Reduced Oxygen Packaing

The Food Processing Center Author

06/05/2019 Added

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In this lecture an overview of Reduced Oxygen Packaging is provided, along with some definitions, risks and misconceptions associated with this process.

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[00:00:04.720]So I'll just start with a introduction to myself.
[00:00:07.180]So my name is Jayne Stratton,
[00:00:08.820]and I'm a research assistant professor
[00:00:10.820]in the Food Science department.
[00:00:12.750]I've been with the university for a very long time.
[00:00:16.850]And my role here is as a food safety microbiologist.
[00:00:20.950]So I manage a service lab
[00:00:23.260]that does testing for the food industry.
[00:00:26.150]We test for pathogens, indicator organisms.
[00:00:29.910]We do shelf life studies.
[00:00:31.860]I also do acidified food reviews.
[00:00:35.540]For anybody that's doing acidified foods,
[00:00:38.130]I do that work as well.
[00:00:40.660]So my colleague Dr. Bianchini and I have done a number
[00:00:44.070]of workshops like this.
[00:00:45.410]We also teach preventive controls for human food
[00:00:48.510]and for animal food.
[00:00:50.470]So we've kinda been a team over the years,
[00:00:53.610]so it's been a real pleasure to work with her
[00:00:55.620]on projects like this.
[00:00:58.450]So we've set it up as basically three different topics.
[00:01:03.340]Our first one is gonna be the overview
[00:01:05.380]of reduced oxygen packaging.
[00:01:08.340]And instead of saying reduced oxygen packaging
[00:01:10.950]throughout all of our lectures, we're just gonna say ROP,
[00:01:14.080]so that'll make things a little bit simpler.
[00:01:16.750]And this is what I'll be covering in this first lecture,
[00:01:19.740]and then I'll be covering the types of processes
[00:01:22.750]that fall under the ROP category.
[00:01:25.930]And then Dr. Bianchini is gonna be looking
[00:01:28.570]at the safety concerns, particularly with the microbiology
[00:01:32.780]of these types of processed foods.
[00:01:37.310]So our first topics, we have an introduction.
[00:01:40.320]So what is ROP, okay?
[00:01:43.130]And then there's gonna be definitions related to that
[00:01:46.090]and what the benefits are.
[00:01:48.440]Why are people using this?
[00:01:50.370]As we heard from one of the inspectors,
[00:01:52.310]there's a lot of idle machines out there, okay,
[00:01:54.890]and we need to get those running
[00:01:56.320]because ROP is really a great process,
[00:01:59.360]not only for certain types of cooking processes,
[00:02:03.090]it can enhance flavor,
[00:02:04.690]but also just to improve shelf life, okay.
[00:02:07.950]And then we'll kinda cover a few misconceptions
[00:02:10.780]and risks associated with ROP.
[00:02:13.650]So this first lecture is gonna be fairly brief,
[00:02:16.520]but I think it's gonna put us on the right track.
[00:02:20.620]So what is ROP?
[00:02:22.570]Pretty simple.
[00:02:23.403]You have food.
[00:02:25.660]You put it in a package.
[00:02:28.040]You remove the oxygen.
[00:02:30.360]And then you have a sealed product, okay.
[00:02:32.750]Pretty simple, right?
[00:02:34.420]Okay, well, it gets a little bit more complicated
[00:02:37.030]as we go into some of those processes,
[00:02:38.820]but essentially that's the basic concept.
[00:02:44.110]So there's two definitions that we have to be aware of,
[00:02:46.730]and the first one is the term aerobic, okay.
[00:02:51.400]When we think of the word aerobic, what do we think of?
[00:02:54.890]Exercise, right?
[00:02:56.190]Aerobic exercise,
[00:02:57.780]because you're breathing, bringing in oxygen.
[00:02:59.910]So aerobic, that just means with air.
[00:03:02.860]Okay, so aerobic conditions mean
[00:03:05.870]that your product is in the air.
[00:03:10.090]It's in the environment.
[00:03:11.440]So you see a piece of meat here sitting on a cutting board,
[00:03:14.490]maybe being processed, maybe being cooked.
[00:03:17.950]So these are aerobic conditions, okay.
[00:03:21.170]And as we'll find out, there are certain organisms
[00:03:24.630]that like the aerobic conditions.
[00:03:27.160]They need oxygen to reproduce.
[00:03:31.710]The second definition is an anerobic condition.
[00:03:34.640]So there's gonna be no oxygen in that environment, okay.
[00:03:39.080]So we can see in this first picture,
[00:03:40.910]somebody is placing these meat products into a bag,
[00:03:44.260]probably to go into some type of a water bath cook process.
[00:03:47.800]And then this last picture is a pretty good picture showing
[00:03:51.380]that meat products that's been vacuum-sealed.
[00:03:55.450]So you've pulled all of the oxygen
[00:03:57.527]and the air out of that bag.
[00:03:59.970]Okay, so that's an anerobic condition.
[00:04:02.900]And as we'll see later on,
[00:04:04.780]the anerobic condition is conducive
[00:04:08.070]to certain microorganisms' growth.
[00:04:10.890]Okay, they don't like air,
[00:04:12.250]so they're perfectly happy growing
[00:04:13.750]in these types of environments.
[00:04:17.720]So the benefits of ROP,
[00:04:21.070]I've talked about it a little bit already.
[00:04:22.620]It prevents the growth of spoilage organisms.
[00:04:25.530]So can anybody name some spoilage organisms?
[00:04:29.078]Botulism.
[00:04:30.010]Botulism, is that a spoilage organism?
[00:04:33.620]I don't know.
[00:04:35.034]Well, it makes you sick, right?
[00:04:36.520]Mm-hmm.
[00:04:38.760]What else might you see on food products that spoils it?
[00:04:44.537]The moisture.
[00:04:46.290]What about that moldy cheese
[00:04:47.650]in the back of your fridge? (laughs)
[00:04:50.810]So mold.
[00:04:52.520]What about that slimy green piece of meat
[00:04:55.250]that you forgot about that's in the back of your fridge?
[00:04:58.290]That's bacteria that causes that spoilage.
[00:05:01.500]And then yeast.
[00:05:03.050]Yeast can also spoil products as well.
[00:05:05.380]One common thing with these spoilage organisms
[00:05:08.510]is most all of 'em require oxygen.
[00:05:10.910]Okay, so if you take the oxygen out, then you can,
[00:05:15.390]that goes a long way
[00:05:16.290]towards preventing something like mold growth.
[00:05:19.790]Prolongs the quality, okay.
[00:05:22.680]So in addition to preventing microorganisms from growing,
[00:05:26.360]it can also reduce things like rancidity.
[00:05:29.340]Okay, so oxidative rancidity.
[00:05:31.530]If you have a product that's high in oils,
[00:05:34.460]if there's a lot of oxygen in there,
[00:05:36.030]then it can cause a rancid product.
[00:05:37.690]So if you take out that oxygen,
[00:05:40.400]then you can reduce that rancidity from occurring.
[00:05:45.040]And then finally, all of these benefits
[00:05:47.270]will extend the shelf life of the product.
[00:05:54.880]So the benefits, again, I've mentioned,
[00:05:56.870]prevention of spoilage organisms.
[00:05:58.710]So you have a low oxygen environment.
[00:06:01.520]Prevents the growth of aerobic bacteria, yeasts, and molds.
[00:06:08.720]Here it shows some pictures of some moldy products.
[00:06:13.220]Again, so our moldy cheese.
[00:06:14.910]We have some mold growing on some strawberries.
[00:06:17.780]So what spoilage organisms do,
[00:06:21.750]in addition to just really looking really terrible,
[00:06:24.610]is they can cause slime, texture changes, off odors.
[00:06:29.520]So it's really a product that nobody's gonna wanna consume.
[00:06:35.600]And this is just a summary slide
[00:06:37.170]that talks about the different benefits of ROP processing.
[00:06:41.270]So it's gonna prolong your quality
[00:06:42.800]by reducing fat oxidation and rancidity,
[00:06:45.840]prevent chemical reactions
[00:06:47.440]that produce off odors and color change,
[00:06:49.900]reduces aerobic bacterial growth,
[00:06:52.450]and then eliminates the risk
[00:06:53.550]of contamination during storage.
[00:06:55.890]And it's gonna extend the shelf life.
[00:06:57.910]So one of the things you're also doing
[00:06:59.430]in addition to taking out the oxygen
[00:07:01.170]is you're placing an airtight barrier over that product.
[00:07:04.680]So that barrier or that film,
[00:07:06.930]that's also gonna prevent other things
[00:07:08.730]from getting in there,
[00:07:09.930]like people's hands being able to move that product around.
[00:07:13.610]You're not directly touching that product.
[00:07:16.700]I like to think of insects too.
[00:07:18.560]I mean, insects are everywhere,
[00:07:19.780]but that product is protected by that seal,
[00:07:22.800]that airtight package.
[00:07:27.580]So why would you wanna use ROP in retail?
[00:07:30.380]It's gonna reduce your preparation and clean-up times.
[00:07:33.810]You can have portion control.
[00:07:37.800]Sometimes there's a problem maybe making too much product.
[00:07:40.600]How do you store it properly?
[00:07:42.380]This way you can do individualized bags.
[00:07:45.570]Less mess, fewer utensils, extends shelf life,
[00:07:48.560]and then creates a tender or more flavorful food product.
[00:07:52.730]So, for example, with the sous vide processing.
[00:07:58.720]So misconceptions.
[00:08:01.110]So let's read this statement.
[00:08:03.850]Sealing food in vacuum packs eliminates the need
[00:08:06.720]to handle it properly.
[00:08:08.350]True or false?
[00:08:09.783]False.
[00:08:10.616]False.
[00:08:11.449]I'm so glad nobody said true. (laughs)
[00:08:14.210]But sometimes you think about it,
[00:08:16.190]when we go to the grocery store,
[00:08:18.300]we see all of this beautiful product
[00:08:21.070]that's beautifully packaged.
[00:08:22.990]We kinda grab it and toss it into our basket, right?
[00:08:28.143]Okay, we think that the packaging is,
[00:08:30.767]we're attributing a lot more
[00:08:32.930]to that packaging than we should.
[00:08:35.030]So we really wanna make sure
[00:08:36.530]that we're handling all of this product properly,
[00:08:38.960]even though it looks like it's packaged.
[00:08:41.720]One of the other things about ROP in particular is
[00:08:45.170]that we have this issue of foodborne botulism,
[00:08:48.570]which was brought up earlier.
[00:08:51.180]When we're taking out oxygen in that package,
[00:08:54.490]that means this particular organism, clostridium botulinum,
[00:08:59.100]it's a perfect environment for that organism to grow, okay.
[00:09:03.930]And we use refrigeration primarily
[00:09:07.450]to prevent the organism from growing.
[00:09:09.900]Okay, so this is a extremely dangerous organism.
[00:09:12.710]And there have been some cases associated with ROP packages,
[00:09:18.090]and I've added a couple of those here.
[00:09:19.790]So this first one is a case in 2009.
[00:09:23.540]It was an outbreak of botulism linked
[00:09:25.380]to vacuum-packed hot-smoked whitefish in France, okay.
[00:09:30.150]And then we have a table over here of incidents
[00:09:32.990]of foodborne botulism with, involving C. botulinum.
[00:09:38.920]So this table starts in 1982 and goes up to about 2004,
[00:09:44.020]but what I really wanna point out in this table
[00:09:48.100]is the factors contributing to the botulism outbreak.
[00:09:51.800]So time after time,
[00:09:53.210]you're seeing temperature abuse pop up, okay.
[00:09:57.220]So even though you're vacuum-packaging,
[00:09:59.100]you have a good seal,
[00:10:00.320]everything is being done correctly on the process side,
[00:10:03.240]you have to make sure that the temperature
[00:10:06.360]of your holding temperatures
[00:10:09.410]are not gonna be abusing that product.
[00:10:12.710]Okay, so that's gonna be one important thing
[00:10:15.720]to really note when you're doing this process.
[00:10:19.220]And also any of you out there
[00:10:21.000]making homemade fermented beaver tail and paw
[00:10:24.740]or homemade beluga whale?
[00:10:28.150]Just be careful, that made the list. (laughs)
[00:10:34.790]okay, a couple more misconceptions and risks,
[00:10:37.530]so a couple more outbreaks.
[00:10:40.410]Not outbreaks, but these are recalls.
[00:10:43.170]So the last thing if you're processing food
[00:10:45.960]and it's going out to your consumers is you wanna recall it.
[00:10:49.510]That's just a nightmare, right?
[00:10:52.060]So in this first case,
[00:10:53.990]we had a recall of smoked wild coho salmon,
[00:10:57.060]and this was recalled for a botulism risk.
[00:10:59.570]And if you note the date on that, that's 2018,
[00:11:02.410]so it's a pretty recent occurrence.
[00:11:04.610]And the problem with this is it was a low salt,
[00:11:07.450]vacuum-packed fish.
[00:11:09.390]And on the label,
[00:11:10.740]it said you could refrigerate it or freeze it.
[00:11:13.970]Well, according to the rules,
[00:11:16.740]low salt fish has to be kept frozen until use.
[00:11:20.330]Okay, so that's why they had to do this recall.
[00:11:24.370]There's a potential of one type of clostridium
[00:11:28.580]that can grow at the lower temperatures,
[00:11:30.940]okay, and it's especially associated with fish.
[00:11:33.290]So it was a high-risk product,
[00:11:35.770]and it needed to be kept frozen until use.
[00:11:39.590]In this other case, the title up here says,
[00:11:42.297]"Illinois Firm Recalls Chicken Products Produced
[00:11:44.527]"Without Adequate Ready-To-Eat HACCP Plan
[00:11:47.047]"and a Listeria Monocytogenes Program."
[00:11:50.420]And the problem with this is they were doing fully cooked,
[00:11:54.610]vacuum-packed chicken tamales,
[00:11:56.570]but they were processing without a HACCP plan.
[00:11:59.070]Okay, and they needed to have a HACCP plan
[00:12:01.440]in order to produce this product, so they had to recall it.
[00:12:04.860]So again, when we get into the regulatory part,
[00:12:07.390]it's gonna be very important to comply
[00:12:09.490]with some of these items,
[00:12:11.620]like making sure you have a HACCP plan.
[00:12:16.030]So just to summarize.
[00:12:18.290]So with the misconceptions and risks,
[00:12:19.830]you need to store frozen food in the freeze,
[00:12:22.110]thaw in appropriate manner.
[00:12:23.860]The vacuum seal is not gonna kill bacteria.
[00:12:26.690]And the vacuum packaging does not
[00:12:28.410]automatically make food safe
[00:12:30.160]and eliminate that need to take precautions, okay.
[00:12:35.130]So it's gonna be important
[00:12:36.060]to maintain vigilance in food safety
[00:12:38.610]when you're producing these types of products, okay.
[00:12:44.200]So that finishes out our overview,
[00:12:46.540]next, we'll switch over
[00:12:47.690]and go over some of the processes that we use.

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Reduced Oxygen Packaing

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