Farmland Foods took convenience to a whole new level in the fresh red meat category with the introduction this summer of its Oven Perfect Fresh Pork line.
As so often happens with a new-product introduction, this launch is all about packaging. Farmland’s “revolutionary” cook-in package—which locks in juices, seals in flavor, and self-vents at just the right time to ensure the pork is perfectly browned—is thermoformed from DuPont Teijin Film’s patented Mylar Cook film. Lidding material is also from the Mylar Cook family. These PET materials have been specially developed for the preparation of food in the high-temperature range of up to 425º F. When a certain internal pressure is reached, the side seal where lidding material meets the thermoformed bottom web opens on its own. The food is then browned in the vented pack. The constant heat transfer during the two cooking phases ensures that consistent cooking results are achieved, and it reduces the cooking time by up to 30%.
When asked precisely what the film spec is for the Farmland packages, DuPont Teijin Films chooses not to be terribly specific. We’re told that the pork tenderloin package shown here has a 6-mil forming web and a 2-mil lidstock, while depth of draw is 55 mm (2.17 in.). When pressed for more detail on film composition, we’re told that Mylar Cook is a cast PET that can be monolayer in some applications and multilayer in others. The lidding material gets an adhesive layer—also made by DuPont—that can be applied as a coating or by way of extrusion. All these variables are managed with one thing in mind: optimal control over the self-venting feature so that no matter how the package is assembled, it becomes the best possible cooking vessel for the specific cut of meat it contains.
“We have conducted extensive consumer research to understand the different types of pork consumers, what motivates them, and what needs are most important,” says Brendan Smith, vice president of marketing for Farmland. “A common theme across several consumer groups was an ongoing pursuit of a fresh, high-quality, homemade meal solution without the time and hassle of starting from scratch. Oven Perfect delivers on this need, offering a wide range of fresh pork products that are simple and convenient to prepare while delivering juicy, tender, and delicious pork every time. Oven Perfect is the ideal solution for a weekday dinner or casual get-together with friends or family. With Oven Perfect, the perfect dinner is in the bag.”
Kansas City-based Farmland, a division of Smithfield Foods, points out that “the exclusive Mylar package is FDA-approved and BPA-free.” As for cleanup, it’s simply a matter of package disposal.
It’s worth noting that cook-in bags have been around for some time, both in foodservice and retail applications. But these have all been pre-made bags, many of them made of nylon. A number of advantages are enjoyed when, in place of a pre-made bag, the packaging is thermoformed in line from Mylar Cook rollstock. Cost savings can be significant because meat packers are in effect making their own “bags” instead of paying someone else to make them. There are also some operational benefits to be had, since putting meat in a premade bag and then sealing it can be pretty labor intensive compared to placing product in a thermoformed cavity. Finally, cook-in bags made of nylon may not stand up to the freezer all that well since nylon has a tendency to absorb moisture. Farmland’s PET packages, on the other hand, are perfectly happy in the freezer. Not only that, they can go from the freezer to the oven with no need for defrosting. A “use-or-freeze-by-date” is imprinted on the lidding material.
