Abstract:
A method for manufacturing a packed product includes the steps of: a) bringing a product into a superheated steam atmosphere with an O 2  content of maximum 10 vol.-%, a pressure of between 950 mbar and 1100 mbar and a temperature of minimum 100° C., b) making available a packing container in the steam atmosphere and filling the packing container with a predetermined quantity of the product, wherein a residual volume of the packing container not filled with product is filled with the steam atmosphere, c) replacing at least 50% of the residual volume of steam atmosphere in the packing container by a sterile inert gas, d) sealing the packing container, and e) cooling the packing container and the product contained therein to a temperature of between 10° C. and 25° C.

Description:
FIELD 
       [0001]    The present disclosure relates generally to a packaged food product and, more specifically, to a food product packaged in an environment of super heated steam. 
       BACKGROUND 
       [0002]    Food products packaged in an environment of super heated steam may experience uncontrolled condensation of steam remaining in the packing container after sealing, which may affect quality and long term stability of the product. 
       SUMMARY 
       [0003]    A method for the manufacture of a packed product may, for example, comprise the steps of transporting a product into a superheated steam atmosphere with an O 2  content of less than 10 vol.-%, a pressure of between 950 mbar and 1100 mbar, and a temperature of at least 100° C., providing a packing container in the superheated steam atmosphere and filling the packing container with a predetermined quantity of the product, wherein a residual volume of the packing container not filled with product is filled with the superheated steam atmosphere, replacing at least 50% of the residual volume of superheated steam atmosphere in the packing container with a sterile inert gas, sealing the packing container, and cooling the packing container and the product contained therein to a temperature below 100° C. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0004]    The subject matter of the present disclosure is particularly pointed out and distinctly claimed in the concluding portion of the specification. A more complete understanding of the present disclosure, however, may best be obtained by referring to the detailed description and claims when considered in connection with the drawing figure, wherein like numerals denote like elements. 
           [0005]      FIG. 1  illustrates a device for manufacturing a packed product in accordance with various embodiments. 
       
    
    
     DETAILED DESCRIPTION 
       [0006]    In various embodiments in accordance with the present disclosure, a portion of the steam atmosphere in the packing container may be replacing by an inert gas, which may reduce the potential for the remaining gaseous atmosphere in the container to condense within the packing container after cooling. Further, the production of a negative pressure within the packing container may also be reduced, such as, for example, in embodiments in which a rigid packing container such as a screw-top jar is utilized. 
         [0007]    In various embodiments, reducing the condensation of the steam atmosphere within the packaging container may reduce or prevent condensed water from contacting packaged product. Condensed water may cause moisture within the packaged product, as well as an increased a w -value for individual pieces of the packaged product, which may reduce the durability of the product and may permit the growth of bacteria on the product. 
         [0008]    The packing container and the product contained therein can be cooled to a temperature below 50° C., 40° C., 30° C., 20° C. or 10° C. 
         [0009]    The product can be a food product. The product may be moist before it is brought into the steam atmosphere and have an a w -value of up to 0.9, for example up to 0.8, 0.7, 0.6, 0.5, 0.4 or 0.3. 
         [0010]    The product can consist of protein, particularly animal or vegetable protein, and/or cereals. It may be contemplated that the product is extruded directly into the steam atmosphere. 
         [0011]    In various embodiments, the product is dried in the superheated steam atmosphere to an a w -value of 0.9 or less, for example, less than 0.8, 0.7, 0.6 or 0.5 before it is filled into the packing container. 
         [0012]    For example, the packaging container can comprise a rigid packing container in which a portion of the residual volume of superheated steam atmosphere in the packing container is replaced by the inert gas, and, after cooling to a temperature of 20° C., the container comprises a pressure of less than 500 mbar, 550 mbar, 600 mbar, 650 mbar, 700 mbar, 750 mbar, 800 mbar, 850 mbar, 900 mbar or 950 mbar. 
         [0013]    In various embodiments, at least 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 98% or 99% of the residual volume of superheated steam atmosphere in the packing container is replaced by the inert gas. 
         [0014]    The step of replacing at least 50% of the residual volume of superheated steam atmosphere in the packing container with a sterile inert gas, can, for example, be implemented within the superheated steam atmosphere. Further, before the step of replacing the residual volume of superheated steam, the inert gas can be heated to a temperature of at least 60° C., 80° C., 100° C., or to the temperature of the superheated steam atmosphere. 
         [0015]    In various embodiments, the sterile inert gas may comprise N 2 , CO 2 , N 2 O, CO, H 2 , or mixtures thereof. For example, a mixture of N 2  or CO 2  with at least 10 vol.-%, 20 vol.-%, 30 vol.-%, 40 vol.-%, 50 vol.-%, 60 vol.-%, 70 vol.-%, 80 vol.-% or 90 vol.-% of CO 2  can be used. 
         [0016]    Packing containers in accordance with the present disclosure may comprise, for example, a receptacle with screw cap (such as a glass receptacle), a can, and a plastic bag. 
         [0017]    In various embodiments, the product can be packed in a superheated steam atmosphere having an O 2  content less than 7.5 vol.-%, 5 vol.-%, 3 vol.-% or 1 vol.-%. Further, the product can be packed in a superheated steam atmosphere having a temperature of at least 110° C., 120° C., 130° C., or 150° C. 
         [0018]    Apparatus for carrying out the methods of the present disclosure may comprise, for example, a steam generator for producing the superheated steam atmosphere, a chamber for holding the superheated steam atmosphere, means for making available a packing container in the chamber, transport equipment for transporting product into the chamber, a filling unit for filling the product into a packing container, a gas injector for controlled injection of sterile inert gas into a packing container filled with product and superheated steam atmosphere, a sealing apparatus for sealing the filled packing container, and/or transport equipment for removing the sealed packing container from the chamber. The packing container with the product contained therein may be cooled in a cooling device, such as, for example, a cooling device utilizing a controlled time-temperature profile, or only through contact of the packing container with the environment. 
         [0019]    In various embodiments, a gas injector may be disposed within the chamber. The gas injector can comprise, for example, a gas supply pipe, which can be immersed in the packing container such that a gas discharge opening of the gas supply pipe is located at or near the bottom of the container. In such embodiments, when inert gas is injected from the gas discharge opening into the packaging container, residual volume of steam atmosphere is expelled from the packing container. For example, the inert gas may displace steam atmosphere located between individual pieces of the food product, such as food products which are lumpy, granular or granular-type foods having cavities or gaps between the individual pieces. In other embodiments, a gas nozzle may be utilized to provide sterile inert gas into the packing container. 
         [0020]    In various embodiments, a sealing apparatus can be disposed within the chamber. 
         [0021]    With reference to  FIG. 1 , a chamber  2  comprises a superheated steam atmosphere  4  having a temperature above 100° C. by, for example, heating system (not illustrated). The pressure in the chamber  2  may be atmospheric, i.e. generally 1000 mbar. The oxygen content of the steam atmosphere  4  may comprise less than 10 vol.-% of O 2 , and further, less than 3 vol.-%. The chamber  2  can further comprise a boundary layer  4   a  between steam atmosphere  4  and the ambient air  5 . 
         [0022]    A product  6 , such as, for example, a food product, is transported by transport equipment  8  into the chamber  2  and further into a product funnel  10 . Before entering the product funnel  10 , the product  6  may be dried to a predetermined moistness, such as, for example, to an a w -value of 0.9 or less, which may reduce or prevent the cultivation of microorganisms within the packed condition. In various embodiments, the product  6  dwells in the steam atmosphere  4  for a sufficient time period to dry the product to the desired an a w -value before transport to product funnel  10 . 
         [0023]    The product passes through an opening  10   a  of product funnel  10  and into a packing container  12 , which may be positioned under the product funnel  10 . The packing container  12  can comprise a bottom  12   a  and a seal opening  12   b  which is located directly under the opening  10   a.    
         [0024]    The packing container  12  can comprise, for example, a plastic bag, which may be formed within the chamber  2  from a film material. Further, packaging container  12  can comprise a can or a receptacle with a cap or a lid configured to seal the packaging container  12 . In various embodiments, a rigid packing container  12  is conveyed from outside of housing  2  into the steam atmosphere  4  in an upside-down position, in which the bottom  12   a  points upwards and the seal opening  12   b  downwards. In this position, ambient air contained in the packing container  12  may escape due to gravity, while the internal volume of the packing container fills with steam atmosphere. 
         [0025]    The packing container  12  can then be transported into a filling position, in which it is filled with product. In the filling position gas supply pipe  14  extends into the packing container  12 , whereby a gas discharge opening located at the end of gas supply pipe  14  is positioned at or near the bottom  12   a  of the packing container  12 . 
         [0026]    In various embodiments, gas supply pipe  14  is connected to a gas injector  16 , which can comprise a pressure cylinder  18  and/or a pressure cylinder  20 . One or both of pressure cylinders  18 ,  20  can be filled with one or more sterile inert gas. For example, pressure cylinder  18  can be filled with N 2 , pressure cylinder  20  filled with CO 2 . The pressure cylinders can further comprise a pressure control valve  22 , a manifold  24 , a solenoid valve  26 , a heating station  28 , as well as temperature gauge  30 , and pressure gauge  32 . Gas injector  16  is provided with a control unit (not illustrated), which can act on the pressure control valves  22 , solenoid valve  26 , and heating station  28 , in order to control the supply timing, the quantity, the composition and the temperature of the gas mixture fed to gas supply pipe  14 . 
         [0027]    In various embodiments, product  6  is fed via transport device  8  or alternatively directly through an extruder into chamber  2  and steam atmosphere  4 . Depending on the drying requirement, the product is exposed for a certain time to the steam atmosphere  4  and thereby dried. Subsequently, the product is transported to the product funnel  10 , and further, into an available packing container  12 . 
         [0028]    Packing container  12  is conveyed into the chamber by, for example, transport equipment, rotated there by 180° or conveyed into the chamber already in the rotated position, so that the bottom  12   a  points upwards, and then rotated by 180°, so that the seal opening  12   b  points upwards, and brought into the filling position. The gas supply pipe can then be located in packing container  12  before it is filled with product. 
         [0029]    Subsequently, packing container  12  can be filled with product  6 , such as a lumpy or a granular-type food product. The volume or bulk volume of filled product  6  can comprise at least 50%, 60%, 70%, 80%, 90%, 95% or 99% of the fillable internal volume of packing container  12 . 
         [0030]    Before, during or after filling the product into the packing container, a sterile gas, such as, for example, a mixture of N 2  and CO 2 , is injected through gas supply pipe  14  into packing container  12 , and a residual volume of steam atmosphere is expelled from packing container  12  and/or replaced by the sterile gas. In the case of a lumpy or granular-type product  6 , a residual volume of steam atmosphere can exist between the individual pieces of product  6 . By disposing the gas discharge opening directly above bottom  12 a of packing container  12 , the remaining steam atmosphere can be expelled to a large extent from between the individual food pieces. 
         [0031]    In various embodiments, packing container  12  is lowered or gas supply pipe  14  is raised, so that gas supply pipe  14  is located outside packing container  12 . Packing container  12  can then be moved horizontally to a sealing station, in which packing container  12  is sealed as to be gas-tight, particularly by applying and sealing a lid  34 . The sealing station is preferably disposed within chamber  2  in order to avoid contact with ambient air. 
         [0032]    After being sealed, packing container  12  is removed from chamber  2  by, for example, transport equipment (not illustrated) and either cooled down in a cooling device in accordance with a predetermined time-temperature profile or cooled down only by leaving to stand in the environment. 
         [0000]    
       
         
               
             
               
               
               
             
           
               
                   
               
               
                 Reference symbol list 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                   
                  2 
                 Chamber 
               
               
                   
                  4 
                 Steam atmosphere 
               
               
                   
                  4a 
                 Boundary layer 
               
               
                   
                  5 
                 Ambient air 
               
               
                   
                  6 
                 Product 
               
               
                   
                  8 
                 Transport equipment 
               
               
                   
                 10 
                 Product funnel 
               
               
                   
                 10a 
                 Opening 
               
               
                   
                 12 
                 Packing container 
               
               
                   
                 12a 
                 Bottom 
               
               
                   
                 12b 
                 Seal opening 
               
               
                   
                 14 
                 Gas supply pipe 
               
               
                   
                 16 
                 Gas injector 
               
               
                   
                 18 
                 N 2  pressure cylinder 
               
               
                   
                 20 
                 CO 2  pressure cylinder 
               
               
                   
                 22 
                 Pressure control valve 
               
               
                   
                 24 
                 Manifold 
               
               
                   
                 26 
                 Solenoid valve 
               
               
                   
                 28 
                 Heating station 
               
               
                   
                 30 
                 Temperature gauge 
               
               
                   
                 32 
                 Pressure gauge 
               
               
                   
                 34 
                 Lid