NZ713493B2 - Flash freezing for campylobacter reduction - Google Patents
Flash freezing for campylobacter reduction Download PDFInfo
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- NZ713493B2 NZ713493B2 NZ713493A NZ71349312A NZ713493B2 NZ 713493 B2 NZ713493 B2 NZ 713493B2 NZ 713493 A NZ713493 A NZ 713493A NZ 71349312 A NZ71349312 A NZ 71349312A NZ 713493 B2 NZ713493 B2 NZ 713493B2
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- New Zealand
- Prior art keywords
- temperature
- meat item
- meat
- item
- treated
- Prior art date
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- 241000589876 Campylobacter Species 0.000 title claims description 27
- 238000007710 freezing Methods 0.000 title description 12
- 230000008014 freezing Effects 0.000 title description 11
- 230000009467 reduction Effects 0.000 title description 11
- 235000013372 meat Nutrition 0.000 claims abstract description 130
- 238000000034 method Methods 0.000 claims abstract description 52
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- 238000001816 cooling Methods 0.000 claims abstract description 31
- 230000008569 process Effects 0.000 claims abstract description 30
- 244000005700 microbiome Species 0.000 claims abstract description 27
- 230000000694 effects Effects 0.000 claims abstract description 20
- 101001083553 Homo sapiens Hydroxyacyl-coenzyme A dehydrogenase, mitochondrial Proteins 0.000 claims abstract description 17
- 210000003205 muscle Anatomy 0.000 claims abstract description 15
- 239000000523 sample Substances 0.000 claims abstract description 11
- 101710088194 Dehydrogenase Proteins 0.000 claims abstract description 6
- 244000144977 poultry Species 0.000 claims description 31
- 238000010411 cooking Methods 0.000 claims description 3
- 238000005554 pickling Methods 0.000 claims description 2
- 238000009938 salting Methods 0.000 claims description 2
- 102100029107 Long chain 3-hydroxyacyl-CoA dehydrogenase Human genes 0.000 claims 1
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- 102100030358 Hydroxyacyl-coenzyme A dehydrogenase, mitochondrial Human genes 0.000 abstract description 16
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- 230000036541 health Effects 0.000 description 2
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Classifications
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23B—PRESERVING, e.g. BY CANNING, MEAT, FISH, EGGS, FRUIT, VEGETABLES, EDIBLE SEEDS; CHEMICAL RIPENING OF FRUIT OR VEGETABLES; THE PRESERVED, RIPENED, OR CANNED PRODUCTS
- A23B4/00—General methods for preserving meat, sausages, fish or fish products
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23B—PRESERVING, e.g. BY CANNING, MEAT, FISH, EGGS, FRUIT, VEGETABLES, EDIBLE SEEDS; CHEMICAL RIPENING OF FRUIT OR VEGETABLES; THE PRESERVED, RIPENED, OR CANNED PRODUCTS
- A23B4/00—General methods for preserving meat, sausages, fish or fish products
- A23B4/06—Freezing; Subsequent thawing; Cooling
- A23B4/08—Freezing; Subsequent thawing; Cooling with addition of chemicals or treatment with chemicals before or during cooling, e.g. in the form of an ice coating or frozen block
- A23B4/09—Freezing; Subsequent thawing; Cooling with addition of chemicals or treatment with chemicals before or during cooling, e.g. in the form of an ice coating or frozen block with direct contact between the food and the chemical, e.g. liquid N2, at cryogenic temperature
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23V—INDEXING SCHEME RELATING TO FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES AND LACTIC OR PROPIONIC ACID BACTERIA USED IN FOODSTUFFS OR FOOD PREPARATION
- A23V2002/00—Food compositions, function of food ingredients or processes for food or foodstuffs
Abstract
Disclosed is a process of reducing the number of viable microorganisms present on the surface of meat, comprising the steps of: a) providing an untreated meat item having a surface membrane and muscle tissue, said untreated meat item having viable microorganisms on the surface membrane, and an atmosphere surrounding the meat item; b) cooling the meat item by reducing the temperature of the atmosphere surrounding the meat item at a rate of between 0.5 °C/s and 5 °C/s, until the surface membrane reaches a first temperature as measured by a probe inserted within or just below the membrane of between -5 °C and 2 °C; c) allowing the surface membrane to warm to a second temperature higher than the first temperature to give a treated meat item; wherein the number of viable microorganisms present on the surface membrane is reduced, whilst the ß-hydroxyacyl-CoA dehydrogenase (HADH) activity of the muscle tissue is not increased by more than a factor of 2 in the treated meat item compared with the untreated meat item. sphere surrounding the meat item; b) cooling the meat item by reducing the temperature of the atmosphere surrounding the meat item at a rate of between 0.5 °C/s and 5 °C/s, until the surface membrane reaches a first temperature as measured by a probe inserted within or just below the membrane of between -5 °C and 2 °C; c) allowing the surface membrane to warm to a second temperature higher than the first temperature to give a treated meat item; wherein the number of viable microorganisms present on the surface membrane is reduced, whilst the ß-hydroxyacyl-CoA dehydrogenase (HADH) activity of the muscle tissue is not increased by more than a factor of 2 in the treated meat item compared with the untreated meat item.
Description
Flash freezing for campylobacter reduction
Summary
The invention relates to a process for reducing the number of viable rganisms
present on the surface of meat, and to meat items so treated.
Introduction
Food-borne ens represent a significant and serious threat to human and
animal health. us s of microorganism reside naturally on many types
of food, some of which are capable of causing diseases in man (and other animals)
upon ingestion. Sensible precautions, such as thorough cooking at an appropriate
temperature, observation of correct storage protocols for raw and cooked food, and
adhering to proper hygiene standards when handling food, can all reduce but not
eliminate incidence of such disease.
Amongst the disease-causing pathogens, Campylobacter is the most common
bacterial cause of food poisoning. It is responsible for around 62,000 reported cases
of s in the UK every year; however, the estimated number of actual incidences
is much higher, of the order of 600,000, as it is believed that most individuals affected
by the pathogen do not seek medical assistance. The total number of
campylobacter cases across the European Union states is calculated at 9 n
cases per annum.
obacter ion is also extremely common in retail poultry. The ence
of Campylobacter in chicken at retail in the UK was 65.2%, based on the results from
both methods combined, for the 927 samples tested (Food Survey Information sheet
04/09, A UK survey of Campylobacter and Salmonella contamination of fresh chicken
at retail sale, UK Food Standards Agency).
Campylobacter is ore one of the key organisms that health agencies are
tackling in order to reduce levels of food-borne illness. Campylobacter can be found
on meat, unpasteurised milk, and in untreated water; however there is strong
evidence that poultry is the most common cause of illness.
Campy/abacter is naturally present in many poultry birds, and is often found in the
cecum. Transfer to the skin is thought to occur when the birds are slaughtered and
eviscerated.
it would be very desirable to kill or remove Campylobacter (and other pathogens)
from meat, in particular poultry and poultry ts, which are intended for human
(or animal) consumption.
Brief Description of the Prior Art
A known method of ecting y carcasses involves spraying or immersing the
carcasses with water containing antimicrobial agents. However, in Europe, legislation
specifies that potable water must be used to wash carcasses.
GB 2105570 (A) discloses a method of reducing “weepage” in fresh-pack poultry
that includes the steps of first washing the carcasses with jets of unrefrigerated water
to pre-cooi them and add p moisture, then tumbling the carcasses to equalize
the amount of pick-up moisture carried by each carcass, to reduce the general level
of pick-up moisture content somewhat, draining the carcasses by y to remove
e moisture, and finally subjecting them to a supercold atmosphere, such as
may be obtained by directing expanded liquid carbon e in rapidly moving
currents over the carcasses for a time to freeze—crust the carcasses.
The “freeze-crusting" s the skin to squeeze out p moisture from the fatty
fascia layer under the skin to reduce the pickup moisture level to the allowable
amount of 8%, and to remove sufficient body heat that when a carcass is then
allowed to temper to an even" temperature throughout, it will be below the freezing
point of water, but above the —3.30 °C freezing point of the flesh, for a very short time.
The process is said to reduce seepage from the'poultry products so treated.
The method is said to inhibit bacterial growth, and thus prolong shelf life. There is no
disclosure of the method having any icidal effect, however.
US 3637405 discloses a s for packaging and preserving meats to give long
‘35 shelf life and greater tenderness. The portioned or whole chicken is exposed to cold
air at a temperature of -40 °C for 1 hour. The crust~frozen chicken is then held at 0 °C
for at least 3 hours. The method is said to inhibit bacterial growth, and thus prolong
shelf life. There is no disclosure of the method having any bactericidal effect,
however.
WO 2004080189 discloses a method comprising rapidly cooling meat by exposure to
a rapid cooling temperature of below about ~10 °C for sufficient time to provide a
frozen crust on the meat and chilling the resultant crust-frozen meat by exposure of
said crust-frozen meat to a chilling temperature greater than the rapid cooling
temperature but no higher than about +10 °C to raise the temperature of the surface
of the meat and to maintain said e at a temperature no higher than the freezing
temperature of the meat for at least ient time to injure lethally and/or kill bacteria,
is used to reduce the viability of bacteria on meat. The method is stated to have
particular application in the processing of poultry meat to kiil bacteria comprising the
Campylobacter and/or Salmonella species.
Although the method disclosed in WO 2004080189 apparently achieves the objective
of reducing the count of Campylobacter (and other bacterial species), the poultry
treated according to the process cannot be sold in the EU as ”fresh". The sale of
poultry either as whole birds or ns is ted under the EC Poultrymeat
ing Regulation 1906/90 (which has been incorporated into a combined EC
ing Regulation 1234/2007). This tion categorizes poultry meat and
only allows y to be ed as fresh, frozen or quickvfrozen. Fresh poultry is
defined ‘iresh poultry meat' means poultry meat not which has not been stiffened at
any time by the cooling process, prior to being kept at a temperature not below -2°C
and not higher than +4°C. it is not ted to market chilled/fresh poultry which has
been previously frozen and then thawed.
Studies have been conducted to determine rates of Campy/obacterjejunl inactivatioo
on poultry d to different cooling and freezing temperatures (Reduction of C.
jejunl on the Surface of Poultry by Low Temperature (J. Food Prot, 66, 4, 2003, 652—
655)). A mixture of three strains of C. jejuni originally isolated from poultry was
inoculated onto chicken wings. Storage of wings at -20 and -30°C for 72 h reduced
the population of C. jejuni on wings by 1.3 and 1.8 logic CFU/g, respectively.
ols were developed to superchill chicken wings with liquid nitrogen at -80, -120,
—160, and ~196 °C such that the internal portion of each wing guickly reached -3.3 °C
but did not freeze. The study concluded that conditions used in the poultry industry to
superchill poultry to a nonfrozen—state internal temperature are not likely to
substantially reduce Campy/obacter tions on fresh products.
Summary of the Invention
in a first aspect, the invention relates to a process for reducing the number of viable
microorganisms present on the surface of» a meat item, comprising the steps
a) providing an untreated meat item;
to b) exposing the meat item to an atmosphere at a temperature T‘;
c) rapidly ng the temperature of the atmosphere at a selected
cooling rate to a temperature T2 below ~20 °C;
d) optionally maintaining the atmosphere at temperature T2 for a selected
period of time;
e) allowing the meat item to warm, optionally at a ed slow warming
rate, by ing the temperature of the atmOSphere to a temperature
characterized in that
selected temperatures T‘, T2 and T3, the selected g rate, selected
period of time and selected warming rate are selected such that the number
of viable microorganisms present on the surface is d, whilst the
temperature of the meat item does not fall below -2 °C and remains unfrozen.
in a second aspect, the invention es a process for reducing the number of
viable microorganisms present on the surface of meat, comprising the steps
a) providing an'untreated meat item having a surface membrane and
muscle tissue, said ted meat item having viable microorganisms
on the e ne;
b) exposing the surface membrane to cooling at a selected cooling rate
until the surface membrane reaches a selected first temperature;
c) optionally maintaining the surface membrane at the selectedfirst
temperature for a selected period of time;
. d) allowing the surface membrane to warm to a selected second
temperature higher than the first temperature to give a treated meat
item;
WO 68685
characterized in that
the selected rate of cooling; the selected
first ature, selected period of
time
and selected second temperature are selected such that the number of viable
microorganisms present on the surface membrane is reduced, whilst the 13-
yacyl-CoA dehydrogenase (HADH) activity of the muscle tissue is not
significantly increased in the treated meat item
compared with the ted meat
item.
According to a third embodiment, there is provided a meat item prepared
by the
process of the invention.
Summary of the Figures
Figure 1 is a graph showing the ature of the surface, or and atmosphere
ot a turkey carcass d for 4 minutes
Figure 2 is a graph graph showing the temperature of the surface, interior and
atmosphere of a turkey carcass treated for 40 seconds.
Figure 3 is a graph graph showing the temperature of the e, interior and
atmosphere of a turkey carcass treated for 1.5 minutes.
Figure 4 is a graph graph showing the temperature of the surface, interior and
atmosphere of a turkey carcass treated for 2 minutes.
Figure 5 is a graph graph showing the temperature of the surface, interior and
atmosphere at a turkey carcass treated for 1 minute. '
Figure 6 is a graph showing a summary of Campylobacter
levels on ns —
excluding warm bird data on day K+1.
Figure ’7 is a graph showing a y of Campylobacter levels on chickens -
excluding warm bird data on day K+1.
Figure 8 is a graph showing a summary of' Campylobacter
levels on chickens —
ing warm bird data on day K+1
Figure 9 is a graphshowing a summary of Campylobacter
levels on chickens —
excluding warm bird data on day K+1 with 2 min treatment time.
Figure 10 is a graph showing a summary of Campylobacter
levels on chickens —
excluding warm bird data on day K+1 with 2.5 min treatment time.
Figure 11 is a graph showing a
summary of Campylobacter levels on chickens ~
excluding warm bird data on day K+1 with 2.5 min
treatment time.
Figure 12 is- a graph showing the temperature
profile of a meat item subject to an
embodiment of the inventive process.
Figure 13 is a graph graph showing the temperature of the
surface, interior and
here of a chicken carcass treated for 1 minute.
Detailed Description of the Preferred Embodiments
The term “meat" as used herein refers to
any form of edible (by human or animal)
flesh, and includes, without limitation, pork, lamb, , veal, beef, venison, fish,
shellfish, molluscs and poultry. The methods of the invention are, however,
particularly appropriate for the treatment of poultry.
“Poultry" in this context includes edible birds of any type. Examples of poultry are
n, turkey, pheasant, quail, duck, goose, guinea fowl and swan.
Chicken and
turkey are preferred.
The term “meat item" encompasses whole animal carcasses, both entire and
eviscerated, as well as ns of meat (cuts), which comprise at least
a tion
of muscle tissue. Examples of meat items are whole, eviscerated y
carcasses,
and poultry breasts, thighs, drumsticks, lower legs
and wings.
The term “untreated meat item" refers to
a meat item as hereinbefore defined, which
has not been subjected to the'inventive
process. it may (and ably will have)
undergone a number of preceding steps ary in the preparation of meat, such
as stunning, slaughter, evisceration, scalding, removal of head and legs,
water or air chilling and jointing.
_ defeathering,
The term “microorganism” refers to
any organism that is capable of g illness or
disease in humans or other animals. Examples of microorganisms include bacteria,
fungi, archaea, and protists. Preferred microorganisms which are controlled by the
methods of the invention include Campy/obacter spp., Clostridium
I perfringens,
Escherichia coli, Salmonella spp., Bacillus cereus, Shigella spp., Staphylococcus
aureus, Streptococcus, Listeria monocytogenes, Vibrio cholerae, Vibrio
parahaemO/yticus, Vibrio vulnificus, Yersinia enterocolitica, Yersinla
pseudotubercu/qsis, Coxiella ii, Bruce/Ia spp., bacterium
ulcerans, and
P/esiomonas shigeiloides. More preferred microorganisms are Campylobacter
spp.
‘ and Salmonella spp. Highly red are gram negative bacteria, especially
Campy/obacter species including Campy/obacter jejuni and Campy/obaoter coll,
especially Campy/obacterjejuni. I
The term “viable rganism” refers to a microorganism as hereinbefore defined, ~
which is capable of causing illness" or disease when ingested. it encompasses
nonCUlturable bacteria that are in a state of very low lic activity and do not
divide, but are alive and have the ability and become able once resuscitated, as
well as culturable and reproducing microorganisms.
The term “membrane” refers to any biological layer which covers or adheres to the -
e of the meat item to be treated, which is not muscle tissue. It includes, for
e, skin (dermis and mis), as well as layers of fat or cartilage. It also
includes the inner membrane of the body cavity of eviscerated poultry fowl.
The term “B-hydroxyacyl-CoA dehydrogenase (HADH) activity” refers to the activity
muscle mitochondrial enzyme, B—hydroxyacyl-CoA-dehydrogenase, which is released
into the intracellular fluid when the mitochondrial membranes are damaged during
freezing and thawing.
B-hydroxyacyl-CoA dehydrogenase (HADH) activity is measured using the protocol
described in “The Effect of Superchilling and Rapid ng on the HADH Assay for
Chicken and Turkey”, J. Assoc. Publ. Analysts, 2010, 38, 13-23, a modification of the
method described in “Verification of Labelling of Previously Frozen Meat and Poultry
by Measurement of HADH Activity" Hargin, K., J. Assoc. Publ. Analysts, 1997‘, 33, '1-
46. These documents are incorporated herein by nce. The protocol is briefly
summarised below.
A cuboid shaped portion of flesh with base dimensions of approximately 30x30mm
and a height of 20mm is used for the HADH test. For the poultry cuboid it is
necessary to have six out surfaces.
3O Preferably, the cuboid is taken from a predetermined 'depth below the surface of the
surface membrane, such as between 1 and 10 mm below the surface.
Any excess e liquid on the sample is wiped off with a tissue. The meat juice is
expressed from the sample and d with a phosphate buffer. Aliquots of EDTA,
phosphate buffer and NADH are added to diluted press juice, followed by
acetoacetyl~Coenzyme A solution, in a quartz spectrophotometer cuvette. USing a.
U.V. spectrophotometer the rate of conversion of NADH to NAD * is measured by the
rate of decrease in the absorption of the solution. The extinction at 340mm is read.
The difference between the two gs AE is the decrease in absorption at 340mm.
HADH activity U/ml = V x AE / min x on factor of meat juice
dexa
Where V = volume of test mixture = 3ml
C = extinction of co-efficient for NADH at 340nm = 6.3
d = light pathof cell = 1cm
a = volume of diluted meat juice = 0.1ml
T = time over which decrease in is measured in
7 absorption
minutes
AE / min = Extinction at start of reaction — extinction at T min
The equation becomes:-
HADH activity U/ml = 3 x AEJ/ min x dilution factor of meatjuice *
6.3 x 1 x 0.1
(* e.g. 200 for beef)
The juice pressed from meat that has been frozen and thawed will therefore exhibit
higher HADH activity than meat which has not been previously frozen. Since some
HADH may be released when the meat is cut during sample preparation the method
is a comparative one, where the HADH activity is determined on the untreated meat
item as received (X0), and then determined after treatment (X1). The ratio of the
HADH activities (X1/Xo) is ed to as the R value. if the R value is less than 1.2,
’ ably less than 1.1, more ably less than 1.05, then theHADH activity of
3O the meat or poultry is regarded as not significantly increased.
Cooling may be achieved by any oneof a number of "methods. Meat items may be
placed in a chamber containing airlor other refrigerant gas) held at an riate
ature to achieve the selected cooling rate. One or more gas circulation means
(such as fans, blowers etc.) may be provided to increase the flow of cold air over the
meat item, to increase the rate of cooling of the surface membrane.
2012/000499
Alternatively, and ably, the surface ne of the meat item may be cooled
with a cryogen. Suitable cryogens include liquefied , such as liquid nitrogen,
liquid air, liquid carbon dioxide and liquid argon, and solids, such as solid carbon
dioxide (“dry ice", preferably in finely divided form), and combinations of these.
Liquid nitrogen is a preferred cryogen.
Cryogen may be applied to the surface membrane as a jet, spray or bath. It is
preferred that cryogen is applied as a spray. Various types of spray nozzle, such as
roses or spraybars may be utilised, depending on the size and shape of the meat
item to be treated.
Preferably, the cryogen is d in combination with an impinging gas. lmpinging
gas serves to convey the cryogen to the surface membrane of the meat item and
thus increases the rate of cooling. Suitable impinging gasses include nitrogen, air,
and carbon e, and mixtures of these. The pressure of the impinging gas, and
the amount relative to the cryogen, are adjusted so as to achieve the selected
cooling rate.
One embodiment of the process utilizes impingement type
gas flow of cryogen, Such
as carbon dioxide or nitrogen gas, in a straight pass-through COnfiguration. The meat
item is loaded into one end of the apparatus, and is removed with the surface
. membrane at a selected first temperature» at the opposite end. Conveyors or driven
shackle lines may be used to convey the meat item through the cooling
apparatus
and process.
In certain ments, the meat item is conveyed tor stirtace cooling along a
passage formed between a pair of impingement plates through which a g flow
of a n, such as carbon dioxide or nitrogen
gas, is circulated to cool the surface
membrane. In an alternative embodiment, the impingement plates 'may be ed
to one side, as opposed to being beneath the blower which circulates the
cryogen. In
embodiments where the meat item is a poultry carcass, the conveyer in these
ments is a shackle conveyor.
In an alternative embodiment, a cryogenic food cabinet freezer is used.
A suitable
‘ device is the CRYOLINE® CF, supplied by LlNDE AG, Linde Gases Division,
rstrasse 70 82049 Pullach, Germany. This embodiment is more appropriate
for batch freezing and chilling ses where
an in—line system is not appropriate.
In one embodiment, n is supplied to the interior of a meat item by means of a
Spray nozzle connected to a cannula or probe. This embodiment is convenient for
the internal sterilisation of the body cavity of eviscerated poultry carcasses, for
example.
As used herein, the term “temperature of the meat item" refers to the average
temperature throughout the item. in some ments, the temperature of the
‘ meat item does not fall below -2 °C at any point during the procedure. Preferably, no
part of the meat item fails below -2 °C at any point during the ure. Preferably,
no part of the meat item is frozen at any point during the inventive process.
As used herein, “surface temperature" refers to the average temperature of the whole
or part of the surface of a meat item, as ed by a surface ature
thermocouple probe.
As used herein, “interior temperature“ refers to the average temperature at a 4
predetermined depth below the surface of the meat item measured by a temperature
probe. Preferably, the interior temperature is measured at a depth of at least 3mm
below the surface, mere preferably at least 5mm. Preferably, the temperature of the
interior does not fall below —2 °C at any point during the inventive process.
The temperature of the meat item may be (in the case of freshly slaughtered whole
poultry ses, for instance), be around or just below body heat, such as between
25 and 37 °C. atively, the interior temperature may be around ambient
‘ ature, such as between 15 and 25 °C.
However, it has been found preferable that the temperature of the meat item is below
ambient temperature, such as below 20 °C. More preferably, the interior temperature
is below 15 °C. Still more preferably, interior temperature is below 10 °C. Still more
preferably, the interior temperature is below 5 °C. When employing such l
temperatures, good control of bacteria and consistency of results is achieved.
Preferably, the temperature of the meat item is above 0' °C. More preferably, the
interiortemperature is above 1 .°C. Still more preferably, the or temperature is
above 2 °C.
WO 68685
The untreated meat item is exposed to an atmosphere at an initial temperature T'.
The atmosphere may be air, nitrogen or any other suitable gas. Preferably, T1 is
between -5 and 20’ °C. More preferably, T1 is between -3 and 10 °C.
As used herein, the term ted cooling rate” refers to the
. average rate of g
from initial temperature T1 to maintenance temperature T2. This is illustrated
schematically in Figure 12, and is calculated as the ence between T,1 and T2
(referred to as AT‘) divided by the time taken to achieve this reduction (referred to as
' At‘), and
is expressed in terms of °Cs". The d person will appreciate that it is
not always practicable or desirable to provide a linear decrease in temperature.
The selected cooling rate is preferably between 0.1 and 10 °Cs", more preferably
between 0.3 and 1.5 °Cs“.
Temperature T2 is preferably between -20 and -120 °C. Temperature T2 is more
preferably between -20 and -100 °C. More preferably, temperature T2 is between —25
and -95 °C. More preferably, is between -40 and -90 °C. Still more preferably, T2 is
between ~50 and -80 °C.
in preferred embodiments, the here is maintained at the selected temperature
T2. Some variation of e temperature may occur during this maintenance
phase,
as when g is periodically applied, Preferably,»such deviations from T2 are no
more than i 20 °C, more preferably 1r 15 °C, still more preferably 1 10 °C.
in preferred embodiments, the atmosphere is maintained at the selected temperature
T2 for a selected period of time. The period of time is selected in order to optimise
bacterial l in the l process, whilst avoiding freezing of the of
any part of
the meat item. it has been found in particular that the duration of the maintenance
phase (Le. the selected period of time at which the atmosphere is maintained at T2) is
a factor in determing, in certain embodiments, the warming rate in the subsequent
process step.
Preferably, the atmosphere is maintained at the selected temperature T2 for a period
of between 10 seconds and 10 minutes, more preferably between 30 seconds and 5
‘ 35 minutes, still more preferably between 1 minute and 4 minutes.
In the third phase of some embodiments, the
atmosphere is warmed at a selected
warming rate to a temperature T3. Temperature T3 is above temperature T2, such as
above -20 °C more preferably above -10 °C,
more preferably above 0 °C. Preferably,
Ta is between -1 and 4 °C.
Warming may be achieved by any conventional means, and is most conveniently
achieved by simply ceasing the application of cooling. In this case, the latent heat
stored in the interior of the meat item will permeate through
to the surface of the meat.
Alternatively, the meat item can be transferred to a warmer environment, or warm air
or other warm gas may be applied to the e of the
meat.
ln an alternative embodiment, the ambient temperature is gradually raised by
passage of the meat item through an area having a temperature gradient, such
as an
in-line processing tunnel having a temperature which varies
along its length.
- As used herein, the term “selected warming rate” refers to the average rate of
warming from maintenance temperature T2 to final temperature T3. This is illustrated
schematically in Figure 12, and is calculated as the difference betWeen T2 and T3
(referred to as ATZ) divided by the time taken to achieve this reduction
(referred to as
Ate), and is expressed in terms of °Cs". The skilled person ‘
will appreciate that it is
_not always cable or desirable to e a linear increase in temperature.
ably, the selected warming rate is less than 20 °Cs1 ,more preferably less than
°Cs ,more preferably less than 5 °Cs“,
more preferably less than 2 °Cs, more
preferably less than 1 °Cs still more preferably less than 0 5 °Cs“, most preferably
less than 0.1 °Cs
singly, it has been'found that warming the meat item at a slower warming rate
from maintenance temperature T2 to final temperature T3 leads to ed
reduction of the number of viable microorganisms t
on the surface of a meat
item. This was contrary to the expectations of the inventors,
and the reasons for this
enon are not properly understood.
A number of factors affect the warming rate. These include the maintenance
temperature T2, the ed period of time at which the meat item is held at this
temperature, the initial temperature T‘, the mass of the meat item and its surface
area to mass ratio. In ular, a slow warming rate which favours bacterial control
is favoured by a low temperature T‘.
in some embodiments, the surface membrane of the meat is exposed to cooling
conditions until the surface membrane reaches the selected first temperature. The
ed first temperature is chosen such that at least a proportion of the viable
rganisms present on the surface become non-viable when allowed to warm to
the selected second temperature.
The prior art indicates that in order to achieve successful control of microorganisms
present on the surface of meat, rapid cooling to a temperature of less than -10 °C for
sufficient time to provide a frozen crust on the meat, followed by subsequent warming,
is necessary. singly, the inventors have found that an extremely ive
antimicrobial effect can be achieved by rapid surface chilling to temperatures well
above —10 °C. ln addition, the prior art indicates that a frozen crust is necessary to
achieve the sterilisation effect. Surprisingly, the inventors have found that providing
a frozen crust is not a requirement, and indeed superior results are obtained in
certain instances when the e membrane remains unfrozen.
Preferably, the selected first ature is below 2 °C.~ More preferably, the
selected first temperature is below 1 °C. More preferably, the selected first
temperature is below 0.5 °C. Still more preferably, the selected first temperature is
below 0 °C. Still more preferably, the selected first temperature is below —O.5 °C.
ably, the selected first temperature is above -5 °C. More preferably, the
selected first temperature is above 4 °C. Still more preferably, the selected first
temperature is above -3.5 °C. Still more preferably, the selected first temperature is
above —3 °C. Still more preferably, the selected first temperature is above -2.5 °C.
Most preferably, the selected first temperature is above -2 °C. Utilising a
temperature above -2 °C has the age that meat treated according to the
process fulfils the requirement that ‘fresh poultrymeat‘ is to be kept at a not
below 2°C at any time
Preferably, the selected first temperature being in the range of n -5 °C and 2
°C. More preferably, the selected first ature is n ~3 °C and 1 °C. Still
more preferably, the selected first temperature is between -2 °C and 0.5 °C
The selected first temperature and selected second temperature refer to temperature
of the surface as measured by infrared meter or a probe inserted within or just
below the membrane.
Prior to exposure of the surface membrane to the cooling step of the invention, the
meat item may be at t temperature (for example, between 20 °C and 29 °C),
or it may be (and preferably is) pre—chilled to below ambient temperature. In one
embodiment, the meat item is pre~chilled to a ature below ambient
temperature, such that the ature of the meat item is substantially uniform
throughout the meat item, Preferably, the meat item is pre~chilled to below 15 °C,
more preferably to below 10 °C, still more preferably to below 5 °C, still more
preferably to below 2 °C.
it may be more ient, however, to carry out the process of the invention on
meat items which arrive from the preceding steps in the processing plant without a
preliminary step of refrigeration.
The cooling rate is selected such that the d temperature ion of the
surface membrane occurs sufficiently y that no substantial change in the
temperature of the underlying muscle occurs. The skilled person will be able to
determine a suitable g rate for each particular type of meat item.
in a particularly preferred embodiment, the meat item is cooled by reducing the
ambient temperature (i.e. the temperature of the atmosphere surrounding the meat
item) at a rate of between 0.1 "Cs‘1 and 5 °C 5", more preferably at a rate of between
0.2 °C 5‘1 and 3 Ce", most preferably at a rate of between 0.5 °C 5‘1 and 3 °C 5".
Preferably, the ambient temperature of the atmosphere surrounding the meat is
cooled to a ature of between ~10 °C'and 450 °C, more preferably
between -20 °C and -100 °C, still more preferably between -30 °C and -90 °C.
Preferably, the meat item is exposed to the surface cooling conditions for as short a
' period of time as feasible. This ensures that the ature gradient through the ,
meat item is high, and a large differential between theftemperature of the surface
membrane and the temperature of the underlying muscle is maintained.
Optionally, and ably, the surface membrane of the meat item is ined at
the preselected temperature for a period of time. This period of time is selected such
that insufficient heat is transferred from the muscle meat to cause a significant
increase in the activity of HADH.
ln one preferred embodiment, the cooling is achieved by use of a refrigerated tunnel
having a predetermined temperature profile. The rate of passage of the meat items
through the tunnel is adjusted so as to obtain the correct rate of g. This
embodiment is ularly convenient when the
process of the invention is part of the
production line for the preparation of meat products.
Preferably, the surface membrane of the meat item is maintained at the selected first
temperature for between 30 seconds and 20 minutes, preferably n 1 minute
and 10 minutes, more preferably between 1.5 minutes and 7 minutes, most
preferably between 2 and 6 minutes.
Alternatively, the meat item need not be maintained at the selected first temperature,
but on reaching the ed first temperature
may instead be warmed or allowed to
warm to the selected second temperature.
The selected second temperature is higher than the selected first temperature.
differential between the selected first and selected second temperature is selected
such that the number of viable microorganisms is reduced, and also to fit efficiently
with subsequent steps in the processing of the meat item. Preferably, the selected
, second temperature is above -1 °C. Preferably, the selected second temperature is
below 20 °C, more preferably below 15 °C, still more preferably below 10 °C, still
more preferably below 5 °C, most preferably below 4 °C. Very preferably, the
ed second temperature is between -1 °C and 4 °C. Maintaining the
temperature not higher than +4°C at any time fulfils the requirement for fresh poultry '
meat under European ation.
Quantitative assessment of the number of viable microorganisms
t on surface
ne is carried out in accordance with riate protocols. For example,
Campy/obacter is quantified according to lSOfTS 10272-2:2006(E) “Microbiology of
food and animal feeding stuffs — Horizontal method for detection and enumeration of
Campy/obacter spp. — Part 2: —count technique". Other microorganisms may-
be quantified using ent techniques. The term '"number of viable '
microorganisms” will be understood by the skilled person as referring to the number
of such rganisms present per unit surface area of surface tissue.
The rate of cooling, the selected first temperature and the selected second
temperature are chosen such that the reduction in the number of viable
microorganisms present on the surface of the meat observed is at least tically
significant within the limits of the quantification method used. ably, at least a
log (ten-fold) reduction in the number of microorganisms present is achieved. More
preferably, at least a 2-log ed-fold) reduction in the number of rganisms
present is achieved.
Preferably, the R, of the HADH activity in the treated item is less than 2, more
preferably less than 1.5, more preferably less than 1.2, more preferably less than 1.1.
Because the muscle tissue s largely unaffected by the treatment of the skin (or
other surface membrane) according to the present invention, the meat item retains
the organoleptic and nutritional qualities of fresh meat.
Subsequent to treatment with the inventive process, the treated meat items may be
subjected to any further processes customary for the treatment of fresh meat, such
as jointing, chilling (air and water chilling are contemplated),-and packing or wrapping.
Preferably, the inventive process is one of- the last steps on the production line prior
to packing to prevent the possibility cf recontamination of the treated meat item.
in some embodiments, the presentfood hygiene s may be combined with
additional foodphygiene treatments. Suitable additional treatments include chemical
treatments (such as chlorine, chloramine, chlorite, chlorine dioxide, ozone, organic
acids (such as citric and lactic acid), hydrogen peroxide and potassium
permanganate. Other ents include gamma wave ation, treatment with
steam, treatment with electrified water, and crust-freezing;
The process mayalso include r process steps such as curing, g, salting,
pickling, or cooking.
Examples
The process involved using a CRYOLINE® CF
unit which has a temperature control
system with an ability to inject cryogenic gases into the unit for
cooling purposes.
The cabinet has an inner chamber into which slaughtered
y carcases were
hung by their legs which allowed the neck skin to hang clear of the
bird, and the
body cavity entrance to be open.
The unit was set to a temperature that allowed
rapid cooling of the skin of the bird
and other outer or exposed membranes SUCh
that a temperature of below -2 °C
achieved, with no. parts going below ~ 3.8 °C. This was achieved via the use of
cwogenic gas spray bar which introduced liquid nitrogen into the t, and a
ation fan ablevto deliver impingement,
or rapid temperature exchange,
on the
exposed membranes.
The flesh of the bird was not frozen, but the
skin and membranes underwent rapid
g. This was followed by removal from the
unit, and the carcass was then
allowed to rise backin temperature to the normal
chilled holding range of -1 °C to +4
This process was designed to rapidly cool the
surface membrane and campy/obacfer
bacteria present upon the carcass es, and
to render them into a cold tempered
state, similar to that seen just before the product pasSes h the
latent heat
phase, thus ng full freezing of the poultry carcasses. The rapid cold shock
administered to the bacteria on the bird renders them
damaged such that during the
ature rise back to normal chill temperatures the Campy/abacter bacteria
severely damaged or killed, rendering them unable to create ion.
The birds were rapidly chilled in the cabinet and this was completed
satisfactorily
without the freezing of the muscle units of the birds,
in times from around 30 seconds
,30 up to a dwell time of five minutes, depending upon carcass size and ingoing
atures ‘
Example 1
The cabinet was set to a temperature of -80
°C (other temperatures delivered the
same result but took more or less timer to deliver the cold tempered
state).
2012/000499
In some cases the campylobacter bacteria were fully destroyed, and in all cases in
excess of a two log ion was delivered. This damage and destruction of
Campylobacter is delivered by faster and simpler means than any previous process.
Table 1 indicates the obacter count achieved after treatment of naturally
infected chicken or turkey carcasses according to this protocol.
Figures 1 to 5 indicate the temperature profile of the surface of turkey carcasses
exposed to rapid chilling conditions at i) the surface and ii) 5mm depth penetration of
the wing and breast.
Table 1
Sample Temperature/ SURFACE SURFACE Campylobacter count
No TEMP°C_IN °C cfu/g
--80°C 2 mins 05°C 0.00E+00 .
°C~80°C 2 mins 1-1.5°C 05°C 0.00E+00
_—=m-1.5°C 0.00E+00
.0.00E+00
~80°C 6 mins 1-1.5°C 0.3 0.00E+00 A
~80°C 6 mins 1-1.5°C 0.3 00
80°C 5 mins -o.2°c 0.00E+OO
_,-80°C 5 mins 1~1.5°c -o.2°c 0.00E+OO
---m~80°05mms_ 1-1.5°C -1.1 0.00E+OO
E~80°051mins 1-1.5°C -1.1 0.00E+00
‘ to -1.9°C
CONTROL _ 1.00E+02
E——12 -— 5.00E+01
III-- 3.00E+02 -
“- 2.00E+01
1.00E+01
2.00E+02
lt- CONTROL 1.00E+01
IE- 1.00E+01
All birds were pre chilled to 4 °C es testing was completed externally. They were '
treated for between 30 seconds and for 2 minutes under the ions used for
Example 1. The reduction in campylobacter count is shown in Table 2.
Table 2
2' 3.. an no
t: c 3.. L 1: ‘- ‘O \-
.<_> 3 mg or a m 3.
7:1 8- E» E u .5 ~
E. 2 0% “at?
"’ “5%
«I ‘- m 0
.0) u o m
° a- 0.3 ug Us
2 9 “52 “52 '52
:5 > >
a u I“ >-
o = e = a
§ = a
8 is g N 8 ‘V
mummwai-a n Control 0 12,000,000 <10
Chicken Control 3,200,000 370 370 25,000,000 ' <10
Chicken Control 23,000,000 460 460 12,000,000 90
Chicken Control 1,900,000 2 10 210 16,000,000 <10
Chicken Control 140,000 60
, 60 13,000,000 <10
Chicken l 380,000 490 490 14,000,000 <10
Chicken l 350,000 830 830 16,000,000 340
Chicken Control 1,100,000 80 <10 21,000,000 <10
Chicken Treated 130,000 <10 <10 12,000,000 _
Chicken d 84,000 <10 <10 14,000,000 <10
Chicken Treated 660,000 <10 <10 16,000,000 <10
Chicken Treated 0 <10 <10 14,000,000 <10
Chicken Treated 0 <10 <10 12,000,000 <10
Chicken Treated 740,000 110 <10 ,000 <10
Chicken Treated 450,000 <10 <10 14,000,000 <10 ,
Chicken Treated 80,000 <10 <10 13,000,000 <10
Chicken Treated 75,000 <10 <10 13,000,000 <10
Chicken Treated 120,000 , <10 <10 14,000,000 <10
Turkey Control 26,000 50 <10 13,000,000
Turkey Control 58,000 300 60 16,000,000 50
Turkey Control 26,000 140 84 12,000,000 <10
Turkey Control 51,000 , 19,000,000 60
Turkey Treated 17,000 10 10 21,000,000
Turkey Treated 17,000 . <10 <10 23,000,000 '<10
Tu rkey Treated 15,000 20 20 16,000,000 <10
Turkey Treated 35,000 90 90 18,000,000 ,<10
Tu rkey d 9,900 50 30 20
, 19,000,000
Turkey Treated 52,000 23,000,000
Example 3
- 21 _
This example used only chickens. All birds were pre chilled to 4 °C. They were
treated for between 1 minute and 2.5 minutes under the conditions used for Example
1. The redUction in campylobacter count is shown in Table 3.
Table3
Initial Bird Treatment ICount (log) Day Control Treated Difference
Condition Campylobaoter Campylobacter
Count (log)
-—__
Example4
Chilled turkey ses (10 in total) at 4 ‘0 are treated under the conditions
described in example 1 and held in the cryogenic cabinet for 2 minutes to an average
surface temperature of -2 °C. All turkeys are allowed to warm to 4 °C. Five turkeys
are allowed to warm over a period of 1 . The remaining turkeys are allowed to
warm over a period of 10 minutes. Warming rates are varied by allowing ingress of
ambient temperature air at differing rates. The carcasses allowed to warm more
y ted lower counts of campylobacter compared with those d to
warm‘ Over '
1 minute;
Example 5
d chicken carcasses (10 in total) at 4 °C were treated under the conditions
described in example 1 and held in the cryogenic'cabinet for 1 minute or 45 Seconds
with the atmospheric temperature at -80 °C. Some birds were removed from the
cabinet immediately after treatment, and allowed to
warm to 4 °C. A further set of
birds were allowed to remain in the cabinet after the cessation of refrigeration,
for a
period of between 45 seconds and 2 minutes (referred to as "with dwell"
birds). The
ion in campylobacter count is shown in Table 4.
GEOMETFlIC LOG DIFFERENCE
AVERAGE LOG” VALUES
(compared to control)
CONTROL ‘ '525
1:324 —_“
‘15“ __“
Conclusions:
0 45 second treatment with no dwell in the cabinet
produced almost exactly the
same value as control.
0 45 second treatment plus dwell in the cabinet ed a small 0.1 log
difference.
0 1 minute treatment looks even more effective than
shorter residence times.
Claims (8)
1. A process of reducing the number of viable rganisms present on the surface of meat, comprising the steps of: a) providing an untreated meat item having a e membrane and muscle tissue, said untreated meat item having viable microorganisms on the surface membrane, and an atmosphere surrounding the meat item; b) g the meat item by reducing the temperature of the atmosphere surrounding the meat item at a rate of between 0.5 °C/s and 5 °C/s, until the surface membrane reaches a first temperature as measured by a probe inserted within or just below the membrane of between -5 °C and 2 °C; c) allowing the surface ne to warm to a second temperature higher than the first temperature to give a treated meat item; wherein the number of viable microorganisms present on the surface membrane is reduced, whilst the oxyacyl-CoA dehydrogenase (HADH) activity of the muscle tissue is not sed by more than a factor of 2 in the treated meat item compared with the untreated meat item.
2. A process according to claim 1 wherein the temperature of the atmosphere surrounding the meat item in step b) is cooled at a rate of between 0.5 °C/s and 3 °C/s.
3. A s according to any one of the preceding claims wherein cooling step b) is achieved by passage of the meat item through a refrigerated tunnel.
4. A process according to any one of the preceding claims wherein the meat item is selected from a whole poultry carcass, optionally eviscerated.
5. A process according to any one of the preceding claims wherein the meat item is a poultry portion.
6. A process according to any one of the preceding claims wherein the selected second temperature is below 4 °C.
7. A s according to any one of the preceding claims wherein the microorganisms comprise at least Campylobacter species.
8. A s according to any one of the preceding claims comprising at least one further step of curing, smoking, salting, pickling, or cooking the treated meat item. -
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB1109454.7 | 2011-06-07 | ||
GB201109454A GB2491590C (en) | 2011-06-07 | 2011-06-07 | Food hygiene method and food product |
GBGB1203366.8A GB201203366D0 (en) | 2011-06-07 | 2012-02-27 | Food hygiene method and food product |
GB1203366.8 | 2012-02-27 | ||
NZ618108A NZ618108B2 (en) | 2011-06-07 | 2012-06-07 | Flash freezing for campylobacter reduction |
Publications (2)
Publication Number | Publication Date |
---|---|
NZ713493A NZ713493A (en) | 2017-05-26 |
NZ713493B2 true NZ713493B2 (en) | 2017-08-29 |
Family
ID=
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