Presentation on theme: "Vacuum Technology & Techniques"— Presentation transcript:
1 Vacuum Technology & Techniques FOR CULINARY PROFESSIONALSPACKAGING MACHINES & SYSTEMSMGK Electromechanical Works LLCP.O. Box Dubai UAEPhone:
2 Our technology helps you to control Who?> We are minipack:Our technology helps you to controlFOOD QUALITY | FOOD COST | FOOD SAFETY
3 ATMOSPHERE Composition & Pressure Main factors> WHEN STORING & COOKING FOOD…2 MAIN FACTORS INFLUENCE FOOD QUALITY!TEMPERATUREATMOSPHERE Composition & Pressure>How can I control atmosphere?
4 > Vacuum is the key to controlling atmosphere Why vacuum technology?> Vacuum is the key to controlling atmospherevacuum: “space empty of matter”1Create Vacuum -> Remove Oxygen2Define Atmosphere -> Add Other Gases3Maintain Atmosphere -> Packaging>Wow! How does this work in practice?
5 Defined atmosphere packaging > 5 DEFININNIG PACKAGING METHODS (ROP) REDUCED OXYGEN PACKAGING1Vacuum2Modified Atmosphere3Controlled Atmosphere4Cook Chill5Sous Vide
6 Defined atmosphere packaging > Vacuum Packaging1Air is mechanically removed2Package is hermetically sealed3Vacuum remains inside the package>Used in the world’s best kitchens!
7 Defined atmosphere packaging > Modified Atmosphere Packaging (MAP)1Atmosphere is mechanically modifiedto a different composition than air:Reduction or replacement of oxygenIncrease proportion of other gases (carbon dioxide, nitrogen)2Package is hermetically sealed. Atmosphere remains inside the package for certain period.>Used in Meat & Cheese plants!
8 Defined atmosphere packaging > Controlled Atmosphere Packaging1Atmosphere is mechanically modifiedto a different composition than air.2Continuous control is maintained by:Use of oxygen scavengers or total replacement of oxygenImpermeable packaging material, no respiring food3Package is hermetically sealed. Atmosphere remains inside the package>Used to control Temperature, Gas, H2O.
9 Defined atmosphere packaging > Cook Chill Packaging1Cooked hot food is filled into impermeable bags2Air is expelled and bag sealed or crimped closed3Food is rapidly chilled and refrigerated to inhibit growth of pathogens>Used for Soups, Sauces, Vegetables etc…
10 Defined atmosphere packaging > Sous Vide Packaging1Raw or partially cooked food is vacuum sealed in impermeable bag2Food in bag is cooked at precisely controlled temperature3Food is served or rapidly chilled and refrigerated for storage>Used for Meats and Vegetables.
11 Cooking techniques with vacuum > Additional benefits of vacuum in the kitchen…4 basic techniques benefit from vacuum!STORAGEMARINATIONCOMPRESSIONCOOKING>Let’s look at each individually!
12 Cooking techniques with vacuum > Storagevacuum sealing versusstoring in containers has many benefits!EconomicCulinaryFood Safetylonger shelf lifeless spoilageno freezer burnless wasteless storage spaceno moisture lossprevents oxidation & discolorationmaintains shape of foodreduced activity of aerobic bacterialess chance for cross-contamination>Ideal for meats, seafood, stocks
13 Cooking techniques with vacuum > Marination / Infusionvacuum sealing with marinade or brine is neat, efficient and convenient!EconomicCulinaryFood Safetyless marinadeless wasteconvenient handlingspace-saving in refrigeratorperfectly distributedenhanced effectno spillless chance for cross-contamination>Faster for porous foods. Enhanced flavors for all foods when vacuum is released.
15 Cooking techniques with vacuum > Sous vide cookingvacuum sealing allows to cook in precisely controlled water bath!EconomicCulinaryFood Safetyless shrinkageless wastethrough 100%success rateperfect portioncontrolholds up longerPerfect doneness throughoutEnhanced flavorMoist textureMaintaining more nutrition100% repeatability100% transparency of cooking temperatureReduced activity of aerobic bacteriaLower chance of cross-contamination>Beef Tenderloin at 138F/59C for 45 min!
16 Cooking techniques with vacuum > Sous Vide: Beef Tenderloin 45 min at 59°C16
17 Cooking techniques with vacuum > Compressiona technique to apply high pressure to porous foods!Transform crisp, light food texture into dense, meaty texture1. 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, tomatoManipulate food shape and maintain while cooking1. Vacuum seal chilled food under high pressure and set form2. 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
18 Cooking techniques with vacuum > CompressionFruits, 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 slices18
19 > What do I need to get started? Getting started> What do I need to get started?1HACCAP Plan2Vacuum Bags3Vacuum Machine4Thermal Circulator or Combi-Oven>Let’s look at each individually!
20 a standard plan includes: Getting started> HACCAP Plana standard plan includes:1. Proper cleaning and sanitation2. Temperature control3. Labeling requirements4. Personal hygieneWatch out for typical short comings:1. Temperature abuse2. Poor sanitation and hygiene3. Cross contamination4. Use by Date/ Expiration Date / Lot Code
21 3 different types of bags are relevant Getting started> Vacuum bags3 different types of bags are relevantStorageCookingShrink“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° ( °C)transparent - great visibilitygreat to cook infor MAP4 sec. at 80°C/176°FFDA approved powder inside prevents it from sticking togethergreat for raw, processed or smoked meat and cheese
22 Getting started> Vacuum bagsChoosing the right size bag needed…
23 Getting started > Vacuum machines 3 basic requirements ApprovalEase of useLocal serviceANSI 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 gasSealing time? -> bag composition and thicknessLid opening time?Adding inert gas?Label specifications? -> name/date/lot/addressDealer authorized?Service support? -> service quickly available in case of break down on critical business times?
24 Getting started> Vacuum machineDefine appropriate size of vacuum sealer
25 Define appropriate size of vacuum sealer Getting started> Vacuum machineDefine appropriate size of vacuum sealer1Bag 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 cycle2Packages per cycle!- The length of the seal bars and the quantity of seal bars determines how many bags per cycle.3Pump & chamber!- The size and quality of the pump in relation to the chamber size determine the cycle speed.
26 Getting started > Gases Oxygen Carbon Dioxide Gas Mixtures Nitrogen 1NitrogenOdorless, 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.2OxygenSustains the basic metabolism of free breathing foods, such as fruits and vegetables.3Carbon DioxideGreatly inhibits bacterial growth. It can retard the development of micro-organisms when it comprises at least 10% of the air mixture.4Gas MixturesMost establishments use a commercially available prepared mixture to simplify the process.
27 Getting started > Thermal circulator or Combi-oven What’s the right choice?Thermal CirculatorCombi-Oven
28 > Thermal circulator or combi-oven What’s the right choice? Getting started> Thermal circulator or combi-ovenWhat’s the right choice?Thermal CirculatorCombi-Oven#1 tool for sous vide cookingControls water bath with precision of 1/10th °F1 circulator controls up to 30 quarts / 30 liter-> for more simply add another circulator to tankmobile / small foot printAvailable at 800 USD from PolyScienceDesigned for multi-useCannot control temperature as precise as circulatorGreat for re-thermal process or big volume cateringNot mobile / big foot printHigh investment -> low temperature cooking occupies expensive combi-oven for up to 72 hours for one item
29 Minipack solutions > Food Code 2009 Does your machine meet the newest standards?NSF/ETL Sanitation CertifiedSeamless constructionEasy movable componentsElevated legs for table unitsDirect thermal printerNon-corrosive construction
30 The Newly Designed MINIPACK XP SERIES Meets and Excels…
31 Minipack solutions> Minipack XP series excels past all others with…Sloped Seamless Face for Easy CleaningChamber Depth of Nine Inches for RoastFlat Recessed Key Pad for Easy SanitizingLeg Extensions for Easy Cleaning & SanitationFlat Level Bottom for Steam Pan CompressionLCD Display with Classic Display or Full DisplaySelectable Vacuum in Percentage or Mil BarsPop-Out Components for Easy SanitationAdjustable Slant Tray for Soups, Sauces, etc…AND MORE
32 Minipack solutions > Direct thermal printing! Business Address Product NamePacked Date & TimeExpiration DateOperator CodeDry Package CounterVacuum AmountGas PercentIMPORTANT-Keep frozen until used, thawunder refrigeration immediately before use.
33 > Cleaning & Sanitation Minipack solutions> Cleaning & SanitationWall chart with each machineSTEP 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 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.STEP 3Use approved cleaning solution to remove any food soil from seamless chamber. Wipe down with approved sanitation solution.
34 > Volume Plate Cleaning and Sanitation. Minipack solutions> Volume Plate Cleaning and Sanitation.Remove volume plates and place in approved sanitation solution, follow normal cleaning & sanitizing procedures.
35 > Sealing Bar Cleaning and Sanitation. Minipack solutions> Sealing Bar Cleaning and Sanitation.Remove sealing bars and use approved cleaning solution to remove any food soil. Wipe down with approved sanitation solution.
36 > Vacuum Chamber Cleaning and Sanitation. Minipack solutions> Vacuum Chamber Cleaning and Sanitation.Use approved cleaning solution to remove any food soil from seamless chamber. Wipe down with approved sanitation solution.
37 > Outer Body, Legs Cleaning and Sanitation. Minipack solutions> Outer Body, Legs 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.
38 Foodservice Operations in Institutions Food Code 2009> Food Code 2009 by FDA, CDC, HHS & USDAA model code and reference document forState, City, County and Tribal Agencies who regulate:1Restaurants2Retail Food Stores3Vending Operations4Foodservice Operations in InstitutionsSchools / Hospitals / Nursing Homes / Child Care Centers
39 Cooking Techniques with Vacuum Review> CoverageWhat was discussed in this presentation:1(ROP) Reduced Oxygen Packaging2Cooking Techniques with Vacuum3Getting Started4Minipack Solutions5Food Code 2009
40 THANK YOU PACKAGING MACHINES & SYSTEMS MGK Electromechanical Works LLC P.O. Box Dubai UAEPhone:PACKAGING MACHINES & SYSTEMS