PACKAGING MACHINES & SYSTEMS Vacuum Technology & Techniques FOR CULINARY PROFESSIONALS MGK Electromechanical Works LLC P.O. Box 113558 Dubai UAE Phone:

PACKAGING MACHINES & SYSTEMS

Vacuum Technology & Techniques

FOR CULINARY PROFESSIONALS

MGK Electromechanical Works LLCP.O. Box 113558 Dubai UAEPhone: 04 3200924Email: [email protected]

PACKAGING MACHINES & SYSTEMSwww.minipack.us/ www.mgk.ae

mailto:[email protected]

http://www.minipack.us/

http://www.mgk.ae/

PACKAGING MACHINES & SYSTEMSWho?

> We are minipack: Our technology helps you to control FOOD QUALITY | FOOD COST | FOOD SAFETY

PACKAGING MACHINES & SYSTEMSMain factors

> WHEN STORING & COOKING FOOD… 2 MAIN FACTORS INFLUENCE FOOD QUALITY!

TEMPERATURE ATMOSPHEREComposition & Pressure

How can I control atmosphere?>

PACKAGING MACHINES & SYSTEMSWhy vacuum technology?

> Vacuum is the key to controlling atmosphere vacuum: “space empty of matter”

Wow! How does this work in practice?>

1 Create Vacuum -> Remove Oxygen

2 Define Atmosphere -> Add Other Gases

3 Maintain Atmosphere -> Packaging

PACKAGING MACHINES & SYSTEMSDefined atmosphere packaging

> 5 DEFININNIG PACKAGING METHODS (ROP) REDUCED OXYGEN PACKAGING

1 Vacuum

2 Modified Atmosphere

3 Controlled Atmosphere

4 Cook Chill

5 Sous Vide


> Vacuum Packaging

1 Air is mechanically removed

2 Package is hermetically sealed

3 Vacuum remains inside the package

Used in the world’s best kitchens!>


> Modified Atmosphere Packaging (MAP)

1 Atmosphere is mechanically modified

2 Package is hermetically sealed. Atmosphere remains inside the package for certain period.

to a different composition than air: - Reduction or replacement of oxygen- Increase proportion of other gases (carbon dioxide, nitrogen)

Used in Meat & Cheese plants!>


> Controlled Atmosphere Packaging

1 Atmosphere is mechanically modifiedto a different composition than air.

2

Package is hermetically sealed. Atmosphere remains inside the package

Continuous control is maintained by: - Use of oxygen scavengers or total replacement of oxygen- Impermeable packaging material, no respiring food

3

Used to control Temperature, Gas, H2O.>


> Cook Chill Packaging

1 Cooked hot food is filled into impermeable bags

2 Air is expelled and bag sealed or crimped closed

3 Food is rapidly chilled and refrigerated to inhibit growth of pathogens

Used for Soups, Sauces, Vegetables etc…>


> Sous Vide Packaging

1 Raw or partially cooked food is vacuum sealed in impermeable bag

2 Food in bag is cooked at precisely controlled temperature

3 Food is served or rapidly chilled and refrigerated for storage

Used for Meats and Vegetables.>

PACKAGING MACHINES & SYSTEMSCooking techniques with vacuum

> Additional benefits of vacuum in the kitchen… 4 basic techniques benefit from vacuum!

Let’s look at each individually!>

COOKINGCOMPRESSION

STORAGE MARINATION


> Storage vacuum sealing versus

storing in containers has many benefits!

Economic

Ideal for meats, seafood, stocks>

Culinary Food Safety

- longer shelf life

- less spoilage

- no freezer burn

- less waste

- less storage space

- no moisture loss

- prevents oxidation & discoloration

- maintains shape of food

- reduced activity of aerobic bacteria

- less chance for cross-contamination


> Marination / Infusionvacuum sealing with marinade or brine is neat, efficient and convenient!

Economic

Faster for porous foods. Enhanced flavors for all foods when vacuum is released.

>


- less marinade - less waste- convenient

handling- space-saving in

refrigerator

- perfectly distributed

- enhanced effect

- no spill

- less chance for cross-contamination


> Marination / Infusion: Rapid Pickling


> Sous vide cooking vacuum sealing allows to cook in precisely controlled water bath!

Economic

Beef Tenderloin at 138F/59C for 45 min!>


- less shrinkage- less waste through 100% success rate - perfect portion control- holds up longer

- Perfect doneness throughout

- Enhanced flavor

- Moist texture

- Maintaining more nutrition

- 100% repeatability

- 100% transparency of cooking temperature

- Reduced activity of aerobic bacteria

- Lower chance of cross-contamination


> Sous Vide: Beef Tenderloin 45 min at 59°C


> Compressiona technique to apply high pressure to porous foods!

Transform crisp, light food texture into dense, meaty texture 1. Remove air from porous foods in vacuum sealer2. Seal bag and re-apply atmospheric pressure3. Cell structure collapses & transforms into dense meaty textureGreat examples: melon, cucumbers, tomato

Manipulate food shape and maintain while cooking

1. Vacuum seal chilled food under high pressure and set form 2. Briefly cook sealed food bag in water to set shape of food3. Finish cooking process in water bath or apply other methodGreat examples: fish fillet, stuffed chicken breast


> Compression Fruits, sealed with maximum vacuum level change.

Results: Dramatic change in texture and color.

Flavor does not change through compression.

Variation:Adding alcohol or juices, e.g. gin-infused apple slices

PACKAGING MACHINES & SYSTEMSGetting started

> What do I need to get started?

Let’s look at each individually!>

1 HACCAP Plan

2 Vacuum Bags

3 Vacuum Machine

4 Thermal Circulator or Combi-Oven


> HACCAP Plan a standard plan includes:

1. Proper cleaning and sanitation2. Temperature control3. Labeling requirements4. Personal hygiene

Watch out for typical short comings: 1. Temperature abuse2. Poor sanitation and hygiene3. Cross contamination4. Use by Date/ Expiration Date / Lot Code


> Vacuum bags 3 different types of bags are relevant

Storage Cooking Shrink

- “3 mil bags” - 0-160°F

(-17-71°C)

- great for liquids, meats, cheeses, vegetables etc.

- not for sharp pointed foods

- “sous vide bags”

- 0°F-212°(-17.78-100°C)

- transparent - great visibility

- great to cook in

- for MAP

- 4 sec. at 80°C/176°F

- FDA approved powder inside prevents it from sticking together

- great for raw, processed or smoked meat and cheese


> Vacuum bags Choosing the right size bag needed…


> Vacuum machines 3 basic requirements

Approval Ease of use Local service

- ANSI certified?(American National Standards Institute)

-> compliant with FDA Food Code (chapter 4-1 & 4-2)

- NSF or ETL Sanitation certificate?

- Type of vacuum?-> full/partial-> added gas

- Sealing time?-> bag composition and thickness

- Lid opening time?

- Adding inert gas?

- Label specifications?-> name/date/lot/address

- Dealer authorized?

- Service support?-> service quickly available in case of break down on critical business times?


> Vacuum machine Define appropriate size of vacuum sealer


> Vacuum machine Define appropriate size of vacuum sealer

1

2 Packages per cycle!- The length of the seal bars and the quantity of seal bars

determines how many bags per cycle.

3 Pump & chamber!- The size and quality of the pump in relation to the chamber size

determine the cycle speed.

Bag size! How many bags fit the seal bar?- Example: a 12.5” seal bar can accommodate 1-12”bag or 1-

10”bag or 1-8”bag or 2-6”bags per cycle


> Gases 1

2 Oxygen- Sustains the basic metabolism of free breathing foods, such as fruits

and vegetables.

3 Carbon Dioxide- Greatly inhibits bacterial growth. It can retard the development of

micro-organisms when it comprises at least 10% of the air mixture.

Nitrogen- Odorless, colorless, and tasteless with minimal water solubility. It

is the main component in air. Mainly used in dry ingredients. Main benefit in sous vide: it displaces oxygen from air in bags.

4 Gas Mixtures- Most establishments use a commercially available prepared mixture

to simplify the process.


> Thermal circulator or Combi-oven What’s the right choice?

Thermal Circulator Combi-Oven


> Thermal circulator or combi-oven What’s the right choice?

Thermal Circulator Combi-Oven

- #1 tool for sous vide cooking- Controls water bath with

precision of 1/10th °F- 1 circulator controls up to

30 quarts / 30 liter -> for more simply add another circulator to tank

- mobile / small foot print- Available at 800 USD from

PolyScience

- Designed for multi-use

- Cannot control temperature as precise as circulator

- Great for re-thermal process or big volume catering

- Not mobile / big foot print

- High investment-> low temperature cooking occupies expensive combi-oven for up to 72 hours for one item

PACKAGING MACHINES & SYSTEMSMinipack solutions

> Food Code 2009

Does your machine meet the newest standards?

- NSF/ETL Sanitation Certified- Seamless construction- Easy movable components- Elevated legs for table units- Direct thermal printer- Non-corrosive construction


The Newly Designed MINIPACK XP SERIES

Meets and Excels…


> Minipack XP series excels past all others with…

- Sloped Seamless Face for Easy Cleaning- Chamber Depth of Nine Inches for Roast- Flat Recessed Key Pad for Easy Sanitizing- Leg Extensions for Easy Cleaning & Sanitation- Flat Level Bottom for Steam Pan Compression- LCD Display with Classic Display or Full Display- Selectable Vacuum in Percentage or Mil Bars- Pop-Out Components for Easy Sanitation- Adjustable Slant Tray for Soups, Sauces, etc…

AND MORE


> Direct thermal printing!

Business Address

Product Name

Packed Date & TimeExpiration DateOperator Code

Dry Package CounterVacuum Amount

Gas Percent

IMPORTANT-Keep frozen until used, thaw

under refrigeration immediately before use.


> Cleaning & Sanitation Wall chart with each machine

STEP 1Remove volume plates and place in approved sanitation solution, follow normal cleaning & sanitizing procedures.

STEP 2Remove sealing bars and use approved cleaning solution to remove any food soil. Wipe down with approved sanitation solution.

STEP 3Use approved cleaning solution to remove any food soil from seamless chamber. Wipe down with approved sanitation solution.

STEP 4Use standard approved cleaning agent to remove any food soil from the body and underneath the vacuum machine including the legs.

Finish by wiping down with approved sanitation solution.


Remove volume plates and place in approved sanitation solution, follow normal cleaning & sanitizing procedures.

> Volume Plate Cleaning and Sanitation.


Remove sealing bars and use approved cleaning solution to remove any food soil. Wipe down with approved sanitation solution.

> Sealing Bar Cleaning and Sanitation.


Use approved cleaning solution to remove any food soil from seamless chamber. Wipe down with approved sanitation solution.

> Vacuum Chamber Cleaning and Sanitation.


Use standard approved cleaning agent to remove any food soil from the body and underneath the vacuum machine including the legs.

Finish by wiping down with approved sanitation solution.

> Outer Body, Legs Cleaning and Sanitation.

PACKAGING MACHINES & SYSTEMSFood Code 2009

> Food Code 2009 by FDA, CDC, HHS & USDAA model code and reference document for

State, City, County and Tribal Agencies who regulate:

1

2 Retail Food Stores

4 Foodservice Operations in InstitutionsSchools / Hospitals / Nursing Homes / Child Care Centers

Restaurants

3 Vending Operations

PACKAGING MACHINES & SYSTEMSReview

> CoverageWhat was discussed in this presentation:

1

2 Cooking Techniques with Vacuum

4 Minipack Solutions

(ROP) Reduced Oxygen Packaging

3 Getting Started

5 Food Code 2009


THANK YOU

PACKAGING MACHINES & SYSTEMSwww.minipack.us

MGK Electromechanical Works LLCP.O. Box 113558 Dubai UAEPhone: 04 3200924Email: [email protected]

mailto:[email protected]

Documents

PACKAGING MACHINES & SYSTEMS Vacuum Technology & Techniques FOR CULINARY PROFESSIONALS MGK Electromechanical Works LLC P.O. Box 113558 Dubai UAE Phone: