A process for processing protein product involves providing a meat product in a raw state, searing at least one outside surface of the meat product so that the meat product, save for the at least one outside surface, remains in the raw state, slicing the meat product into a plurality of slices, vacuum sealing a stack of the slices within a pouch with the slices of the stack directly stacked together, and cooking the vacuum sealed slices of the stack stacked together such that, during the cooking, the cut faces of the stacked slices remain in contact with one another to essentially maintain the size and entire outer surface shape of the stack to have the size and entire outer surface shape of the entirety of the stack prior to the slicing, and such that the slices do not coagulate together as a result of the vacuum sealing and cooking.

A chiller bath includes a tank for holding a volume of chiller water; a dosing system for dosing a first solution and a second solution into the chiller water, arranged to create a plurality of zones within the volume of water, wherein each zone has a higher concentration of either the first or the second solution than surrounding portions of the volume of water; and a meat or poultry immersion arrangement for immersing and moving carcasses in the chiller water. A method for reducing bacterial load on meat or poultry includes generating a plurality of zones within a chiller bath containing water by dosing a source of alkalinity and antimicrobial into the water, wherein the plurality of zones comprises at least one alkaline zone with a pH above 8.5, and at least one antimicrobial zone with pH below 8.5; and submersing meat or poultry in the bath. The zones can also be generated using spray nozzles in a meat or poultry operation.

An apparatus and method for thawing foodstuff that includes a thawing chamber for accommodating the foodstuff, the thawing chamber includes a sensor for sensing a level of frozenness of the foodstuff in the thawing chamber, the sensor includes a microwave transmitter and a microwave receiver that is spaced from the microwave transmitter, the microwave receiver configured to receive a transmission signal transmitted by the microwave transmitter, the microwave transmitter and the microwave receiver are arranged inside the thawing chamber such that the foodstuff is, at least temporarily, situated between the microwave transmitter and the microwave receiver during a thawing process carried out with the apparatus.

The present invention addresses the problem of providing a novel freezing system and a method for producing frozen ingredients, the system and method being such that the amount of free water after defrosting of the frozen ingredients is lower than with conventional freezing. The present invention solves the above problem by providing an ingredient freezing system comprising two or more freezing units for freezing the ingredient, and a transport unit for transporting the ingredient to the two or more freezing units, the two or more freezing units being configured so as to freeze the ingredient in stages so that the ingredient is frozen at progressively lower temperatures as the ingredient is transported on the transport unit.

Methods and devices heat or cool viscous materials, such as meat emulsions useful for producing food and other products. The devices have a heat exchanger including a first plate, a second plate attached to the first plate, and a first spacer and a second spacer arranged between the first plate and the second plate. The first plate, the second plate, the first spacer, and the second spacer define at least one temperature controlled passage for a product to pass through the heat exchanger.

Methods and devices heat or cool viscous materials, such as meat emulsions useful for producing food and other products. The devices have a heat exchanger including a first plate, a second plate attached to the first plate, and a first spacer and a second spacer arranged between the first plate and the second plate. The first plate, the second plate, the first spacer, and the second spacer define at least one temperature controlled passage for a product to pass through the heat exchanger.

An electrostatic spray chilling system is configured to rapidly cool foodstuffs. A conveyor traverses foodstuffs through a chilling tunnel. A chilled primary airflow is provided to the chilling tunnel to cool the foodstuffs. As the foodstuff is traversed through the chilling tunnel, spray modules generate and apply sprays of electrostatically charged fluid onto the foodstuff. The charged fluid droplets are attracted to the grounded foodstuff. The charged fluid droplets can be guided onto the foodstuff by secondary fans, configured to generate subflows of the chilled primary air, and by air guiding baffles.

An improved system and method for treating, precooling, handling, and packaging perishable products uses a mobile container enhanced with increased capacity refrigeration and air flow to recirculate functional substances including sanitizers, and ripening management and conditioning agents across the surface of perishable products during the precooling step. The mobile container is a prefabricated container or is modified from a standard intermodal container or over-the-road semi-trailer. The enhanced forced air and/or refrigeration equipment is contained within the container and/or mounted on the top and/or side exterior of the container and can accomplish rapid cooling. The mobile container can be located near harvest or facilities with no cooling assets. A combined system using conveyors and operational controls provides automated handling of the perishables from receiving, through precooling and treatment, through processing and packaging, preferably to a MAP process, and then to distribution.

An improved system and method for treating, precooling, handling, and packaging perishable products uses a mobile container enhanced with increased capacity refrigeration and air flow to recirculate functional substances including sanitizers, and ripening management and conditioning agents across the surface of perishable products during the precooling step. The mobile container is a prefabricated container or is modified from a standard intermodal container or over-the-road semi-trailer. The enhanced forced air and/or refrigeration equipment is contained within the container and/or mounted on the top and/or side exterior of the container and can accomplish rapid cooling. The mobile container can be located near harvest or facilities with no cooling assets. A combined system using conveyors and operational controls provides automated handling of the perishables from receiving, through precooling and treatment, through processing and packaging, preferably to a MAP process, and then to distribution.

A cold forming process for forming a meat patty includes heating a ground meat product to a temperature T.sub.1, wherein T.sub.1≤40° F. The ground meat product is formed into an uncooked patty at temperature T.sub.1. The uncooked patty is precooked to form a precooked patty having a skin of depth D comprising denatured protein. The skin is formed on at least an area on the outside of the precooked patty. At least a first portion of the meat product disposed beneath said skin is at approximately T.sub.1. The precooked patty is cooked to form a cooked patty, wherein said at least a first portion of the meat product is at a temperature T.sub.2. The cooked patty is then frozen and then packaged.