entry for 2012 rca student culinology competition

RCA 2012 STUDENT CULINOLOGY® COMPETITION PROPOSAL

1

729

��

TABLE OF CONTENTS

Executive Sell Sheet 3

Product Summary 3

Photo 3

Costing 3

Packaging 4

Shelf Life and Storage 4

Serving Options 4

Nutritional Fact Panel 4

Ingredient Statement 4

Allergens 4

Description of Tex-Mex Appetizer Cuisine 5

Gold Standard Recipes 7

Commercialized Production 9

Formulations 9

Technical Ingredients 11

Production 12

Processing Flow Chart 15

Packaging 16

Packaging Costs 17

Shelf Life and Storage 18

Preparation and Plating 18

References 19

Works Cited 20

2

729

COSTING

A single box (unit) of Mini Pork Taco Dippers includes 6 portions, each costing $1.33 for a total

unit cost of $7.99 and $191.76 per case (24 units). The food cost per portion is 20.18% and the

packaging cost per portion is 4.49% for a combined cost of 24.67%. This is just under the goal of

25%, which leaves room for modification if needed. The food cost accounts for a 20% pork trim

loss, 20% pork cook loss, and a 15% loss in the milling of the corn. The packaging cost includes

film for pouches, nitrogen flush for the taco shells, carton, and case. Although it is not currently

factored into the cost, the high amount of automation in the processing flow and the use of

equipment with high capacities will reduce production time and therefore labor costs.

3

729

EXECUTIVE SELL SHEET

PRODUCT SUMMARY

A premiere provider of frozen foods, Hill Country Foods presents Mini Pork Taco Dippers as

the newest addition to their line of Tex-Mex inspired products. This sharable appetizer is a

delicious and easy-to-prepare dish that the whole family can enjoy. Each kit features diced and

fully-cooked pork shoulder with carne asada seasoning, blue and white crunchy corn taco shells,

a roasted corn guacamole, Sargento® white queso sauce, and a classic garden salsa.

The vibrant colors and bold flavor combinations

will make this prepared appetizer stand out in the

frozen food section of any major club store. The

product has been designed to target busy families,

specifically families of Hispanic heritage. United

States 2010 Census data indicates that over half of the

increase in total population in the US between 2000 and 2010

was due to the increase in the Hispanic population. This Tex-Mex style product incorporates both

exotic Mexican and familiar American ingredients making this appetizer just adventurous

enough to intrigue any club store shopper. Parents will love the high value ingredients at an

exceptional price and the simple preparation that caters to a busy schedule. Kids will enjoy the

interactive aspect of dipping the multicolor taco shells into three different sauces. Mini Pork

Taco Dippers are a perfect finger food for game day gatherings or fiesta themed dinner parties.

INGREDIENTS: SEASONED PORK MEAT: (pork, water, salt, onion powder, g a r l i c p o w d e r, s u g a r, s o d i u m phosphate, chili powder, paprika, ground black pepper, liquid smoke), WHITE QUESO SAUCE: (water, milk, interesterified soybean oil, whey, red bell peppers, contains less than 2% of cheese culture, citric acid, enzymes, lactic acid, salt, sodium alginate, sorbic acid (preservative), spice, sugar, xanthan gum), TACO SHELLS: (white and blue corn masa, water, soybean oil, salt), SALSA: (tomato, white onion, lime juice, cilantro, garlic, s a l t , g r o u n d b l a c k p e p p e r ) , GUACAMOLE: (Hass avocado, roasted corn, red onion, cilantro, lime juice, salt, ground black pepper)

ALLERGENS: Contains milk.

PACKAGING

The five components of Mini Pork Taco Dippers (pork

meat, taco shells, and three sauces) are packaged separately

in film pouches for optimum flavor and texture

preservation. All components will be packaged in a carton,

and 24 cartons will be packaged into a case. All packaging

films and boxes were specifically chosen to withstand

freezing temperatures.

SHELF LIFE AND STORAGE

In order to reduce the amount of technical ingredients used

and to produce a cleaner label, the product utilizes a

combination of processing methods and packaging to

extend shelf life to 180 days. The extended shelf life was

tailored to optimize the time necessary to sell the product in

a club store.

SERVING OPTIONS

Mini Pork Taco Dippers are to stored frozen until 24 hours

before serving. At that point, the taco shells can be removed

from the carton and allowed to thaw at room temperature,

and the rest of the components can be placed under

refrigeration. After 24 hours, both the pork meat and white

queso sauce can be reheated prior to serving. The consumer

plays a very interactive role with this sharable appetizer

and is able to fill the mini taco shells with savory pork meat

and dip them into each sauce.

Shown to the right are the Nutrition Facts and Ingredient

Statement for our product.

4

729

5

729

DESCRIPTION OF APPETIZER TEX-MEX CUISINE

Neither truly Texan nor truly Mexican, Tex-Mex cuisine is a blending of the two cultures.

This unique amalgamation of cuisines resulted from the many flags that have flown over Texas.

Spain, France, and Mexico have all retained possession of Texan territory at some point in

history and each culture has left its imprint on the region. The ancient civilization of the Aztecs

also contributed many staples foods like corn and beans. This fusion cuisine has been

perpetuated by the influx of immigrants from Mexico and by Tejanos (Texans of Mexican

decent). The mighty Rio Grand river carves the border between the United States and Mexico.

Close to the border lay cities like El Paso, Houston, and San Antonio where Texan and Mexican

cultures collide and Tex-Mex cuisine thrives.

Although they share many similar ingredients, Tex-Mex cuisine is not to be confused

with Southwestern cuisine, which originated from Native American tribes that inhabited the

southern regions of the United States. Tex-Mex dishes are traditionally composed of a

combination of authentic Mexican and native Texan ingredients and require the use of unique

cooking equipment such as cast iron skillets and tortilla presses. Common Tex-Mex dishes

include such preparations such as chili con carne, tamales, goriditas, enchiladas, tortas, and

fajitas. Entrée dishes usually consist of very generous portions of the main component

accompanied by mountainous sides of rice and beans. Appetizers are usually more composed

and served in smaller portions or in a communal family style. Common appetizers include

ceviche, quesadillas, nachos, chili con queso, empanadas, and flautas accompanied by dipping

sauces. The product development team at Hill Country Foods has chose ingredients for this

product that are commonly found in Tex-Mex cuisine, including pork, corn, avocado, tomato,

garlic, onion, cumin, and cilantro.

The Mini Pork Taco Dippers can be found in the frozen foods sections of a club store

and has all the components needed for a delicious sharable Tex-Mex style appetizer. Initially, the

consumer will be intrigued by the vibrant colors of the product as shown on the front of each

box. This is especially important because consumers often eat with their eyes first. Each six

portion kit includes 6 ounces of fully-cooked carne asada seasoned pork meat, 18 mini crunchy

blue and white corn taco shells (9 shells of each color), 3 ounces of roasted corn guacamole, 3

6

729

ounces of Sargento® white queso sauce, and 3

ounces of classic garden salsa. Each kit includes

enough pork meat to fill every shell and sauce to dip

every taco. The product development team at Hill Country Foods

designed small portions (3 taco shells, 1 ounce of pork meat, and 0.5

ounces of each sauce) that would intrigue the palate and set the stage for

the rest of the meal. Crunchy tacos, queso, salsa, guacamole, and carne asada meat are all

common preparations in Tex-Mex cuisine. The product takes these elements that are

familiar to most consumers and combines them in a new and innovative way.

The specific target market for this product is a busy Hispanic family in

search of an appetizer that is easy to prepare, includes high quality ingredients,

and can be purchased at a relatively low cost. These delicious Mini Pork Taco Dippers, priced at

$7.99 for six portions, will meet all criteria for this family. The Hispanic population in the

United States has undergone rapid growth over the past few decades. According to the US 2010

Census, over half of the total population growth in the United States from 2000 to 2010 was

attributed to the increase in the Hispanic population, which accounted for 15.2 million people, of

which 75% were of Mexican heritage. Although the Hispanic population grew in every region of

the United States, the most significant growth occurred the South and Midwest. It is because of

these statistics it is believe that the target market will grow along with profits derived from the

product. The quick and easy preparation of this product is aligned with current

food industry and market trends leaning toward convenience items.

Families of non-Hispanic heritage will also be interested in this new

twist on Tex-Mex appetizers. This particular cuisine is just

adventurous and exotic enough to intrigue most consumers

without being too far outside their comfort zone. Hill Country

Foods is excited to make this addition to its repertoire of

Tex-Mex inspired dishes.

7

729

GOLD STANDARD RECIPES

170.1 g Pork Butt, Diced

55 g Water

6 g Salt

4.5 g Onion Powder

4.5 g Garlic Powder

3 g Sugar

1.5 g Chili Powder

0.75 g Paprika

0.75 g Black Pepper

0.75 g Liquid Smoke

0.75 g Lime Juice

100 g Blue Corn Masa

OR

100 g White Corn Masa

200 g Water

2 g Salt

Sauté pork until the meat is cooked through

and reaches an internal temperature of

145˚F. Mix all other ingredients together and

add to the pork. Cover and simmer for 15

minutes or until pork is tender.

Heat a pot of vegetable oil to 350˚F. In a

bowl, mix together the masa, water, and 0.8

grams of the salt. Work dough together by

hand until cohesive but not sticky. Shape

dough into small balls and use a tortilla

press or rolling pin to flatten the masa

dough. Use a 3 inch circle cutter to cut out

taco shells. Use a modified miniature taco

basket to deep fry taco shells for 1-2 minutes

or until crispy and golden brown. Place fried

taco shells on a paper towel to remove

excess oil. Sprinkle remaining salt on

outside of taco shells.

BLUE AND WHITE CORN TACO SHELLSCARNE ASADA SEASONED PORK

ROASTED CORN GUACAMOLE

WHITE QUESO SAUCE

CLASSIC GARDEN SALSA

100 g Avocado, pit and peel

removed

20 g Corn

10 g Vegetable Oil

10 g Red Onion

10 g Lime Juice

5 g Cilantro

4 g Salt

0.5 g Black Pepper

10 g Butter

7.5 g Flour

112.5 g Milk

35.5 g White Cheddar Cheese

7.5 g Pepper Jack Cheese

2.5 g Red Bell Pepper

2.5 g Green Bell Pepper

0.13 g Onion Powder

0.13 g Garlic Powder

0.06 g Chili Powder

0.06 g Cumin

1.25 g Lime Juice

1 g Salt

0.5 g Black Pepper

150 g Tomato

30 g White Onion

10 g Jalapeño, seeded

10 g Lime Juice

4 g Cilantro

1 g Garlic, peeled

1 g Salt

1 g Black Pepper

Preheat oven to 375°F. Toss

corn in vegetable oil and roast

for 40 minutes. Push avocado

pulp through a sieve to

remove veins and slow

browning. Dice red onion into

1/4 inch cubes and finely

chop cilantro. Once corn has

cooled, combine all

ingredients.

Make a white roux with butter

and flour. Incrementally add

milk and simmer for 5

minutes. Add grated cheese

and heat until completely

melted. Dice bell peppers into

1/4 inch cubes. Add remaining

ingredients blend in a food

processor until smooth.

Dice tomato and white onion

into 1/2 inch cubes. Dice

jalapeño into 1/4 inch pieces.

Roughly chop the garlic and

finely chop the cilantro.

Combine all ingredients into

a food processor and blend

for two seconds.

8

729

Ingredient (Supplier) Amount (g)

Percent (%)

Wholesale Price

($/unit)

Cost of Ingredient in Formulation

Boneless Pork Butt (Cargill) 34.01 87.79 1.12/lb. 0.084

Filtered Tap Water 3.15 8.13 0.00/lb. 0

Carne Asada Seasoning (Newly Weds Foods) 1.58 4.08 72.50/ 50 lb. bag

0.0051

Subtotal 38.74 100 - 0.0891

FORMULATION FOR ONE PORTION OF COMMERCIALIZED PRODUCT

CARNE ASADA SEASONED PORK

BLUE AND WHITE CORN TACO SHELLS

9

729


Percent (%)

Wholesale Price

($/unit)


Filtered Tap Water 12.75 40.99 0.00/lb. 0

Commercial Blue Corn (Sunny State Products) 7.33 23.56 0.36/lb. 0.0058

Commercial White Corn (Sunny State Products) 7.33 23.56 0.21/lb. 0.0034

Soybean Salad Oil (Cargill) 3.6 11.57 0.6173/lb. 0.0049

Classic Salt (Sysco) 0.1 0.32 6.70/25 lb. 0.00006

Subtotal 31.11 100 - 0.01416


Percent (%)

Wholesale Price

($/unit)


White Queso Sauce with Particulate (Sargento) 14.18 100 0.3236/pouch

0.0539

Subtotal 14.18 100 - 0.0539

WHITE QUESO SAUCE



10

729


Percent (%)

Wholesale Price

($/unit)


Avocado Pulp (Calavo) 10.27 72.43 2.42/lb. 0.0548

IQF Roasted Corn (Van Drunen Farms) 2.05 14.46 1.69/lb. 0.0076

IQF Red Onion, 1/4” (Van Drunen Farms) 1.03 7.26 1.05/lb. 0.0024

FF Cilantro, Small (SupHerb Farms) 0.51 3.6 1.70/lb. 0.0019

Lime Juice (Sun Orchard) 0.18 1.27 30.95/4 Gal 0.0004

Cargill Classic Salt (Sysco) 0.09 0.63 6.70/25 lb. 0.00005

McCormick Ground Pepper (Sysco) 0.05 0.35 73.63/5 lb. 0.0016

Subtotal 14.18 100 - 0.06875


Percent (%)

Wholesale Price

($/unit)


IQF Tomato, 3/8” (Van Drunen Farms) 10.31 72.71 1.44/lb. 0.0327

IQF White Onion, 3/8” (Van Drunen Farms) 2.05 14.46 0.86/lb. 0.0039

FF Jalapeno, 1/4” (SupHerb Farms) 0.69 4.87 1.35/lb. 0.0021

Lime Juice (Sun Orchard) 0.69 4.87 30.95/4 Gal 0.0015

FF Cilantro, Small (SupHerb Farms) 0.27 1.9 1.70/lb. 0.001

FF Garlic, Minced Small (SupHerb Farms) 0.07 0.49 1.80/lb. 0.0003

Cargill Classic Salt (Sysco) 0.07 0.49 6.70/25 lb. 0.00004

McCormick Ground Pepper (Sysco) 0.03 0.21 73.63/5 lb. 0.001

Subtotal 14.18 100 - 0.04254



Please note that potential loss of some of the ingredients caused by preparation and cooking was

factored in to give a more realistic estimation of the total food cost. The formulation for the carne

asada seasoned pork accounts for a 20% trim loss followed by a 20% cook loss for the pork

meat. This actual amount of fully-cooked pork per portion (23.62 grams) along with seasoning

and water bring the total amount of seasoned pork meat to 28.35 grams or 1 ounce per portion.

Please also note that the formulation for the taco shells accounts for a 15% loss caused by the

nixtamalization of each type of corn. The actual amount of each color of masa included in the

formulation will be 6.37 grams. The taco shell formulation also accounts for a 40% loss of water

during deep frying (approximately 5.08 grams of water will be vaporized). This brings the total

weight of the cooked blue and white corn taco shells (3 per portion) to 24.11 grams.

The final weight of the fully-cooked carne asada seasoned pork (28.35 grams), the taco shells

(24.09 grams), and the accompanying sauces (14.18 grams each) brings the total portion size to

95 grams, which is reflected on the Nutritional Facts panel.

MINI PORK TACO DIPPERS


Percent (%)


Carne Asada Seasoned Pork 39.75 35.06 0.0891

Blue and White Corn Taco Shells 31.11 27.44 0.0142

White Queso Sauce 14.18 12.5 0.0539

Roasted Corn Guacamole 14.18 12.5 0.0688

Classic Garden Salsa 14.18 12.5 0.0425

Total 113.4 100 0.2685

11

729

The production plan for this product was designed to emphasize processing techniques and

packaging to extend shelf life, rather than technical ingredients.


The seasoning developed by Newly Weds Foods for this product includes salt and sodium

phosphate, eliminating the need for it to be accounted for in the formulation. The sodium

phosphate binds water in the formulation, making it less available for microbial activity.


Experimental formulations of taco shells including various modified starch ingredients were

conducted. The best texture, flavor, and color results were observed in the formulations that did

not include any technical ingredients and were packaged in nitrogen flushed pouches. Shelf

stability is not a major concern in this product because of the low water activity and the frozen

storage. The naturally bright color of the deep fried blue and white corn taco shells also prevents

the need of any coloring agents.


The high pressure processing of the guacamole pouches alleviates the need for acidulants to

lower the pH and inhibit microbial growth because the process kills any pathogenic

microorganisms of concern.


The ingredients in the salsa inherently lower the pH, making addition of acetic acid, citric acid,

or any other type of acidulant unnecessary.

Overall, our processing techniques take care of the major microbial concerns, eliminating the

need for additional antimicrobials and resulting in a fairly clean label.

TECHNICAL INGREDIENTS

PRODUCTION


Blue and white corn kernels will be processed separately until after deep frying. Upon arrival,

the kernels will be visually inspected. The kernels will also pass through a magnet separator to

remove any metal particles that could damage processing equipment. A sieve, aspirator, or

gravity table may also be used to sort the kernels and remove any foreign particles. To begin the

nixtamalization process, the kernels will enter into the Casa Herrera Corn Cooking System. This

batch cooking system includes a scale for repeatable results and accuracy. The system includes a

jacketed cook kettle, a quench tank to cool corn to desired steeping temperature, multiple steep

tanks, and a corn washer to remove excess lime and loose paricarp. The cooked corn kernels

(nixtamal) will then enter the Casa Herrera Corn Feeder and Heavy-Duty Corn Grinder System.

The system monitors volume and moisture to produce masa with a consistent moisture content. It

can mill up to 6,000 pounds per hour. From here, the masa and a portion of salt will enter into the

Casa Herrera Presheeter, Sheeter, and Odyssey Oven System. The masa will pass through

primary and secondary rollers and will be wire cut into small, 3 inch diameter circles. The

miniature tortillas will pass through the oven to remove part of the moisture. Before frying, the

tortillas will pass through the Casa Herrera Equilibration Conveyor. Baking can cause a moisture

gradient in the tortillas, which can lead to excessive puffing and inconsistent crunchy texture in

the final product. The Equilibration Conveyor corrects this problem. The mini tortillas will then

enter a modified Heat and Control TACO-FORM Frying System where it will lose water and

absorb a small amount of oil. This system can produce up to 24,000 taco shells per hour using a

very low oil volume. At this point, the two colors of corn taco shells can be processed together.

After frying, the taco shells will pass through the Casa Herrera Exhaust Cool Down Conveyor.

The taco shells will also pass underneath the Heat and Control Mastermatic Roll Salter (RS42X).

The salter has a 42 inch salting width and will evenly dispense salt onto the shells. Finally, the

shells will be packaged using the Parsons-Eagle Phaser XP Vertical Form-Fill-Seal System with

nitrogen flush option. This modified air packaging system will create a pillow-type pouch that

will preserve the crunchy texture of the taco shells during frozen storage. Before entering the

packaging system, employees will manually sort and align the taco shells to ensure that each

pouch contains 18 mini taco shells, 9 of each color.

12

729

PRODUCTION


The cost of the Calavo avocado pulp includes the freight cost to ship the product from Mexico to

Texas to Lincoln, Nebraska. The fresh (not frozen) pulp will arrive in 6 pound pouches. The pulp

will be manually removed from the pouches and added to the Ross Vertical Cone Screw Blender

along with the IQF ingredients, lime juice, and seasonings. This low impact blender will gently

incorporate the ingredients. The guacamole will exit through the bottom of the blender into the

Cryovac Onpack Model 2052 VFFS. This vertical form-fill-seal system is able to pump sauces

with particulate into 3 ounces portioned pouches. The pouches will be loaded in batches into the

Avure Technologies QFP 215L-600 High Pressure Processing System. The pressure applied to

the pouches must reach 87,000 psi for 3 minutes to achieve the critical control point for this

component. This procedure will kill any pathogenic microorganisms of concern (including

Listeria, Salmonella, and E. coli) while preserving the bright green color and freshness of the

guacamole. This will give the guacamole the extended shelf life needed for a club store product.


All of the IQF ingredients for the salsa, along with the lime juice and seasonings can be added

directly to the Ross Vertical Cone Screw Blender. After a short period of blending, a pH

determination will be performed before the salsa exits the blender to ensure that the salsa has

achieved the critical control point of a pH below 4.4. In development testing, the salsa was found

to have an average pH of 3.8. The low pH will inhibit the growth of many pathogenic organisms

and thereby extend the shelf life of the salsa. After the pH has been verified, the salsa will be

pumped aseptically into a vacuum sealed 3 ounce pouch by the Cryovac Onpack Model 2052

VFFS (vertical form-fill-seal system).

WHITE QUESO SAUCE

The commercialized queso pouches are manufactured by Sargento®. They will be added to the

conveyor system along with the other components just before packaging into cartons.

13

729

PRODUCTION


After passing arrival safety checks, the Cargill boneless pork butt will be unloaded onto a

fabrication line where employees will perform visual inspections of the meat and trim any silver

skin or excessive fat with a medium sized Bettcher Industries Whizard 850M2 circular cutting

tool. The pork butt will also be fabricated into portions (no more than 620 mm in length) that

will feed easily through the MPBS Industries Pro Dice 3200 Multi Purpose Dicer with Hopper.

The dicer will be fitted with a 15 mm cutting grid to produce small cubes of diced pork meat.

The raw diced pork meat will be fed into the Mapeco Continuous Cooker that has a capacity of

up to 10,000 pounds per hour. This system is much more efficient than batch cooking and will

increase production speed. The pork meat must reach the critical control point of 145°F internal

temperature before it exits the Continuous Cooker. In a separate area, the carne asada seasoning

and water will be combined by passing the ingredients through an Inline High Speed Powder

Induction Mixer. This high shear mixer incorporates the powder at a constant rate into a stream

of water, producing a consistent marinade that will be added to the fully cooked pork meat using

a Cryovac Onpack Model 2070 VFFS System. This unique system is able to portion and package

6 ounces of solids and liquids together using a vertical form-fill-seal mechanism. Once

packaged, the pouch will travel through a circular cooling system to lower its temperature to

41°F before joining the other components on the carton packaging line.

CARTON ASSEMBLY

All components will converge on a single conveyor where they will pass through an x-ray and

metal detector to ensure the removal of any hazardous foreign objects that may have entered the

product during processing. For quality assurance purposes, components will travel down a

conveyor line and will be manually packed into cartons. Cartons will be assembled using a

Bosch Cobra Carton Forming Machine. Corrugated cases will be assembled using a Loveshaw

Little David CF-25 Case Former. Each case will be packaged manually with 24 cartons. After the

cases are palletized and wrapped, they are ready to be stored in the freezer and shipped to club

store warehouses.

14

729

PROCESSING FLOW CHART

15

729

PORK MEATTACO SHELLS

SALSA

GUACAMOLE

QUESO

Boneless Pork Butt

Bettcher Model 850M2 Medium Whizard Trimmer

MPBS Industries Pro Dice 3200 Multi Purpose Dicer

Mapeco Continuous Cooker

Cryovac Onpack Model 2070 VFFS (Vertical

Form, Fill, Seal System)

Spiral Cooler

Visual inspection of blue and white corn kernels

Magnet Separator

Sieve, Aspirator, or Gravity Table

Casa Herrera Corn Cooking System

Casa Herrera Corn Feeder and Heavy-Duty Corn

Grinder System

Casa Herrera Presheeter, Sheeter, and Odyssey

Oven System

Casa Herrera Equilibration Conveyor

Heat and Control TACO-FORM Frying System

Casa Herrera Exhaust Cool Down Conveyor

Heat and Control Mastermatic Roll Salter

(MS42X)

Manual sorting

Parsons-Eagle Phaser XP Vertical Form, Fill, Seal System with Nitrogen

Flush Option

Pre weighed avocado pulp, IQF ingredients,

lime juice, and seasonings

Ross Vertical Cone Screw Blender

Pumping system


Form-Fill-Seal System)

Avure 215L-600 HPP System IQF ingredients, lime

juice, and seasonings

Ross Vertical Cone Screw Blender

Pumping system


Form, Fill, Seal System)

Carne asada style seasoning and tap water

Ross High Speed Powder Induction Mixer

Pumping system

MARINADE

X-ray and Metal Detector

Manual packaging of components into carton

Carton

Case

Palletizer

Frozen Storage

KEY Indicates the flow of the product Indicates an addition of ingredients Indicates a critical control point


WHITE QUESO SAUCE

FRESH GARDEN SALSA

PACKAGING

In order to preserve the crisp texture of the taco shells and the desired organoleptic properties of

the pork meat, all of the components are packaged separately. A variety of films were used for

the components, most from the Cryovac FS Series VFFS Films. These rollstock films create

flexible pouches that can be used for liquid and pumpable foods containing particulate. The

pouches can be filled hot or cold and can be used to store frozen products. For the pork meat and

marinade, FS 5035 film is used to create an 8 inch by 4.5 inch pouch. For the salsa, FS 7135 film

is used to create a 7 inch by 3 inch pouch. For the guacamole, a special film (FS 7045) that can

withstand high pressure processing is used to create a 7 inch by 3 inch pouch. The taco shells are

portioned into modified atmosphere packaging using a Parsons-Eagle Phaser XP Vertical Form-

Fill-Seal System with nitrogen flush option. Each bag will contain about 0.0376 standard cubic

feet of nitrogen gas, which will be supplied by Linde Gas. The removal of oxygen allows the

taco shells to maintain their crisp texture during freezing. The components are manually

packaged into Full Overlap Seal End Paperboard Cartons supplied by Malnove and then into 18

inch x 16 inch x 14 inch Uline corrugated cases. Each case will contain 24 cartons and will be

placed in frozen storage after packaging. Below are examples of each type of packaging.

16

729

CARNE ASADA STYLE PORK


PACKAGING COSTS PER PORTION

Material (Supplier) Type of Packaging Wholesale Price

($/unit)

Cost of Packaging in Formulation

FS 5035 Film for Pork Meat (Sealed Air) 8” x 4.5” pouch 0.60/msi 0.0072

Laminated Film for Taco Shells (Exopack) 10” x 7” pouch 0.27/msi 0.0063

Nitrogen for Taco Shells (Linde Gas) 0.0376 scf 0.52/scf 0.0033

FS 7045 Film for Guacamole (Sealed Air) 7” x 3” pouch 0.75/msi 0.0053

FS 7135 Film for Salsa (Sealed Air) 7” x 3” pouch 0.69/msi 0.0048

Full Overlap Seal End Paperboard Carton (Malnove)

8” x 6.5” x 2.5” carton

142.90/ 1000 cartons

0.0238

Corrugated Box (ULINE) 18” x 16” x 14” corrugated box

1.31/box 0.0091

Total - - 0.0598

17

729

SHELF LIFE AND STORAGE

The estimated shelf life of the Mini Pork Taco Dippers is 180 days. When estimating the shelf

life for this product, the elements of major concern include the color and flavor of the avocado in

the guacamole as well as the preservation of the crisp texture of the taco shells. The use of high

pressure processing for the guacamole, modified atmosphere packaging for the taco shells, and

the various critical control points all contribute to an extended shelf life of 180 days under

frozen temperatures.

PREPARATION AND PLATING

Mini Pork Taco Dippers are to be stored under frozen conditions until 24 hours before

consumption. At that point, the carton and its contents (except for the pouch containing the taco

shells) are to be removed from the consumer’s freezer and placed under refrigeration so that the

components may thaw. The taco shells are to be placed at room temperature to thaw. After 24

hours, the pork meat may be removed from its packaging, placed in a microwave safe dish, and

reheated in a microwave oven for 30-45 seconds or until warmed through. If desired, the queso

sauce can also be removed from its packaging, placed in a microwave safe dish, and heated in a

microwave oven for 15-20 seconds. The taco shells can then be filled with the pork meat and the

remaining sauces removed from the packaging and placed in serving bowls. Mini Pork Taco

Dippers make an excellent interactive, sharable appetizer that the whole family can enjoy.

18

729

REFERENCES

CARNE ASADA SEASONED PORKChod Morrow, Cargill Meat SolutionsKelly Perrier, Cargill Pork PricingMike Peters, Cargill Pork PricingTim Hoilman, Newly Weds FoodsKathy Connolly, Newly Weds Foods

BLUE AND WHITE CORN TACO SHELLSJulie Bryant, Sunny State ProductsSteven Weier, University of Nebraska, Lincoln

ROASTED CORN GUACAMOLERick Joyal, CalavoJeff Morris, Fresherized Foods

CLASSIC GARDEN SALSADelroy Gibb, Cargill Dressing, Sauces, and OilsBrian, Cargill Dressings, Sauces, and OilsMike Brem, SupHerb FarmsScott Adair, SupHerb FarmsMark Stagg, Van Drunen FarmsTracy Sheehan, Van Drunen FarmsSusan Grisdale, Sun OrchardStacy Sanford, Sun Orchard

WHITE QUESO SAUCETony Benedict, SargentoMike Lieber, Sargento

PACKAGINGDaniel McKamy, Sealed AirKaye Smith, Sealed AirSue Winstone, MalnoveSusan Elles, Exopack

DESIGNATED SUPPLIERSNicholo Plaze, GPIJulie Snarski, David Michael & Co.Bethany Hall, National StarchAnh Nguy, National Starch

19

729

WORKS CITED

2010 Census. Web. 10 Nov. 2011. <http://2010.census.gov/2010census/>."A World of Packaging Solutions from Sealed Air." Web. 10 Nov. 2011. <http://www.cryovac.com/en/default.aspx>.

Fain, Lisa. The Homesick Texan Cookbook. New York: Hyperion, 2011. Print.

Flour Tortilla, Corn Chip, Chapati, Pita, Pizza Flatbread Machinery, Equipment. Web. 10 Nov. 2011. <http://www.casaherrera.com/>.

"Heat and Control: Food Processing & Packaging Equipment." Manufacturing, Industrial & Business Machinery, Supplies, Equipment and News. Web. 10 Nov. 2011. <http://www.industrysearch.com.au/Suppliers/Heat-and-Control>.

"High Pressure Processing Food Systems - Avure Technologies." Avure Technologies Cold Isostatic Presses CIP Hot Isostatic Presses HIP HPP Flexform Hydroform Fluid Cell Pressing. Web. 10 Nov. 2011. <http://www.avure.com/food/>.

Industrial Mixers and Blenders - Ross. Web. 10 Nov. 2011. <http://mixers.com>.

Kittler, Pamela Goyan, and Kathryn Sucher. Food and Culture. Australia: Wadsworth/Thomson Learning, 2004. Print.

Loveshaw- Packaging Equipment for the Real World including Auto Case Sealers, Case Erecting Equipment and Label Application Systems. Web. 10 Nov. 2011. <http://www.loveshaw.com/>.

Lynch, Francis Talyn. The Book of Yields: Accuracy in Food Costing and Purchasing. Hoboken, NJ: John Wiley, 2012. Print.

Meat Processing Equipment, Defatting, Pneumatic Scissors, Breading Machine, Gyro Knife, Meat Scissors, Poultry Shears, Trimmer Blades, Cutting Kevlar, Taxidermy Tools | Bettcher Industries, Inc. Web. 10 Nov. 2011. <http://www.bettcher.com/>.

MPBS Industries: Meat Processing Equipment, Meat Packaging Equipment, Food Processing Equipment, Food Packaging Equipment. Web. 10 Nov. 2011. <http://www.mpbs.com/>.

TEMCO Scales - Net Weighing and Bag Handling Equipment. Web. 10 Nov. 2011. <http://parsons-eagle.com/>.

20

729

http://2010.census.gov/2010census/

http://2010.census.gov/2010census/

http://www.cryovac.com/en/default.aspx




http://www.casaherrera.com/

http://www.casaherrera.com/

http://www.industrysearch.com.au/Suppliers/Heat-and-Control




http://www.avure.com/food/

http://www.avure.com/food/

http://mixers.com

http://mixers.com

http://www.loveshaw.com/

http://www.loveshaw.com/

http://www.bettcher.com/

http://www.bettcher.com/

http://www.mpbs.com/

http://www.mpbs.com/

http://parsons-eagle.com/




entry for 2012 rca student culinology competition

Documents