Zero-OxTech® Process for preservation of enzymes in the protein muscle and its applications

Abstract

The present invention relates to Zero-OxTech process and method for preserving natural enzymes with the protein muscle, and its application for increasing the shelf-life of retail-ready meat & poultry cuts. This invention explicitly proves that the oxygen absorption is a FIRST-ORDER chemical reaction, and henceforth, an absolute zero-oxygen atmosphere is possible. This absolute zero-oxygen atmosphere prevents the natural enzymes within the protein muscle, which assists in the long-term shelf-life extension of proteins. The Zero-OxTech process, its components, and its application for proteins' enzymes preservation is described in detail in this invention and has application for domestic and inter-continental trade of proteins while retaining the natural protein enzymes.

Claims

1. A process system for preservation of natural MRA enzymes within the protein by creating an absolute zero-oxygen atmosphere surrounding the proteins.

2. A process system for converting the oxymyoglobin pigment in protein to de-oxymyoglobin pigment in protein in an absolute zero-oxygen atmosphere surrounding the protein.

3. A process system for converting the de-oxymyoglobin pigment in protein in an absolute zero-oxygen atmosphere to oxymyoglobin in a high oxygen atmosphere, >20%, surrounding the protein.

4. A Package packaged with process system of claims 1-3, to preserve the natural MRA enzymes, resulting in the shelf-life extension of proteins, comprising of: a. Protein [case-ready/portion-cut/primal]; b. Specially designed oxygen scavenger based on iron-chemical system to deliver zero ppm in the atmosphere surrounding the protein; c. Packaging equipment capable to create vacuum+seal or vacuum+gas-flush+seal or gas-flush+seal the atmosphere surrounding the proteins creating an initial oxygen concentration of <10% in the atmosphere surrounding the protein; d. Packaging film structure surrounding the protein with an ultra-high oxygen barrier property with an OTR of <10 cc/square m at 23 C. dry; e. Packaging film structure with an ultra-high oxygen barrier property with an OTR of <10 cc/square m at 23 C. dry housing the protein packaged in foam tray with an over-wrap film of OTR>100 cc/square m at 23 C. dry.

5. The packaging system for extending shelf life of protein by preserving natural enzymes of protein of claim 4, wherein the oxygen scavenger comprises of: 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 0.001 mm to 1.5 mm in diameter; and a total weight of absorbing chemical of between 1 gram to 300 grams.

6. The packaging system for extending shelf life of protein by preserving natural enzymes of protein of claim 4, 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.

7. The packaging system for extending shelf life of protein by preserving natural enzymes of protein of claim 4, wherein the chemical granules comprise less than 10% zeolites.

8. The packaging system for extending shelf life of protein by preserving natural enzymes of protein of claim 4, wherein all the oxygen scavenger sachets sealed within the master bag obtain an absorption capacity of at least 10 mL per pound of protein.

9. The packaging system for extending shelf life of protein by preserving natural enzymes of protein of claim 4, wherein the injected gas comprises of carbon dioxide or nitrogen.

10. The packaging system for extending shelf life of protein by preserving natural enzymes of protein of claim 4, 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.

11. The packaging system for extending shelf life of protein by preserving natural enzymes of protein of claim 4, wherein the protein consists of beef, pork, lamb, veal, and poultry.

12. The packaging system for extending shelf life of protein by preserving natural enzymes of protein of claim 4, wherein the packaging equipment may be closed system, open system, modified atmosphere packaging for trays or vacuum skin packaging for trays.

12. The packaging system for extending shelf life of protein by preserving natural enzymes of protein of claim 4, wherein the barrier bag has properties similar to that given in FIG. 3;

13. The packaging method for extending shelf life of protein by preserving natural enzymes of protein for long-term storage, as described in FIGS. 4-16, comprising: packaging meat cuts or primal or full poultry birds or bird pieces, inside or outside of a retail meat tray, inside a sealed oxygen barrier bag used for storage and transport; vacuum and/or flushing oxygenated air from the oxygen barrier bag to obtain an initial atmosphere containing less than 5% residual oxygen using; injecting into said oxygen barrier bag a CO2 gas rich mixture of greater than or equal to 50% CO2 and balance nitrogen; creating vacuum into said oxygen barrier bag; sealing said oxygen barrier bag, which contains oxygen scavengers of claims 5-6, with first-order oxygen absorption rate, for absorbing the residual oxygen with an absorption capacity reduces the residual oxygen level to 0 ppm within 96 hours of sealing as per the rate-constants of First order oxygen absorption; storing said master bag at a temperature of between 1.5-6 C./28-42 F.

14. The packaging operation for extending shelf life of protein by preserving natural enzymes of protein for long-term storage, as described in FIG. 17, using different and similar packaging configurations as shown in FIGS. 10-16.

Description

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF ZERO-OXTECH PROCESS

[0081] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiment(s) are merely exemplary of the invention that may be embodied in various and alternative forms. Specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention. Further, the particular materials and amounts thereof, as well as other conditions and details, recited in these examples should not be used to unduly limit this invention.

[0082] The present invention in its several disclosed embodiments alleviates the drawbacks described above with respect to traditional meat packaging and incorporates several additionally beneficial features. The process of packaging meat, namely retail-ready meat, is known in the prior art. Disclosed herein is a packaging system and method of the same developed to prevent meat discoloration of prepared fresh meat cuts and to provide extended shelf-life of meat-cuts, such as beef, pork, lamb, and chicken. Specifically, different packaging configurations of components of the system use self-activated oxygen scavengers and structures to extend the shelf life of fresh meat cuts. Zero-OxTech process has the following key-components:

Zero-OxTech Oxygen Scavengers

[0083] Oxygen scavengers based on iron chemical systems were employed for the Zero-OxTech process. A sachet placed within the packaging bag contains chemical granules ranging from 0.001 mm to 1.5 mm in diameter. The half-life of oxygen in a bag containing these oxygen scavengers was in the range of 30 to 1500 minutes, with the quantity of oxygen absorption material ranging from 1 gram to 300 grams. The oxygen absorption material was placed in a package, which was either laminated or unlaminated with porosity levels ranging from 20 to 120 gurly a second, and an active surface area of 4 to 64 square inches. The preferred material for the bag is tyvek. The scavengers are typically formed from iron (<25%, preferably 15-20%), carbon (<35%, preferably 20-30%), vermiculite (<20%, preferably 10-15%), and de-ionized water (<10%, preferably 5%), salt [NaCl] (<10%, preferably 5%). A small amount (<10%) of zeolites can also be added for increased oxygen absorption rates. Oxygen scavengers can also be based on magnesium, copper, and enzymes. The oxygen scavengers are activated upon exposure to air and/or oxygen in an atmosphere greater than 60% relative humidity, and work under a temperature range of 28 to 45 F.

Meat Characteristics

[0084] The meat can be of any type such as pork, lamb, beef, veal, chicken, fish, turkey, venison, or any other meat type. In the actual meats studied developing the invention, meats used included beef, veal, pork, lamb, and chicken. The cuts used were primal and/or sub-primal, and the grades of fresh meat cuts were prime, choice, and/or select. The meats included both boned and boneless cuts, and the size of fresh cut meat product was in the range of 1 to 5 lbs. The meat carcass was cooled either though blast cooling and/or cold room storage, with a cooling temperature of between 5 to 40 F. The time between slaughter and packaging was in the range of one day to 28 days. Packaging temperatures were less than 40 F.

Zero-OxTech Retail Tray Characteristics

[0085] The retail tray composition was of plastic and/or polystyrene/foam and/or combination of both. The inherent oxygen content of the retail tray was in the range of 10 to 23,000 ppm. The surface of the retail tray exhibited either a grid or ridged pattern, or a flat surface upon which to place the fresh meat product. The retail tray cover was either lidded or over-wrapped. The retail tray surface area was in the range of 15,000 to 325,000 square mm. A moisture absorbent pad was either placed in the retail tray before the fresh meat product or was not included. The oxygen scavenger pads were placed in the retail tray or exterior to the retail tray.

[0086] The retail tray overwrap used has an oxygen permeability in the range of 3,000 to 10,000 cc of oxygen per square meter per 24 hours at 73 F. and 70% relative humidity. Additional atmospheric permeability of the retail tray overwrap consisted of additional ambient atmosphere flow with multiple holes, each having a diameter of less than 5 mm, punched through the overwrap or a single needle hole with a diameter of less than 5 mm.

Zero-OxTech Bag/Packaging Film Characteristic

[0087] The meat trays containing different meat cuts in different numbers (one to six retail trays) are placed in a master bag possessing good seal strength or single meat cuts can be placed in the bag having the packaging film characteristics as FIG. 3. The bag possesses good seal strength with either a foil lining or an ethyl vinyl alcohol (EVOH) lining. The oxygen permeability of the master bag was less than 13 cc of oxygen per square meter per 24 hours at 73 F. and 70% relative humidity. The master bag could be prepared by gas-flushed with different gas-compositions and sealed. Alternatively, meat cuts can be placed in the bag and vacuumed with no gas flush. FIG. 3 gives key packaging film structure to be used with the Zero-OxTech process.

Zero-OxTech Process Vacuum or Vacuum+Gas-Flush or Gas Atmospheres to be Created in the Master-Bag

[0088] The Zero-OxTech process can either be used with vacuum or with the modified atmosphere characteristics composed of different gas mixtures of carbon dioxide, carbon monoxide, and nitrogen/inert gas. Typical gas mixtures either consisted of 100% nitrogen and/or any inert gas or contained 100% carbon dioxide or different percentages of gases generally in the concentrations of <1% carbon monoxide, <40% carbon dioxide, and the balance either nitrogen and/or some other inert gas. The oxygen scavengers of different characteristics were placed in the master bags or in the retail trays or both. The residual oxygen content in the master bag after gas flushing using single or multiple cycles was less than 6%. The storage temperature of the master bags was less than 40 F., and the master bags were stored for up to 15 weeks. Similarly, meat cuts can be placed in Zero-OxTech bags which were packaged only with vacuum without any gas-flush.

[0089] Zero-OxTech Packaging Equipment:

[0090] Zero-OxTech process can be used utilizing either Closed system packaging equipment/chamber packaging machine [FIG. 4], or Vacuum skin packaging machine [FIG. 5], or Modified Atmosphere Tray Packaging Machine [FIG. 6], or Open system packaging machine [FIG. 7].

[0091] For experiment #2, several meats cuts, whether retail-ready/portion-cuts/case-ready cuts as well as primal-meat were packaged using different machines [FIG. 4-7] as per the Zero-OxTech process: Zero-OxTech oxygen-scavenger designed to deliver absolute Zero PPM within 24 hours of pack-closure; Zero-OxTech gas combinations [CO.sub.2:N.sub.2=30:70; CO.sub.2:N.sub.2:CO=30:69.6:0.4]; Zero-OxTech vacuum-package; Zero-OxTech MAP-tray with gas-flush; Zero-OxTech MAP tray with vacuum; Zero-OxTech bags with single and/or multiple over-wrapped foam trays using open and closed packaging system; FIG. 10-13 presents the process flow for packaging different meat cuts as well as primal-cuts using different packaging machines as per the Zero-OxTech process, and FIGS. 14-16 depicts illustrative Zero-OxTech package-formats using different Zero-OxTech packaging process. FIG. 17 depicts shelf-life extension process-operation of beef, pork & lamb using Zero-OxTech process.

Experiment #2 Display and Sampling of Primal-Cuts and Retail-Trays Containing Meat-Cuts

[0092] Upon removal from primary storage at weekly intervals, and on day 0 of retail display, each package was removed and Primal-cuts and retail trays containing meat cuts were placed in the center of the display shelf. The displayed meat cuts were examined for discoloration, retail acceptability, off odor intensity, and odor acceptability, and odor description for every 24 hours for up to 15 days. A similar procedure was repeated for all storage intervals for up to 15 weeks.

Visual Assessment of Primal and Meat Cuts

[0093] A five-member panel was used for the subjective evaluation of the meat cuts. Surface discoloration was evaluated using a seven-point descriptive scale: 1=0% (none), 2=1-10%, 3=11-25%, 4=26-50%, 5=51-75%, 6=76-99%, 7=100%. Retail appearance was assessed on a seven-point hedonic scale: 1=Extremely undesirable, 2=undesirable, 3=Slightly undesirable, 4=Neither desirable nor undesirable, 5=Slightly undesirable, 6=Desirable, and 7=Extremely desirable.

Odor Assessment of Primal and Meat Cuts

[0094] A five-member panel was used for odor assessment. Off odor intensity scores were assessed using a four-point descriptive scale: 1=No off odor, 2=Slight off odor, 3=Moderate off odor, 4=Prevalent off odor. Odor acceptability scores were assessed using a five-point scale: 1=Acceptable, 2=Slightly acceptable, 3=Neither acceptable no unacceptable, 4=Slightly unacceptable, 5=Unacceptable.

Microbial Analysis

[0095] A 10 cm.sup.2 sample was obtained at each sampling time (on day 0 and last day of each storage interval) from each meat cut using a sterile cork borer. The sample was the placed into a stomacher bag with 10 mL of 0.1% peptone solution and was massaged for 120 seconds using a commercial stomacher, yielding a dilution of 10. The homogentate was further diluted 10-, 100-, and 10,000-, and 100,000-fold, after which 0.1 mL volumes of undiluted homogenate. Each dilution prepared was spread on duplicate plates of All Purpose Tween (APT). The plates were then incubated aerobically for 3 days at 25 C. The micro flora was determined from plates bearing 20-200 colonies.

Results Summary

[0096] The oxygen concentration was 0 ppm (zero) after 24 hours of storage and was 0 ppm throughout the storage period of up to 15 weeks for all packaging configurations as per the Zero-OxTech. Based on sensory and microbial analysis:

[0097] 1) beef cuts were acceptable for 10 weeks storage plus 10 days at the retail display for all packaging configurations,

[0098] 2) pork chops were acceptable for 15 weeks during storage plus 15 days at the retail display,

[0099] 3) lamb chops were acceptable for 10 weeks during storage plus 12 days at the retail display, and

[0100] 4) chicken pieces were acceptable for up to 4 weeks during storage plus 15 days at the retail display.

[0101] Demonstrated Principles:

[0102] 1. Zero-OxTech process preserves the MRA enzymes within the protein muscles by reducing the oxygen to absolute zero ppm within a few hours of sealing the package.

[0103] 2. Zero-OxTech process designed oxygen scavengers provides single-order absorption rate and hence, an absolute zero-oxygen ppm atmosphere is guaranteed. Zero-OxTech process also utilizes the packaging equipment as per the Zero-OxTech process to deliver a specific initial oxygen concentration so the single-order oxygen absorption rate is obtained.

[0104] 3. Pre-treating the Zero-OxTech process oxygen scavengers by moisture causes faster activation.

[0105] 4. Zero-OxTech process oxygen scavengers based on an iron chemical system will be effectively utilized to reduce the oxygen concentration in the Zero-OxTech process bag.

[0106] 5. Zero-OxTech process is dependent specifically to deliver a specific oxygen half-life and hence, will be dependent upon the initial oxygen concentration in the package and the ambient temperature. Therefore, all components of Zero-OxTech process shall be customized for each specific packaging configuration.

[0107] 6. Zero-OxTech process, where mother-bag houses single or several meat trays, is affected by the permeability of packaging films surrounding the tray inside the mother-bag, which have very high oxygen ingress rate and is significantly reduced at sub-zero temperatures, hence this film acts as an oxygen barrier, hence, pin-holes will be needed on packaging films surrounding the meat-trays in the mother-bag to prevent entrapment of oxygen within the tray.

[0108] 8. Zero-OxTech process provides shelf-life extension of poultry can be obtained with the current invention with or without treatment of PAA [peracetic acid] or any other anti-microbials in the poultry processing lines, which is desired for organic poultry, and using different Zero-OxTech packaging formats, thereby, Zero-OxTech process has the capability to provide extended shelf-life for organic poultry without any anti-microbial chemical treatment.

[0109] Included within the scope of the present invention and the abovementioned examples are compositions, comprising various combinations of these substances and materials. Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope thereof.

INDUSTRIAL APPLICABILITY

[0110] The present invention finds specific industrial applicability in the centralized meat distribution and retail industries. The Zero-OxTech process with its components disclosed herein used to package meat cuts achieves zero oxygen packaging in a central packaging facility for master bag storage and retail display. The storage and display times are significantly increased using the components of Zero-OxTech process for all proteins due to preservation of natural enzymes within the protein.

DESCRIPTION OF THE DRAWINGS

[0111] 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:

[0112] FIG. 1 depicts different myoglobin states of the protein-muscle and MRA enzymes, which can reduce the met-myoglobin to de-oxymyoglobin;

[0113] FIG. 2 is a x-y graph depicting the influence of oxygen concentration on three chemical states of myoglobin;

[0114] FIG. 1A is a table displaying the half-life of oxygen in bags containing scavengers based upon enzymes and iron chemical systems;

[0115] FIG. 1 B is a table showing constants of first order kinetics equation for various scavengers used in the calculation of the Zero-OxTech process;

[0116] FIG. 3 depicts an example of Zero-OxTech process packaging film structure;

[0117] FIG. 4 depicts illustrative picture of closed systems packaging machine;

[0118] FIG. 5 depicts illustrative picture of vacuum skin packing machine;

[0119] FIG. 6 depicts illustrative picture of Modified Atmosphere Packaging [MAP] machine;

[0120] FIG. 7 depicts illustrative picture of open system packaging machine;

[0121] FIG. 8 depicts steps in Conventional meat operations;

[0122] FIG. 9 depicts steps in Zero-OxTech centralized meat operations;

[0123] FIG. 10 depicts Zero-OxTech process to produce MAP tray;

[0124] FIG. 11 depicts Zero-OxTech process to produce vac-pac tray;

[0125] FIG. 12 depicts Zero-OxTech process to produce closed system packaged tray;

[0126] FIG. 13 depicts Zero-OxTech process to produce open system packaged tray;

[0127] FIG. 14 depicts illustrative picture of Zero-OxTech bags with carcass or primal using open or closed packaging machine [gas-flush or vacuum];

[0128] FIG. 15 depicts illustrative picture of Tray [rigid/semi-rigid] with fabricated meat cuts/portions using Zero-OxTech film & Zero-OxTech oxygen scavenger [gas flush or vacuum];

[0129] FIG. 16 depicts illustrative picture of over-wrap foam tray with fabricated meat cuts/portions using Zero-OxTech bags & Zero-OxTech oxygen scavenger with single or multiple trays [gas flush or vacuum];

[0130] FIG. 17 depicts shelf-life extension process-operation of beef, pork & lamb or for any proteins using Zero-OxTech process;

[0131] FIG. 18 is an x-y graph showing mean color score of meats, packaged using Zero-OxTech process for all Zero-OxTech packaging configurations;

[0132] FIG. 19 is an x-y graph showing mean discoloration score of meats, packaged using Zero-OxTech process for all Zero-OxTech packaging configurations;

[0133] FIG. 20 is an x-y graph showing mean retail appearance score of meats, packaged using Zero-OxTech process for all Zero-OxTech packaging configurations;

[0134] FIG. 21 is an x-y graph showing mean off-odor intensity score of meats, packaged using Zero-OxTech process for all Zero-OxTech packaging configurations;

[0135] FIG. 22 is an x-y graph showing mean odor acceptability score of meats, packaged using Zero-OxTech process for all Zero-OxTech packaging configurations;

[0136] FIG. 23 is an x-y graph showing mean microbial plate count of meats, packaged using Zero-OxTech process for all Zero-OxTech packaging configurations.