Sous-VIDE cooking method for mass production of readymade meat and vegetables

Abstract

An alternative sous-vide cooking method for mass-production of cooked meat and vegetables with improved nutritional quality is disclosed. The method includes the steps of (a) cutting raw meat and vegetables into uniform pieces; (b) marinating of meat slabs of step a) with a mix of spices and oil; (c) exposure of marinated meat and portioned vegetables to purified smoke concentrate (d) rapid thermal treatment at 220°C with sharp steam and purified smoke for safety and aesthetic appeal; (e) vacuum packaging of the semi-cooked product; (f) pasteurization at 65°C for 90 minutes; and (g) rapid cooling in ice water (0.5-2°C) for at least 20 minutes. This efficient process ensures food safety and nutrient retention, offering a scalable solution for the production of healthy, ready-to-eat meals with extended shelf-life.

Description

[0001] SOUS-VIDE COOKING METHOD FOR MASS PRODUCTION OF READYMADE MEAT AND VEGETABLES DESCRIPTION

[0002] Field of the invention

[0003]

[0001] The present invention relates to a field of food industry, namely, to a method for manufacturing meat and vegetables products using sous -vide cooking technology.

[0004] Background of the invention

[0005]

[0002] Sous-vide is a widely known method of food preparation. The technology involves the precise control of cooking temperatures and times by vacuum-sealing food in airtight plastic pouches and cooking it in a water bath or steam environment. The food is thermally processed at pasteurization temperatures and can be chilled and stored before being reheated and served.

[0003] This method ensures that food is cooked evenly, retaining its natural flavours, moisture, and nutrients. Unlike conventional cooking methods, sous-vide operates at lower temperatures, typically between 55°C and 85°C, which allows food to reach a desired level of readiness without overcooking or losing texture. It is known that food products obtained by cooking using sous-vide technology have organoleptic properties which are highly appreciated by consumers.

[0004] During cooking stage, moderate core temperatures are reached, ensuring high quality in terms of nutrition and taste. The key factors influencing the microbiological safety of sous-vide products include the low intensity and a prolonged duration of heat treatment, cooling speed, temperatures achieved, and strict control of storage conditions, such as time and temperature during refrigeration.

[0006]

[0005] In addition, sous-vide cooking can facilitate batch processing and extended shelf life. After cooking, the food can be rapidly cooled and stored at low temperatures of 0-6°C, remaining safe for consumption over several days or weeks, depending on storage conditions. This feature makes sous-vide ideal for commercial sales and foodservice operations where consistent quality and efficiency are essential.

[0007]

[0006] The European patent EP2363048 Bl discloses a steam oven and a method for cooking food placed in a vacuumized and sealed pouch. The process described in EP2363048 Bl includes an optional pre-cook step, followed by sealing the food in a barrier multilayer film pouch. The pouch is heat-sealed under vacuum and stored at approximately 3 °C for no more than seven days to prevent pathogen growth. The food is then cooked at temperatures below 100°C for a specified duration, rapidly cooled to around 3 °C, and made ready for consumption or storage.

[0008]

[0007] US patent application US 2023 / 0172236 Al discloses a commercial-scale fresh sous-vide cooking method that includes a step of food searing with infrared radiation. Despite the significant economical and time-wise advantages of infrared cooking appliances, from the technological point of view, the processes occurring during the treatment of the food at this stage of the disclosed procedure are similar to that of the conventional cooking at high temperatures. Namely, the Mallard reaction that occurs on the surface of a meat piece when the products are processed or cooked at elevated temperature. The Maillard reaction is responsible for the browned, complex flavours of the food and is known from the prior art. However, the products of the Maillard reaction may have an adverse effect on health, triggering and promoting disease progression.

[0009]

[0008] US patent application US 2023 / 0027583 Al discloses a method for food processing that provides an alternative method that is implementing a step of sous-vide cooking technology, that allows to prepare ready-made food products that uphold the flavour as that of cooked via conventional cooking methods. In the disclosed invention the browning and caramelisation was achieved by oil searing of the food or deep frying at about 190°C for about 2.5 minutes, which in its essence is identical to browning via conventional cooking as discussed above.

[0010]

[0009] The present invention aims to introduce an alternative sous-vide cooking technology that ensures reliable, safe and repeatable sous-vide cooking technology for the mass production of meat and vegetables, resulting in enhanced organoleptic properties, retention of vitamins and nutrients at high, i.e. above 80%, levels compared to that of uncooked food products and extended shelf life, without technological steps that could negatively impact nutritional properties of the resulting product.

[0011] Summary of the invention

[0012]

[0010] The summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description of the invention.

[0013] [Oi l] According to embodiments of the present invention the sous-vide cooking technology for mass production allows to obtain cooked meat and vegetables with enhanced nutritional properties and reduced content of harmful substances, therefore, contributing to the health of a potential consumer. In an embodiment, sous-vide ready-made meat and vegetables are produced by a) preparation of raw meat and vegetables by cutting into pieces; b) marinating of meat with a mix of herbs and oil; c) misting the marinated meat and portioned vegetables with a purified smoke to give the product an appealing look; d) rapid thermal treatment of the raw ingredients of step c) at controlled temperature of 220°C with a steam to eliminate growth of pathogenic bacteria; e) packaging of the semi-cooked product into vacuumed trays; f) subsequent pasteurization of the semi-cooked product in controlled environment of 65 °C for 90 minutes, thus obtaining pre-ready product; g) rapid cooling of the pre-ready product in ice water at a temperature of 0.5-2°C for a period of time not less than 20 minutes, to obtain final product.

[0014] Detailed description of the embodiments

[0015]

[0012] Embodiments of the present invention effectively overcome the issues present in the prior art. Further aspects, benefits, features, and objectives of this invention will become evident from the detailed description of the exemplary embodiments, considered alongside the claims.

[0013] As reference the following is a typical procedure for sous-vide cooking: The raw food is subjected to an optional pre-cook step, in order to induce a Maillard reaction. In conventional sous-vide technology the food after pre-cook step is introduced into a shaped pouch of a barrier multilayer film and the pouch is further heat sealed under vacuum. The general cooking process may have a step of storing of the vacuum-sealed food at a low temperature (around 3°C), but is may have an adverse effect on the quality of the product; therefore, it cannot be longer than 7 days in order to prevent an increase of pathogens. Afterwards the food is heated / cooked at a temperature usually lower than 100°C for a predetermined time. The pouch is subsequently cooled at around 3 °C and it is ready for consumption or for storage.

[0016]

[0014] Embodiments consistent with the present disclosure advantageously provide means of manufacturing of ready-made sous-vide meat and vegetables with enhanced food quality and safety, as well as with a prolonged shelf-life. An advantage of sous-vide meat and vegetable products produced according to the present disclosure is that a final product retains 80% of its vitamin composition, 90% of its macronutrient composition, while preserving all organoleptic properties, and achieving a shelf life of at least 30 days. A further advantage of sous-vide products is that they have taste, texture and mouthfeel characteristics which consumers will readily accept as being preferable due to enhanced delicacy, improved flavour and aroma.

[0017]

[0015] In the advantageous embodiment of the invention the method is carried out such it comprises seven main procedural steps.

[0018]

[0016] Step 1: An initial step of the disclosed sous-vide cooking includes a through preparation of the raw meat and vegetables, which involves cleaning and portioning to ensure uniformity. The average thickness of the portioned slab of meat is in a range of 1.5 to 2 cm, and an average weight does not exceed 200 g. It should be understood that the disclosed method may be applied to a variety of meat types, including, but not limited to, pork, beef, and poultry, with pork being preferred. Similarly, a wide range of vegetables may be utilized, preferably including, but not limited to, potatoes, broccoli, com, cauliflower, lentils, beans, and carrots.

[0019]

[0017] Step 2: The portioned meat is subsequently marinated with a mix of spices and oil in a rotating marinator for 10 minutes at 4 rpm.

[0020]

[0018] Step 3: The surface of the prepared vegetables of Step 1 and marinated meat of Step 2, is exposed to an aromatic, natural substance produced to impart a smoky aroma and a roasted colour to the final product. Smoking as a method of food processing is widely known from the prior art. In the disclosed method a smoke concentrate is used for flavouring and browning of the meat and vegetables. The smoke concentrate is a purified natural smoke that is eliminated of cancerogenic substances that might adversely impact the nutritional properties of the final product. The mist is applied until it gives the raw ingredient the desired appearance, and it could be alterated depending on the preferences of the consumer. However, the general principle of a direct proportion between misting time and resulting properties, like flavour and browning rate, is applicable.

[0021]

[0019] Step 4: The ingredients of Step 3 of the disclosed cooking method are further thermally treated with a sharp steam in order to effectively disinfect the product's surface, eliminating bacteria while ensuring that the interior of the product remains uncooked. A crust is formed on the surface of the ingredients through rapid searing with the sharp steam at a controlled temperature of 220°C with a duration time in the range of 7 to 10 minutes. This process not only enhances the visual appeal of the final product — eliminating the need for additional frying after packaging — but also significantly reduces the release of moisture, particularly meat juices containing proteins. As a result of the thermal processing carried out during Step 4, the semicooked product is obtained, wherein it retains its raw state while achieving a decontaminated and aromatic surface, effectively neutralizing bacterial contaminants such as Listeria. The proteins within the semi -cooked product remain in a non-denatured state. By avoiding prolonged exposure to high temperatures, the risk of carcinogenic compound formation is minimized, and the natural vitamins and minerals are preserved without undergoing degradation. To ensure uniform treatment from all sides and to reduce a direct contact with metal surfaces (such as trays or pans), the contact surface of the equipment is designed in a form of a grid.

[0022] 020] Step 5: Following the misting of Step 3 and the thermal treatment of Step 4, the semicooked product is placed in vacuum trays. The vacuum environment plays a critical role in influencing the subsequent thermal processing step — specifically, the pasteurization. The vacuum tray serves as both a key technological element and as the primary packaging for the final product. The vacuum applied to the semi-cooked product not only isolates it from pathogenic microorganisms, but also enhances the efficiency of exchange processes during the subsequent heat treatment. Conventional thermoforming equipment and film are used, resulting in tray-shaped packaging with a height of 3 cm. The tray load of 400 g is considered to be as a maximum value admissible for assuring the efficient reduction of food pathogens under determined conditions, but lower values can be used as well.

[0023]

[0021] Step 6: This step includes thermal processing of the semi-cooked product placed in vacuum trays under sous-vide conditions. The semi-cooked product is subjected to pasteurization in controlled conditions, which involves thermal processing in water environment until it reaches a state of readiness. In order to achieve product readiness an alternative technological approach involves the application of water and an extended duration of heat treatment, specifically for 90 minutes at a controlled low temperature of 65 °C, resulting in sufficient pasteurization to inhibit the growth of all types of pathogenic microflora. As a result, a pre-ready product is obtained. This controlled exposure allows for the preservation of vitamins and minerals while preventing meat protein denaturation, thereby maintaining the resulting product's juiciness and tenderness. The pasteurization process also ensures the sterility of the final product, resulting in an extended shelf life up until 30 days.

[0024]

[0022] Step 7: The final step of production of the product obtained by the method of the present invention is a rapid cooling of the pasteurised meat and vegetables in vacuum trays. This step is critical in preserving the quality of the final product. The invention employs a rapid cooling technique utilizing an ice bath of 600 Liters, with a water-to-ice ratio of 1 : 1. The relationship between the product weight in kilograms and the ice water volume is 1:5, meaning, for e.g., that 500 Liters of ice water are used to cool 100 kilograms of the product.

[0025]

[0023] The water in the ice bath is maintained at a temperature close to the freezing point, specifically within the range of +0.5°C to 2°C. This cooling method allows for a significantly faster temperature reduction within 20 minutes compared to other traditional techniques, swiftly passing through the temperature range that supports bacterial growth.

[0026]

[0024] The primary issue addressed by the method of rapid cooling is bacteria proliferation during cooling stage of the sous-vide method. As food cools, it passes through a temperature range between 20°C and 45°C that is optimal for bacterial growth, in particular, with a peak for a psychrophilic bacteria proliferation at about 20°C, and for mesophilic bacteria at around 40°C. Although the rate of bacterial reproduction decreases as the temperature drops, it is crucial to manage this cooling process carefully. Once the food reaches a temperature of about 10°C bacterial growth significantly slows or halts altogether. Thus, optimizing the cooling phase is essential to mitigate the risk of bacterial growth and ensure the safety and quality of the food product, reinforcing the importance of integrating effective cooling techniques within the overall cooking process.

[0027]

[0025] The method of cooling utilised in the present invention, known as hydro-cooling, effectively reduces the temperature of the food products, cooked by sous-vide technology, at a rate that is 15 times faster than that of air cooling. The cold water rapidly extracts heat from the products, significantly lowering their temperature. The efficiency of this cooling method is attributed to two main factors: (1) the high heat transfer coefficients that can reach up to 2000 W / m2K, and (2) the ability to cool the ice water to temperatures close to the freezing point (0.5°C). The use of ice water as a coolant presents numerous advantages. Water is non- aggressive, non-toxic, and cost-effective coolant allowing for rapid cooling while maintaining the integrity of the food products. Additionally, its low viscosity and high specific heat capacity further enhance its effectiveness as a heat transfer medium. By integrating this advanced cooling technique into the overall cooking process, the invention ensures that the food retains its nutritional value, sensory characteristics, and extends its shelf life, thus providing a significant improvement over conventional sous-vide cooking method.

[0028]

[0026] The steps of the method described above results in an advantageous combination of significant technical effects, including retention of vitamin content at 80% of the original composition, ensuring that the nutritional value of the food is largely preserved; preservation of macroelement composition at 90% of the original levels, which contributes to the overall nutritional integrity of the product; maintenance of all organoleptic properties, including flavour, aroma, and texture, resulting in a high-quality culinary experience; and an extended shelf life of at least 30 days, enhancing the product's viability for storage and distribution, if stored at a temperature in the range from 2°C to 4°C. These combined effects demonstrate the effectiveness and advantages of the proposed cooking technology, distinguishing it from prior methods and contributing to improved food quality and safety.

[0029]

[0027] While the invention may be susceptible to various modifications and alternative forms, specific embodiments of which have been described in detail herein, it should be understood that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention includes all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the following claims.

Claims

CLAIMS1. A commercial scale sous-vide meat and vegetable cooking method comprising the steps of: a) cleaning and portioning of a raw meat and vegetables; b) marinating of the portioned meat slabs of step a) with a mix of spices and oil; c) exposure of the meat of step b) and vegetables of step a) to a purified smoke concentrate; d) thermal treatment of the meat and vegetables obtained in step c) of the method with a sharp steam, wherein semi-cooked product is obtained; e) packaging and vacuum -sealing of the semi-cooked product of step d) in vacuum trays; f) pasteurizing the vacuum-sealed semi-cooked product of step e) under sous-vide conditions, wherein a pre-ready product is obtained; g) obtaining a ready-made final product by rapid cooling of the pasteurized preready product of step f); characterised in that the thermal treatment of step d) is performed at controlled temperature of 220°C for at least 7 to 10 minutes.

2. The method according to claim 1, wherein step f) is performed in a water environment at a controlled temperature of 65 °C for 90 minutes.

3. The method according to any of preceding claims, wherein step g) is performed for at least 20 minutes in an ice bath with a water-to-ice ratio 1: 1, wherein the temperature of the ice bath is in the range of 0.5 to 2°C.

4. The method according to any of preceding claims, wherein step b) is performed in a rotating marinator for 10 minutes at 4 rpm.

5. The method according to any of preceding claims, wherein the weight of the portioned meat of the step a) is preferably 200 g per slab.

6. The method according to any of preceding claims, wherein the thickness of the meat is in the range of 1.5 to 2 cm.

7. The method according to any of preceding claims, wherein a weight of the semicooked product in the tray is 400 g.

8. The method according to any of preceding claims, wherein the vegetables are selected from a group comprising: potatoes, broccoli, com, cauliflower, lentils, beans, and carrots.

9. The method according to any of preceding claims, wherein the meat is selected from a group comprising: pork, beef, or poultry.

10. The method according to claim 9, wherein, preferably, the meat is pork.

11. A ready-made food product obtained by a method according to any of claims 1