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Sous Vide Processing DEVELOP DOCUMENT IMPLEMENT MONITOR CORRECTIVE ACTION VERIFY VALIDATE SKILLS AND KNOWLEDGE TEMPLATES
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Training participants will gain a basic understanding of Sous Vide Processing and its applications within food safety and quality systems. Basic knowledge competency will be verified through successful completion of the accompanying Sous Vide Processing assessment activity. Basic skill competency can be verified through the Sous Vide Processing competency checklist available as a resource for this training activity. Key Definitions For Sous Vide Processing - Anaerobic Micro-organism: Micro-organisms that do not requiring oxygen to survive. - Core Temperature: The temperature at the core or middle of the items being assessed for temperature. - Pathogenic Micro-organism: Any microbiological entity including viruses, bacteria or other micro-organisms that can cause food borne illness in humans. - Sous Vide: Sous Vide , French for under vacuum, is a method of cooking that is intended to maintain the integrity and desirable attributes of food items by heating them for an extended period at relatively low temperature within a sealed plastic bag. - Validated: The process of gathering evidence to provide a scientific basis for the documented act of demonstrating that a procedure, process and activity will consistently lead to the expected results. It often includes the qualification of systems and equipment. Sous Vide Processing Development When considering the development, documentation and implementation of Sous Vide Processing within food safety and quality management systems, the following information should be considered to ensure effective outcomes: About Sous Vide Processing Sous vide is a professional cooking method which utilises plastic oxygen barriers and precise temperature controls to cook food items with reduced oxidization and extend shelf life as outcomes. The process allows the controlled cooking of items in an oxygen free environment, which if maintained, will last longer that foods cooked using more traditional methods by excluding food contact with aerobic bacteria after cooking. The outcomes of sous vide cookery include foods with naturally enhanced flavours and organoleptic qualities. History of Sous Vide Cookery Cooking foods in sealed environments is a technique used by numerous civilisations for hundreds of years. Whether it is in a clay pot, underground in plant leaves or plastic, the general technique delivers outcomes that are sought after for their high quality aspects. The development of food grade high temperature resistant plastics recognised sous vide as a viable commercial cookery technique in the second half of the 20th century. The modern sous vide cookery technique is generally attributed to a group of French Chefs, who discovered its many benefits in the mid to late 1960's. This discovery showed that by packing meat products into a vacuum sealed plastic bag, and submersing it in a water bath with controlled heating, the shrinkage from the cooking process was significantly less than with traditional cookery methods. The organoleptic properties of the foods cooked in this way also showed significant improvement regarding flavour, texture and colour. The lack of oxygen, and protection from the heated water prevented the loss of flavour while the gentle controlled heating action protected the protein from unnecessary damage during the cooking process. Sous vide is now commonly used in both high volume and boutique catering and food manufacturing operational around the globe. The technique is favoured for the favourable yields from cooking of meat products in particular; yields which would otherwise be lost through conventional cookery methods. When applied under controlled conditions under the management of a HACCP based food safety and quality system, sous vide can also replicate significant extensions in product shelf life and product consistency. Benefits of Sous Vide Cookery With foods sealed in an oxygen free environment and gently heated over an extended timeframe, sous vide produces foods which are generally far more nutritionally sound than foods cooked using traditional methods. Precise control over heat, oxygen and the omission of added water all support the sous vide technique in retaining significantly higher percentages of nutrients than other cookery methods. Because the foods are not directly contacted by the heating source, there is also no requirement for added fats, which is also more nutritionally sound. Where fats are added to sous vide foods, these are generally for flavour or technological function. The fact that the foods are totally sealed during the sous vide process also retains water soluble minerals that may otherwise be lost through other cookery methods. The oxygen free environment in which the foods are cooked also reduces the amount of oxidation; another acclaimed health benefit. Moisture retention is perhaps the most noticeable of all outcomes of sous vide cookery; this also impacts upon volatile flavours being retained in cooked foods. With the availability of significantly more natural flavour, the requirement for flavourings and additives such as salt are lessened. The lower temperatures at which sous vide cooking is conducted also assists in the preservation of vitamin content within foods. Though vitamin degradation will occur at any temperature, the oxygen free cooking environment and lower cooking temperatures generally preserve significantly more vitamin content that with more common cookery techniques. Sous Vide Food Safety Considerations Contrary to popular belief, vacuum packaging of foods does not totally exclude microbial growth. It is therefore important, as with any cookery method, to ensure standards of sanitation are maintained at their highest levels for sous vide cookery. One disadvantage with sous vide cookery is the inability of the facilitator to smell the product during the cooking process. In this context, it is generally considered good practice to assess items as they become available for product assessments. As with any cooking method, sous vide relies on good quality hygienic ingredients and inputs to achieve appropriate outcomes. The lower the levels of micro-organisms on items packaged into sous vide bags; the lower the risk of potential microbiological food borne illness occurring. There are no miracles with the sous vide process; bad inputs will result in bad end products. Pathogen growth is perhaps one of the most important factors to consider when addressing potential hazards within a sous vide HACCP application. The low cooking temperatures combined with lack of oxygen can replicate an environment in which pathogens such as Clostridia can thrive. In this context, it is of utmost importance that sous vide techniques are scientifically validated and supported by ongoing verification activities. Potential risk from anaerobic microbiological pathogens growth within a sous vide process can be reduced by consideration of the following factors, many of which are unique to anaerobic methods of cookery: - Due to the lack of preservatives such as salt in sous vide foods, the growth of microbiological pathogens may be enhanced; whereas with preservatives, pathogen growth would be minimised through the action of such preservatives; - Temperature control plays a critical role within the sous vide technique, and dictates the success of outcomes for many foods. It is important that the core temperature of sous vide items are maintained at appropriate temperatures during the cooking process to ensure the growth of pathogenic micro-organisms does not manifest as a food safety concern. The structured validation of sous vide cookery times for specified sizes and shapes of items is required to ensure appropriate core temperatures are reached and maintained without the use of an invasive probe during the actual process, as the use of such a probe would “ruin” the sous vide process; - Though general shelf life is expected to be extended for sous vide cooked items, it is of utmost importance that cookery time and temperatures are sufficient to effectively achieve a “kill” of anaerobic pathogens; which will otherwise thrive and may lead to food poisoning or even death of consumers; - As with other cooking methods, sous vide items should be maintained at temperatures of 5 Degrees Celsius or 40 Degrees Fahrenheit prior to and after cooking. Likewise, the sous vide process itself should achieve a rapid transition through the temperature danger zone of 5 Degrees Celsius or 40 Degrees Fahrenheit and 60 Degrees Celsius or 140 Degrees Fahrenheit to the designated cooking temperature. Cooling of sous vide cooked items should also be conducted rapidly to ensure cooked items spend as little time as possible passing back down through the temperature danger zone until they reach 5 Degrees Celsius or 40 Degrees Fahrenheit or below; - Items intended for reheating must be heated rapidly through the Temperature Danger Zone of between 5 degrees Celsius or 40 degrees Fahrenheit and 60 degrees Celsius or 140 degrees Fahrenheit. It is recommended that food for reheating be taken straight from refrigerated storage for reheating. Higher risk items may need to be subjected to higher temperatures for food safety requirements. When applied under controlled conditions, including implemented food, personal and premise hygiene standards by trained professionals, the sous vide method can provide outcomes that are extremely safe and exclusive of uncontrolled risk of food borne illness. Sous Vide Handling and Storage Time and temperature are among the two most important factors in the effective storage and handling of sous vide items; prior to, during and after the sous vide process itself. The following considerations should be made as elements of any applied sous vide process: - Raw vacuum packaged items should be stored for minimal time prior to sous vide cookery. This ensures the least growth time for any anaerobic micro-organisms that may be sealed within the plastic bag; - Use calibrated temperature monitoring equipment to verify storage and handling temperatures; - Store packaged raw or cooked sous vide items separately, and preferably in regularly changes ice baths of circulated chilled water cooled systems to ensure core temperatures are maintained at appropriate levels; - Ensure the least amount of time as possible for all sous vide items, both raw and cooked is spent within the temperature danger zone of 5 degrees Celsius or 40 degrees Fahrenheit and 60 degrees Celsius or 140 degrees Fahrenheit; - Sous vide cooked items should be stored with a core temperature of less than 5 degrees Celsius or 40 degrees Fahrenheit and used, or frozen within a specified validated timeframe; - Use specialized equipment for the sous vide cooking process; not a standard bain marie or water bath. The sous vide process requires accurately controlled water temperatures to achieve desired outcomes and reduce the risk of food borne illness; - Only cook foods to validated safe temperatures within appropriate timeframes. If suitable timeframes and temperatures are not met; a very real risk of food borne illness may be an outcome. Because of the high-risk nature of outcomes where the sous vide process is not validated, verified or standardised; it is often recommended that a competent food industry specialist is consulted regarding the development, validation, implementation, monitoring and verification of the cooking method. Additional Relevant Information The following information is provided from other foodindustrycompliance.com Training Activities as the content is relevant to the Development of Sous Vide Processing: Process Control Management: Cook Chill Method It is important to consider the staff who are involved with the monitoring of cook chill critical limits. They must be competent in all food safety related activities involved, and must be of sound ability to make objective judgements. Hazards present may include Chemicals, Foreign Objects and Pathogenic Micro-organisms. The concept of Cook Chill catering has been used predominantly since the early 1970’s, but it was not until the middle of the 1980's that this concept began to gather momentum within various areas of modern food industries. No matter what size a food business is, there are obvious advantages and benefits from using cook chill methods, especially regarding the requirement to maintain time and temperature controls in all areas of food production and delivery. With Cook Chill systems, there are no miracles; badly prepared and cooked food will be just as bad when regenerated some days later. Foods correctly prepared and handled in a cook chill system will be impossible to distinguish from freshly cooked food. In many cases, the organoleptic benefits from some cook chill applications produce outcomes that are better than freshly prepared food. In foodservice operations, the problem with most cook serve production kitchens is that there is a time lag between cooking an item and availability to the customer. During this time lag the food is kept hot for extended periods, which destroys the taste, colour and nutritional value of the food. When applied appropriately, a Cook Chill system will deliver a higher standard of foods than those held at hot temperatures for any timeframe. The fundamentals of a best practice based cook chill system include: - All food items should be cooked to a core temperature of at least 72 degrees Celsius or 162 degrees Fahrenheit and held at or above that temperature for a number of minutes prior to serving; - Once cooked, food items should be portioned into shallow containers to facilitate cooling within an appropriate timeframe. This process should be completed within a suitable timeframe as soon as possible after cooking. From the completion of the cooking stage to commencement of the chilling cycle must not exceed a suitable nominated timeframe; - As a general rule, food items should achieve a core temperature of at least 5 degrees Celsius or 40 degrees Fahrenheit within 6 hours of entering the chiller; - Once chilled, all food must be stored at a temperature of between 1 degree Celsius or 34 degrees Fahrenheit and 5 degrees Celsius or 40 degrees Fahrenheit in a separate dedicated chilled area. At all stages of storage and distribution, appropriate temperature control must be maintained; - Depending on the type of packaging used, the shelf life of chilled foods may vary. Ongoing product and process validation should be completed and industry references should be obtained in order to ascertain the shelf life of a Cook Chill product; - Food should not be removed from refrigeration for longer than 30 minutes prior to reheating. Foods should be regenerated to a core temperature of at least 72 degrees Celsius or 162 degrees Fahrenheit and held at or above that temperature for a number of minutes prior to serving; - Once reheated, all leftover food should be hygienically disposed of. If your food business supplies foodstuffs manufactured to a customer’s specifications, it is important to consider any specific Sous Vide Processing Development requirements in relation to their items. Premium Users can download the full current folder of over 50 GENERAL CONTENT subjects at the click of a button. We constantly update and upgrade our content so that you always have access to the most current and relevant Food Safety and Quality information and resources. 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