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RCA 2012 STUDENT CULINOLOGY COMPETITION PROPOSAL

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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
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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.
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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,
gar l i c powder, sugar, sodi um
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.
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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. Entre 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
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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.
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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
Saut pork until the meat is cooked through
and reaches an internal temperature of
145F. 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 350F. 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 SHELLS CARNE 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 Jalapeo, seeded
10 g Lime Juice
4 g Cilantro
1 g Garlic, peeled
1 g Salt
1 g Black Pepper
Preheat oven to 375F. 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
jalapeo 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.
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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
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Ingredient (Supplier) Amount
(g)
Percent
(%)
Wholesale
Price
($/unit)
Cost of
Ingredient in
Formulation
Filtered Tap Water 12.75 40.99 0.00/lb. 0
Commercial Blue Corn (Sunny State Products) 7.33 23.56 0.36/lb. 0.0058
Commercial White Corn (Sunny State Products) 7.33 23.56 0.21/lb. 0.0034
Soybean Salad Oil (Cargill) 3.6 11.57 0.6173/lb. 0.0049
Classic Salt (Sysco) 0.1 0.32 6.70/25 lb. 0.00006
Subtotal 31.11 100 - 0.01416
Ingredient (Supplier) Amount
(g)
Percent
(%)
Wholesale
Price
($/unit)
Cost of
Ingredient in
Formulation
White Queso Sauce with Particulate (Sargento) 14.18 100 0.3236/
pouch
0.0539
Subtotal 14.18 100 - 0.0539
WHITE QUESO SAUCE
ROASTED CORN GUACAMOLE
CLASSIC GARDEN SALSA
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Ingredient (Supplier) Amount
(g)
Percent
(%)
Wholesale
Price
($/unit)
Cost of
Ingredient in
Formulation
Avocado Pulp (Calavo) 10.27 72.43 2.42/lb. 0.0548
IQF Roasted Corn (Van Drunen Farms) 2.05 14.46 1.69/lb. 0.0076
IQF Red Onion, 1/4 (Van Drunen Farms) 1.03 7.26 1.05/lb. 0.0024
FF Cilantro, Small (SupHerb Farms) 0.51 3.6 1.70/lb. 0.0019
Lime Juice (Sun Orchard) 0.18 1.27 30.95/4 Gal 0.0004
Cargill Classic Salt (Sysco) 0.09 0.63 6.70/25 lb. 0.00005
McCormick Ground Pepper (Sysco) 0.05 0.35 73.63/5 lb. 0.0016
Subtotal 14.18 100 - 0.06875
Ingredient (Supplier) Amount
(g)
Percent
(%)
Wholesale
Price
($/unit)
Cost of
Ingredient in
Formulation
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
FORMULATION FOR ONE PORTION OF COMMERCIALIZED PRODUCT
FORMULATION FOR ONE PORTION OF COMMERCIALIZED PRODUCT
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
Ingredient (Supplier) Amount
(g)
Percent
(%)
Cost of
Ingredient in
Formulation
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
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The production plan for this product was designed to emphasize processing techniques and
packaging to extend shelf life, rather than technical ingredients.
CARNE ASADA SEASONED PORK
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.
BLUE AND WHITE CORN TACO SHELLS
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.
ROASTED CORN GUACAMOLE
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.
CLASSIC GARDEN SALSA
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 TACO SHELLS
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.
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PRODUCTION
ROASTED CORN GUACAMOLE
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.
CLASSIC GARDEN SALSA
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.
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PRODUCTION
CARNE ASADA SEASONED PORK
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 145F 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
41F 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.
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PROCESSING FLOW CHART
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PORK MEAT TACO 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
Cryovac Onpack Model
2052 VFFS (Vertical
Form-Fill-Seal System)
Avure 215L-600 HPP
System
IQF ingredients, lime
juice, and seasonings
Ross Vertical Cone Screw
Blender
Pumping system
Cryovac Onpack Model
2052 VFFS (Vertical
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
ROASTED CORN
GUACAMOLE
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.
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CARNE ASADA
STYLE PORK
BLUE AND WHITE
CORN TACO SHELLS
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
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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 consumers 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.
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REFERENCES
CARNE ASADA SEASONED PORK
Chod Morrow, Cargill Meat Solutions
Kelly Perrier, Cargill Pork Pricing
Mike Peters, Cargill Pork Pricing
Tim Hoilman, Newly Weds Foods
Kathy Connolly, Newly Weds Foods
BLUE AND WHITE CORN TACO SHELLS
Julie Bryant, Sunny State Products
Steven Weier, University of Nebraska, Lincoln
ROASTED CORN GUACAMOLE
Rick Joyal, Calavo
Jeff Morris, Fresherized Foods
CLASSIC GARDEN SALSA
Delroy Gibb, Cargill Dressing, Sauces, and Oils
Brian, Cargill Dressings, Sauces, and Oils
Mike Brem, SupHerb Farms
Scott Adair, SupHerb Farms
Mark Stagg, Van Drunen Farms
Tracy Sheehan, Van Drunen Farms
Susan Grisdale, Sun Orchard
Stacy Sanford, Sun Orchard
WHITE QUESO SAUCE
Tony Benedict, Sargento
Mike Lieber, Sargento
PACKAGING
Daniel McKamy, Sealed Air
Kaye Smith, Sealed Air
Sue Winstone, Malnove
Susan Elles, Exopack
DESIGNATED SUPPLIERS
Nicholo Plaze, GPI
Julie Snarski, David Michael & Co.
Bethany Hall, National Starch
Anh Nguy, National Starch
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