Abstract:
The invention is directed to a method and apparatus for sanitizing perishable goods by mixing the goods with sanitizing liquor for a suitable period of time followed by separating the liquor and substantially neutralizing any residual sanitizing agent left in the goods. In one instance, the sanitizing agent includes ozone and water; therefore, separation of the ozonated water advantageously proceeds with a squeezing effect to more adequately remove the ozonated water from the goods.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of application Ser. No. 10/418,558, filed Apr. 16, 2003, which claims the benefit of Provisional Application No. 60/373,232, filed Apr. 16, 2002, both of which applications are herein expressly incorporated by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to the sanitizing, decontaminating, analyzing, proportioning, grinding and blending of perishable food items in enclosed conduits. 
       BACKGROUND 
       [0003]    Ozone has been recognized as safe to use in food processing. Accordingly, food processors have begun to use ozone in washing various foods. One processor has developed a process that utilizes ozone in the treatment of poultry. In this system, ozonated water is sprayed on the food products as the products pass through ozonated water sprays on a conveyor system. A pump moves water from the chiller bath through a filter. The filtered ozonated water is then titrated with ozone gas, effectively killing any pathogens, such as  E coli  0157:H7,  Listeria , and  salmonella , and oxidizes any residual organic materials before being recycled through the process, thus saving on wastewater treatment costs. 
         [0004]    A turkey processor also uses ozone to enable the recycling of process wash water. Once the water has been used, the water passes through a series of ozone vessels. Ozone gas is pumped into the vessels to kill any microorganisms. The system strips out any residual ozone prior to returning the water to a chiller. Any residual ozone is captured and run through a catalytic destruction unit. This provides for up to about 80% of recycled water, thus saving the company water, energy, and wastewater treatment costs. 
         [0005]    However, the prior art methods for using ozonated water to wash food products are, for the most part, conducted in open vats or in ambient environments wherein the amount of ozone exposure is relatively uncontrolled. 
         [0006]    Ozonated water remains a viable method of sanitizing or decontaminating meat or any other perishable good. However, widespread use of ozone has been hampered by the inability to properly control the amount of ozone&#39;s exposure to the meat. Ozone is a strong oxidizer and will render perishable goods, such as meat, unsuitable for consumption if the exposure time to ozone is not properly controlled. 
         [0007]    Therefore, methods and apparatus for treating meat with ozone are in need of development. The present invention fulfills these needs and provides further related advantages. 
       SUMMARY 
       [0008]    This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. 
         [0009]    One aspect of the invention is a method for sanitizing perishable goods by exposing the goods to ozone gas in an atomized solution for a suitable period of time followed by scrubbing of the ozone gas with other gases, such as air and then carbon dioxide, thereby substantially neutralizing any sanitizing agent with the goods. 
         [0010]    The invention is directed to a method and apparatus for sanitizing perishable goods by exposing the goods to ozone for a suitable period of time followed by scrubbing the ozone gas with air and then carbon dioxide and substantially neutralizing any residual sanitizing agent left in the goods. Following neutralization, the goods may further be treated with an antioxidant to reduce the deleterious oxidizing effects of ozone on the goods. Goods can include meats, such as beef, lamb, veal, pork, chicken, and the like. 
         [0011]    In another aspect of the present invention, a sanitizing apparatus for goods includes a horizontal conduit pressure vessel with a first section in which the goods are treated and a second scrubbing section. The pressure vessel encloses an Archimedes screw disposed on a horizontal, rotating axis, which carries and rotates the goods. The apparatus is configured to expose all surfaces of the goods to the gases contained within the pressure vessel, from the point of entry, through the first section of the vessel, the scrubbing section, and to the exit end of the pressure vessel. Any number of similar sections can process meat with differing agents, such as neutralizing fluids, gases, or antioxidants. Following the sanitizing step, the goods are ground (to ensure rapid adjustment of the pH level of the goods that may otherwise cause excessive oxidizing at the surface of the goods) and then selectively transferred and divided into at least two streams carried through corresponding conduits prior to subsequent proportioning and blending equipment. 
         [0012]    The present invention can thus provide precise control of exposure time to concentrated ozone to a minimum, thus sanitizing the meat without causing deleterious effects on meat. A further advantage is the ability to keep the meat enclosed within a conduit and thus minimize exposure to atmospheric oxygen. 
         [0013]    In one aspect of the invention, ozone and water are introduced into a vessel containing meat. Any amount of water can then be removed with a dry gas. The addition of water enhances the activity of ozone in beneficial ways for washing and sanitizing the meat. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0014]    The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein: 
           [0015]      FIG. 1  shows an illustration of an apparatus arranged to sanitize a continuous stream of boneless meat; 
           [0016]      FIG. 2  shows an illustration of an apparatus arranged to sanitize a continuous stream of boneless meat; and 
           [0017]      FIG. 3  shows an illustration of equipment arranged to produce ground meat after sanitizing with apparatus described in association with  FIGS. 1 and 2 . 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    Referring now to  FIG. 1 , an apparatus  100  constructed for the purpose of sanitizing boneless meat is shown. The apparatus  100  includes a horizontally disposed conduit  9  with end caps  7  and  25  sealed thereto. End caps  7  and  25  are securely attached to conduit  9  and are removable to allow cleaning of the internal components of the apparatus  100 . Port  2  is located centrally on the upstream side of the apparatus  100  in the end cap  7  and arranged to allow injection under pressure of boneless meat in a continuous stream therethrough, and into the pressure vessel  9 . At the downstream end of the conduit  9 , a driveshaft  28  is centrally located in end cap  25 . A connection to pressure vessel  9  is located on the downstream underside of pressure vessel  9  to connect to a receptacle  31 . A driveshaft  32  is mounted to receptacle  31 . Gas injection ports  4 ,  20 , and  24 , for example, are provided and an exhaust port  14 , is located centrally and on the upper side of pressure vessel  9 . 
         [0019]    Referring now to  FIG. 2 , a cross section illustration through the apparatus  100  shown in  FIG. 1  is provided. Port  2  allows the pressurized transfer of boneless meat in the direction shown by arrow  1 , and into the pressure vessel  9 . Boneless meat is transferred therein, under pressure, by pumping means such as with a meat pump manufactured by Marlen. Meat is transferred in the direction shown by arrow  1  continuously and at an adjustable mass flow rate. Endplate  7  is attached to pressure vessel  9 , by suitable means such as bolts, and gas ports shown as  5  and  4  provide for the injection of selected gases, such as ozone or carbon dioxide, both of which may be in atomized solution form, wherein the quantity of ozone and water is injected at a variable and precise rate, and generally according to the mass flow of boneless meat transferred into the pressure vessel also. At the downstream end of pressure vessel  9 , endplate  25  is securely attached and sealed, and is arranged with driveshaft  28  centrally disposed on endplate  25 ; driveshaft  28  is attached to Archimedes screw  8 , which is located inside pressure vessel  9  in such a way that, when shaft  28  is rotated, the flights of Archimedes screw  8  rotate in close proximity to the internal surface of conduit  9  but do not touch the internal surface. As the screw  8  is rotated, boneless meat is transferred through pressure vessel  9 . As the meat is transferred along a substantially horizontal path, boneless meat is rotated thereby exposing all surfaces of the meat to gas also injected into pressure vessel  9 , thereby allowing for the killing of bacteria that may be present at the surfaces of meat by contact with the ozone solution and ozone gas. Ozone gas is injected at a suitable pressure that may be at 25 psi, or as high as 200 psi or more, and in volumes adequate to substantially ensure killing of surface bacteria on the meat. Ports  20  and  19  are also provided and ozone gas can be injected therethrough in the direction of arrows  10  and  11 . Additionally, a precisely measured quantity of water may be injected via an atomizing injection device (not shown) directly into the pressure vessel  9 . The water can be any amount. In some instances, the amount is any amount that exceeds the regulated allowable quantity of water in meat, for example. However, the water content in beef can be reduced with a gas as will be described below. The amount of water introduced can be metered and regulated. The water injection devices can be located adjacent the ozone injection ports  19  and  20 , for example, such that ozone gas can dissolve into the atomized water. In this way, the dissolved ozone gas will provide a solution of ozonated water that can then contact the boneless meat&#39;s surfaces. Therefore, both ozone gas and ozonated water in an atomized condition will be present in the free spaces in the chamber of vessel  9  such that the gas can dissolve in the moisture on the meat&#39;s surfaces. Additionally, ozonated water will also be available to increase the quantity of ozone that contacts the meat&#39;s surface. In order to satisfy hazard analysis and critical control point (HACCP) requirements for meat decontamination processes, ozone measuring (monitoring) devices can be located at the point of ozone entry into the chamber  9  and even inside the ports such as  4  and  5 , for example, so as to provide a reliable means of measuring the concentration of ozone gas at the entrance to vessel  9 . An additional ozone measuring (monitoring) device(s) can be located at the point of gas exhaust from the chamber  9  and inside the exhaust port  14  so as to provide a reliable means of measuring the concentration of ozone gas at the point of exhaust and after it has been transferred through the chamber  9 . In this way, when all relevant conditions such as temperature of the meat and the mass flow of the meat transferred through the chamber  9  are known and maintained within acceptable ranges, a reproducible process of decontaminating meat can be specified by controlling the quantity of ozone that is transferred into the chamber  9 . A large proportion of the ozone gas that is provided into chamber  9  through ports, such as ports  4  and  5 , will decompose into oxygen gas but a quantity may survive and therefore be exhausted via port  14 . The bactericidal effectiveness of the ozone gas during its passage through the chamber  9  can be determined by the quantity of ozone gas that remains in the exhausted gases through port  14 . In this way, a reproducible process of decontaminating meat that meets the HACCP standards, for example, can be developed and maintained. Ports  18 ,  38 , and  40  are located immediately downstream from exhaust port  14 , and a suitable gas that has, for example, been pretreated, such as by compressing, filtering and chilling, is injected therethrough in the direction of arrows  17  and  39  (arrow for port  40  not shown). Gas injected through ports  18 ,  38 , and  40  can be chilled and dried thoroughly; and such gas may be filtered air, and injected at a pressure equal to other gases that are injected into pressure vessel  9 , through other gas injection ports, such as ports  4  and  5 . The purpose of injecting a dry gas, such as air, through ports  18 ,  38 , and  40  is to dry and to reduce to a desired level the quantity of water that has been injected with ozone gas, through ports  5 ,  4 ,  20 , and  19 , for example. In some instances, the dry gas will reduce the amount of water in the vessel to produce a water content in the meat that is acceptable. The amount of dry gas can be metered and regulated in a specific amount. The dry gas injected through ports,  40 ,  38 , and  18  will become saturated with water vapor, which will then be carried out of pressure vessel  9 , through exhaust port  14 , and in the direction of arrows  15  and  16 . Ports  21 ,  24 ,  26 ,  41 ,  42 , and  44  are provided to allow the injection of other selected gases, such as carbon dioxide, at a pressure equal to the injected pressure of other gases that are injected into pressure vessel  9 . Carbon dioxide injected into these ports may be in atomized and chilled and be in solution form, where the carbon dioxide has been dissolved in water, under pressure, thereby producing carbonic acid that is then atomized prior to injection into pressure vessel  9 . Such carbonic acid, which may have a pH of approximately 3.7, will provide additional sanitizing capability by killing bacteria that may have been injured by ozone injected upstream, or alternatively any bacteria that have escaped contact with ozone at the upstream end of pressure vessel  9 . Exhaust port  14  is centrally located on the upper side of conduit  9 , and has a pressure regulator  13  fitted thereto. Unused ozone gas, oxygen, moisture-laden air, and carbon dioxide or other gases will escape through exhaust port  14 , at a preset pressure, such as 200 psi. However, the pressure within vessel  9  may be at more or less than 200 psi, and is most preferably at an optimum pressure that will maximize death of bacteria that may be present at the surface of the boneless meat being processed in the apparatus. Exhaust gas escapes in the direction shown by arrow  12 , and may be vented to atmosphere or bubbled through water, and cleaned prior to exhausting to atmosphere. When used in the manner hereinabove described, the apparatus shown in  FIG. 2  will not only process boneless meat at a controlled mass flow rate, and in doing so kill bacteria contained therein, it also provides a means of adjusting, with precise accuracy, the amount of water added to the boneless meat. For example, a mass flow of boneless meat equal to “x” pounds per hour, can be injected into pressure vessel  9 , through port  2 , and a quantity of water equal to 10% of “x,” for example, can be injected through gas injection ports, with the ozone gas and/or alternatively, with carbon dioxide gas. However, dry chilled air (or nitrogen gas), or any other suitable gas that is chilled and dried prior to injection, can be injected at such a rate that will vaporize the equivalent of half of the water transferred therein, and carry this vaporized water out of pressure vessel  9  through exhaust port  14 . Therefore, in this way, a quantity of water equal to 5% of the volume of meat transferred therethrough, will be retained with the meat as it is transferred out of pressure vessel  9 , and into receptacle  31  in the direction of arrows  36 . To this end, injection ports for meat, ozone, dry gas or any other injection port can be fitted with a measuring instrument. A driveshaft  32 , with Archimedes screw  33 , is arranged to rotate and compress boneless meat into a single stream and directly into a coarse grinding plate, and in the direction of arrows  34  and  35 . The rate of mass flow of coarse ground meat is equal to the rate of boneless meat transferred into pressure vessel  9  through conduit  2 . 
         [0020]    Referring now to  FIG. 3 , a plan view of a plant layout is illustrated. The equipment detailed in  FIG. 3  is arranged to automatically sanitize or wash, grind, and proportion boneless meat with a selected lean to fat ratio. Combination dumpers  201  and  202  transfer boneless meat, in the direction shown by arrows  203  and  204 , into conduits  205  and  206  via meat pumps  255  and  256 . A supply of low fat content boneless meat is loaded at combination dumper  201 , and a supply of relatively high fat content boneless meat is transferred in the direction of arrow  204 , by dumper  202 . Meat transferred in the direction shown by arrow  203 , is pumped by pump  255 , through conduit  205 , and through x-ray fat measuring device  207 , toward valve  209 , and boneless meat is transferred in the direction of arrow  204 , by pumping into conduit  206 , by meat pump  256 , through x-ray fat measuring device  208  and toward valve  209 . Valve  209  is arranged to combine the two streams, or alternatively divert only meat from either stream  203  or stream  204 , according to the measured fat content of each stream. Therefore, a single stream of meat is transferred directly into conduit  215 , and transferred into meat processing apparatus  214 , which is the apparatus described in connection with  FIGS. 1 and 2  hereinabove. Gas injection ports  210 ,  211 ,  212 ,  213 , and  220  allow selected gas injection in the direction of dotted arrows associated with each port. Processed boneless meat is then transferred through receptacle  219 , into coarse meat grinder  218 , and through x-ray fat measuring device  217 , and into conduit  222 . Conduit  222  is arranged to hold a predetermined quantity of boneless meat and is connected directly to diverter valve  223 . Diverter valve  223  is arranged to directly transfer coarse ground meat from conduit  222 , into any one of three conduits shown as  224 ,  225 , or  226 . The selection of any of the conduits  224 ,  225 , and  226 , is made according to the measured fat content continuously transferred through conduit  222 , and according to the fat content measured by x-ray fat measuring device  217 . In this way, a stream of boneless meat can be transferred along conduit  224 , wherein the stream of meat has a relatively high level of fat. Alternatively, a stream of meat with a relatively low fat content can be transferred into conduit  225 . In the event that any quantity of boneless meat has a level of fat content that is greater or lower than is acceptable, it can be transferred through conduit  226  into silo  227 . Most preferably, the boneless meat stream directed through conduit  225  will be of relatively high fat content. The stream of meat transferred through conduit  224 , is delivered into preblender  240 , where it is blended and treated with liquid carbon dioxide. Similarly, boneless meat transferred along conduit  225  is delivered into preblender  229 , where it is also blended and chilled with liquid carbon dioxide. Carbon dioxide gas is collected at locations  231  and  230 , and tested for its purity. If testing shows that the carbon dioxide gas is substantially free of any other gases, such as atmospheric oxygen, it can be diverted to compressor  239  and stored in pressure vessels  243  until required for further use. Such further use may be in processing pressure vessel  214 . In which case, the pressurized CO 2  gas can be transferred along conduits  244  and  245 . Blended, coarse ground meat is transferred into continuous blender  234 , from preblender  240 , through x-ray fat measuring device  232 , at a rate that is determined by the fat content as measured in x-ray device  232 . Preblended boneless meat is transferred into continuous blender  234 , from preblender  229 , through x-ray fat measuring device  233 , at a flow rate that is determined by fat content measured by device  233 . A continuous single stream of blended boneless, coarse-ground meat is transferred from continuous blender  234 , along conduit  236 , through x-ray measuring device  235 , and into diverter valve  237 . Coarse-ground meat produced to specification is then diverted into either conduit  248 ,  247 ,  246 , or  257 , according to its measured fat content. Any such coarse-ground meat that does not meet specification, to the extent that its fat content is too high or too low, will be transferred into silo  238 . Coarse-ground meat that has been produced according to requirements will be transferred into silos  249 ,  250 , or  251 , and retained therein, until required for further processing when the stored coarse-ground meat will be transferred from each silo, through respective conduits  254 ,  253 , and  252 . Any ground meat that does not meet specification and therefore has been transferred into silo  238  is then gradually transferred along conduit  228 , into blender  227 . Boneless meat that is stored in  227  is gradually transferred at a slow rate, into preblender  229 . It should be noted that the entire apparatus shown in  FIG. 3  has an atmosphere maintained within it that substantially eliminates the presence of oxygen gas, and is maintained at substantially 100% carbon dioxide. It should be noted that x-ray measuring devices  207 ,  208 ,  217 ,  232 ,  233 , and  235 , can be arranged to provide a sanitizing effect on the boneless meat that is transferred therethrough by elevating the intensity of x rays to the extent that bacteria is injured or killed as it passes therethrough. In this way, a systematic and gradual reduction in bacteria can be achieved, without the need for exposing the meat to a single source of x rays, sufficient to kill bacteria in a single step. X-ray measuring devices may also be configured to measure flow rate as well as any other meat attribute, including fat content. 
         [0021]    While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.