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

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Presentation on theme: "PACKAGING MACHINES & SYSTEMS Vacuum Technology & Techniques FOR CULINARY PROFESSIONALS MGK Electromechanical Works LLC P.O. Box 113558 Dubai UAE Phone:"— Presentation transcript:

1 PACKAGING MACHINES & SYSTEMS Vacuum Technology & Techniques FOR CULINARY PROFESSIONALS MGK Electromechanical Works LLC P.O. Box 113558 Dubai UAE Phone: 04 3200924 Email: info@mgk.aeinfo@mgk.ae PACKAGING MACHINES & SYSTEMS www.minipack.us/www.minipack.us/ www.mgk.aewww.mgk.ae

2 PACKAGING MACHINES & SYSTEMS Who? > We are minipack: Our technology helps you to control FOOD QUALITY | FOOD COST | FOOD SAFETY

3 PACKAGING MACHINES & SYSTEMS Main factors > WHEN STORING & COOKING FOOD… 2 MAIN FACTORS INFLUENCE FOOD QUALITY! TEMPERATURE ATMOSPHERE Composition & Pressure How can I control atmosphere? >

4 PACKAGING MACHINES & SYSTEMS Why 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

5 PACKAGING MACHINES & SYSTEMS Defined atmosphere packaging > 5 DEFININNIG PACKAGING METHODS (ROP) REDUCED OXYGEN PACKAGING 1 Vacuum 2 Modified Atmosphere 3 Controlled Atmosphere 4 Cook Chill 5 Sous Vide

6 PACKAGING MACHINES & SYSTEMS Defined atmosphere packaging > Vacuum Packaging 1 Air is mechanically removed 2 Package is hermetically sealed 3 Vacuum remains inside the package Used in the worlds best kitchens! >

7 PACKAGING MACHINES & SYSTEMS Defined atmosphere packaging > 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! >

8 PACKAGING MACHINES & SYSTEMS Defined atmosphere packaging > Controlled Atmosphere Packaging 1 Atmosphere is mechanically modified to 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. >

9 PACKAGING MACHINES & SYSTEMS Defined atmosphere packaging > 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… >

10 PACKAGING MACHINES & SYSTEMS Defined atmosphere packaging > 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. >

11 PACKAGING MACHINES & SYSTEMS Cooking techniques with vacuum > Additional benefits of vacuum in the kitchen… 4 basic techniques benefit from vacuum! Lets look at each individually! > COOKINGCOMPRESSION STORAGEMARINATION

12 PACKAGING MACHINES & SYSTEMS Cooking techniques with vacuum > Storage vacuum sealing versus storing in containers has many benefits! Economic Ideal for meats, seafood, stocks > CulinaryFood 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

13 PACKAGING MACHINES & SYSTEMS Cooking techniques with vacuum > Marination / Infusion vacuum sealing with marinade or brine is neat, efficient and convenient! Economic Faster for porous foods. Enhanced flavors for all foods when vacuum is released. > CulinaryFood Safety - less marinade - less waste - convenient handling - space-saving in refrigerator -perfectly distributed -enhanced effect -no spill -less chance for cross- contamination

14 PACKAGING MACHINES & SYSTEMS Cooking techniques with vacuum > Marination / Infusion: Rapid Pickling

15 PACKAGING MACHINES & SYSTEMS Cooking techniques with vacuum > Sous vide cooking vacuum sealing allows to cook in precisely controlled water bath! Economic Beef Tenderloin at 138F/59C for 45 min! > CulinaryFood Safety - 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

16 PACKAGING MACHINES & SYSTEMS Cooking techniques with vacuum > Sous Vide: Beef Tenderloin 45 min at 59°C

17 PACKAGING MACHINES & SYSTEMS Cooking techniques with vacuum > Compression a 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 sealer 2. Seal bag and re-apply atmospheric pressure 3. Cell structure collapses & transforms into dense meaty texture Great 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 food 3. Finish cooking process in water bath or apply other method Great examples: fish fillet, stuffed chicken breast

18 PACKAGING MACHINES & SYSTEMS Cooking techniques with vacuum > 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

19 PACKAGING MACHINES & SYSTEMS Getting started > What do I need to get started? Lets look at each individually! > 1 HACCAP Plan 2 Vacuum Bags 3 Vacuum Machine 4 Thermal Circulator or Combi-Oven

20 PACKAGING MACHINES & SYSTEMS Getting started > HACCAP Plan a standard plan includes: 1. Proper cleaning and sanitation 2. Temperature control 3. Labeling requirements 4. Personal hygiene Watch out for typical short comings: 1. Temperature abuse 2. Poor sanitation and hygiene 3. Cross contamination 4. Use by Date/ Expiration Date / Lot Code

21 PACKAGING MACHINES & SYSTEMS Getting started > Vacuum bags 3 different types of bags are relevant StorageCookingShrink -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

22 PACKAGING MACHINES & SYSTEMS Getting started > Vacuum bags Choosing the right size bag needed…

23 PACKAGING MACHINES & SYSTEMS Getting started > Vacuum machines 3 basic requirements ApprovalEase of useLocal 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?

24 PACKAGING MACHINES & SYSTEMS Getting started > Vacuum machine Define appropriate size of vacuum sealer

25 PACKAGING MACHINES & SYSTEMS Getting started > 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 1-12bag or 1- 10bag or 1-8bag or 2-6bags per cycle

26 PACKAGING MACHINES & SYSTEMS Getting started > 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.

27 PACKAGING MACHINES & SYSTEMS Getting started > Thermal circulator or Combi-oven Whats the right choice? Thermal CirculatorCombi-Oven

28 PACKAGING MACHINES & SYSTEMS Getting started > Thermal circulator or combi-oven Whats the right choice? Thermal CirculatorCombi-Oven -#1 tool for sous vide cooking -Controls water bath with precision of 1/10 th °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

29 PACKAGING MACHINES & SYSTEMS Minipack 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

30 PACKAGING MACHINES & SYSTEMS The Newly Designed MINIPACK XP SERIES Meets and Excels…

31 PACKAGING MACHINES & SYSTEMS Minipack solutions > 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

32 PACKAGING MACHINES & SYSTEMS Minipack solutions > Direct thermal printing! Business Address Product Name Packed Date & Time Expiration Date Operator Code Dry Package Counter Vacuum Amount Gas Percent IMPORTANT-Keep frozen until used, thaw under refrigeration immediately before use.

33 PACKAGING MACHINES & SYSTEMS Minipack solutions > Cleaning & Sanitation Wall chart with each machine STEP 1 Remove volume plates and place in approved sanitation solution, follow normal cleaning & sanitizing procedures. STEP 2 Remove sealing bars and use approved cleaning solution to remove any food soil. Wipe down with approved sanitation solution. STEP 3 Use approved cleaning solution to remove any food soil from seamless chamber. Wipe down with approved sanitation solution. STEP 4 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.

34 PACKAGING MACHINES & SYSTEMS Minipack solutions Remove volume plates and place in approved sanitation solution, follow normal cleaning & sanitizing procedures. > Volume Plate Cleaning and Sanitation.

35 PACKAGING MACHINES & SYSTEMS Minipack solutions Remove sealing bars and use approved cleaning solution to remove any food soil. Wipe down with approved sanitation solution. > Sealing Bar Cleaning and Sanitation.

36 PACKAGING MACHINES & SYSTEMS Minipack solutions Use approved cleaning solution to remove any food soil from seamless chamber. Wipe down with approved sanitation solution. > Vacuum Chamber Cleaning and Sanitation.

37 PACKAGING MACHINES & SYSTEMS Minipack solutions 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.

38 PACKAGING MACHINES & SYSTEMS Food Code 2009 > Food Code 2009 by FDA, CDC, HHS & USDA A model code and reference document for State, City, County and Tribal Agencies who regulate: 1 2 Retail Food Stores 4 Foodservice Operations in Institutions Schools / Hospitals / Nursing Homes / Child Care Centers Restaurants 3 Vending Operations

39 PACKAGING MACHINES & SYSTEMS Review > Coverage What 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

40 PACKAGING MACHINES & SYSTEMS THANK YOU PACKAGING MACHINES & SYSTEMS www.minipack.us MGK Electromechanical Works LLC P.O. Box 113558 Dubai UAE Phone: 04 3200924 Email: info@mgk.aeinfo@mgk.ae


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