| 1. | Method for the preparation ot foodstuffs (1), more in particular meaiε (2) hy: a) heating the foodstuffs (1, 2) until nearly done; D) putting the prepared foodstuffs (1,2) into a ciosabie wrapping (3), after cooling; c } filling the wrapping (3; with a N. and CO. mixture; d) closing the wrapping (3); and e) submitting the foodstuffs (1,. |
| 2. | ) to a thermical shock, by rapid cooling, by which the temperature in the heart reaches a temperature of about 2°C, characte¬ rized in that successively after the heating until nearly done under step a), the prepared food stuffs (1, 2) are being submitted within reasonably short notice to tne tnermicai shock under step e), under controlled relative humidity, to be named RH nereatter, depending on the nature of the foodstuff (1), after which a W./CO. mixture is inserted in the closahle wrapping (3) in an appropriate way. |
| 3. | 2 Method according to claim 1, characterized in that the heating of the foodstuffs (1, 2) happens entirely or partially high frequency. |
| 4. | 3 Method according to claim 2, characterized in that the frequency applied is 915 MHz, to be indicated further as radiowave frequency. |
| 5. | Method according to each of the previous claims, charact i∑ed in that potatoes and or pasta and/or vegetables are heated in a steam heater. |
| 6. | Method according to eacn or the previous claims, characte¬ rized in uiά aroma components, flavourings, nerns, spices and salt are added to the roodstufts (.1, 2). |
| 7. | Method according to each of the previous claims, characte¬ rized in that meat (4), and/or fish (41) is added to the foodstuffs (1, 2), of which the surface is seared up in an infrared oven (5) preferably after seasoning. |
| 8. | Method according to each of the claims 1 including 6, characterized in that sauces (6) are added to the foodstuffs i, 2, which are supplied to the cooiing directly without extra heating. |
| 9. | Method according to each of the previous claims, characte¬ rized in that the ioodstufis (1, 2) contain vegetables (8), which is being heated as needed in a steam heater (7), micro wave heater (9) or radio wave heater (10). |
| 10. | Method according to each of the previous claims, characte¬ rized in that the foodstuffs (1, 2) contain meat that has been seared up in an infrared oven (5), which is heated in a microwave heater (9) . |
| 11. | Method according to each of the previous claims, that the foodstuffs (1, 2) do or do not contain fish that was seared up in an infrared oven, which is conducted according to desire through the steam heater (7) or the microwave heater (9). |
| 12. | Method according to each of the previous claims, characte¬ rized in that the foodstuffs (1, 2) contain sauces (6), heated separately during preparation, to a temperature of at least 80°C during five minutes and transported separately to the wrapping (3), which is cooled down thereafter, provided by a CO /N, atmosphere and closed. |
| 13. | Method according to each of the previous claims, characterized in that the closable wrapping (3) is filled with a mixture of 3040 volume percent CO. and the rest N.. E SHEET . |
| 14. | Method according to each of the previous claims, characterized in that the starting point is foodstuffs (1, 2) originally at 13°C, preferably at 2°C, which are heated afterwards. |
| 15. | Method according to each of the previous claims, characterized in that the wrapping (3) is vacumated with foodstuffs (1, 2) before filling it up with the CO. and N. mixture. |
| 16. | Method according to eacn of the previous claims, characterized in that as material for the wrapping (3) PEΪ, preiarably cPET is applied. |
| 17. | Packed prepared meals (1,) and/or meals (2) in a closed wrapping (3) treated according to one or more of the claims 1 to 15. |
| 18. | Packed prepared meals (1) and/or meals (2) according to claim 16, characterized in that the wrapping (3) consists entirely or mainly of cPET, with a thickness of 0,3 to 0,4 mm and size per foodstuff (1) of 10x17x5 cm. |
| 19. | Packed prepared foodstuffs (1) and/or meals (2) according to claim 16 or 17, where the foodstuff (1, 2) is provided with sauce (6), characterized in that the sauce (6) is in trays of cPET size 5xbx3 cm. |
| 20. | Device for the preparation of prepared foodstuffs (1) or meals (2), which are in a wrapping (3), according to claims 1 18, which device contains means for quickly heating and there¬ after quickly cooling down of the foodstuffs (1) and/or meals (2), characterized in that this contains a cooling device (11) with means for controlling of the RH during cooling down. |
| 21. | Device according to claim 19, characterized in that the cooling device 11 is a cooling tunnel. |
| 22. | Product line for the preparation of prepared meals (2) according to claim 118, characterized by the fact that this contains the now followinging phases with means of treatment: I Reception foodstuff (1) raw materials, inclusive of quality control II Preparation in meal (2) component streams; III Preparation of meal (2) components; IV Control on preparation of meal (2) components; V Process step, containing searing up of meat (4; and optionally of fish (4') in infrared oven (5j followed by putting into trays and treatment ot prepared foodstuffs (1, 2, 4, 4', 6, 8) respective¬ ly in steam heater (7), microwave heater (9) or radio wave heater (10), followed by cooling down in a cooling tunnel (12) with means for the direction of the RH, depending on the foodstuff (1) concerned, followed by the filling of the trays (3) with a CO. and N. mixture, closing of the trays (3) and microbio¬ logical quality control; VI Weight control and labelling, joining into meals (2), including general quality control and stacking; VII Storage of ready meals (2). |
Tne interest tor freshly cooled reaαy ior use mea^s grows steadily these days.
Freshly cooled ready for use meals are meals that are mainly, but not exclusively, without artificial additions ' , ike pre¬ servatives or anti-oxydant limitidly preservable in the refri¬ gerator. Before final consumption, the prepared product, which has received a treatment that exists amongst other things of heating until nearly done, only has to he reheated. The rehea¬ ting often takes place in a micro wave oven.
In connection with preparing preservable foodstuffs for con¬ sumption, a method is known from European Patent 0230978 for packing with pasteurisation of foodstuffs that can taint. The above mentioned method consists of stewing the foodstuff with a temperature around 90-95° C, inserting the product directly under natural convection so that cooling takes place in the wrapping, during whicn according to wish t " . or a mixture of . and O. is inserted, closing the wrapping and finally sunmitting the foodstuff to a thermical shock which brings the foodstuff in the center to a temperature of 2-6°C.
When one indicates in the continuation of the specification the preparation of foodstuffs with 1, and an assembly of foodstuffs and meals with 2 that are contained in a wrapping 3, it is remarked that with the eals prepared by the method known from the above mentioned EP 0.230.978, after heating and opening the wrapping 3 most probably no foodstuffs or meals can be prepared with Michelin two star quality.
With prepared meals of Michelin two star quality, meals are meant with an excellent taste and good microbiological tenabi- lity, wnich can be stocked at a low temperature, i.e. around 2 C C, and can be prepared by the user by simply heating of the wrapping 3 witn contents 1, 2.
According to said EP 0.230.978, foodstuffs 1, and more in particular meals 2, can ϊ>e prepared by subjecting tnese sue-
SUBSTITUTE SHEET
cessively to the following process steps: a) heating the foodstuffs 1,2 until nearly done; b) inserting the neated ooαstuffs 1, 2 after cooling down into a wrapping 3 that can be closed; c ) filling the wrapping 3 with a mixture ot N_ ana CO.; d) closing the wrapping 3; and e) subjecting the foodstuffs 1, 2 to a thermical shock by fast cooling down, in such a way that the temperature in the hart reaches a temperature of about 2°C.
Such as mentioned earlier this method most probably does not result into prepared meals and/or foodstuffs of the high Michelin two star quality.
The object of the invention is to remove the mentioned objec¬ tion by subjecting the heated foodstuffs 1, 2 within a short term after heating until nearly done below above mentioned step a) to the thermical shock mentioned below ej, by cooling under controlled relative humidity, to be named RH in the following, depending on the nature of tne fooαstuft 1, after which a mixture of N. and CO. is inserted into the closable wrapping and the closing takes place.
About the RH, which is dependent on the nature of the food¬ stuff 1, is remarked that in case of meat, this amounts to about 75% and in case of vegetables 80-90%.
The invention also relates to prepared foodstuffs 1 or meals 2 and also to a production line and pertaining device for the preparation thereof.
By having the fast cooling down taking place soon after the heating to nearly done under controlled RH, an excellent taste is maintained of the foodstuffs I or meals 2 tnat are ultima¬ tely prepared by the user.
By inserting a suitable mixture of N and CO i. in the closed
meals 2 is ensured. It is remarked that from EP 0.242.183 a method is known for conditioning and packing of mussels and other bivalved seefood. According to this known method, mus¬ sels are brought into a wrapping which encloses these mussels closely and prevent them to open, during the following cooking process, in which the mussels are partially cooked.
After the partial cooking, the packages of mussels are cooled down to ambient temperature, during which the mussels either stay at ambient temperature or are frozen.
In connection with the method known from the EP 0.242.183, it is remarked that the conservation of the exceptionally fine taste of the ultimate product is obtained by causing the mussels to keep their shells closed during the relatively short precooking process. In order to increase the tenability of the mussels, in general freezing should always take place.
A difference with the etnod according to the invention is, that it is quite sure that no mixture of N. and CO. is applied, because before tne cooκ.ing tne mussels are provided with a deep drawn plastic vacuum wrapping.
It stands to reason that with the preparation of mussels no fast cooling down under controlled RH is applied.
In view of the known state of art it is not evident that the proper sequence of essentially very simple measures as cooking until nearly done, followed by fast cooling down under con¬ trolled RH, which is dependant of the foodstuff 1 or mealcom- ponent 2 in question, and providing with an ad osphere in the closable wrapping 3 essentially consisting of a mixture of N. and CO., results in prepared foodstuffs 1 or meals 2 of Miche¬ lin two star quality, which have moreover an exceptionally good tenability, without strong cooling.
Preferably, the heating of the meals will completely or partly
take place by microwave, with the exception of the case that the foodstuffs 1 consists of pasta or potatoes.
A preferred frequency that is applied during the high frequen¬ cy heating or microwave heating is 915 MHz.
At the frequency of S15 MHz the deptn of penetration or the microwaves is increased until about 10 cm. The increased depth of penetration causes a more uniform heating ct the complete foodstuff 1.
An increased depth of penetration is the more important if the separate parts of the foodstuffs 1 have an irregular shape
The frequency of 915 MHz will further be indicated as radiowa- ve frequency.
Because of the lower frequency than with the usual heating methods with high frequencies, the available power is limited, through which the method is limited to foodstuffs requiring only temperatures to 90°C.
With foodstuffs, of which the separate parts are irregularly shaped, and/or require a higner preparation temperature, a more usual high frequency device can be applied, which opera¬ tes at a frequency of 2480 MHz. A heating device operating at a frequency of 2480 MHz will be further indicated below as a microwave device.
Potatoes, pasta products and some vegetables require an am¬ bient water vapour during the heating until nearly done.
A preferred method for the application of the heating is the use of a steam heating tunnel 7, in which steam of 100-120°C is injected.
More in particular, when the foodstuffs 1 or meals 2, comprise
meat 4 ana in some cases fish 4 " ' , preferably these are seared up in an infrared oven 5, after seasoning the surface.
Ihe seasoning of the meat 4, of fish 4 ! can be done manually or continuously, with which one preferably uses a "seasoning bath". The seasoning hath consists of an emulsion containing the fish or meat seasonings.
After the seasoning of the surface of the meat 4 or the fish 4', these foodstuffs 4, 4' are submitted to the usual conditi¬ oning according to the invention. The searing up serves the conservation of the juices of the meat 4 or the fish 4' and obtaining a good crust.
In case of complete meals 2, these contain often sauces 6, which are directly supplied to the cooling down after prepara¬ tion in which heating takes place.
In case that the foodstuffs 1,2 comprise vegetables 8, these are heated as needed in a steamheater 7, a microwaveheater 9, or a radiowaveheater 10. The meat 4 or fish 4' that nas been seared up in an infrared oven 5, are preferably heated in a microwaveheater 9 in connection with the uniform heat develop¬ ment therein.
It is also possible to lead the seared up or not seared up meat 4 or the fish 4 1 through the steam heater 7 or the micro¬ wave heater 9, as needed.
In connection with the sauces 6 which are added to the food¬ stuffs 1, 2 it is further remarked, that during the preparati¬ on these are separately heated to a temperature of at least 80°C during 5 minutes, before the transport to the wrapping 3 which is thereafter cooled, provided witn a CO. - N. atmosphere and closed. This with a view to pasteurization.
- b -
The preferred composition of the gas mixture with which the wrapping 3 is filled, is 30-40 volume % CO. and the rest N..
Preferably, when heating the foodstuffs 1, 2 , one starts from cleaned raw materials, which are at a temperature of 1-3°C, preferably 2°C.
According to another preferred method, the wrapping, in which the heated arid subsequently cooled down foodstuffs 1, 2 are present, is first vacuumed and afterwards filled with the CO -. -
N. gas mixture.
By the vacuum treatment the oxygen which gives rise to perish promoting bacteria and the germination of spores, is removed as much as possible.
A preferred material for the wrapping 3 is PET, preferably c- PET. The term c-PET means crystalline polyethylene terephta- late (Bordex, 1990).
In view of the method of preparation of the foodstuffs 1, the material for the wrapping 3 has to meet the following de¬ mands :
- to be suited for use in microwave and oven ("duo ovena- ble")
- to dispose of good barrier properties, so that the quali¬ ty of tne prepared meal deteriorates as iittie as possible during storage and transport;
- to remain firm during heating, cooiing and transport, ana not to deform;
- to be able to resist sudden temperature changes
- to be well closable "sealing"
- to be as little burden to the environment as possible, and preferably recycleable
The material c-PET is £>eing preferred because: it is duo-ovenable - it disposes of good barrier properties with respect to other wrapping materials;
c-PET transmission with respect to:
- 0, = 30.10 '* cm/cm s cm Hg
- CO 1 = 100.10 -Y * ' cm/cm2 s cm Hg
- H.O - 4.10 l cm/cm s cm Hg
(for 0, and CO. these values are measured at 23°C and 30% RH, i l for H„0 was measured at 37,8°C and 90-95 RH) .
The c-PET is used in a thickness of 0,3-0,4 mm preferably at the wrapping 3.
As mentioned before, the invention also relates to wrapped prepared foodstuff ' s 1 or meals 2 in a closed wrapping 3 and prepared according to the method discussed.
Preferably, the separate foodstuff components 1 or parts of meals 2 , are in trays of c-PET with a thickness of 0,3 - 0,4 mm and a dimension per foodstuff 1 of 10x17x5 cm.
The one and the other relate to process technical considerati¬ ons for causing the necessary thermical shock in order to obtain unexpected good taste properties.
For the same reason as mentioned above, when the meal 2 com¬ prises sauces, this sauce 6 is in c-PET trays with a dimensi¬ on of 5x5x3 cm.
Such as also mentioned before, the invention also relates to characterising apparatus for the preparation of foodstuffs 1 and/or meals 2 and a production line therefore.
From the document FR-A-2.54 .179 an apparatus is known for the preparation and pasteurisation of packed foodstuffs. According tc the method known from FR-A-2-544-179 , foodstuffs that are
under vacuum in their wrapping, are shortly heated by immersi¬ on in a cooking or stewing bath and subsequently guicklv cooled down to about 2°C by immersion in a cooling bath. It is remarked that by the vacuum treatment followed by hea¬ ting and cooling down in a wrapping, undesired changes of taste can easily occur. Moreover, the tenability of foodstuffs 1 or meals 2 is most probably snorter than in the case where a N - CO gas filling is applied.
A characteristic device for the application ot the important cooling down step arter the short heating step, is a cooling device 11 with means for controlling the RH during the cooling down of the foodstuffs 1 or meals 2.
Preferably, the cooling device 11 is a cooling tunnel 12, with means for controlling the RH. The control of the RH can be made by spraying water in a controlled way.
The invention also relates to a production line for the prepa¬ ration of prepared meals 2, comprising the now following steps I-VII with, conditioning means for:
I Reception of raw materials for foodstuff I inclusive of quality control;
II Preparation in component streams of meal 2;
III Pre-conditioning of components of meal 2;
IV Checking of preparation of components of meai 2;
V Process step, comprising searing up of meat 4 and optio¬ nally of fish 4 'in an infrared oven 5, followed by filling in trays 3 of prepared foodstuffs 1, 2, 4, 4', 6,
8 and insertion in a steam heater 7, microwave heater
9 or radio wave heater 10, respectively, followed by cooling down in a cooling tunnel 12, with means for controlling the RH, dependant of the foodstuff 1 in question, followed by filling the trays 3 with a mix¬ ture of CO. and N., closing the trays
3 and checking the microbiological quality; I Weight check and labelling, combination to meals 2, in-
elusive general quality control and stacking; VII Means for storage and transport to user of prepared meals 2.
At the above mentioned phases, reception and quality control means of raw materials for the meals 2 are indicated under I by A.
At the following phase II, the distribution of streams of potatoes 13, pasta 14, fish 4', meat 4 and sauce components 6" are indicated by respectively 13, 14 (II), 8 (17), 4' (II) and 6 " (II)
Furthermore, at the prepreparation stage III, successively is indicated from left to right with
- 13 (III) the preconditioning of the potatoes 13, consis¬ ting of scraping, pealing, washing, immerse into water with eventual adding of salt;
- 8 (III) the preconditioning of the different vegetables consisting of cutting, washing, eventual adding of spi¬ ces;
4' (III) the adding of pepper, salt and eventually fish seasonings to the fish 4';
- 4 (III) the adding of pepper, salt and eventual meat seasonings to the meat 4;
- 6 (III) the mixing of the sauce components 6" to the sauce 6.
With reference to the process between quality judgment phase IV, the now following phases refer to:
13, 14 (IV) considering whether the potatoes 13 meet the quality requirements and are provided with salt and sufficient water; 8 (IV) considering whether the different vegetables 8 meet the quality requirements and furthermore are well cut and mixed; 4' (IV) considering whether the fish 4' is well seasoned;
4 (IVj considering whether the meat 4 is well seasoned; 6 (IV) considering whether the sauce 6 is well prepared.
In the process phase V, the following descriptions indicate:
- 4', 4 (V) 5 the searing up of fish 4' , eventually optio¬ nal, and also optional of meat 4 in the infrared oven 5;
- 13, 14 (V) 3 the putting into trays 3 of respectively preconditioned potatoes 13 and pasta 14;
- 8 (V) 3 the putting into trays 3 of vegetable 8;
4' (V) 3 the putting into trays 3 of preconditioned fish
4'; 4 (V) 3 the putting into trays 3 of preconditioned meat
4;
- 6 (V) 3 the putting into trays 3 of sauce 6.
ith reference to the process step 6(V; 3, it is noticed that at the reaching of sufficiently high cooking temperatures in connection with the necessary pasteurization, it is possible now to directly connect the trays 3 with sauce 6 to the cool¬ ing step (V) 12 to be treated later.
In connection with the process heating phases of phase V the now following indications can be made.
Some vegetables 8, potatoes 13 and pasta 14 are heated prefe¬ rably in a steam heater 7, this is indicated by 8, 13, 14 (V) 7.
Depending on the sizes and necessary temperatures, some pre¬ conditioned foodstuffs 1 can be best heated in a microwave heater 9, which worts preferably at 2480 MHz, this now is indicated in Figure 1 very generally with i (Vj 9; here it is indicated very generally by 1 that it is about foodstuffs 1.
Other foodstuffs, however, are better heated in a so-called radio wave heater 10, which is indicated in a similar way with 1 (V) 10.
After the heating step of phase V, all eal components are being subjected to a cooling step in a cooling tunnel 12 with means for the control of the RH depending on the foodstuff 1 concerned. This is indicated by (V) 12.
The phase V is concluded by tne filling of the separate boxes 3 3 wwiitthh aa NN.. -- CCOO.. mmiixxttuurree,, aa:fter which these are being sealed
This is indicated by (V) 15.
Before or after the sealing of the trays 3 at the process phase (V) 15, a microbiological quality control is being performed, this is indicated by B.
In the phase VI which relates to the finishing of the meals 2 to be obtained, a combined control of the weight, together with a labelling is being performed under (VI) 16, at which a quality control is performed under C. The phase VI is finished by stacking the obtained meals under step (VI)17.
In the phase VII the stacked meals 2 are finally stored in a warehouse that is cooled, until transportation to the customer takes piace. This is indicated with D.
Figure 2 relates to the heating and cooling down curves as a function of the time m which respectively:
E - potatoes (pom es anna)
F = vegetable (mixed vegetable)
G = fish
H = meat (baking dishes)
I = meat (stewing dishes)
J = coq au vin.
All cuves E, F, G. H, I and J start at time zero at 2°C and end after the passing through of the cooling tunnel 12 also at 2°C.
The data of curve E of potatoes (pommes anna) are as follows Time Temperature Point in graph
Jll E2 E3
Data curve F (mixed vegetable):
Time Temperature Point in graph
Data curve G (fish):
Time Temperature Point in graph
0 mm. 2°C
6 min. I00°C Gl
16,5 mm. 2°C G2
Data curve H (meat frying dishes)
Time Temperature Point in graph
0 min. 2°C
2 min. 100°C HI
16 min. 100°C H2
25 min. 2°C H3
Data curve I (meat stewing dish)
Time Temperature Point in graph
Data curve J (coq au vin)
Time Temperature Point in graph
Jl J2 J3