Patent Publication Number: US-2018027847-A1

Title: Method for Processing a Food Product and Corresponding Processing Apparatus

Description:
BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present invention concerns a method and an apparatus for processing a food product. 
     In particular, the present invention concerns a method and a corresponding apparatus for processing a food product both intended for the production of ready-made food products, to be sold in shops, supermarkets, shopping malls, bars or other type of premises used for the sale of such products. 
     Description of Related Art 
     Due to numerous cultural, organizational and work factors, nowadays life is rather frantic and hurried. 
     This frenzy of contemporary society means that less time is dedicated to food. Indeed, on the counters of supermarkets and the menus on offer in hotels, restaurants, trattorias or bars there is a great increase in fast food, easy to prepare and to serve. 
     A growing demand for such foods has led many food producers in the sector to increase the range and supply of gastronomical pre-packed foods. 
     Indeed, there are more and more bars serving customers pre-packed, already cooked foods which only need heating up or “regenerated” as the jargon goes, ready to eat, considerably limiting the service times. 
     It has been calculated that from the moment the customer (clerk, workman, traveler) enters the premises, sits down and orders, he/she is served within five minutes, while consumption of the dish takes on average ten minutes, and so within about twenty minutes the customer is in and out. 
     It is very convenient for the manager of the eatery to use these commercial products since they avoid many expenses such as:
         managing specialized staff to prepare dishes;   cost of waste in preparation;   cost of waste of products that can no longer be sold.       

     Moreover, the manager of the eatery enjoys many advantages such as:
         limited preparation times;   use of low cost equipment or utensils for the possible regeneration of the food,   almost complete elimination of waste, since only what is ordered is made ready to eat,   greater food-hygiene safety.       

     The dishes that are often offered, above all in eateries such as bars or snack bars, are toasted sandwiches, snacks or salads. 
     To manage a service more like a restaurant, frozen products are used (frozen lasagna, pre-cooked vegetables for example). Products of this type do not have a balanced calorie or dietary contribution, since they are without nutritive properties necessary for our daily quota, they have too many fats and often are not good. Moreover, these pre-packed products must guarantee a certain length in terms of shelf life, which is ensured by using different strategies such as the adoption of physical strategies, such as managing a cold chain, refrigeration or freezing, or using chemical products such as additives or adjuvants. 
     These strategies allow to increase the life of the product, giving advantages from the point of view of food safety and appeal and taste of the product, but to the detriment of the consumer&#39;s health. It is widely agreed that these numerous food products on the one hand ensure food safety, preventing possible illnesses (intoxication, toxic infections or infections), but on the other hand they can, in the long term, cause imbalances in the human body, because of the accumulation of many additives or ingredients. 
     Consumers and managers of eateries therefore request, more and more often, packed foods that are easy to prepare, without preservatives, which respect nutritional, dietary and biological values and which have medium-to-long use-by-dates. 
     These aspects can clearly be traced back to an increasing tendency for more genuine products. 
     The food companies find considerable obstacles in meeting all these requests to ensure a healthy and genuine product from the point of view of hygiene, health and nutrition. 
     For this reason some consumers are diffident in buying ready-made food products since they may not be genuine and can cause damage to one&#39;s health. 
     There is therefore a need to supply food products that are easy to prepare, that do not contain preservatives, that respect nutritional, dietary and biological values and have medium-to-long use-by dates. 
     BRIEF SUMMARY OF THE INVENTION 
     One purpose of the present invention is to achieve a method and an apparatus for processing a food product, both intended to obtain a food product ready and to be regenerated, that has a long shelf life, is highly appealing and appetizing, that does not use additives such as preservatives or flavor enhancers, that respects nutritional, biological and dietary values, that is easy to prepare and/or serve and that ensures a high level of food safety and hygiene. 
     It is also a purpose of the present invention to perfect a method and an apparatus for processing a food product that allows to produce pre-packed gastronomic specialties with no additives or adjuvants, ensuring a long shelf life without necessarily resorting to freezing the food product but maintaining it under cold chain conditions. 
     The Applicant has devised, tested and embodied the present invention to overcome the shortcomings of the state of the art and to obtain these and other purposes and advantages. 
     The present invention is set forth and characterized in the independent claims, while the dependent claims describe other characteristics of the invention or variants to the main inventive idea. 
     In accordance with the above purposes, a method for processing food products comprises:
         a step of preparing a food product during which one or more raw materials, which constitute the food product to be obtained, are worked;   a cooking step during which the food product previously processed during the preparation step is cooked in vacuum mode;   a packing step during which the food product is put in a pack;   a cold pasteurization step during which the food product is subjected to a pressure of at least 3,000 bar; and   a step of preserving the food products at a temperature comprised between 0 and 4° C.       

     The sequence of the above steps allows to obtain a food product that has a long shelf life, is very appealing and appetizing, does not use additives such as preservatives or flavor enhancers, respects nutritional, biological and dietary values, is easy to prepare and/or serve and has high food-hygiene safety. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
       These and other characteristics of the present invention will become apparent from the following description of some forms of embodiment, given as a non-restrictive example with reference to  FIG. 1  which shows a block diagram of steps of the method for processing a food product. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention concerns a method and an apparatus for processing a food product intended for the production of a ready-made food product, to be sold in shops, supermarkets, shopping malls, bars or other type of eatery used for the sale of such products. 
     By ready-made food products we intend to include food products, packaged and already pre-cooked, that require a much reduced regeneration and/or preparation time and are easy and convenient to regenerate and/or prepare for almost immediate consumption. 
     According to one form of embodiment of the present invention, the method  10  comprises a step  12  of preparing a food product during which one or more raw materials, which make up the food product to be obtained, are worked. 
     In accordance with a possible form of embodiment, the preparation step  12  of the food product can be carried out in a preparation station. 
     The preparation step  12 , depending on the raw material processed, can comprise at least one of cutting, pre-cooking, sectioning, weighing the raw material or other operations that persons of skill provide in order to obtain a semi-worked product possibly already ready for immediate consumption. 
     The preparation step  12  can be obtained starting from fresh raw materials or materials that have undergone specific working processes. 
     In accordance with possible forms of embodiment, the equipment used for the preparation step  12  can respect specifications dictated by the main norms of the food sector (for example in Europe, norms 852/04, 853/04 and 81/2008) in terms of cleanliness, healthiness and safety. The personnel employed have a high level of training that includes the sanitary hygiene needs concerning handling of said products. 
     In accordance with the present invention, the method  10  also comprises a cooking step  14  during which the food product previously processed during the preceding preparation step  12  is cooked in vacuum mode. 
     According to a form of embodiment of the present invention, the cooking step  14  can be carried out in a cooking station. 
     The cooking step  14  in vacuum mode, also called “sous vide” is also known as cooking at low temperature. 
     Before the cooking step  14  an operation can be provided to introduce the food product into a container functional to the subsequent cooking step  14 . 
     The container can be defined by an airtight bag approved for cooking. 
     In this introduction operation, the container with the food product is hermetically sealed and air is extracted from it in order to create a physical condition of depression. 
     In accordance with a possible form of embodiment of the present invention, during the cooking step  14  the food product is kept in a vacuum condition comprised between 0.2 bar and 0.5 bar. 
     After the introduction of the food product into the container, the cooking step  14  can include a cooking operation proper, carried out in either a convection steam oven or a Roner. 
     The convection steam oven provides that inside a cooking chamber steam is conveyed, through fans, that can reach a temperature of more than 100° C. 
     The Roner is an instrument equipped with a resistance, a thermostat and a fan. Once the resistance is immersed in a receptacle full of water, the temperature is set by the thermostat and the water is heated; when this has reached a pre-fixed temperature, the container with the food product is immersed therein and one proceeds with the cooking. 
     Independently of the cooking instruments indicated above, each food product developed to be cooked in vacuum mode needs its own times and temperatures, pre-fixed and determined on each occasion on the basis of the specific food formulations of the food product. 
     The cooking modes and parameters must be suitably chosen to improve, both the qualitative aspects (microbiological, shelf life, transfers, texture) and the quantitative aspects (weight loss, labels) of the food product. 
     The cooking step  14  in vacuum mode allows to safeguard to the utmost the freshness, the intensity of aromas, the texture, the taste and the maximum healthiness and safety of the food product, guaranteeing that a food product is obtained that is qualitatively superior in which the preparation is safeguarded from possible sanitary and hygiene damage. 
     The vacuum cooking mode allows to obtain all the above listed objectives with extreme safety, thanks to the fact that:
         the vacuum allows to better preserve the food product; indeed, removing the air and preserving a food product in a hermetic container, allows to eliminate damage from pests (e.g. insects or rodents) and allows to eliminate damage of 50% of the micro-organisms that live only where there is oxygen (e.g. fungi, yeast, and aerobe bacteria), and   with the vacuum cooking technique, moreover, the process can be considered as a “cooking-pasteurization” process: all the bacteria, even anaerobic ones (that live without air) present in the container, are killed during cooking. This is the decisive aspect of the vacuum cooking step  14  to increase shell life.       

     Another extremely important aspect obtained during the above cooking step, is the high quality and freshness of the foods, not obtainable with traditional cooking methods during which the products lose their nutritive properties to bring to our dietary needs, since the food is deprived of a great deal of vitamins (because of the high cooking temperature) that are destroyed by heat. 
     With vacuum cooking, based on low temperatures, a large part of the vitamins which have not been denatured and therefore lost are preserved, the aromas, or more properly the flavors are safeguarded which, trapped in the hermetic container cannot exit and therefore, with this system, the product is full of flavor. 
     Moreover, with the vacuum cooking mode, salt, spices and herbs are less intense with respect to traditional preparations, giving the food the right amount of tastiness with attention paid to the amounts used, therefore respecting dietary rules. This aspect is fundamental not only for healthy people, but above all for those forced to follow low sodium diets (those with hypertension, nephropathy). 
     During the vacuum mode cooking step  14 , the food product also undergoes a pasteurization. 
     The pasteurization can be obtained by imparting a heating to the food product based on heating curves whose development determines the penetration of the heat into the food product subjected to treatment. 
     Merely by way of example, the cooking step  14  can provide reference heat treatments at 71° C. for 30 minutes (calculated in Z 5) that is equivalent to a pasteurization process on the microbial load and value suitable for storing the products at 4° C. Or at 90° C. for 10 minutes (calculated in Z 10) that is equivalent to a pasteurization process on the pathogen microbial load (C. Botulinum) value suitable for storing between 0 and 10° C. 
     These heat treatments ensure that the product can be sold in complete safety and does not cause any harm to the final consumer. 
     The vacuum cooking method allows to obtain at least the following advantages:
         extension of the preservability of food products;   reduction of up to 40% of condiments and fatty materials;   reduction of the waste caused by drying, in the cooking and storage steps, on the surfaces of meats, fish, doughs, vegetables, etc.;   the yield of food products is much higher than in the classic method (about 60% more) with consequent reduction in production costs: a lower drop in weight of the food product cooked in vacuum mode compared to the traditional mode, is equivalent to a lowering of costs;   increase in flavor since the food is cooked in vacuum mode and the flavors and aromas are not lost;   improvement of the visual appearance thanks to cooking at low temperature: the color of the food product remains the same since there is no oxidation, particularly in vegetables with chlorophyll (which is inactivated at 108° C.) which remain a natural green and not a faded yellow;   optimization of portions;   increase in yield, given that in order to be able to extend the preservation of the food for as long as possible, food purchases will be mainly oriented toward seasonal products, in order to ensure the best quality from a nutritional point of view, at the same time obtaining the economic advantage determined by considerably lower prices thanks to a greater availability of the products on the market;   reduction in energy consumption due to the use of lower cooking temperatures compared to traditional ones;   planning of production as a function of the extended time for the preservation of the products; and   rationalization of the use of cold stores with the possibility of reducing their number.       

     In accordance with another aspect of the present invention the method  10  comprises a cold pasteurization step  18  during which the food product is subjected to a pressure of at least 3,000 bar. 
     In accordance with possible solutions, the cold pasteurization step  18  can provide to take the food product to a pressure of about 6,000 bar. 
     Merely by way of example, the cold pasteurization step  18  can last a few minutes, for example from five to ten minutes. 
     In accordance with other forms of embodiment of the invention, during the cold pasteurization step  18  it is provided that the food product does not exceed a temperature near to room temperature. 
     The cold pasteurization step  18  has the function of irreversibly damaging the microbial cells present in the food products and stabilizing microbiologically both solid and liquid foods. 
     The high pressures reached in the food product during the cold pasteurization step  18  allow the destruction of the micro-organisms and/or favorable modifications to the texture of the food, which maintains at the same time all its nutritional and organoleptic characteristics thanks to the absence of thermal deterioration. The food product will thus have a fresher aroma and flavor compared with the same food subjected to heat pasteurization. 
     The cold pasteurization step  18  can provide for example to insert the food product in a chamber resistant to high pressures, and to induce in the latter a high pressure suitable to crush and completely eliminate any possible bacterial vegetative form present therein. 
     In accordance with possible solutions, the high-pressure cold pasteurization step  18  can also be used for foods such as fruit juices, milk and dairy products, meat, fish and wine products etc. 
     According to one form of embodiment of the present invention, the cold pasteurization step  18  can be carried out in a pasteurization station. 
     The cold pasteurization step  18  comprises a propaedeutic operation of inserting the food product in a container for its pasteurization, for example a bag, a tray or other. 
     In accordance with another aspect of the present invention, the method comprises a packing step  16  during which the food product is packed in a pack. 
     The pack can comprise at least one of either a bag, a plastic wrapper, a tray, or similar or comparable packs. 
     The pack can have different formats, for example single portion or multi portion, depending on the particular distribution requirements. 
     The packing step  16  can be done in a packing station and the latter can be equipped to this purpose at least with a heat packer machine. 
     According to possible solutions, the heat packer machine can be the Skin type, that is, configured to generate a vacuum pack in a tray in which an upper layer of cling film is made to adhere to the product, as if it were a second skin. 
     In accordance with another aspect of the present invention, the packs can all be made of plastic material and therefore the waste deriving therefrom is homogeneous, facilitating the process of disposal and recycling. 
     In accordance with other forms of embodiment of the present invention, the packs are suitable for microwaves, which makes them particularly suitable for the regeneration process of the food product before serving it to a customer. 
     In accordance with a possible variant form of embodiment, the packing step  16  can be carried out before the cooking step  14 . In this way the container used for the cooking step  14  is the same as that then used for the subsequent cold pasteurization step  18  and defines the pack which subsequently the food product is supplied to the distribution chain. 
     In accordance with another variant form of embodiment of the present invention, the packing step can be carried out before the cold pasteurization step  18  and after the cooking step  14 . 
     In this case, after cooking, the food product is removed from the container inside which it has been cooked and introduced into the pack that is functional both for the cold pasteurization step  18  and the subsequent preservation of the food product before its consumption. 
     In accordance with another variant form of embodiment of the invention, the packing step  16  is carried out after the cooking step  14  and after the cold pasteurization step  18 . 
     In this case the pack in which the food product is inserted is particularly suitable for the subsequent steps of preservation, transport and introduction onto the market of the food product. 
     For example, the pack can include indications as to the ingredients, provenance, nutritional value, weight etc. of the product. 
     According to possible forms of embodiment of the present invention, the packing step  16  of the food product can comprise, as well as packing the food product in a pack, the packing of the packs in secondary packs in order to identify the food product for example. 
     In accordance with the present invention, the method  10  comprises a step  20  of preserving the food products at a temperature comprised between 0 and 4° C., preferably at a temperature comprised between 0 and 1° C. 
     Respecting these temperature values of the food product avoids the possibility of freezing the food product, and therefore guarantees that the organoleptic properties of the food products are maintained. 
     Moreover, keeping the temperature at no more than the range of temperatures indicated above allows to preserve the preservation characteristics of the food product. 
     According to possible solutions, the preservation step  20  can also occur at the same time as the transport step of the food product, for example on its way to distribution to various shops, supermarkets, bars etc. 
     During the preservation step  20  a substantially continuous, direct or indirect, detection of the temperature of the food product can be provided. 
     Merely by way of example, and in accordance with a possible variant form of embodiment of the present invention, a device to detect the temperature over time can be associated to the pack of the food product; such devices, also known as data loggers, are configured to detect and memorize data relating to the temperatures of the pack, for example during transport. 
     The data memorized can be transmitted to and processed by electronic devices, a smartphone for example, in order to verify that the temperature values during the preservation step  20  have been respected. 
     The preservation step  20  can occur in a preservation station that, merely by way of example, can comprise at least one of either a cold store, a food transport vehicle or suchlike. 
     It is clear that modifications and/or additions of parts may be made to the apparatus for processing a food product as described heretofore, without departing from the field and scope of the present invention. 
     It is also clear that, although the present invention has been described with reference to some specific examples, a person of skill in the art shall certainly be able to achieve many other equivalent forms of apparatus for processing a food product, having the characteristics as set forth in the claims and hence all coming within the field of protection defined thereby.