AU682475B2 - Multifaceted mold for cook-in, method therefor, and product thereof - Google Patents

Description

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION NAME OF APPLICANT(S): W. R. Grace Co.-Conn.

ADDRESS FOR SERVICE: DAVIES COLLISON CAVE Patent Attorneys 1 Little Collins Street, Melbourne, 3000.

INVENTION TITLE: Multifaceted mold for cook-in, method therefor, and product thereof The following statement is a full description of this invention, including the best method of performing it known to me/us:-

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C. C C BACKGROUND OF THE INVENTION 1. Field of the Invention 4 WMg oe The present Invention relates generally to an apparatus for forming a meat productt cook-in mold cooking and the meat product so produced.

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More particularly, this invention relates to cook-in molds having a means of molding a multifaceted design into a cased cook-in meat product and the product so produced.

2. Description of the Related Art Many foods during preprocessing are stuffed Into a casing and then placed in a heated medium, such as a hot water bath. for cook-in to produce a *precooked, encased food product. Generally, a portion of a moldable raw meat.

such as sectioned ham or meat emulsion, is pressed into a bag or casing lined smooth wall stainless steel cooking mold having a generally rectangular shape, then cooked while in the mold. and thereafter packaged as a pre-cooked compacted meat product. Alternatively, the moldable raw meat or emulsion can be pressed Into the casing without the use of a mold and then cooked or after loading into a casing, the casing can be loaded into a mold for cooking. The term "cook-in' conventionally refers to cooking of a food product while contained in a package. Alternatively, the package may be a heat shrinkable bag which shrinks tightly about a contained food product upon initial exposure to cook-in conditions.

The term "cook-in package" Is intended to refer to packaging material structurally capable of withstanding exposure to cook-in time-temperature conditions while containing a food product Cook-in time-temperature conditions typically imply a long slow cook. for example by submersion In water at I a S a 97 13:22 -2- 70°-80* C. for 4-6 hours. Under such conditions, a packaging material properly characterized as cook-in will maintain heat seal integrity and will be delamination resistant. The packaging material typically will also be heat shrinkable under these conditions so as to form a neady fitting package and preferably should have a tendency toward product adhesion to minimize "cookout" or collection of fluids between the surface of the food product, and the interior surface of the bag.

It is desirable that a cook-in package closely conform to the contained food product to prevent "cook-out". exudation of fluids from the food product during cooking. By restricting exudation of fluids from a cook-in contained food product, the yield of the precooked food product Is increased, since fluid retention tends to increase product weight. It is also desirable that the cook-in S contained food product maintain uniform size over its full length, and optionally have flattened ends, so as to produce uniform size and weight portions S when further processed, thereby further increasing the yield. It is further desirable in the up-scale deli market to produce such a cook-in contained food product having a multifaceted design molded Into the cased cook-in product.

U. S. Patent No. 3.765,090 (Roberts et. al.) discloses a method of making a cheese including loading the curd into a casing using a tube to help compress the curd and direct the partially compressed curd into the container. Containers contemplated include those of cardboard and of metal as well as plastic bags. There is no cook-in of the cheese product. There is also no appreciation of utilizing the mold to create designs in the molded product.

U. S. Patent No. 4.672.793 (Terlizzi. Jr. et. al.) discloses an improved method of vacuum packaging a molded meat product in a cook-in bag lining a cooking mold. The teaching is directed to an Improved vacuum system for use during packing of the meat product. This patent does not appreciate the mold S apparatus of the present invention, nor does it suggest forming designs in the molded product.

0 8 07 13:22 Id/ 27 P:OPERPWHHI183rI J157l -3- SUMMARY OF THE INVENTION One form of the present invention relates to a cook-in mold comprising shaped body sections sealed together by a mold sealing means to form a generally tubular mold body having a first end and a second end, said cook-in mold body having a plurality of holes to produce a multifaceted design cut through the walls of each of said shaped body sections.

Another form of the present invention relates to a method of forming a moldable meat product having a design molded therein, including the steps of: loading a moldable meat product into a stuffing horn of a meat stuffer; placing a cook-in casing, having a first casing 10 reck end, and a second neck end, onto said horn, the length of said casing being greater than the length of the cook-in mold, into which said casing will later be introduced, t define a second casing neck end; advancing said meat product from said horn to fill the thermoplastic cook-in casing; substantially removing meat product from within said first and second casing neck ends; retracting said casing from said horn and closing said first and second casing neck 0 ends by, for example, gathering and clipping; and introducing the filled, neck clipped casing .0 into a cook-in mold in accordance with the invention.

Yet another form of the present invention relates to a method of forming a moldable meat product, including the steps of: loading a moldable meat product into a stuffing horn of a meat stuffer; placing a cook-in casing onto said horn; placing a cook-in mold over said 20 casing so that said casing lines said mold, the length of said casing being greater than the length of said mold to define first and second casing neck ends; advancing said meat product from said horn to fill the cook-in casing; substantially removing meat product from within said casing neck ends; retracting said casing from said horn and closing said casing neck ends by, for example, gathering arid clipping; wherein the cook-in mold is in accordance with the invention.

A further form of the invention relates to a method for forming a vacuum packaged moldable meat product, employing a vacuum stuffing apparatus, said apparatus having a stuffing horn portion and a vacuum chamber portion, including the steps of: loading a moldable meat product into a stuffing horn of a meat stuffer; placing a heat shrinkable, thermoplastic cook-in casing onto said horn; placing a rigid to semi-rigid cook-in mold over 6 97:13 c2 2 11/ 27i P:\OPERU\PUHMI5I.S7 -6/6P7 -4said casing so that said casing lines said mold, the length of said casing being greater than the length of said mold to define first and second casing neck ends; vacuumizing said chamber; and after a holding period sufficient to deaerate said meat; advancing said meat product from said horn to fill the casing lined mold; substantially removing meat product from within said neck ends; retracting said mold from said horn and closing said casing neck ends by, for example the gathering and closing; and venting said vacuum chamber wherein the cook-in mold is in accordance with the invention.

The closing of the first and second casing neck ends alternatively may be by heat sealing.

The cook-in casing may be thermoplastic or fibrous.

A still further embodiment of the invention relates to a cased cook-in meat product having a multifaceted design molded therein using any of the methods of the present invention. The product may then be cooked in the mold.

*o Preferred forms of the invention, given by way of example only, as well as other embodiments, objects, features and advantages of this invention, will be apparent from the following detailed description which is to be read in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows a side plan view of one embodiment of a cook-in mold with a pressure sate, a spring and end plate assemblies.

SFIG. 2 shows a st side view of the cook-in mold of Fig. 1 with a casing and packaged meat product ti~re a fare cooking.

FIG. 3 shows a schematic side view of the cook-in mold of Fig. 1 with a casing and packaged meat product therein after cooking.

FIG. 4 shows an end view of a two piece cook-in mold of the present invention using a hinge means to allow opening of the mold and removal of the cased cook-in meat product.

FIG. 5 shows a cross-sectional view of several slices of meat product produced using

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4 A Vte cook-in mold of the present invention.

/T O (jfY II 6 7:13:22 12/ 27 POPERIUr0 l835. 157 6/9 DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION The present invention will be better understood from the specification taken in conjunction with the accompanying drawings in which like reference numerals refer to like parts.

In FIG. 1 there is shown a cut away view of a preferred embodiment of the present invention comprising a two piece cook-in mold 10 having body sections 1 2, end plates 3 at each end secured via securing means 4 attached thereto. Additionally, to provide flattened ends of the cased cook-in meat product pressure plate 5 having pressure exerted against it by 10 spring 6 may be used. Further, each mold zection 1 2 has holes to produce a multifaceted design 8 cut into the mold section walls in a desired pattern.

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PATENT

S Case No. 41928 FIG. 2 shows the cook-in mold 10 of FIG. 1 with a casing 24 containm~a in Fi ore meat product 23 (not shown nside the mold before cooking. Further is shown both casing ends having been clipped with clips 21 on neck portions 22. As can be seen pressure plate 5 and spring 6 have caused the meat filled ends of casing 24 to be flattened. This flattening is colloquially referred to as "squaring off" of the ends of the cased meat product and it increases product yield by providing a greater amount of uniform sized meat product per casing length.

In FIG. 3 is shown the cook-in mold 10 of FIG. 1 with a casing 24 containin meat product 23 inside the mold after cooking. The cook-in procedure causes the cased meat product to swell and enter the multifaceted design pattern cutouts 8, producing the desired molded shape in the cooked cased meat product.

FIG. 4 shows an end view of the mold 10 having sections 1 2 and having a hinge means 40 and opening seam 41 for opening and closing said mold FIG. 5 shows cross-sectional views of several slices of cased meat product which have been molded during the cook-in process using molds of the present invention. These shapes are desirable for sale in up-scale dell shops and meat departments where they will bring a premium price for the meat product.

In practice the mold sections of the present invention are sealed together by a sealing means, a casing is introduced into the mold. and one end cap and one pressure plate are put in place on the mold first end. The uncooked meat product is introduced into the casing and once the casing is filled the second end cap. with or without a second pressure plate, is placed on the second end of the mold. The meat product Is then cooked utilizing a cook-in means. The swelling of the meat product during the cook-in process forces the casing and meat product to enter the multifaceted design cut outs in the mold sections thereby molding the multifaceted design into the meat product. The cooked, molded meat product is then removed from the heat. and then it is chilled following standard industry practice. The mold end plates and pressure plates are removed and the mold sections are separated, allowing the cooked meat product with the multifaceted design molded therein to be removed so that it is ready for shipment and sale.

The cook-in mold sections 1 2. of the present invention, may be made from stainless steel or from polymeric material, Preferably, the mold sections i -Y IliU- 91-- 1411111116111

PATENT

Case No. 41928 are made from polymeric material which lowers cost, decreases the mold weight and provides safer handling by workers.

The use of stainless steel, its composition. forming, and mold construction are well known by those skilled in the art. Likewise. methods and procedures for introducing the multifaceted designs into the walls of the mold sections are well known and need no further discussion here. Suffice to say that known methods of cutting and punching shaped holes Into stainless steel sheet is well known and is not critical to the present invention. The stainless steel cook-in molds of the present invention may be of any desired length. For example lengths of 15 inches to 6 feet are easily provided. Further. these stainless steel cook-in molds may be utilized in the stuffing and cooking equipment currently In use. This eliminates the need for the meat processor to install new equipment and the consequent expenses entailed therewith.

Polymeric cook-in mold sections 1 2 may be made from any semi-rigid to rigid polymeric material which maintains Its shape and dimensions under the temperature and pressure conditions encountered during the cook-in process and subsequent storage. Such conditions are well known and understood in the art. Suitable polymeric materials include, for example, polymers such as, polyoleflns, polyvinyl chloride, polyethylene, polypropylene. cop"-ymers thereof. as we.ll as cast acrylic, and the like. The presently preferred polymeric mold material Is a propylene copolymer. because this material is approved for S food contact. The mold profile can be of any desired shape and is not restricted to the rectangular shape of stainless steel molds. In addition the cost of the polymeric cook-in mold ft.Lr: i. is substantially less expensive than stainless steel molds currently used in the cook-in packaged meat industry. Mold shapes such as the highly desirable round shape for luncheon meats. D shape for turkey breast emulsion, tear drop shape, and mandolin q shape for ham products are all easily produced by known extrusion processes of the polymeric mold materials. It is to be understood that square shapes are also easily accomplished. In addition, almost any other desired irregular shape. for use in upscale deli products for example, may be obtained as well as rectangular shapes where desired. The polymeric cook-in molds o..e e =inventi9may be of any desired length. For example lengths of 15 Inches to 6 feet are easily provided. Further, these polymeric cook-in molds may be utilized in the stuffing and cooking equipment currently in use. Again, this ellmii irsl -L r14

PATENT

Case No. 41928 nates the need for the meat processor to install new equipment and the consequent expenses entailed therewith.

In the case where the polymeric cook-in mold S p-iw e'-nt arf is used in machinery having metal molds, the end caps of the metal molds may be utilized thereby eliminating the need for separate end caps and pressure plates in the polymeric cook-in molds. Thus, the polymeric cook-in molds.af: -the pi-- "Fr maybe inserted into the preexisting metal molds and then the metal mold end caps and pressure plates put in place.

It is to be appreciated that while two body sections are, preferred, a mold comprised of more than two body sections may be utilized without departing from the Intent and scope of the present invention. This may be particularly advantageous for some elaborate mold shapes.

The sealing means for combining the mold body sections may be any suitable sealing means well understood In the art and is not critical to the invention. Suitable means include hinge and latch, and straps, for example.

Methods and means of sealing mold sections together such that they may be separated after processing of the mold contained product are well known and understood in the art.

Any of the well known "cook-in package" meat casing materials may be used with the present invention. Thus, a packaging material structurally capable of withstanding exposure to cook-in time-temperature conditions while containing a food product is suitable. The use of shrinkable casing material is especially well suited for use with the present invention. Suitable casing materials include, for example, fibrous casings, moisture proof fibrous casings, cellulosic casings, and casings made from thermoplastics, elastomers, thermoplastic elastomers. polyesters, polyolefins, polyesters, dopolyesters, polyurethanes, polysytrenes, polycarbonates, polyvinyl acetate, polyvinyl chloride, polyvinylidene chlorides, polyamides, and polyalkaline carbonates. A particularly preferred packaging.material is thermoplastic bi-axially oriented polyolefin film. The casings may be in the form of individual bags, sticks of shirred casings or continuous casing tubing, Further, the casings may be clipped on both ends and the Individual bags may have one heat sealed end or one end closed by any other known means. The use of such casing materials and forms is well understood by routineers In the art.

0- 6-97:' 3:22 1 1i/ vi P:;OPER\FPHH1 3 1i7 1- &W -9- Suitable design shapes which may be cut into the mold sections walls include, for example, circles, half circles, squares, rectangles, diamonds, and ovals. Other shapes are also suitable and may be utilized and are considered within the scope of the present invention.

The present invention may be used with any suitable casing stuffing or sizing machine.

Examples of suitable stuffing, sizing and vacuum packaging machinery include, for example, the ROBOT 3000 DC av4ilable from Robert Reiser Co., Inc. and Handtmann VF available from TW Kutter, Inc., the RS 4201 available from Tipper Tie, the Shirmatic 400 and 600 series available from Viskase and the Mepaco stuffing system and the Cryovac® 8490/8150 vacuuming packaging system. These machines are well known in the art and need 10 no further discussion here.

Although the illustrative embodiments of the present invention have been described herein with reference to the accompanying drawings it is to be understood that the invention is not limited to those precise embodiments, and that various other changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of 15 the invention, as defined by the appended claims.

Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion Sa..

of any other integer or group of integers.

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Claims (16)

1. A cook-in mold comprising shaped body sections sealed together by a mold sealing means to form a generally tubular mold body having a first end and a second end, said mold body having a plurality of holes of a multifaceted design cut through the walls of each of said shaped body sections.

2. A cook-in mold as claimed in Claim I wherein said mold body has a composition selected from the group comprising, stair steel, polyvinyl chloride, polyethylene, 10 polypropylene, cast acrylic polymer and cot ations thereof. e 9g

3. A cook-in mold as claimed in Claim 1 or Claim 2 wherein said mold body comprises two body sections. a S

4. A cook-in mold as claimed in Claim I or Claim 2 wherein said mold body comprises more than two body sections.

A cook-in mold as claimed in any one of Claims 1 to 4 wherein said mold sealing S* means comprises a hinge means and a latching means.

6. A cook-in mold as claimed in any one of Claims 1 to 4 wherein said mold sealing means comprises a strap means. 20

7. A cook-in mold as claimed in any one of the preceding claims which is further defined as having a respective end plate securable by a securing means on each end of said cook-in mold body.

8. A cook-in mold as claimed in Claim 7 wherein at least one of said end plates has a hole therein to allow for a neck end of a casing in the mold body to protrude outside of the mold body. ii i ri 1 1 a i 2 P;oPERMWisH\ ,3S7 -S&7 11

9. A cook-in mold as claimed in Claim 2 or any claim dependent therefrom wherein, said mold body comprises propylene copolymer.

A method of forming a moldable meat product having a design molded therein, including the steps of: a) loading a moldable meat product into a stuffing horn or a meat stuffer; b) placing a cook-in casing, having a first casing neck end, onto said horn, the length of said casing being greater than the length of the cook-in mold, into which said casing will later be introduced, to define a second casing neck end; c) advancing said meat from said horn to fill the thermoplastic cook-in casing; d) substantially removing meat from within said first and second casing neck ends; e) retracting said casing from said horn and closing said first and second casing neck ends; and 0* 0 f) introducing the filled, neck closed casing into a cook-in mold, wherein the cook-in mold is comprised of: shaped body sections sealed together by a mold sealing means to form a generally tubular mold body having a first end and a second end, said cook-in mold body having t*o a plurality of holes of a multifaceted design cut through the walls of each of said 20 shaped body sections. 06 a. 0

11. A method of forming a moldable meat product, including the steps of: Sa) loading a moldable meat product into a stuffing horn of a meat stuffer; b) placing a cook-in casing onto said horn; c) placing a cook-in mold over said casing so that said casing lines said mold, the length of said casing being greater than the length of said rmold t' define first and second casing neck ends; d) advancing said meat from said horn to fill the thermoplastic cook-in casing; e) substantially removing meat from within said casing neck ends; f) retracting said casing from said hom and closing said casing neck ends; a. 07,1322 *BV 87 P.:oPERPHH\5183l.157 d6I -12- wherein the cook-in mold is comprised of: shaped body sections sealed together by a mold sealing means to form a generally tubular mold body having a first end and a second end, said cook-in mold body having a plurality of holes of a multifaceted design cut through the walls of each of said shaped body sections.

12. A method for forming a vacuum packaged moldable meat product, employing a vacuum stuffing apparatus, said apparatus having a stuffing horn portion and a vacuum chamber portion, including the steps of: 10 a) loading a moldable meat product into a stuffing horn of a meat stuffer; b) placing a heat shrinkable, thermoplastic cook-in casing onto said horn; c) placing a rigid to semi-rigid polymeric cook-in mold over said casing so that •S said casing lines said mold, the length of said casing being greater than the length of said mold to define first and second casing neck ends; 15 d) vacuumizing said chamber; and after a holding period sufficient to deaerate said meat; e) advancing said meat from said horn to fill the casing lined mold; f) substantially removing meat from within said neck ends; g) retracting said mold from said horn and closing said casing neck ends; and S 20 h) venting said vacuum chamber, wherein the cook-in mold is comprised of: so shaped body sections sealed together by a mold sealing means to form a generally tubular mold body having a first end and a second end, said cook-in mold body having a plurality of holes of a multifaceted design cut through the walls of each of said shaped body sections.

13. The method of any one of Claims 10 to 12, wherein said closing of the neck ends is by gathering and clipping or heat sealing.

14. A method for forming a moldable meat product substantially as herein described with &T 0 i 6 0 7 11i22 I 17/ 2 7 PA0PEaRf1.nM~18S1 WM9 13 reference to the accompanying drawings.

A product produced by the method of any one of Claims 10 to 14.

16. A cook-in mold substantially as hereinbefore described with reference to the drawings. S S SOe S S. 55 o S S S OS S S S6SSSS S *S 5 0 S S 055 10 DATED this 6th day of June, 1997. W. R. GRACE CO. -CONN. By its Patent Attorneys DAVIES COLLISON CAVE :0. 0 s 0* 0 *o*so S.0 1__1 ~I ABSTRACT A cook-in mold for use with cased meat product Is disclosed. This cook- in mold has a multifaceted design incorporated In its side walls to produce a cook-in cased meat product having said design molded therein. Further, this cook-in mold can be formed into any desired cross sectional shape. Including for example, round, square. rectangular,. oval. D shaped, tear drop shaped and mandolin shaped. The cook-in mold leads to very uniform diameter of the cased meat product and with the use of end plates and pressure plates, flat- tened casing ends. all ofwhich lead to more uniform slices of the cased product and increased yield after cooking. e* e S o S O i Fi I P~