IN SITU METHOD FOR EXTENDING THE SHELF LIFE OF PERISHABLE PRODUCTS

Abstract: A method for prolonging the shelf life of products is disclosed, said method generally comprising sealing said product in a gas tight package where said sealing operation is conducted in the presence of an oxidizing agent so as to entrap a selected amount of said agent in said package in direct communication with said product, maintaining said oxidizing agent around said product for a time sufficient to substantially reduce microbial activity on the surface of said product, and then removing said agent while maintaining the sealed condition of said package.

Description: IN SITU METHOD FOR EXTENDING THE SHELF LIFE OF PERISHABLE PRODUCTS The present invention generally relates to a method for extending the shelf life of perishable products by exposing said products to an oxidizer, preferably ozone gas, for a time sufficient to substantially reduce microbial activity on the surface of said product. More specifically, the present invention relates to a method whereby a selected concentration of an oxidizer is introduced into a sealed container containing a perishable product for a time sufficient to neutralize or eliminate microbial activity present on said product, whereupon said oxidizer is removed or diluted. When microbial activity has thus been neutralized, the product may be exposed to a vacuum or other gases for purposes of transportation or presentation to the consumer. Perishable products, specifically meat, poultry, or fish products, are generally cleaned and packaged at a slaughterhouse or other processing facility preparatory to shipment to various retail outlets. These products are commonly packaged in containers such as plastic wrapped trays, pouches of plastic, paper or plastic coated paper bags, food storage tubes and the like- These containers are typically pliant relative to rigid cans, bottles and cans in that they are flexible or soft to the touch. They are also frequently transparent, as in the case of meats, to enable customers to view the product. These products, especially meats, are also commonly packaged in the oxygen-nitrogen atmosphere naturally occurring at such processing facilities. Packaging of perishable products in such a fashion, however, ordinarily causes fairly rapid reduction of the quality of the product with resultant spoilage. This phenomenon occurs, though at a slower pace, even when such products are maintained in a refrigerated condition. Product spoilage is partially a result of the multiplication of bacteria introduced onto the surface of the product during processing. Such contamination is particularly pronounced in the processing of poultry. Moreover, the atmosphere introduced into the product container also contributes to spoilage since such atmosphere may contain a variety of airborne bacteria. Spoilage is also enhanced by "cross contamination" which is often brought about as a result of the common handling of such products by human or mechanized devices during the packaging stage. In such cases, contamination may be widely spread and distributed as the result of common handling. The rate of increase in the number of surface bacteria determines in large part the shelf life of the product. In this respect, a perishable product is generally considered to have a shelf life determined by the amount of time necessary for the bacterial count to reach proportions which render the product unfit for consumption. This shelf life varies depending on the product and the conditions under which the product is processed and packaged. Fish and poultry traditionally have very short shelf lives when stored in an unfrozen state, whereas the shelf life for meat is generally longer. Regardless of the type of product, however, the presence of certain bacteria, especially the salmonella bacteria, can render the product dangerous for consumption even when present in small amounts. As a result of the above described problems relating to bacterial growth, perishable products are refrigerated or frozen to enhance their shelf life. A lowering in temperature is effective to reduce spoilage, since it results in a slowing of the rate of reproduction of the bacteria. For this reason, a perishable product generally will not spoil if frozen, but will almost immediately spoil if stored at room temperature in the absence of preservatives. A number of techniques have evolved to utilize the benefits of freezing. One commercial preservation and storage method involves subjecting various products, especially pork and poultry, to temperatures slightly below 32"F (O'C). This technique, often referred to as "crusting" literally involves the freezing of the outer layer of the product. Products subjected to this technique are "slacked out" and displayed for sale in a refrigerated, non frozen state. Bulk retail and institutional packages of various perishable products are sometimes handled in this fashion. Some products, however, especially poultry products, are felt to deteriorate in quality once subjected to freezing. Additionally, it is often times undesirable to freeze a product if further processing is contemplated at a secondary processing facility. For these reasons, other techniques have been developed to store or transport the product while maintaining the product at temperatures above freezing. One such technique is vacuum packing. Vacuum packing inhibits bacterial growth by removing the operative oxygen environment necessary to sustain aerobic growth. Disadvantages with vacuum packing, however, include the purplish color induced in meat products which often times inhibits the appearance of such products for purposes of retail sale. Vacuum packing also results in the creation of an undesirable liquid exudate which is caused by package pressure differential. If commercial sale of vacuum packed products is desired, the product also must often be removed from the vacuum pack and exposed to oxygen such that the meat may "bloom." When exposed to oxygen, however, surface bacteria derived from the processing or packing stage are then able to multiply and soon begin to move the product toward spoilage. Other non-frozen techniques have been employed to enhance the life of a perishable product. A second technique involves packing the product in a carbon dioxide atmosphere. The C0 2 atmosphere, like the vacuum pack, also inhibits the growth of aerobic bacteria. Similar to the vacuum pack, however, the C0 2 atmosphere does not reduce the number of bacteria on the product resultant from processing or packing. Thus the product, when exposed to an aerobic environment, begins to degrade as a result of residual bacteria. The above described techniques are useful, therefore, only from the standpoint of marginally prolonging the life of a perishable product during shipping, or when it is otherwise possible to maintain an aerobic environment around the product. These techniques do not, however, result in the destruction of bacteria. Moreover, these techniques fail to check the growth of anaerobic bacteria. Ozone (0 3 ) has been widely used as an oxidizing agent for bacterial, virus, and mold control for meat and fish storage, fresh fish processing, produce storage, restaurants, cooling towers, animal feed products, marine life, beverage plants, swimming pools, potable water systems, and tertiary waste systems. Ozone is also currently widely used for odor control in air conditioning systems, industrial plants, restaurants, mortuaries, rest homes and other applications. Ozone gas is a very strong oxidizing agent having an oxidation potential more than twice that of chlorine and approximately three times that of hydrogen peroxide. Ozone also has the advantage of breaking down upon use as an oxidant into oxygen, which is normally beneficial. The use of ozone for the sterilization or preservation of food products is described in U.S. Patent No. 4,549,477. The 77 patent describes both the historical applications (batch process) as well as the application of ozone in a continuous process whereby the perishable product is moved through a treatment zone filled with ozone. Disadvantages associated with the above described prior art techniques utilizing ozone include the possibility of recontamination of the product after it is moved out of the ozone flushed region and into a packaging area. This possibility of contamination is enhanced if the product is not already positioned in the package but must be positioned either mechanically or manually. Further, the aforedescribed processes do not allow for the possible retention of a partial amount of the oxidizing gas in the package. The present method addresses the above noted and other disadvantages by providing a method in which the non-frozen shelf life of a perishable product may be greatly enhanced. Additionally, the present method may enable the storage of products at temperatures above those ordinarily believed necessary to prevent spoilage. Thus, the invention is especially directed at the packaging of non-frozen, perishable products which are marketed in pliant containers. Treatment of the products to enhance their quality, appearance or other aspects is carried while the products are in a sealed, packaged condition. In a general aspect, the present invention is directed to a method whereby a perishable product is exposed to an oxidizer for a time sufficient to eliminate or substantially reduce the number of microorganisms present on the surface of said product. More specifically, the present invention is directed to a method of sealing a perishable product in a gas tight package while simultaneously subjecting the product to direct contact with an oxidizer so as to result in the containment of the oxidizer environment in the package. This oxidizing environment is maintained around the product for such time as is necessary to neutralize microorganisms present on its surface. A second gas may then be introduced into the package for purposes of transportation, storage, or presentation of the product to the consumer. In accordance with the spirit of the invention, the package is sealed in a controlled environment containing a selected concentration of an oxidizing gas. When the product has been exposed to the oxidizer for a sufficient time, depending on a number of variables including the type of product, the product weight, etc. , the oxidizer is withdrawn or flushed from the package and the package is filled with a gas suitable for transportation, or alternatively, an environment suitable for presentation to the consumer. This gas may include a C0 2 atmosphere adapted to suppress the growth of any bacteria not eliminated as a result of exposure to the oxidizer. Alternatively, an oxygen rich atmosphere may be introduced into the package so as to enhance the appearance of the meat product for purposes of retail sale. In another aspect, a vacuum may also be drawn around the product subsequent to introduction of the oxidizer. In a preferred aspect of the invention, the oxidizer is withdrawn from the product package via a valve disposed in the package so as to maintain the sealed gas tight integrity of the package itself. A septum valve is especially contemplated, because of its self-sealing activity. The method of the present invention has a number of advantages over the art. One such advantage is the ability of the present method to significantly reduce the number of aerobic and anaerobic microorganisms present on the surface of a given product. In such a fashion the shelf life of the product can be substantially increased. When used in combination with conventional preservation techniques such as freezing, an even greater shelf life may be realized. Further, the elimination or substantial reduction in the number of surface bacteria resultant from the present method allows for the storage of some perishable products for extended periods of time without the need for refrigeration. This is beneficial in remote areas or in the event that refrigeration facilities are unavailable. Other objects and advantages of the invention will become apparent from the following detailed description made in conjunction with the accompanying drawings. The present invention is directed to a method for substantially extending the shelf life of a perishable product, e.g., a meat, poultry, or fish product, by exposing the product to an oxidizing agent for a time sufficient to kill or substantially reduce a substantial majority of microorganisms present on the surface of the product. When the perishable product has been in contact with the oxidizer for a sufficient period of time, the oxidizer is entirely or partially removed, whereupon the package is evacuated or filled with a second gas compatible with the considerations of the consumer. Though the present invention has particular application to fresh meat, poultry or fish products, application of the method of the invention to other perishable products is also contemplated within the spirit of the invention. Likewise, the present invention may have application in the area of medical technology or research or similar areas where sterilization is desired. In a preferred mode of the present invention, a perishable product is placed in a gas tight package tray having means to raise the product above the surface of the tray so as to allow maximum gas circulation about the exterior of the product. Such a tray design is seen in applicant's co-pending application Serial No. 214,195. A gas tight top is then secured to the tray, thus sealing the atmosphere present during the packaging process. Alternately, other hermetically sealed containers may be used such as for example, flexible film pouches, plastic coated paper bags, or food storage tubes. It is desirable that such package or tray be provided with a septum valve or other resealable system valve or the like so as to enable gas extraction or modification while the sealed condition of the package is maintained. An example of such a package design is seen in applicant's corresponding application serial no. 214,915. During this packaging procedure, a controlled concentration of an oxidizer solution is introduced into the package so as to ensure contact between the oxidizer and all surfaces of the product. It is envisioned that ozone gas (0 3 ) may be used, although gaseous forms of other oxidizers such as fluorine (F 2 ) , hydrogen peroxide, (H 2 0 2 ) potassium permangerate (KMn0 ) , hypobromous acid (HOBr) , hypochlorous acid (HOCI) , chlorine (Cl 2 ) , chlorine dioxide (C10 2 ) , Oxygen (0 2 ) , Bromine (Br 2 ) , or Iodine (I 2 ) , are also contemplated within the spirit of the present invention though not all such oxidizers would be compatible with food products. Moreover, it will be recognized that some oxidizers may be more effective than others for any given product. Preferably, the above described packaging processes are undertaken in a sealed chamber such as those utilized to manufacture gas flush packaging. The type, weight, and age of the product determine both the concentration of the oxidizer and the amount of time it is maintained in contact with the product's surface. Retention time is also determined by the type of oxidizer us<= * d in conjunction with the product. In instances involving fish or poultry, it may be necessary to use higher concentrations of the oxidizer. In such instances, it may also be desired to allow a longer residence time of the oxidizer around the product. Such may also be true when the product includes a high fat content which may be particularly susceptible to oxidation. For instances where the sterilization of a medical or other nonorganic material is contemplated, concentrations and residence times of the exposure may expectedly increase. When a desired residence time has been completed, the oxidizer may be flushed or evacuated from the package. Alternatively, the oxidizer may be diluted by the injection of a second gas into the sealed container. In some instances it may be desired to draw a vacuum in the package for purposes of transporting the product. This latter option may be desirable since the maintenance of a vacuum substantially inhibits bacterial growth which is already substantially reduced by exposure to the oxidizer. In other instances, it may be desirable to replace the oxidizer with a growth inhibiting gas such as C0 2 . In all instances where gas injection or replacement is contemplated, however, it is desired that the replacement gas be controlled so as to be substantially free of bacteria. It is further desired that gas exchange or modification be conducted while the product remains in the sealed container. Gas exchange may be conducted in a manner disclosed in applicant's corresponding application. Utilizing such an apparatus, gas exchange, extraction or modification may be accomplished while maintaining the sealed condition of the package.

Claims: CLAIMS : 1. A method for processing a perishable product so as to enhance its shelf life comprising the sequential steps of: positioning the product in a gas impermeable package; sealing said product in said package while simultaneously exposing said product to an oxidizer capable of reducing microbial activity on the product so as to include said oxidizer in said package; maintaining said oxidizer in said package and in communication with said product for a time sufficient to inhibit microbial activity on the surface of said product; and removing said oxidizer from said package while maintaining the sealed condition of said package. 2. The method of claim 1 wherein said oxidizer comprise 0 3 , F 2 , H 2 0 2 , KMn0 4 , V x , Cl 2 , 0 2 , Br 2 , I 2 ι HoBr, or HoCl. 3. The method for enhancing the shelf life of a perishable product comprising the sequential steps of: sealing the product in a gas tight container in the presence of an oxidizer; maintaining said oxidizer in said container for a time sufficient for said oxidizer to react with microorganisms occurring on the surface of said product; extracting said oxidizer from said container through a valve located in said container; and introducing a second, microorganism growth inhibiting gas in said container. 4. A method to extend the shelf life of a perishable product which has been sealed in a container with a first gas, the method comprising: extracting said first gas from the interior of said package while maintaining the sealed condition of said package; injecting a selected concentration of a gaseous oxidizing agent into said package while again maintaining the sealed condition thereof; maintaining said agent in said package for a time sufficient to substantially reduce microorganisms present on the surface of said product; and withdrawing the majority of said oxidizing agent from said package and replacing said agent with a third gas. 5. The method of claim 4 wherein gas exchange is accomplished via a resealable valve disposed in said package. 6. The method of claim 4 wherein the oxidizing agent is 0 3 , F 2 , H 2 0 2 , KMn0 4 , Cl 2 , 0 2 , Br 2 , I 2 HoBr, or HOCI. 7. The method of claim 4 where said third gas reduces spoilage on said product. The method of claim 4 where said third gas includes CO. 9. A method of packaging in a pliant container a product which is subject to bacterial spoilage, which comprises: sealing the product in a pliant container with an atmosphere containing a gaseous oxidizing agent capable of reducing spoilage bacteria within the container, and thereafter reducing the amount of the gaseous oxidizing agent while maintaining the seal of the container. 10. The method of claim 9 in which the reduction in the amount of the oxidizing agent comprises evacuating the oxidizing agent from the container. 11. The method of claim 9 in which the reduction in the amount of the oxidizing agent comprises flushing the oxidizing agent from the container with a second gas capable of suppressing the growth of bacteria within the container. 12. A method of packaging in a pliant container a food product subject to spoilage by " bacteria which comprises: sealing the food product in the pliant container with a gaseous oxidizing agent of a type and in a concentration capable of sterilizing the food product; maintaining the gaseous oxidizing agent in the sealed container for a period sufficient to effect such sterilization; and thereafter removing the gaseous oxidizing agent from the container while maintaining the container in its sealed condition. 13. The method of claim 12 wherein the removal of the gaseous oxidizing agent is effected by flushing the gaseous oxidizing agent from the container with another gas capable of suppressing bacterial spoilage of the product. 14. The method of claim 13 wherein the other gas is capable of providing the product with a selected property 15. The method of claim 14 in which the product is a meat product and the other gas comprises oxygen in an amount sufficient to bloom the meat product. 16. A method of packaging in a pliant container a food product subject to spoilage by bacteria which comprises: sealing the food product in the pliant container with a gaseous oxidizing agent capable of providing a sterile atmosphere in the container; maintaining the gaseous oxidizing agent in the container for a time sufficient to provide a sterile atmosphere in the container; and thereafter removing at least a portion of the gaseous oxidizing agent from the container while maintaining the sealed condition of the container.

Inventors: MITCHELL JERRY L, MITCHELL, JERRY, L.
Applicants: PAKOR INC, PAKOR, INC.
Application year: 1991
Main classification: A23L3
IPC codes: A23B4, A23L3, B65B25