Trend Toward Fast-Casual Dining Driven by Innovative Vacuum Packaging Technology

Consumer preference for convenience combined with the increasing sophistication of the American palate is driving food companies to find more efficient ways to quickly deliver safe, fresh and delicious foods to market. Fast-casual dining restaurants are significantly growing in popularity, as consumers still seek the convenience provided by traditional fast food establishments, but demand greater food quality, freshness and taste. Recognizing this trend, Chicago-area based ErdaTek, Inc., experts in developing ready-to-eat fresh, refrigerated premium entrees with extended shelf life for area quick service "kitchenless" restaurants, recently began construction on a USDA approved test kitchen and pilot plant. The new facility will house several vacuum packaging systems recently purchased from Multivac, Inc., a leading manufacturer of chamber vacuum pouch sealers and tray sealers, and will help ErdaTek meet the demand for prepared entrée products. When completed, ErdaTek's pilot plant will be able to produce customized product for small market launches as well as test product scale-ups for both small and large food processors.

"This is a fast growing food service sector being driven by innovative food processing technologies," said chef Eric Carré, founder of ErdaTek. "A critical component of developing ready-to-eat foods is capable equipment. Multivac has been working with me for 20 years on developing prepared entrée systems and solutions. Their machines are reliable, durable, efficient and tremendously versatile. They were a natural choice for the new facility."

The Cook-In-Pack Process
Among the technologies used by ErdaTek to create prepared entrée foods is a process known as cook-in-pack, a method by which ingredients are cooked in a pouch or vacuumed airtight tray, and then quickly chilled and refrigerated or frozen. Prior to serving, the packaged food is reheated in simmering water, or in microwave or convection ovens. Under refrigeration, shelf-life from 6 to 45 days can be achieved, depending on the formulation and packaging method.

"Cook-in-pack is unique and gentle in that it allows the cellular structure of food to remain intact," said Carré. "The food's natural moisture and juices are retained, preserving flavor, aroma, and nutrients. Natural flavors are so enhanced that far less seasoning is required."

Using cook-in-pack methods, natural fibers soften and dissolve, leaving foods like beef tender enough to cut with a fork. The food is improved in taste and it retains its nutritional content. Also, measurable shrinkage of cook-in-pack products is 10% or less compared to 20% or more on conventionally cooked products.

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