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Vacuum Technology & Techniques

Vacuum Technology & Techniques. MGK Electromechanical Works LLC P.O. Box 113558 Dubai UAE Phone: 04 3200924 Email: info@mgk.ae. FOR CULINARY PROFESSIONALS. PACKAGING MACHINES & SYSTEMS. www.minipack.us/ www.mgk.ae. Who?. > We are minipack: Our technology helps you to control

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Vacuum Technology & Techniques

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

  2. Who? > We are minipack: Our technology helps you to control FOOD QUALITY | FOOD COST | FOOD SAFETY

  3. Main factors > WHEN STORING & COOKING FOOD… 2 MAIN FACTORS INFLUENCE FOOD QUALITY! TEMPERATURE ATMOSPHEREComposition & Pressure > How can I control atmosphere?

  4. Why vacuum technology? > Vacuum is the key to controlling atmosphere vacuum: “space empty of matter” Create Vacuum -> Remove Oxygen 1 Define Atmosphere -> Add Other Gases 2 Maintain Atmosphere -> Packaging 3 > Wow! How does this work in practice?

  5. 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. Defined atmosphere packaging > Vacuum Packaging Air is mechanically removed 1 Package is hermetically sealed 2 Vacuum remains inside the package 3 > Used in the world’s best kitchens!

  7. Defined atmosphere packaging > Modified Atmosphere Packaging (MAP) 1 Atmosphere is mechanically modified to a different composition than air: • Reduction or replacement of oxygen • Increase proportion of other gases (carbon dioxide, nitrogen) 2 Package is hermetically sealed. Atmosphere remains inside the package for certain period. > Used in Meat & Cheese plants!

  8. Defined atmosphere packaging > Controlled Atmosphere Packaging Atmosphere is mechanically modified to a different composition than air. 1 2 Continuous control is maintained by: • Use of oxygen scavengers or total replacement of oxygen • Impermeable packaging material, no respiring food 3 Package is hermetically sealed. Atmosphere remains inside the package > Used to control Temperature, Gas, H2O.

  9. Defined atmosphere packaging > Cook Chill Packaging Cooked hot food is filled into impermeable bags 1 2 Air is expelled and bag sealed or crimped closed Food is rapidly chilled and refrigerated to inhibit growth of pathogens 3 > Used for Soups, Sauces, Vegetables etc…

  10. Defined atmosphere packaging > Sous Vide Packaging Raw or partially cooked food is vacuum sealed in impermeable bag 1 2 Food in bag is cooked at precisely controlled temperature Food is served or rapidly chilled and refrigerated for storage 3 > Used for Meats and Vegetables.

  11. Cooking techniques with vacuum > Additional benefits of vacuum in the kitchen… 4 basic techniques benefit from vacuum! STORAGE MARINATION COMPRESSION COOKING > Let’s look at each individually!

  12. Cooking techniques with vacuum > Storage vacuum sealing versus storing in containers has many benefits! Economic Culinary Food 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 > Ideal for meats, seafood, stocks

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

  14. Cooking techniques with vacuum > Marination / Infusion: Rapid Pickling

  15. Cooking techniques with vacuum > Sous vide cooking vacuum sealing allows to cook in precisely controlled water bath! Economic Culinary Food 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 > Beef Tenderloin at 138F/59C for 45 min!

  16. Cooking techniques with vacuum > Sous Vide: Beef Tenderloin 45 min at 59°C

  17. 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. 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. Getting started > What do I need to get started? HACCAP Plan 1 Vacuum Bags 2 Vacuum Machine 3 Thermal Circulator or Combi-Oven 4 > Let’s look at each individually!

  20. 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. Getting started > Vacuum bags 3 different types of bags are relevant Storage Cooking Shrink • “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. Getting started > Vacuum bags Choosing the right size bag needed…

  23. Getting started > Vacuum machines 3 basic requirements Approval Ease of use Local 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. Getting started > Vacuum machine Define appropriate size of vacuum sealer

  25. Getting started > Vacuum machine Define appropriate size of vacuum sealer 1 Bag 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 cycle Packages per cycle! - The length of the seal bars and the quantity of seal bars determines how many bags per cycle. 2 Pump & chamber! • - The size and quality of the pump in relation to the chamber size determine the cycle speed. 3

  26. Getting started > Gases 1 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. Oxygen • Sustains the basic metabolism of free breathing foods, such as fruits and vegetables. 2 Carbon Dioxide • Greatly inhibits bacterial growth. It can retard the development of micro-organisms when it comprises at least 10% of the air mixture. 3 Gas Mixtures • Most establishments use a commercially available prepared mixture to simplify the process. 4

  27. Getting started > Thermal circulator or Combi-oven What’s the right choice? Thermal Circulator Combi-Oven

  28. Getting started > Thermal circulator or combi-oven What’s the right choice? Thermal Circulator Combi-Oven • #1 tool for sous vide cooking • Controls water bath with precision of 1/10th°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. 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. 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 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. 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. 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 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. STEP 3 Use approved cleaning solution to remove any food soil from seamless chamber. Wipe down with approved sanitation solution.

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

  35. 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. 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. 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. 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 Restaurants Retail Food Stores 2 Vending Operations 3 Foodservice Operations in Institutions • Schools / Hospitals / Nursing Homes / Child Care Centers 4

  39. Review > Coverage What was discussed in this presentation: 1 (ROP) Reduced Oxygen Packaging Cooking Techniques with Vacuum 2 Getting Started 3 Minipack Solutions 4 Food Code 2009 5

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

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