Custom-Fit Tray for High Pressure Pasteurization
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Solution Overview
Problem
Conventional high pressure pasteurization packaging is not suitable for perishable products with free space requirements, as high pressure can cause packaging materials and hermetic seals to rupture, limiting the preservation of products with distinct sections or components.
Innovation Solution
A packaging method that positions perishable products in a tray with a compartment of similar shape, allowing for gas flushing and hermetic sealing, followed by high pressure pasteurization without rupturing the package, while maintaining over 10% free space to prevent crushing and preserve the integrity of distinct components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional HPP methods apply high pressure to packages, then pathogenic microorganisms are destroyed and shelf life is extended, but packaging materials and hermetic seals rupture when free space is present
Solution Approach 1:
The compartment is formed to match the product shape before packaging, creating a custom-fit structure that eliminates the need for additional free space while preserving product integrity during HPP processing
Solution Approach 2:
The package structure is customized locally to match the specific shape and dimensions of each product type, allowing optimal use of space without requiring uniform free space throughout the package
2Stability of the object's composition
If packages include free space for product separation and component integrity, then product quality is maintained, but high pressure causes packaging materials and seals to rupture
Solution Approach 1:
The compartment shape is predetermined to match the product before packaging, creating a space-efficient structure that maintains product integrity without requiring excess free space that would rupture under HPP pressure
3Duration of action of stationary object
If conventional gas flush packaging is used, then shelf life is extended compared to vacuum packaging, but shelf life is significantly shorter than HPP packaging
Solution Approach 1:
The custom-fit compartment is formed in advance to match the product shape, enabling the package to withstand HPP pressure while maintaining the product structure, thereby achieving HPP-level shelf life extension for previously ineligible products
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method extends the shelf life of perishable products by triple that of conventional gas flush packaging, maintains the separability of sections, and prevents damage during high pressure pasteurization, while allowing for easy opening and resealing.
Implementation Method 1
The gas or gas mixture can be inserted into the package using gas flushing methods, e.g., modified atmosphere packaging ('MAP') and controlled atmosphere packaging ('CAP'). MAP modifies the internal atmosphere of a package by injecting a desired gas mixture (e.g., nitrogen, carbon dioxide, etc.)
Implementation Method 2
Conventional HPP methods include placing a package in an enclosure (e.g., a water tank) and applying a uniform pressure (e.g., hydraulic pressure) to a surface area of the package. With little to no heat treatment, the intensity and duration of pressure can effectively destroy pathogenic microorganisms in the product by interrupting their cellular functions
Data Source
AI summary
The present disclosure is directed to systems and methods for packaging perishable foods. A packaging method in accordance with several embodiments of the disclosure can include, for example, mating a tray with a product. The tray can include a compartment having a generally similar shape as the shape of the product. The method can further include gas flushing an internal atmosphere around a product, and sealing the product and the internal atmosphere between a lid and the tray. Additionally, the method can include pasteurizing the product with an application of substantially uniform high pressure to a surface area of the package (e.g., high pressure pasteurization).