PROCESS FOR PACKAGING FRESH MEAT

Abstract: A process for packaging fresh meat in a case-ready condi­ tion comprising: cutting fresh meat into small, case-ready cuts of a size to be packaged and displayed to purchasers by positioning the packaged cuts in a retailer's meat case; plac­ ing at least one of said case-ready cuts on each of a plurality of supporting trays sized for deposit and display in said meat case; surrounding the meat cuts on the trays with a pre­ selected gaseous atmosphere; covering each of the trays and the meat cuts thereon with a flexible, gas permeable film of transparent synthetic resin to enclose said meat cuts and preselected gaseous atmosphere within said gas permeable film; and placing said trays in a gas impermeable container; surrounding the trays and filling the impermeable container with a controlled gaseous atmosphere; and sealing said con­ tainer to retain the controlled gaseous atmosphere therein.

Description: DESCRIPTION This invention relates to the packaging of fresh meats for shipment from the packer to a point of retail sale. More particularly, but not by way of limitation, it relates to a process and a special novel container by the use of which fresh pork can be maintained in an attractive, caseready condition from the time of packing, up to the time of sale to the consumer. It is known that meat can be maintained against spoilage by packaging the meat in a relatively air free environment. Carbon dioxide has been employed for this purpose by using it to displace some of the air around the packaged meat cuts. Vacuum packing has also been used. These techniques used by packers have not been totally successful, and many types of original packaging require various labour intensive preparation measures on the part of the butcher at the retail outlet before the meat can be attractively displayed to customers. Part of the difficulty experienced is that discoloration occurs where a significant time period elapses between original packing and placement of the meat in the meat case for sale, or the original package becomes damaged or unsightly or a complete repackaging is necessitated to achieve satisfactory display. In many instances, the final container into which the butcher will transfer the meat for display in the meat case is a styrofoam tray with a plastic film overwrap, but this containerization has not been thought to be satisfactory as original packaging suitable for use by the packer due to the relatively short shelf life before spoilage which is exhibited by fresh meat so packaged. In some European markets, meats have been packaged in a relatively high oxygen atmosphere for the purpose of maintaining a red coloration indicative of freshness. The increased oxygen, however, acxcelerates oxidative reactions which cause the meat to develop an undesirable oxidized flavour. Broadly described, the present invention is a method for packaging fresh meat cuts in small, consumer-attractive, case-ready packages contained within a gas filled exterior packaging system which assures that the meat will retain an attractive red coloration and will remain in a fresh, unspoiled condition over an extended shelf life period of at least 20 days. No handling or repackaging by the butcher at the retail outlet is required. The inventive concepts here described also extend to, and include, the compound package developed in carrying out the packaging method of the invention. In carrying out the packaging method of the invention, the animal from which the packaged cuts are to be derived is slaughtered and the carcass is chilled and subdivided into primal cuts. The primal cuts are then further subdivided into cuts which have a configuration, weight and size corresponding to the ultimate cuts which are to be displayed to, and bought by, the consumer. In this way, no further cutting, trimming or the like is required by the retailer prior to display. The case-ready cuts having a natural or adjusted pH of at least about 5.6 are placed in a primary package which is formed of a gas permeable material. In the course of forming the primary package, a substantial portion of the air is displaced from the interior of the package and is replaced by carbon dioxide. A plurality of the primary packages are then placed within a container constructed of a gas impermeable material, and a substantial portion of the air within the container is removed. The interior of the container is then charged with carbon dioxide so that the oxygen content within the container and over the primary packages located therein is substantially reduced. The container is then sealed to form a compound secondary package which, after placement in a suitable box or carton is shipped to the retailer. By the use of the packaging thus formed, the retailer is enabled to open one or more of the containers forming the compound secondary package, and then have a plurality of the primary packages available and ready for display in the meat case. As previously pointed out, the primary packages are made up to contain meat cuts which have been cut to a size and weight characteristic of the meat cuts customarily marketed to the consumer. Preferably, the primary packaging is itself also selected to have aesthetic appeal to the consumer. An important object of the present invention is to provide a process or method for developing case-ready packages of meat, and a particularly fresh pork, where the meat is preserved in a healthy, unspoiled condition, and for an extended period of time remains as attractive as when freshly cut. A further object of the invention is to provide an initial packaging method for fresh meat cuts which eliminates the necessity for repackaging, or handling and processing of any type, by the retailer after receiving case-ready packages of meat from the packer. An additional object of the present invention is to provide a new method for packaging fresh cuts of meat, and particularly pork, such as pork chops, so that the meat does not become discolored, and the microbial activity on the meat cuts is maintained at acceptable levels over an extended period of time which is more than adequate to facilitate display and sale of the meat to the consumer after allowing for a period of shipment from the packer to the retialer, and placement by the retailer on display for purchase by the consumer. Additional objects and advantages of the invention will become apparent as the following detailed description of the invention is read in conjunction with the accompanying drawing which illustrates a preferred embodiment of the unique compound package developed in carrying out the processing of the invention. The sole figure of the drawings is a perspective view of a preferred embodiment of a compound package which is developed by using as a secondary container, a thermoformed tray provided with an impermeable film overwrap for purposes of containing a plurality of the primary packages developed in an early stage of the process of the invention. The description of the method by which fresh meat cuts are packaged according to the invention will be aided by reference to the sole figure of the drawings which shows the compound package developed in carrying out the method. In the initial step the animal carcass is subdivided into primal cuts. The fresh meat primal cuts are then tested to determine the pH of these cuts. The testing is carried out primarily for the purpose of ascertaining which of the primal cuts have a pH of at least about 5.6. We have determined that prk cuts which have a pH below about 5.6 are adversely affected by the predominantly carbon dioxide atmosphere in which the cuts are to be packaged, in that the cuts turn an unsightly grey colour in a relatively short time of exposure to carbon dioxide. Factors which appear to affect the pH of the meat are the time of year that the animal is slaughtered, the conditions of slaughter, including the trauma encountered, the type of feeding of the slaughtered animal which has been carried out and genetics. By utilizing a treatment entailing the application of a suitable pH-elevating aqueous buffer solution to those cuts which, upon testing, are found to have a pH of less than 5.6 but higher than 5.2, the pH of these cuts can be elevated to at least as high as about 5.6, and the described discoloration thereby substantially avoioded and the yield of case-ready packaged product increased. An especially effective and preferred buffer solution for this purpose is basically a four-component aqueous solution which includes, in addition to water, (a) a phosphate compound selected from the group which includes alkali metal (preferably sodium and potassium), orthophosphates, pyrophosphates, tripolyphosphates and hexametaphosphates; (b) a reducing compound capable of retaining the heme iron of the meat pigment in the meat in the ferrous state, and of retarding the oxidative process in the meat; and (c) a chelating or sequestering agent capable of sequestering setal ions present in the meat and constituting undesirable pro-oxidants. Reducing compounds which have been found to be especially effective include ascorbic acid, isoascorbic (erythorbic) acid and the sodium and potassium salts of these acids. A sequestering agent or compound which has been found to be especially effective is citric acid, although other food grade sequestering agents can also be used. In utilizing the described aqueous buffer solution, the amounts of these components which are incorporated into the meat, based on the total weight of the treated product, are from about 0.1 to about 0.5 weight percent of the phosphate compound; from about 0.01 to about 0.05 weight percent of the reducing compound, and from about 0.01 to about 0.1 weight percent of the sequestering agent. Preferably, the treated meat will contain from about 0.2 to about 0.4 weight percent of the phsophate compound, from about 0.02 to about 0.04 weight percent of the reducing compound and from about 0.02 t60 about 0.08 weight percent of the sequestering compound. The aqueous buffer solution which is utilized will vary in its concentration of the described three components according to which of several application modes is utilized to incorporate the active compounds into the meat. Thus, the primal cuts can be pumped to inject aqueous buffer solution in a quantity of from about 7 weight percent to about 12 weight percent. Where marination is used on smaller subdivided cuts, such as pork chops, as hereinafter described, then a lesser amount of the aqueous buffer solution will be incorporated into the meat, and to bring the concentration of the three active components in the meat to the level desired as hereinbefore described, the concentration of these components in the buffer solution is substantially higher than where injection and pumping of the primal cuts is employed. Those primal cuts which have a natural or a buffer-adjusted pH of at least about 5.6 are next subjected to the subsequent steps of the packaging method. The described primal cuts are further subdivided into case-ready cuts 10 which correspond in shape and weight to that which is optimum for consumer display at the retail outlet as illustrated in the drawing. It should be pointed out that if desired, the tested primal cuts which have a pH lower than about 5.6, but higher than about 5.2, can be subdivided into case-ready cuts, such as pork chops or the like, and these subdivided cuts can then be either marinated or sprayed with the described aqueous buffer solution to elevate the pH of the cuts adequately (to at least about 5.6) to avoid the undesirable discoloration hereinbefore described. Where spraying of the smaller cuts is utilized, the sprayed product will generally contain from about 2.0 weight percent to about 4.0 weight percent of the aqueous buffer solution as evidenced by the total weight increase resulting. In the marinating process, from about 2 weight percent to about 4 weight percent of the aqueous buffer solution is absorbed in the meat. The secondary cuts which have a natural or adjusted pH of at least about 5.6 are then placed individually, or in superimposed layers, upon a relatively small styrofoam tray of the type now commonly used for displaying meat cuts in the meat cases of retail outiets, such as supermarkets. The styrofoam tray 12 has an open top and a peripheral rim, and is preferably provided with a soaker pad 13 in the bottom of the tray for absorbing exudate, blood and juices from the meat cuts. The construction of a typical tray and soaker pad is illustrated in the drawing. The styrofoam tray 12 carrying the meat cuts 10 is then passed into an elongated synthetic resin tube through which carbon dioxide gas is continuously flushed. The tube is made of a plastic film which is gas permeable, and preferably surrounds an elongated conveyor upon which the styrofoam trays are moved longitudinally within the tube. The tube can be preformed, or it may be formed in the process at the time the styrofoam trays are moving on the conveyor. After one of the styrofoam trays bearing the meat cuts enters the tube, the tube is severed at a point in advance of one end of the tray, and this end of the tube is then sealed by bringing the severed edges together to effect closure. After closure of one end of the tube, flushing with CO2 continues for a brief interval ti displace air from the interior of the tube adjacent the closed end and over the styrofoam tray. The tube is then severed at a location spaced from the closed end and adjacent the side of a respective styrofoam tray which is on the opposite side thereof from the closed end. The synthetic resin gas permeable film making up the tube is then pulled down, and an overwrapping process is completed in which the film 14 is pulled down relatively snugly and tightly about the meat and is heat sealed or otherwise secured at its free edges beneath the underside of the styrofoam tray. By the procedure described to this point, a series of primary caseready packages 16 are formed. Several of the small case-ready primary packages 16 containing meat cuts 10 positioned in the predominantly C02 atmosphere are then placed in a larger container to form a compound secondary package 18. In a preferred embodiment of the invention, the first step in the preparation of the secondary package is the placement of a number of the styrofoam trays 12 upon a larger tray which is preferably a thermoformed tray 20 having a number of wells or recesses configured to accommodate a plurality of the primary packages. A typical thermoformed tray 20 suitable for use is shown in the drawing. Preferably from two to ten of the primary packages are located on the larger thermoformed tray, and it can be made to support as many as sixteen of the primary packages. This latter tray, called a secondary tray, is then subjected to a sealing process in which a pas impermeable film 22 of synthetic resin is used for enclosing all of the smaller primary packages 16. In the course of completing the sealing of the secondary tray, a vacuum is initially developed within the package formed by the secondary tray and its gas impermeable closure film so as to remove a substantial amount of the air (at least about 40 volume percent) from the interior of this compound package. Care is exercised, however, to maintain the vacuum at a level sufficiently low that the predominantly carbon dioxide gas within the primary packages is not expanded to the point of bursting or causing excessive stretching of the gas permeable film 14 used to sealingly close the styrofoam trays 12. In this way, the aesthetic appearance of the primary package is maintained. Generally, a vacuum of about 38 cms of mercury is not exceeded. After the compound secondary package 18, which includes the secondary thermoformed tray 20 and its gas impermeable closure film 22, has been evacuated to reprove at least about 40 volume percent and preferably about 70 volume percent of the air, the interior of the compound package is flushed with carbon dioxide. As the partial vacuum which has been developed within the package is relieved and the pressure is restored to approximately atmospheric by flushing with carbon dioxide, the result is that a low oxygen, high carbon dioxide atmosphere is established within the compound secondary package. The oxygen content within the secondary package will generally be between about 2 volume percent and 13 volume percent, with the preferred oxygen concentration being between about 5 volume percent and 10 volume percent. The gaseous atmosphere in the compound secondary package will contain from about 35 volume percent to about 90 volume percent carbon dioxide, and preferably from about 50 volume percent to about 75 volume percent. The package is, of course, sealed after flushing with carbon dioxide to establish approximately atmospheric pressure in the compound package. Several of the compound secondary packajges, each of which includes a gas impermeable thermoformed tray sealingly covered with a gas impermeable synthetic resin film, and containing a plurality of the small overwrapped styrofoam trays of the primary packages, are then placed within a large carton or box preparatory to shipment of the carton or box to the retailer. The containerization thus developed protects the compound fresh meat packaging from mechanical damage during shipment, and upon arrival at the retailers, it can bge easily opened to permit one or more of the compound secondary packages to be removed. The other compound packages can be left in the carton or box and placed on standby shelving or in storage to await later placement in the meat box for immediate sale. In other words, the retailer, without further processing or without any alteration of the packaging can take out one of the compound packages, leaving the others in the carton, and then remove from the compound package the plurality of small styrofoam tray primary packages which are in attractive condition, and ready for placement and display in the meat box. We have determined that meats so packaged arrive at the retail outlet in a fresh condition with a low microbial count, and have an attractive red appearance substantially equal to that which has been achieved by other packaging methods which, in most cases, require some further packaging and handling by the butcher at the point of retail sale. Convenience to the retailer is greatly enhanced, and the cost to the consumer is reduced because the packer can develop the described compound packaging and protective gasification of the meats more economically than the meat can be rehandled by the butcher at the point of retail. The packages developed in the manner described have been found to have a shelf life of at least 20 days when stored and shipped at a temperature of from about 'O to about +10. When the primary packages are removed and placed on display in a meat counter, the meat will keep for an additional three days before any detectable spoilage or unacceptable increase in microbial content occurs, and the meat remains substantially as fresh in appearance as when first cut at the packer. In sum, the consumer is presented with relatively more attractive, yet less expensive meat as a result of the packaging technique. As an alternate method of practicing the present invention, a carbon dioxide atmosphere is developed around the resh meat cuts placed on the styrofoam primary tray by sprinkling a small amount (from 1 to 2 grams) of solid carbon dioxide crystals around the meat on the tray. The tray is then overwrapped by any conventional presently known method, with the gas permeable film used for overwrapping pulled loosely across the meat slices so as to be able to undergo a slight expansion as the solid carbon dioxide sublimes and displaces air from the interior of the primary package through the gas permeable film. The process of the invention can also be altered at the step of development of the secondary package. When this alternate technique is used, the primary packages are placed into a gas impermeable flexible bag. Nost of the air within the bag is then removed by an appropriate combination of evacuation, followed by CO2 flushing. Preferably, a substantial portion of the air is initially removed by first flushing the bag with CO2, then evacuating the bag, being careful not to burst or cause excessive wrinkling of the overwrap of the primary trays as previously described. The bag is then reflushed with CO2 to restore atmospheric pressure within the bag. The bag, constituting the secondary container in the case of this embodiment, is then placed in a suitable carton for shipment to the retailer. The described use of a large flexible bag for containing many of the primary packages is less desirable than the use of thermoformed tray-type secondary containers, since the latter method enables the retailer to select one of the compound packages made utilizing the tray-type secondary containers without the necessity to destroy or debilitates the predominantly carbon dioxide atmosphere around all of the other primary packages. In other words, the retailer has greater flexibility in selecting a limited number of primary packages without thereby destroying or impairing the predominantly carbon dioxide protection afforded the primary packages contained in others of the compound packages using tray-type secondary containers when the first-described preferred method of packaging is employed. Although several preferred embodiments of the present invention have been herein described, it will be understood that other variations in the packaging technique can be effected without departure from the basic and fundamental principles which are encompassed by each of the several variant packaging methods described. Changes and innovations of this type, which do not entail departure from the basic principles of the invention are therefore deemed to be encompassed within the spirit and scope of the invention, except as the same may be necessarily limited by the appended claims or reasonable equivalents thereof.

Claims: CLAIMS 1. A process for packaging fresh meat in a case-ready condition comprising: cutting fresh meat into small, caseready cuts of a size to be packaged and displayed to purchasers by positioning the packaged cuts in a retailer's meat case; placing at least one of said case-ready cuts on each of a plurality of supporting trays sized for deposit and display in said meat case; surrounding the meat cuts on the trays with a preselected gaseous atmosphere; covering each of the trays and the meat cuts thereon with a flexible, gas permeable film of transparent synthetic resin to enclose said meat cuts and preselected gaseous atmosphere within said gas permeable film; and placing said trays in a gas impermeable container; surrounding the trays and filling the impermeable container with a controlled gaseous atmosphere; and sealing said container to retain the controlled gaseous atmosphere therein. 2. A process for packaging fresh meat as defined in claim 1 wherein the meat cuts on the supporting trays are surrounded with a preselected gaseous atmosphere by placing each tray in an elongated, open-ended tube of a gas permeable, transparent, synthetic film; passing the gases making up said preselected gaseous atmosphere through the elongated, open-ended tube from one end thereof toward the other; closing the tube adjacent one side of each said trays, while continuing to flush air out of the elongated, open-ended tube by passing the gases making up the preselected gaseous atmosphere into the open end thereof, then closing the tube on the opposite side of the respective tray from the location where the tube is first closed to completely enclose said gaseous atmosphere and meat cuts. 3. A process for packing fresh meat as defined in claim l, wherein the trays are surrounded by, and the impermeable container is filled with, a controlled gaseous atmosphere by: evacuating said container to remove a substantial amount of the air therefrom without rupturing or stretching the covering film around said meat cuts; then charging one or more chosen gases into the evacuated container until the pressure in said container is restored to substantially atmospheric pressure and said controlled gaseous atmosphere is developed within said container; and sealing said container to retain the controlled gaseous atmosphere therein. 4. A process for packaging fresh meat as defined in claim 1, wherein said gas impermeable container comprises: a shaped, thermoformed synthetic resin tray having divider structure therein for receiving and retaining a plurality of meat cut-supporting trays; and a gas impermeable flexible film extended over said supporting trays and sealed to said thermoformed tray, and wherein said evacuation and charging of said container is accomplished by: initially withdrawing a substantial portion of the air from the interior of the container to collapse the gas impermeable film without bursting or stretching said gas permeable film used to cover each meat cut supporting tray; and then replacing substantially all of the withdrawn air with one or more chosen gases to develop the desired controlled atmosphere within said container; and sealing the container at the location where the one or more chosen gases are. charged thereto. 5. A process for packing fresh meat as defined in claim 1, wherein said gas impermeable container is a flexible synthetic resin bag, and wherein said process includes the further step of flushing air out of said bag by displacement, using said one or more chosen gases, prior to evacuating the bag, and then charging it with said one or more of said chosen gases after evacuating the bag. 6. A process for packaging fresh meat as defined in claim 1, wherein said evacuation of said container is carried out by evacuating to a vacuum not exceeding 15 inches of mercury. 7. A process for packaging fresh meat as defined in claim 1, wherein said supporting trays are styrofoam. 8. A process for packaging fresh meat as defined in claim 3, wherein said evacuation of said container is carried out by evacuating to a vacuum not exceeding 15 inches of mercury. 9. A method for preparing retial meat cuts ready for customer display in a retailer's meat case comprising: cutting fresh meat into cuts of a size1 shape and weight customarily displayed and then sold to consumers; placing the cuts on a rectangular styrofoam tray of a type customarily used to contain and display the meat cuts to consumers by placement of such trays in a retailer's meat case; surrounding the meat cuts on the tray with a preselected gaseous atmosphere retained within a gas permeable, transparent film of synthetic resin which forms with the tray a closed primary package containing the meat cuts; then placing the meat supporting tray in a sealed, gas impermeable container containing a controlled atmosphere of a mixture of gases all at a pressure such that said gas permeable film neither bursts nor wrinkles during the time said trays is within said container, or after it is removed therefrom. 10. A method for preparing retail meat cuts as defined in claim 9 wherein said container comprises: a thermoformed rigid tray having a plurality of said styrofoam trays placed thereon; and a gas impermeable synthetic resin film wrapped around said thermoformed tray and over said styrofoam trays and retaining said controlled atmosphere within said container. 11. A method of preparing retail meat cuts as defined in claim 9 wherein said container comprises a flexible bag of a gas impermeable synthetic resin film. 12. A fresh meat cut package comprising: a plurality of primary packages each having fresh meat cuts therein and each including a transparent, gas permeable film retaining a preselected gaseous atmosphere therein and around the meat cuts; and a gas impermeable swecondary package containing said primary packages, and further sealingly containing, and being filled with, a controlled gaseous atmosphere. 13. A fresh meat cut package as defined in claim 12, wherein each said primary package further includes a styrofoam tray supporting at least one of said meat cuts and overwrapped with said gas permeable film. 14. A fresh meat cut package as defined in claim 12, wherein said secondary package comprises: a thermoformed tray supporting said primary packages; and a gas impermeable film overwrapped around said thermoformed tray and enclosing said primary packages. 15. A fresh meat cut package as defined in claim 12 and further characterized as including a soaker pad beneath said meat cuts and in each of said styrofoam trays.

Inventors: BALSANO, JOSEPH A., CHENG, CHIN S., MCCARTHY, MICHAL J.
Applicants: W.R. GRACE & CO.-CONN. (A CONNECTICUT CORP.)
Application year: 1986
Main classification: B65B31
IPC codes: B65B31, A23B4, B65B25