METHOD AND APPARATUS FOR EXTENDING SHELF-LIFE OF MEAT & POULTRY

Abstract

The current invention covers an improved meat-packaging procedure and machine for packaging meat cuts for long-term storage at temperatures of between 28 and 42 F. The process includes sealing meat cuts or full poultry birds or bird pieces within a master bag containing (i) oxygen scavenger materials capable of reducing the residual oxygen content of the atmosphere within the bag to 0 ppm within 96 hours of sealing, and (ii) a CO2 generator capable to generate CO2 in the amount of at least 100 mL per pound of meat or poultry within 7 days of sealing. Gas is injected into the master bag to form a CO2-rich storage environment of at least 50% CO2. Depending upon the gas-volume and oxygen scavengers design in the master-bag to maintain diffusion, the CO2 generators may not be needed in the master-bag. The over-wrap of the meat or poultry trays, if meat or poultry are packed in trays, can be perforated so that gas exchange occurs within the master bag between the interior and exterior of the meat tray to absorb the residual oxygen inside the meat trays. For meat trays containing meat with poor color stability, oxygen scavengers are preferably placed within the meat trays. For cuts with good color stability, the oxygen scavengers may be placed outside the meat trays. Meat can be stored by this system for up to 10 weeks and up to twelve days of retail display life. Poultry can be stored for 28+ days by this system. Poultry can be treated with PAA or without PAA and can either be air-chilled or water-chilled with or without PAA: in both instances substantial shelf-life extension is obtained. PAA treated poultry tend to show high microbial growth when compared with non-PAA treated poultry.

Claims

1. A packaging system for extending shelf life of meat and poultry comprising: a retail meat or poultry tray comprised of a tray with one or more oxygen scavenger sachets, CO2 generator and an absorbent pad over-wrapped with a gas permeable plastic-based film permitting atmosphere exchange between the interior and exterior of the meat tray, said oxygen scavenger sachets containing an iron-based oxygen absorbing material self-activated in an atmosphere of greater than 70% relative humidity, said CO2 generator activated by injecting small amount of water into the sachet; full poultry birds or bird pieces with one or more oxygen scavengers sachets and CO2 generator, said oxygen scavenger sachets containing an iron-based oxygen absorbing material self-activated in an atmosphere of greater than 70% relative humidity, said CO2 generator activated by injecting small amount of water into the sachet; full poultry birds or bird pieces with one or more oxygen scavengers sachets, said oxygen scavenger sachets containing an iron-based oxygen absorbing material self-activated in an atmosphere of greater than 70% relative humidity; a sealed master bag containing at least one retail meat tray or full poultry birds or chicken pieces, said master bag flushed prior to sealing to remove oxygenated air from the interior of the bag to obtain an initial atmosphere equal to or less than 5% oxygen and injected with an oxygen-free, CO2 gas or inert gas comprised of greater than 50% inert gas; and an oxygen absorption capacity of the oxygen scavenger sachets sufficient to achieve a half-life for the 5% residual oxygen of equal to or less than 10.0 hours and reach a zero oxygen storage atmosphere within 96 hours of sealing said master bag; and a CO2 generator formed by combination of malic acid and sodium carbonate to generate appropriate amount of CO2 in the range of atleast 100 mL per pound of meat or poultry within over period of 7 days of sealing said master bag.

2. The packaging system for extending shelf life of meat and poultry of claim 1, wherein the oxygen scavenger sachets comprise: a porous bag with an active surface area of between 4 to 64 square inches and porosity levels ranging from 20 to 120 gurly per second; chemical granules ranging from .001 mm to 1.5 mm in diameter; and a total weight of absorbing chemical of between 1 gram to 300 grams.

3. The packaging system for extending shelf life of meat & poultry of claim 2, wherein the chemical granules comprise: less than 25% iron; less than 35% carbon; less than 20% vermiculite; less than 10% de-ionized water; and less than 10% NaCl salt.

4. The packaging system for extending shelf life of meat & poultry of claim 3, wherein the chemical granules comprise less than 10% zeolites.

5. The packaging system for extending shelf life of meat & poultry of claim 1, wherein all the oxygen scavenger sachets sealed within the master bag obtain an absorption capacity of at least 10 mL per pound of meat.

6. The packaging system for extending shelf life of meat and poultry of claim 1, wherein the CO2 sachets comprise: a porous bag with an active surface area of between 4 to 256 square inches and porosity levels ranging from 20 to 120 gurly per second; chemical granules ranging from 0.001 mm to 3.0 mm in diameter; and a total weight of CO2 generating material of between 10 to 500 gm.

7. The packaging system for extending shelf life of meat & poultry of claim 6, wherein the chemical granules comprise: less than 80% sodium carbonate; and less than 30% malic acid.

8. The packaging system for extending shelf life of meat & poultry of claim 1, wherein the CO2 generator sachet sealed within the master bag is activated by injecting 5-50 mL of water prior to its placement in the master bag.

9. The packaging system for extending shelf life of meat & poultry of claim 1, wherein the CO2 generator sachet sealed within the master bag obtain a CO2 generating capacity of at least 100 mL per pound of meat within 7 days of pack closure.

10. The packaging system for extending shelf life of meat & poultry of claim 1, wherein the injected gas comprises of carbon dioxide or nitrogen.

11. The packaging system for extending shelf life of meat & poultry of claim 1, wherein the injected gas comprises: 100% CO2; or greater than 50% inert gas and balance CO2; or greater than 50% CO2 and balance inert gas.

12. The packaging system for extending shelf life of meat & poultry of claim 1, wherein the master bag comprises oxygen scavengers placed outside the meat trays.

13. A method for packaging meat to extending shelf life of meat & poultry comprising the steps of: packing a master bag with at least one retail meat or poultry tray or a primal or sub-primal cut of meat or poultry or full poultry birds or loose bird pieces, said master bag constructed of a material exhibiting gas permeability for oxygen of less than 10 mL/m.sup.2/24 hours at 23 C. and including oxygen scavenger material self-activated in an atmosphere of greater than 70% relative humidity to reduce the oxygen half-life within said master bag to ten hours or less after sealing, achieve a zero oxygen storage atmosphere within 96 hours after sealing, and able to function at a temperature range of between 28 and 40 F., and including a CO2 generator to generate atleast 100 mL of CO2 per pound of meat or poultry within 7 days of master-bag closure; packing a master bag with at least one retail meat or poultry tray or a primal or sub-primal cut of meat or poultry or full poultry birds or loose bird pieces, said master bag constructed of a material exhibiting gas permeability for oxygen of less than 10 mL/m.sup.2/24 hours at 23 C. and including oxygen scavenger material self-activated in an atmosphere of greater than 70% relative humidity to reduce the oxygen half-life within said master bag to ten hours or less after sealing, achieve a zero oxygen storage atmosphere within 96 hours after sealing, and able to function at a temperature range of between 28 and 40 F.; flushing said master bag with a non-oxygen gas to reduce the residual oxygen level within said master bag to 5% or less; and storing said master bag at a temperature of between 28 and 42 F.

14. The method for packaging meat to extend shelf life of meat & poultry of claim 13, further comprising the step of: packing retail cuts of meat or poultry in a retail meat tray comprising a tray with (i) an oxygen scavenger contained in a porous sachet, (ii) a CO2 generator contained in a porous sachet, and (iii) an absorbent pad over-wrapped with a gas permeable plastic-based film perforated by one or more holes; or packing loose full poultry birds or bird pieces in a master-bag containing (i) single or multiple oxygen scavengers contained in a porous sachet, and (ii) a CO2 generator contained in a porous sachet. packing retail cuts of meat or poultry in a retail meat tray comprising a tray with (i) single or multiple oxygen scavenger contained in a porous sachet, (ii) an absorbent pad over-wrapped with a gas permeable plastic-based film perforated by one or more holes; or packing loose full poultry birds or bird pieces in a master-bag containing (i) single or multiple oxygen scavengers contained in a porous sachet.

15. The method for packaging meat to extend the shelf life of meat & poultry of claim 14, wherein the meat or poultry tray is arranged in the order of the oxygen scavenger sachet on the bottom, the absorbent pad in the middle, and the meat on top.

16. The method for packaging meat to extend the shelf life of meat & poultry of claim 14, wherein the meat or poultry tray is arranged in the order of the absorbent pad on the bottom, oxygen scavenger sachet in the middle, and the meat on top.

17. The method for packaging meat to extend the shelf life of meat & poultry of claim 14, further comprising the step of: injecting a gas mixture into the master bag comprised of either 100% CO2; or less than 50% CO2 and balance nitrogen; or less than 50% nitrogen and balance CO2.

18. The method for packaging meat to extend the shelf life of meat & poultry of claim 14, further comprising the step of: providing oxygen scavengers sealed in the master bag with a total absorption capacity of between 10 mL and 1000 mL of oxygen per pound of meat inside the master bag.

19. The method for packaging meat to extend the shelf life of meat & poultry of claim 14, wherein the oxygen scavengers comprise: between 15% to 20% iron; between 20% to 25% carbon; between 10% and 15% vermiculite; between 5% and 10% de-ionized water; between 5% and 10% NaCl salt; and between 0% and 10% zeolites.

20. A method for packaging meat for long-term storage, comprising: packaging meat cuts or full poultry birds or bird pieces, inside or outside of a retail meat tray, inside a sealed master bag used for storage and transport; flushing oxygenated air from the master bag to obtain an initial atmosphere containing less than 5% residual oxygen; injecting into said master bag a CO2 gas rich mixture of greater than or equal to 50% CO2 and balance nitrogen; sealing said master bag, which contains oxygen scavengers for absorbing the residual oxygen with an absorption capacity of between 10 mL and 1000 mL per pound of meat sealed within the master bag and sufficient for a residual oxygen half-life of less than or equal to 10.0 hours that reduces the residual oxygen level to 0 ppm within 96 hours of sealing; sealing said master bag, which contains CO2 generator for generating the CO2 with a CO2 generating capacity of atleast 100 mL per pound of meat or poultry within 7 days of sealing within the master bag; and storing said master bag at a temperature of between 28-42 F.

21. The method for packaging meat or poultry for long-term storage of claim 20, wherein the oxygen scavenger comprises: less than 25% iron; less than 35% carbon; less than 20% vermiculite; less than 10% de-ionized water; and less than 10% NaCl salt.

22. The method for packaging meat or poultry for long-term storage of claim 20, wherein the oxygen scavenger comprises: between 15% to 20% iron; between 20% to 25% carbon; between 10% and 15% vermiculite; between 5% and 10% de-ionized water; between 5% and 10% NaCl salt; and between 0% and 10% zeolites.

23. The packaging system for extending shelf life of meat & poultry of claim 20, wherein the CO2 generator comprises: between 60 to 80% sodium carbonate; and between 20-40% malic acid.

24. A method for packaging meat or poultry in a zero-oxygen storage environment, comprising: packaging meat or poultry cuts on meat tray having a gas-impermeable film sealed over the top of the meat tray or packaging meat or full poultry birds or bird pieces in a master-bag without trays; sealing said meat tray or meat or full poultry birds or bird pieces in a high CO2 gas rich environment minimizing trapped oxygen to no more than 5% residual oxygen; sealing within said meat tray an oxygen scavenger for absorbing residual oxygen with an absorption capacity of between 10 mL and 1000 mL per pound of meat sealed within the meat tray and sufficient for a residual oxygen half-life of less than or equal to 10.0 hours that obtains a zero-oxygen storage environment within 96 hours of sealing; sealing said master bag, which contains CO2 generator for generating the CO2 with a CO2 generating capacity of atleast 100 mL per pound of meat or poultry within 7 days of sealing within the master bag; and storing said meat tray at a temperature of between 28-42 F.

25. The method for packaging meat in a zero-oxygen storage environment of claim 24, wherein the meat or poultry tray further comprises an absorbent pad sealed within.

26. The method for packaging meat in a zero-oxygen storage environment of claim 24, wherein the CO2 gas rich environment is 100% CO2.

27. The method for packaging meat in a zero-oxygen storage environment of claim 24, wherein the CO2 gas rich environment comprises: at least 50% CO2; and balance nitrogen or other inert gas.

28. Poultry packaged using the system in claim 24 may or may not need CO2 generator.

29. Poultry packaged using the system in claim 24 may or may not be treated with PAA [peracetic acid], and may be air-chilled or water-chilled.

Description

DESCRIPTION OF THE DRAWINGS

[0295] The objects and features of the invention will become more readily understood from the following detailed description and appended claims when read in conjunction with the accompanying drawings in which like numerals represent like elements and in which:

[0296] FIG. 1 is a x-y graph depicting the influence of oxygen partial pressure on three chemical states of myoglobin;

[0297] FIG. 1A is a table displaying the half-life of oxygen in bags containing scavengers based upon enzymes and iron chemical systems in an air or nitrogen atmosphere as described in Example 1;

[0298] FIG. 1B is a table showing constants of first order kinetics equation for various scavengers;

[0299] FIG. 2A is a table describing treatments for beef steaks and pork chops as described in Example 2;

[0300] FIG. 2B is a table depicting oxygen concentration in master packs containing beef and pork stored at 2 C. in 100% nitrogen atmosphere over the course of seven days as described in Example 2;

[0301] FIG. 2C is a table displaying mean color, surface discoloration and retail appearance scores and standard errors for pork chops and beef steaks after various treatments;

[0302] FIG. 2D is a table depicting mean values of the chemical states of myoglobin (% met-, % deoxy-, and % oxy-myoglobin) and standard errors of difference for pork chops and beef steaks after various treatments;

[0303] FIG. 2E is an x-y graph depicting a discoloration score given to bags undergoing various treatments as described in Example 2;

[0304] FIG. 2F is an x-y graph depicting a retail appearance score given to bags undergoing various treatments as described in Example 2;

[0305] FIG. 2G is an x-y graph showing different treatments given a discoloration score during retail display times as described in Example 2;

[0306] FIG. 2H is an x-y graph illustrating different treatments given a retail appearance score during retail display times as described in Example 2;

[0307] FIG. 2I is an x-y graph showing different treatments having a certain percentages of metmyoglobin during retail display times as described in Example 2;

[0308] FIG. 3A is an x-y graph depicting a control and two experimental types given a discoloration score within storage intervals as described in Example 3;

[0309] FIG. 3B is an x-y graph illustrating the control and two experimental types given a retail appearance score within storage intervals as described in Example 3;

[0310] FIG. 3C is an x-y graph illustrating the control and two experimental types having a percentage of metmyoglobin taken during storage intervals as described in Example 3;

[0311] FIG. 4A is an x-y graph showing different weeks receiving color scores during retail display times as described in Example 4;

[0312] FIG. 4B is an x-y graph showing different weeks receiving discoloration scores during retail display times as described in Example 4;

[0313] FIG. 4C is an x-y graph showing different weeks receiving retail appearance scores during retail display times as described in Example 4;

[0314] FIG. 4D is an x-y graph showing different weeks receiving off odor intensity scores during a course of days of retail display as described in Example 4;

[0315] FIG. 4E is an x-y graph showing different weeks receiving odor acceptability scores during a course of days of retail display as described in Example 4;

[0316] FIG. 4F is an x-y graph depicting different weeks showing a microbial count during a course of days of retail display as described in Example 4;

[0317] FIG. 5A is an x-y graph depicting a microbial plate count for meats, namely lamb chops stored on foam trays over a period of time as described in Example 5;

[0318] FIG. 5B is an x-y graph illustrating microbial plate count for meats, namely lamb chops stored on plastic trays over a period of time as described in Example 5;

[0319] FIG. 5C-I to 5C-II is an x-y graph detailing odor acceptability of meat, namely lamb chops, based on the amount of time the chops are displayed as described in Example 5;

[0320] FIGS. 5D-I and 5D-II is an x-y graph showing scores of off-odor intensity based on the amount of time the chops are displayed as described in Example 5;

[0321] FIG. 5E is an x-y graph depicting scores of retail appearance of meat, namely lamb chops based on time of retail display in plastic trays as described in Example 5;

[0322] FIG. 5F is an x-y graph depicting scores of retail appearance of meat, namely lamb chops based on time of retail display in foam trays as described in Example 5;

[0323] FIG. 5G is an x-y graph illustrating surface discoloration of meat, namely lamb chops in plastic trays based on time of retail display as described in Example 5;

[0324] FIG. 5H is an x-y graph detailing surface discoloration of meat, namely lamb chops, in foam trays based on time of retail display as described in Example 5;

[0325] FIG. 5I is an x-y graph showing color scores of meat, namely lamb chops in plastic trays, based on time of retail display as described in Example 5;

[0326] FIG. 5J is an x-y graph showing color scores of meat, namely lamb chops in foam trays, based on time of retail display as described in Example 5;

[0327] FIG. 6A is an x-y graph showing color score of meat, namely pork chops, based on time of retail display over a period of time as described in Example 6;

[0328] FIG. 6B is an x-y graph showing discoloration of meat, namely pork chops, based on time of retail display as described in Example 6;

[0329] FIG. 6C is an x-y graph depicting scores of retail appearance of meat, namely pork chops based on time of retail display as described in Example 6;

[0330] FIG. 6D is an x-y graph showing scores of off-odor intensity of meat, namely pork chops, based on the time of retail display as described in Example 6;

[0331] FIG. 6E is an x-y graph detailing odor acceptability of meat, namely pork chops, based on the amount of time the chops are displayed as described in Example 6;

[0332] FIG. 6F is an x-y graph depicting microbial plate count for meats, namely pork chops, based on time the chops are displayed as described in Example 6;

[0333] FIG. 7 is a schematic flow chart showing the method of the process used for packaging meat under the invention;

[0334] FIG. 8 is an embodiment of the arrangement of the elements of a meat tray;

[0335] FIG. 9 is another embodiment of the arrangement of the elements of a meat tray;

[0336] FIG. 10 is an embodiment of the arrangement of meat trays inside a master bag;

[0337] FIG. 11 is an embodiment of a master bag containing a large primal or sub-primal meat cut;

[0338] FIG. 12 is another embodiment of the arrangement of meat trays and oxygen scavengers inside a master bag; and

[0339] FIG. 13 is a schematic drawing of an apparatus to package meat according to the disclosed method and process.

[0340] FIG. 14 Shelf-life extension process operation of poultry using Zero-OxTech process.

[0341] FIG. 15 Poultry packaged with Zero-OxTech process in Zero-OxTech bags.

[0342] FIG. 16 Poultry packaged with Zero-OxTech process in tray.

[0343] FIG. 17 Shelf-life data for PAA [Peracetic Acid]-treated poultry using Tewari's Zero-OxTech process [Bag application].

[0344] FIG. 18 Shelf-life data for PAA [Peracetic Acid]-treated poultry using Tewari's Zero-OxTech process [MAP TRAY application].

[0345] FIG. 19 Shelf-life data for Non-PAA [Peracetic Acid]-treated poultry using Tewari's Zero-OxTech process [MAP TRAY application].

[0346] FIG. 20: Shelf-life data for PAA AND Non-PAA [Peracetic Acid]-treated poultry using Tewari's Zero-OxTech process [REISER VACPAC application].

[0347] FIG. 21: APC's for Deli Birds over time using Zero-OxTech process.

[0348] FIG. 22: Anaerobic APC's for Deli Birds over time using Zero-OxTech process.

[0349] Table 23: Lactic Acid Bacteria for Deli Birds over time using Zero-OxTech process.