de mejor manera la oferta y la demanda.  j) The packaging procedure is carried out in individual packages in order to ensure an adequate treatment of the product without suffering mechanical damage and, on the other hand, to administer the quantity in production avoiding losses of roasted product by better adjusting supply and demand.
Gracias a la presente invención se logra transformar materia prima cruda en un producto que presenta las características de un producto recién elaborado, homogéneo con alta flexibilidad para el desarrollo de distintas recetas, logrando un dorado final en tienda buscado por los clientes. Los beneficios en disminución de inversiones, reducción de espacio físico destinado a labores de producción, tiempos de cocción y costos para la cadena de retail son significativos, así como las mejoras en inocuidad alimentaria atribuidas al proceso que se han detalla anteriormente.  Thanks to the present invention it is possible to transform raw raw material into a product that has the characteristics of a freshly prepared, homogeneous product with high flexibility for the development of different recipes, achieving a final golden in store sought by customers. The benefits in decreasing investments, reduction of physical space for production, cooking times and costs for the retail chain are significant, as well as the improvements in food safety attributed to the process detailed above.
BREVE DESCRIPCIÓN DE LOS DIBUJOS BRIEF DESCRIPTION OF THE DRAWINGS
Los dibujos que se acompañan se incluyen para proporcionar una mayor compresión de la invención y constituyen parte de esta descripción.  The accompanying drawings are included to provide greater understanding of the invention and form part of this description.
La figura 1 muestra un esquema de los lugares físicos donde se produce el flujo de pollos cocidos a pollos asados.  Figure 1 shows a diagram of the physical places where the flow of cooked chickens to roast chickens occurs.
La figura 2 muestra un diagrama de flujo del proceso de preparación de pollos cocidos y asados.  Figure 2 shows a flow chart of the process of preparing cooked and roasted chickens.
La figura 3 muestra un gráfico del recuento de aerobios mesófilos.  Figure 3 shows a graph of the mesophilic aerobic count.
La figura 4 muestra un gráfico de curva de crecimiento de Escherichia coli. Figure 4 shows a graph of growth curve of Escherichia coli.
La figura 5 muestra un gráfico de curva de crecimiento de Staphylococcus aureus. La figura 6 muestra un gráfico de curva de crecimiento de Clostrídium perfringens. Figure 5 shows a graph of growth curve of Staphylococcus aureus. Figure 6 shows a growth curve plot of Clostridium perfringens.
La figura 7 muestra un gráfico que describe la calidad total de los pollos enteros cocidos.  Figure 7 shows a graph describing the total quality of cooked whole chickens.
DESCRIPCIÓN DE LA INVENCIÓN DESCRIPTION OF THE INVENTION
La presente invención se refiere a un proceso para la elaboración de pollo cocido y asado que permite la centralización de procesos productivos a gran escala aplicado a cadenas de retail, el cual logra una duración de al menos 25 días, lo que permite disminuir significativamente los tiempos y costos de producción en los locales de atención al público. También la invención es aplicable a pavos, el cual sigue el mismo proceso que los pollos como materia prima.  The present invention relates to a process for the preparation of cooked and roasted chicken that allows the centralization of large-scale production processes applied to retail chains, which achieves a duration of at least 25 days, which significantly reduces the times and production costs in customer service premises. Also the invention is applicable to turkeys, which follows the same process as chickens as raw material.
En la industria del retail uno de productos en venta es el pollo asado, los cuales son elaborados durante el día y puestos en góndolas para que los usuarios los saquen de dichas zonas de expendio y se lleven un producto que ha sido asado en el día. Si el pollo asado no es vendido durante el día, se producen pérdidas en el local del retail por tener que eliminar aquella cantidad de pollos que no han sido vendidos.  In the retail industry, one of the products for sale is roast chicken, which are made during the day and placed in gondolas so that users can take them out of said retail areas and take a product that has been roasted during the day. If the roast chicken is not sold during the day, losses occur in the retail premises because of having to eliminate that amount of chickens that have not been sold.
La invención tiene por objeto proveer de un proceso de elaboración de un pollo asado diseñado para permitir la centralización de plantas productivas distribuidas geográficamente en un área dispersa con una aplicación particular a las necesidades de las cadenas de retail. Este proceso de elaboración permite centralizar la preparación de pollo en plantas productivas y luego llevarlas a los retail, para lo cual se requiere que el producto tenga una duración de al menos 25 días.  The invention aims to provide a process for preparing a roast chicken designed to allow the centralization of production plants geographically distributed in a dispersed area with a particular application to the needs of retail chains. This elaboration process allows to centralize the preparation of chicken in productive plants and then take them to retail, for which the product is required to have a duration of at least 25 days.
La figura 1 muestra un diagrama de flujo de los pollos desde el matadero hasta el expendio como pollo asado a los clientes del retail. Primeramente, en la zona de criadero de los pollos, éstos son matados y sometidos a refrigeración, ya sea para su distribución como pollos frescos, o bien, congelados. Posteriormente, los pollos frescos o congelados son enviados a un lugar centralizado donde son cocidos en bolsas plásticas herméticas. Luego de ello, los pollos en sus bolsas plásticas son enviados al centro de distribución del retail en donde son acondicionados para enviarlos al local específico del retail donde serán asados y comercializados a sus clientes. El objetivo de esta invención es entregar a los clientes del retail un pollo que tenga las características de recién asado, mezclando dos procesos: 1 ) cocción en bolsas plásticas selladas; y 2) asado del pollo en el local del retail. Figure 1 shows a flow chart of the chickens from the slaughterhouse to the sale as roast chicken to retail customers. First, in the chicken hatchery area, these are killed and subjected to refrigeration, either for distribution as fresh or frozen chickens. Subsequently, fresh or frozen chickens are sent to a centralized place where they are cooked in airtight plastic bags. After that, the chickens in their plastic bags are sent to the retail distribution center where they are conditioned to send them to the specific retail location where they will be roasted and marketed to their customers. The objective of this invention is to deliver to the retail customers a chicken that has the characteristics of freshly roasted, mixing two processes: 1) cooking in sealed plastic bags; and 2) roast chicken at the retail store.
Para cumplir con este objetivo se plantea el siguiente proceso productivo con las siguientes etapas, el cual es mostrado en la figura 2:  To meet this objective, the following production process is proposed with the following stages, which is shown in Figure 2:
a) recibir en una planta productiva central la materia prima de pollo en estado fresco o congelado de un rango de calibre en peso de entre 1 ,0 y 2,5 Kg con la finalidad de asegurar la homogeneidad en el comportamiento en cada etapa del proceso posterior. También, para el caso de pavos el calibre en peso es de entre 2,5 a 5,0 Kg.  a) receive in a central production plant the raw material of chicken in a fresh or frozen state of a weight range of between 1.0 and 2.5 Kg in order to ensure homogeneity in behavior at each stage of the process later. Also, in the case of turkeys the weight caliber is between 2.5 to 5.0 Kg.
b) descongelar la materia prima en el caso que sea requerido, dispuesto en un ambiente, espacio y temperaturas que permiten dar los tiempos definidos para un adecuado proceso que asegure las características requeridas de textura y jugosidad en la proteína. La materia prima está en al menos -18°C y se descongela hasta que llega a entre -2 y 0°C. Esto se realiza en un ambiente que se mantiene entre 0 y 5°C. Dependiendo de la técnica de descongelado el tiempo puede variar entre 2 horas (proceso acelerado) a 24 horas (proceso normal).  b) thaw the raw material in the case that is required, arranged in an environment, space and temperatures that allow to give the defined times for an adequate process that ensures the required texture and juiciness characteristics in the protein. The raw material is at least -18 ° C and defrosts until it reaches between -2 and 0 ° C. This is done in an environment that is maintained between 0 and 5 ° C. Depending on the defrosting technique, the time may vary between 2 hours (accelerated process) to 24 hours (normal process).
c) introducir el pollo en su estado crudo en el interior de una bolsa multicapa de alta resistencia térmica e introducir los aliños característicos de la preparación que se está elaborando, asegurando una estandarización en el sabor del producto final, en donde la bolsa es sellada herméticamente.  c) introduce the chicken in its raw state inside a multilayer bag of high thermal resistance and introduce the characteristic dressings of the preparation being prepared, ensuring a standardization in the taste of the final product, where the bag is hermetically sealed .
d) introducir la bolsa que contiene la materia prima cruda y sus respectivos aliños en un baño de agua a alta temperatura de entre 85 y 97°C por un tiempo de entre 1 ,0 y 2,5 horas para lograr que se alcance una temperatura de sobre 75°C, que en el caso de esta etapa es sobre 80°C y no superior a 85°C en el centro térmico del producto, en donde el pollo se cocina en el interior de la bolsa con sus aliños realzando los sabores y logrando una jugosidad única al no perder líquidos por evaporación o deshidratación en el recipiente.  d) insert the bag containing the raw raw material and their respective dressings in a high temperature water bath between 85 and 97 ° C for a time of between 1.0 and 2.5 hours to achieve a temperature of about 75 ° C, which in the case of this stage is about 80 ° C and not exceeding 85 ° C in the thermal center of the product, where the chicken is cooked inside the bag with its dressings enhancing the flavors and achieving a unique juiciness by not losing liquids by evaporation or dehydration in the container.
e) enfriar el producto de manera acelerada hasta alcanzar la temperatura que es superior a los 0°C e inferior a los 5°C, lo cual es medido en el centro térmico del producto. f) introducir en cajas para la entrega del producto, las cuales se transportan a temperaturas controladas y definidas de entre 0 y 5°C, para entregarlas en un centro de distribución que posea la cadena de retail, simplificando de esta manera la recepción de la materia prima por parte de la cadena. e) cooling the product in an accelerated manner until it reaches a temperature that is greater than 0 ° C and less than 5 ° C, which is measured in the thermal center of the product. f) introduce in boxes for the delivery of the product, which are transported at controlled and defined temperatures between 0 and 5 ° C, to deliver them to a distribution center that has the retail chain, thus simplifying the reception of the Raw material by the chain.
g) distribuir en la cadena de retail a temperatura de refrigeración de entre 0 y 5°C específicamente para la adecuada conservación del producto a los puntos donde tenga presencia geográfica.  g) distribute in the retail chain at refrigeration temperature between 0 and 5 ° C specifically for the proper conservation of the product to the points where it has a geographical presence.
h) recibir en las tiendas el producto y se procede a almacenar en cámaras a temperatura de refrigeración de entre 0 y 5°C.  h) receive the product in stores and proceed to store in chambers at a cooling temperature between 0 and 5 ° C.
i) sacar los pollos previamente cocidos de su bolsa en el local procediéndose a introducir en un horno de convección por un tiempo de entre 15 y 30 minutos con la finalidad de dar un dorado que permita la característica presentación del pollo asado en cuanto a su color, temperatura y olor. Este proceso final en tienda implica una reducción de tiempo de producción y costo en el local de un 75% lo que se traduce en una mayor capacidad de rotación del equipamiento necesario para la cocción y por lo tanto en mayor disponibilidad de producto para satisfacer la demanda de los clientes. El proceso de dorado final se realiza con un programa específico de tiempo, temperaturas y humedad. Por ejemplo, precalentado hasta alcanzar 250°C, inicio de programa con 30% vapor y 70% calor seco por espacio de 10 minutos a 250°C, calor 100% seco por 15 minutos a 200°C, programa de vapor 50% y calor seco 50% por 5 minutos a 200°C  i) Remove the previously cooked chickens from their bag at the premises proceeding to enter in a convection oven for a time of between 15 and 30 minutes in order to give a dorado that allows the characteristic presentation of roast chicken in terms of color , temperature and smell. This final process in store implies a reduction of production time and cost in the premises of 75% which translates into a greater capacity of rotation of the necessary equipment for cooking and therefore in greater product availability to meet the demand of customers The final gilding process is carried out with a specific program of time, temperatures and humidity. For example, preheated to 250 ° C, program start with 30% steam and 70% dry heat for 10 minutes at 250 ° C, 100% dry heat for 15 minutes at 200 ° C, 50% steam program and 50% dry heat for 5 minutes at 200 ° C
j) envasar el pollo asado en envases individuales de modo de asegurar un adecuado tratamiento del producto sin que sufra daños mecánicos y por otro lado administrar la cantidad en producción evitando mermas de producto asado al ajustar de mejor manera la oferta y la demanda.  j) pack the roasted chicken in individual packages in order to ensure an adequate treatment of the product without suffering mechanical damage and, on the other hand, to administer the quantity in production avoiding losses of roasted product by better adjusting the supply and demand.
Para que este proceso se lleve a cabo y, además, para entregar al retail un mayor tiempo de venta del producto, se requiere que el pollo asado dure por lo menos 25 días.  For this process to be carried out and, in addition, to give the retail a longer time to sell the product, the roast chicken is required to last at least 25 days.
Para asegurar que el proceso de la presente invención da resultado, se sometieron a pruebas pollos cocidos estudiando la vida útil del“pollo entero cocido, almacenado a 4°C ± 1 °C”. VALIDACIÓN DE LA VIDA ÚTIL: To ensure that the process of the present invention works, cooked chickens were tested by studying the shelf life of "cooked whole chicken, stored at 4 ° C ± 1 ° C". VALIDATION OF LIFE:
El producto sometido a pruebas fue pollo entero cocido, para determinar si su vida útil es de 25 días, almacenado a temperatura de refrigeración (4°C ± 1 °C).  The product under test was cooked whole chicken, to determine if its shelf life is 25 days, stored at refrigeration temperature (4 ° C ± 1 ° C).
Para ello, se utilizaron pollos identificados de un lote para someterlos a pruebas estándar.  To do this, identified chickens from a batch were used for standard testing.
Número de pollo del lote: 3929 a 3933 pollo entero cocido (ni a ns) Lot chicken number: 3929 to 3933 cooked whole chicken (or to ns)
• Peso: 1250 g neto • Weight: 1250 g net
• Envasado: Bolsa plástica hermética  • Packaging: Airtight plastic bag
• Elaborado con tecnología: Sous vide  • Made with technology: Sous vide
• Listo para consumo previa retermalización  • Ready for prior retermalization consumption
• Lote: 43181 -1  • Lot: 43181 -1
• Fecha elaboración: 23.03.2018  • Preparation date: 03/23/2018
• Fecha análisis: 23.03.2018  • Analysis date: 03/23/2018
• Muestras inicio (to)  • Start samples (to)
Número de pollo del lote: 3934 a 3938 pollo entero cocido (ni a ns) Lot chicken number: 3934 to 3938 cooked whole chicken (or to ns)
• Peso: 1250 g neto • Weight: 1250 g net
• Envasado: Bolsa plástica hermética  • Packaging: Airtight plastic bag
• Elaborado con tecnología: Sous vide  • Made with technology: Sous vide
• Listo para consumo previa retermalización  • Ready for prior retermalization consumption
• Lote: 43181 -1  • Lot: 43181 -1
• Fecha elaboración: 23.03.2018  • Preparation date: 03/23/2018
• Fecha análisis: 28.03.2018  • Analysis date: 03/28/2018
• Muestras 5 días a 4°C ± 1 °C (ts)  • Samples 5 days at 4 ° C ± 1 ° C (ts)
Número de pollo del lote: 3939 a 3943 pollo entero cocido (ni a ns) Lot chicken number: 3939 to 3943 cooked whole chicken (or to ns)
• Peso: 1250 g neto • Weight: 1250 g net
• Envasado: Bolsa plástica hermética  • Packaging: Airtight plastic bag
• Elaborado con tecnología Sous vide  • Made with Sous vide technology
• Listo para consumo previa retermalización  • Ready for prior retermalization consumption
• Lote: 43181 -1  • Lot: 43181 -1
• Fecha elaboración: 23.03.2018 • Fecha análisis: 02.04.2018 • Preparation date: 03/23/2018 • Analysis date: 02.04.2018
• Muestras 10 días a 4°C ± 1 °C (tío)  • Samples 10 days at 4 ° C ± 1 ° C (uncle)
Número de pollo del lote: 3944 a 3948 pollo entero cocido (ni a ns) Lot chicken number: 3944 to 3948 cooked whole chicken (or to ns)
• Peso: 1250 g neto • Weight: 1250 g net
• Envasado: Bolsa plástica hermética  • Packaging: Airtight plastic bag
• Elaborado con tecnología Sous vide  • Made with Sous vide technology
• Listo para consumo previa retermalización  • Ready for prior retermalization consumption
• Lote: 43181 -1  • Lot: 43181 -1
• Fecha elaboración: 23.03.2018  • Preparation date: 03/23/2018
• Fecha análisis: 07.04.2018  • Analysis date: 07.04.2018
• Muestras 15 días a 4°C ± 1 °C (t15)  • Samples 15 days at 4 ° C ± 1 ° C (t15)
Número de pollo del lote: 3949 a 3953 pollo entero cocido (ni a ns) Lot chicken number: 3949 to 3953 cooked whole chicken (or to ns)
• Peso: 1250 g neto • Weight: 1250 g net
• Envasado: Bolsa plástica hermética  • Packaging: Airtight plastic bag
• Elaborado con tecnología Sous vide  • Made with Sous vide technology
• Listo para consumo previa retermalización  • Ready for prior retermalization consumption
• Lote: 43181 -1  • Lot: 43181 -1
• Fecha elaboración: 23.03.2018  • Preparation date: 03/23/2018
• Fecha análisis: 12.04.2018  • Analysis date: 04/12/2018
• Muestras 20 días a 4°C ± 1 °C (t2o)  • Samples 20 days at 4 ° C ± 1 ° C (t2o)
Número de pollo del lote: 3954 a 3958 pollo entero cocido (ni a ns) Lot chicken number: 3954 to 3958 cooked whole chicken (or to ns)
• Peso: 1250 g neto • Weight: 1250 g net
• Envasado: Bolsa plástica hermética  • Packaging: Airtight plastic bag
• Elaborado con tecnología Sous vide  • Made with Sous vide technology
• Listo para consumo previa retermalización  • Ready for prior retermalization consumption
• Lote: 43181 -1  • Lot: 43181 -1
• Fecha elaboración: 23.03.2018  • Preparation date: 03/23/2018
• Fecha análisis: 17.04.2018  • Analysis date: 04.17.2018
• Muestras 25 días entre 4°C ± 1 °C (t2s)  • Samples 25 days between 4 ° C ± 1 ° C (t2s)
El estudio de vida útil para estos productos comercializados a temperatura de refrigeración se realizó sometiendo en condiciones de almacenamiento y conservación a temperatura de refrigeración de 4°C ± 1 °C en tiempo real, siendo controlada la variable de temperatura durante todo el periodo del estudio. The study of shelf life for these products sold at refrigeration temperature was carried out subject to storage conditions and conservation at refrigeration temperature of 4 ° C ± 1 ° C in real time, the temperature variable being controlled throughout the study period.
Se planificó realizar análisis microbiológicos, fisicoquímicos y evaluación sensorial a los 0, 5, 10, 15, 20 y 25 días a las muestras de“Pollo entero cocido”, almacenado a 4°C ± 1 °C” siendo conservadas a temperatura de refrigeración de 4°C ± 1 °C y correspondiendo el tiempo inicio (to) al día 23.03.2018.  We planned to perform microbiological, physicochemical and sensory evaluation at 0, 5, 10, 15, 20 and 25 days to the samples of "cooked whole chicken", stored at 4 ° C ± 1 ° C "being stored at refrigeration temperature of 4 ° C ± 1 ° C and corresponding the start time (to) to the day 23.03.2018.
Los parámetros microbiológicos y fisicoquímicos evaluados fueron:  The microbiological and physicochemical parameters evaluated were:
T o, 5 y 20: Recuento de Aerobios Mesófilos, Recuento de Escheríchia coli,  T o, 5 and 20: Mesophilic Aerobic Count, Escheríchia coli Count,
Recuento de Staphylococcus, aureus, Recuento de Clostrídium perfringens, Detección de Salmonella spp, Detección de Listería monocytogenes y Determinación de pH.  Staphylococcus count, aureus, Clostridium perfringens count, Salmonella spp. Detection, Listeria monocytogenes detection and pH Determination.
T 10, 15, 25: Recuento de Aerobios Mesófilos y Determinación de pH, como indicadores de deterioro.  T 10, 15, 25: Mesophil Aerobic Count and pH Determination, as indicators of deterioration.
El estudio de evaluación sensorial se realizó a través de un panel entrenado y en base al“Test de valoración de calidad” con escala por parámetro según esquema de Karlsruhe. Los parámetros analizados fueron: Color, Apariencia, Olor, Sabor y Textura.  The sensory evaluation study was carried out through a trained panel and based on the "Quality Assessment Test" with scale by parameter according to Karlsruhe's scheme. The parameters analyzed were: Color, Appearance, Odor, Taste and Texture.
La descripción de cada parámetro sensorial se realizó en base a los diferentes componentes de la matriz“Pollo entero cocido”. La escala utilizada permitió discriminar sobre la intensidad en que los componentes se presentan, de tal forma, que todos los componentes típicos se describieron en tramo 7-9 (grado de calidad 1 : características típicas). Los componentes extraños, atípicos o que resultaron del inicio del deterioro, se describieron en tramo 4-6 (grado de calidad 2: deterioro tolerable). Los componentes extraños, cualquiera sea su origen, que deterioran la calidad hasta hacerla no comestible y aun desagradable, se incluyeron en tramo 1 -3 (grado de calidad 3: deterioro indeseable).  The description of each sensory parameter was made based on the different components of the “Cooked whole chicken” matrix. The scale used allowed to discriminate on the intensity in which the components are presented, in such a way that all the typical components were described in section 7-9 (quality grade 1: typical characteristics). The foreign components, atypical or resulting from the onset of deterioration, were described in section 4-6 (quality grade 2: tolerable deterioration). Foreign components, whatever their origin, that deteriorate the quality until it is inedible and even unpleasant, were included in section 1 -3 (quality grade 3: undesirable deterioration).
Por medio de los datos sensoriales, se determinó la calidad total de producto en donde cada uno de los parámetros analizados tiene un aporte distinto en la calidad total del producto analizado: Color: 15%, Apariencia: 15%, Olor: 10%, Sabor: 30% y Textura: 30%. El estudio de evaluación sensorial se realizó solo al producto“Pollo entero cocido” al interior de su envase y no se consideraron las características organolépticas presentadas al exterior del envase. Through the sensory data, the total product quality was determined where each of the analyzed parameters has a different contribution in the total quality of the analyzed product: Color: 15%, Appearance: 15%, Odor: 10%, Taste : 30% and Texture: 30%. The sensory evaluation study was performed only on the product "Whole cooked chicken" inside its package and the organoleptic characteristics presented outside the package were not considered.
RESULTADOS MICROBIOLÓGICOS Y FISICOQUÍMICOS: MICROBIOLOGICAL AND PHYSICOCHEMICAL RESULTS:
Figure imgf000017_0001
Figure imgf000017_0001
Figure imgf000018_0001
Figure imgf000018_0001
Comentarios para el tiempo to:  Comments for time to:
Las unidades de muestras correspondientes a producto “Pollo entero cocido, almacenado a 4°C ± 1 °C” cumplen con los parámetros microbiológicos establecidos en el Artículo 173 punto 15.1 y Artículo 174 punto 2 del Reglamento Sanitario de los Alimentos DS 977/96 vigente y con requisito para parámetro“Recuento de aerobios mesofilos” como indicador de deterioro. The sample units corresponding to the product “Cooked whole chicken, stored at 4 ° C ± 1 ° C” comply with the microbiological parameters established in Article 173 point 15.1 and Article 174 point 2 of the current Food Sanitary Regulation DS 977/96 and with requirement for parameter "Mesophilic aerobic count" as an indicator of deterioration.
Figure imgf000019_0001
Figure imgf000019_0001
Figure imgf000020_0001
Figure imgf000020_0001
Comentarios para el tiempo ts: Comments for ts time:
Las unidades de muestras correspondientes a producto “Pollo entero cocido, almacenado a 4°C ± 1 °C” cumplen con los parámetros microbiológicos establecidos en el Artículo 173 punto 15.1 y Artículo 174 punto 2 del Reglamento Sanitario de los Alimentos DS 977/96 vigente y con requisito para parámetro“Recuento de aerobios mesofilos” como indicador de deterioro. The sample units corresponding to the product “Cooked whole chicken, stored at 4 ° C ± 1 ° C” comply with the microbiological parameters established in Article 173 point 15.1 and Article 174 point 2 of the current Food Sanitary Regulation DS 977/96 and with requirement for parameter "Mesophilic aerobic count" as an indicator of deterioration.
Figure imgf000021_0001
Figure imgf000021_0001
Comentarios para el tiempo tío:  Comments for uncle time:
Las unidades de muestras correspondientes a producto “Pollo entero cocido, almacenado a 4°C ± 1 °C” cumplen con requisito para parámetro “Recuento de aerobios mesofilos” como indicador de deterioro. The sample units corresponding to the product “Cooked whole chicken, stored at 4 ° C ± 1 ° C” comply with the requirement for “Mesophilic aerobic count” parameter as an indicator of deterioration.
Figure imgf000022_0001
Figure imgf000022_0001
Comentarios para el tiempo t-15:  Comments for time t-15:
Las unidades de muestras correspondientes a producto “Pollo entero cocido, almacenado a 4°C ± 1 °C” cumplen con requisito para parámetro “Recuento de aerobios mesofilos” como indicador de deterioro. The sample units corresponding to the product “Cooked whole chicken, stored at 4 ° C ± 1 ° C” comply with the requirement for “Mesophilic aerobic count” parameter as an indicator of deterioration.
Figure imgf000023_0001
Figure imgf000024_0001
Figure imgf000023_0001
Figure imgf000024_0001
Comentarios para el tiempo t2o: Comments for time t2o:
Las unidades de muestras correspondientes a producto “Pollo entero cocido, almacenado a 4°C ± 1 °C” cumplen con los parámetros microbiológicos establecidos en el Artículo 173 punto 15.1 y Artículo 174 punto 2 del Reglamento Sanitario de los Alimentos DS 977/96 vigente y con requisito para parámetro“Recuento de aerobios mesofilos” como indicador de deterioro. The sample units corresponding to the product “Cooked whole chicken, stored at 4 ° C ± 1 ° C” comply with the microbiological parameters established in Article 173 point 15.1 and Article 174 point 2 of the current Food Sanitary Regulation DS 977/96 and with requirement for parameter "Mesophilic aerobic count" as an indicator of deterioration.
Figure imgf000025_0001
Figure imgf000025_0001
Comentarios para el tiempo t2s:  Comments for t2s time:
Las unidades de muestras correspondientes a producto “Pollo entero cocido, almacenado a 4°C ± 1 °C” cumplen con requisito para parámetro “Recuento de aerobios mesofilos” como indicador de deterioro.  The sample units corresponding to the product “Cooked whole chicken, stored at 4 ° C ± 1 ° C” comply with the requirement for “Mesophilic aerobic count” parameter as an indicator of deterioration.
REQUISITOS MICROBIOLOGICOS:  MICROBIOLOGICAL REQUIREMENTS:
Reglamento Sanitario de los Alimentos, Art. 173, punto 15 comidas y platos preparados y Art. 174 Punto 2 alimentos LPC que favorecen el desarrollo.  Food Sanitary Regulations, Art. 173, point 15 prepared meals and dishes and Art. 174 Point 2 LPC foods that favor development.
15.1.- Comidas y platos cocidos que se sirven en caliente, listos para el consumo, excepto emparedados. 15.1.- Meals and cooked dishes that are served hot, ready for consumption, except sandwiches.
Figure imgf000026_0001
Figure imgf000026_0001
CURVAS DE CRECIMIENTO DE MICROORGANISMOS: MICROORGANISM GROWTH CURVES:
La figura 3 muestra un gráfico del recuento de aerobios mesófilos, en donde los límites de la unidad formadora de colonia (ufe) por gramo fueron establecidos por el inventor. La curva de crecimiento fue realizada en base a valor promedio de m a ns (ufe/g).  Figure 3 shows a graph of the mesophilic aerobic count, where the limits of the colony forming unit (ufe) per gram were established by the inventor. The growth curve was made based on an average value of m to ns (ufe / g).
La figura 4 muestra un gráfico de curva de crecimiento de Escherichia coli, en donde los límites de ufe por gramo son aquellos establecidos en el Reglamento Sanitario de los Alimentos vigente DS 977/96, Artículo 173. La curva de crecimiento fue realizada en base a valor promedio de n1 a n5 tomando como base la unidad formadora de colonia por gramo (ufe/g).  Figure 4 shows a graph of the Escherichia coli growth curve, where the limits of pfu per gram are those established in the current Food Sanitary Regulations DS 977/96, Article 173. The growth curve was made based on average value of n1 to n5 based on the colony forming unit per gram (ufe / g).
La figura 5 muestra un gráfico de curva de crecimiento de Staphylococcus aureus, en donde los límites de ufe por gramo son aquellos establecidos en el Reglamento Sanitario de los Alimentos vigente DS 977/96, Artículo 173. La curva de crecimiento fue realizada en base a valor promedio de n1 a n5 (ufe/g).  Figure 5 shows a graph of the growth curve of Staphylococcus aureus, where the limits of pfu per gram are those established in the current Food Sanitary Regulations DS 977/96, Article 173. The growth curve was made based on average value from n1 to n5 (ufe / g).
La figura 6 muestra un gráfico de curva de crecimiento de Clostrídium perfringens, en donde los límites de ufe por gramo son aquellos establecidos en Reglamento Sanitario de los Alimentos vigente DS 977/96, Artículo 173. La curva de crecimiento fue realizada en base a valor promedio de n1 a n5 (ufe/g). Figure 6 shows a graph of the growth curve of Clostrídium perfringens, where the limits of pfu per gram are those established in the current Food Sanitary Regulations DS 977/96, Article 173. The growth curve was based on value average from n1 to n5 (ufe / g).
EVALUACION SENSORIAL: SENSORY EVALUATION:
Figure imgf000027_0001
Figure imgf000027_0001
El modo de preparación fue retermalizado, alcanzando temperaturas superiores a 65°C.  The mode of preparation was retermalized, reaching temperatures above 65 ° C.
La figura 7 muestra el gráfico de la tabla de evaluación sensorial de arriba en donde la escala de calidad es: 9=Excelente, 8=Muy Buena, 7=Buena, 6=Satisfactoria, 5=Regular, 4=Suficiente, 3=Defectuosa, 2=Mala, 1 =Muy mala (Tramo 7-9: Grado de calidad 1 características típicas, Tramo 4-6: Grado de calidad 2 deterioro tolerable, Tramo 1 -3: Grado de calidad 3: deterioro indeseable), en donde el límite de comercialización = Calidad Total 5,5 / Limite de Comestibilidad = Calidad Total 4,0  Figure 7 shows the graph of the sensory evaluation table above where the quality scale is: 9 = Excellent, 8 = Very Good, 7 = Good, 6 = Satisfactory, 5 = Regular, 4 = Enough, 3 = Defective , 2 = Bad, 1 = Very bad (Section 7-9: Quality grade 1 typical characteristics, Section 4-6: Quality grade 2 tolerable deterioration, Section 1 -3: Quality grade 3: undesirable deterioration), where the marketing limit = Total Quality 5.5 / Edibility Limit = Total Quality 4.0
Comentarios Resultados Evaluación Sensorial:  Comments Results Sensory Evaluation:
Al analizar en conjunto los parámetros sensoriales evaluados: color, apariencia, olor, sabor y textura: se puede observar que al inicio y a los 5 días de almacenamiento a temperatura de refrigeración, la calidad total del producto es de Grado 1 , por tanto, el producto conserva todas sus características típicas.  When analyzing the sensory parameters evaluated together: color, appearance, smell, taste and texture: it can be observed that at the beginning and after 5 days of storage at refrigeration temperature, the total quality of the product is Grade 1, therefore, the product retains all its typical characteristics.
Al tiempo tío (10 días de almacenamiento a temperatura de refrigeración) la calidad total del producto es de Grado 2, por tanto, el producto presenta un deterioro, pero éste es tolerable y no afecta su comestibilidad. Esta condición se mantiene hasta término del estudio tiempo t25 (25 días de almacenamiento a temperatura de refrigeración).  At uncle time (10 days of storage at refrigeration temperature) the total quality of the product is Grade 2, therefore, the product shows a deterioration, but this is tolerable and does not affect its edibility. This condition is maintained until the end of the study t25 time (25 days of storage at refrigeration temperature).
Tomando en consideración los valores obtenidos en los parámetros microbiológicos es posible concluir que la Vida Útil a 25 días de almacenamiento a temperatura de refrigeración (4°C ± 1 °C) para el producto“Pollo entero cocido” cumple con los parámetros microbiológicos establecidos en el Artículo 173 punto 15.1 y Artículo 174 punto 2 del Reglamento Sanitario de los Alimentos DS 977/96 vigente y con requisito para parámetro“Recuento de aerobios mesofilos” como indicador de deterioro. Taking into account the values obtained in the microbiological parameters it is possible to conclude that the shelf life at 25 days of storage at refrigeration temperature (4 ° C ± 1 ° C) for the product "Cooked whole chicken" complies with the microbiological parameters established in Article 173 point 15.1 and Article 174 point 2 of the Food Sanitary Regulation DS 977/96 in force and with a requirement for parameter "Mesophilic aerobic count" as an indicator of deterioration.
Tomando en consideración los resultados de las evaluaciones sensoriales realizadas, es posible concluir que la Vida Útil a 25 días de almacenamiento a temperatura de refrigeración (4°C ± 1 °C) para este producto“Pollo entero cocido”, cumple con los parámetros sensoriales de comestibilidad y aceptabilidad del producto.  Taking into account the results of the sensory evaluations carried out, it is possible to conclude that the shelf life at 25 days of storage at refrigeration temperature (4 ° C ± 1 ° C) for this product "Whole cooked chicken" meets the sensory parameters of edibility and acceptability of the product.
Con estos resultados el proceso de la presente invención cumple con uno de los requisitos establecido que es una duración de al menos 25 días, para lograr tener una preparación de cocción en un lugar centralizado y una preparación de pollo asado en el local del retail para el expendio a los consumidores.  With these results, the process of the present invention meets one of the established requirements that is a duration of at least 25 days, in order to achieve a cooking preparation in a centralized place and a preparation of roast chicken in the retail premises for the It was sold to consumers.

Claims

REIVINDICACIONES
1 Un proceso para la elaboración de pollo cocido y asado que permite centralización de procesos productivos a gran escala aplicado a cadenas de retail, el cual logra una duración de al menos 25 días, CARACTERIZADO porque comprende las siguientes etapas:  1 A process for the preparation of cooked and roasted chicken that allows centralization of large-scale production processes applied to retail chains, which achieves a duration of at least 25 days, CHARACTERIZED because it comprises the following stages:
a) recibir en una planta productiva central la materia prima de pollo en estado fresco o congelado de un rango de calibre en peso de entre 1 ,0 y 2,5 Kg con la finalidad de asegurar la homogeneidad en el comportamiento en cada etapa del proceso posterior;  a) receive in a central production plant the raw material of chicken in a fresh or frozen state of a weight range of between 1.0 and 2.5 Kg in order to ensure homogeneity in behavior at each stage of the process later;
b) descongelar la materia prima en el caso que sea requerido; c) introducir el pollo en su estado crudo en el interior de una bolsa multicapa de alta resistencia térmica e introducir los aliños;  b) defrost the raw material if required; c) introduce the chicken in its raw state inside a multilayer bag of high thermal resistance and introduce the dressings;
d) introducir la bolsa que contiene la materia prima cruda y sus respectivos aliños en un baño de agua a alta temperatura de entre 85 y 97 °C por un tiempo de entre 1 ,0 y 2,5 horas para lograr que se alcance una temperatura sobre 80°C y no superior a 85°C en el centro térmico del producto, en donde el pollo se cocina en el interior de la bolsa con sus aliños;  d) insert the bag containing the raw raw material and their respective dressings in a high temperature water bath between 85 and 97 ° C for a time of between 1.0 and 2.5 hours to achieve a temperature above 80 ° C and not exceeding 85 ° C in the thermal center of the product, where the chicken is cooked inside the bag with its dressings;
e) enfriar el producto de manera acelerada hasta alcanzar la temperatura que es superior a los 0°C e inferior a los 5°C, lo cual es medido en el centro térmico del producto;  e) cooling the product in an accelerated manner until it reaches a temperature that is greater than 0 ° C and less than 5 ° C, which is measured in the thermal center of the product;
f) introducir en cajas para la entrega del producto, en donde dichas cajas se transportan a temperaturas controladas y definidas de entre 0 y 5°C, entregándose en un centro de distribución que posea la cadena de retail;  f) introduce in boxes for the delivery of the product, where said boxes are transported at controlled and defined temperatures between 0 and 5 ° C, being delivered to a distribution center that has the retail chain;
g) distribuir en la cadena de retail a temperatura de refrigeración de entre 0 y 5°C para la adecuada conservación del producto;  g) distribute in the retail chain at refrigeration temperature between 0 and 5 ° C for the proper conservation of the product;
h) recibir en las tiendas el producto y se procede a almacenar en cámaras a temperatura de refrigeración de entre 0 y 5°C;  h) receive the product in stores and proceed to store in chambers at a cooling temperature between 0 and 5 ° C;
i) sacar los pollos previamente cocidos de su bolsa en el local procediéndose a introducir en un horno de convección por un tiempo de entre 15 y 30 minutos con la finalidad de dar un dorado que permita la característica presentación del pollo asado en cuanto a su color, temperatura y olor; j) envasar el pollo asado en envases individuales de modo de asegurar un adecuado tratamiento del producto sin que sufra daños mecánicos y por otro lado administrar la cantidad en producción. i) Remove the previously cooked chickens from their bag at the premises proceeding to enter in a convection oven for a time of between 15 and 30 minutes in order to give a dorado that allows the characteristic presentation of roast chicken in terms of color , temperature and smell; j) pack the roast chicken in individual packages in order to ensure an adequate treatment of the product without suffering mechanical damage and, on the other hand, administer the quantity in production.
2.- Un proceso según la reivindicación 1 , CARACTERIZADO porque en la etapa b) la materia prima está congelada en al menos -18 °C y se descongela hasta que llega a entre -2 y 0°C, realizándose esta etapa en un ambiente que se mantiene entre 0 y 5°C.  2. A process according to claim 1, CHARACTERIZED because in stage b) the raw material is frozen at least -18 ° C and thawed until it reaches between -2 and 0 ° C, this stage being performed in an environment which is maintained between 0 and 5 ° C.
3.- Un proceso según la reivindicación 2, CARACTERIZADO porque el descongelado puede variar entre 2 horas (proceso acelerado) a 24 horas (proceso normal).  3. A process according to claim 2, CHARACTERIZED because defrosting can vary between 2 hours (accelerated process) to 24 hours (normal process).
4.- Un proceso según la reivindicación 1 , CARACTERIZADO porque en la etapa i) el proceso de dorado final se realiza con un programa específico de tiempo, temperaturas y humedad, como ser un precalentado hasta alcanzar 250 °C, inicio de programa con 30% vapor y 70% calor seco por espacio de 10 minutos a 250 °C, calor 100% seco por 15 minutos a 200 °C , programa de vapor 50% y calor seco 50% por 5 minutos a 200 °C.  4. A process according to claim 1, CHARACTERIZED because in stage i) the final browning process is carried out with a specific program of time, temperatures and humidity, such as being preheated to reach 250 ° C, program start with 30 % steam and 70% dry heat for 10 minutes at 250 ° C, 100% dry heat for 15 minutes at 200 ° C, 50% steam program and 50% dry heat for 5 minutes at 200 ° C.
5.- Un proceso según la reivindicación 1 , CARACTERIZADO porque en la etapa a) el calibre en peso es de 2,5 a 5,0 Kg cuando el pollo es reemplazado por pavo.  5. A process according to claim 1, CHARACTERIZED because in step a) the weight caliber is 2.5 to 5.0 Kg when the chicken is replaced by turkey.
PCT/CL2018/050057 2018-07-26 2018-07-26 Process for producing cooked and roasted chicken with a shelf life of at least 25 days for use in large-scale production processes in retail chains WO2020019088A1 (en)

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PCT/CL2018/050057 WO2020019088A1 (en) 2018-07-26 2018-07-26 Process for producing cooked and roasted chicken with a shelf life of at least 25 days for use in large-scale production processes in retail chains
ARP190102099A AR123402A1 (en) 2018-07-26 2019-07-25 PROCESS FOR THE PREPARATION OF COOKED AND ROASTED CHICKEN WITH A SHELF LIFE OF AT LEAST 25 DAYS, APPLIED TO LARGE-SCALE PRODUCTION PROCESSES IN RETAIL CHAINS

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3966980A (en) * 1969-05-02 1976-06-29 A.G.S. Food System Inc. Method of cooking and storing food in flexible bags
GB2280349A (en) * 1993-07-20 1995-02-01 Sun Valley Poultry Saleable meat product
US5498432A (en) * 1993-09-29 1996-03-12 Minh Food Corporation Method for preparing pre-cooked meat
CN102885324A (en) * 2012-10-29 2013-01-23 仲恺农业工程学院 Preparation method of salt roasted chicken
ES2466541A1 (en) * 2014-01-30 2014-06-10 Grupo Empresarial Palacios Alimentación, S.A. Preparing and packaging roast chicken for later distribution (Machine-translation by Google Translate, not legally binding)
US20170135388A1 (en) * 2014-07-03 2017-05-18 Cargill, Incorported Cooked turkey wing product

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3966980A (en) * 1969-05-02 1976-06-29 A.G.S. Food System Inc. Method of cooking and storing food in flexible bags
GB2280349A (en) * 1993-07-20 1995-02-01 Sun Valley Poultry Saleable meat product
US5498432A (en) * 1993-09-29 1996-03-12 Minh Food Corporation Method for preparing pre-cooked meat
CN102885324A (en) * 2012-10-29 2013-01-23 仲恺农业工程学院 Preparation method of salt roasted chicken
ES2466541A1 (en) * 2014-01-30 2014-06-10 Grupo Empresarial Palacios Alimentación, S.A. Preparing and packaging roast chicken for later distribution (Machine-translation by Google Translate, not legally binding)
US20170135388A1 (en) * 2014-07-03 2017-05-18 Cargill, Incorported Cooked turkey wing product

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