Advanced Meat Processing

8/13/2019 Advanced Meat Processing

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AdvancedMeatProcessing


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ADVANCED PROCESSING

1. Overview of the Meat Industry

2. Role ofVariousIngredients in Meat Processing

3. SlaughteringTechniques for - on Meat Quality

4. ProcessingofVariousMeat Products

5. Quality Control MeasuresinProcessing

6. Packaging

7. Costing ofVariousProducts

8 . Hands on

9. to a Processing


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INDUSTRY IN THEPHILIPPINES

Production of Livestock and Small Animals

1. Hogs2. Cattle3. Poultry(chicken, turkey, ducks)4. Goats

AnimalsMovement From Production to Consumption

ProductionofFoodAnimals

(by Foot)

(Road transport)

Livestock AuctionmarketI

Nearby

Slaughtering

IMortem

meat InspectionPostMortem

Edibles

PrinciplesofMeat Preservation

Meat preservation isprincipally concerned withhe application of measures to delay

meat spoilage which are causedby microbial, chemical andphysical changes. Of these,microbial spoilage (caused by bacteria) is the most common Microbes thrive in moistureand since meat is70% it spoils easily through microbial action.Meat, being arich source of nutrients, alsobecomes an excellent food forbacteria.

Methods of meat preservation, however different superficially, arealike in that theyemploy environmental conditionswhich discourage the growth of micro-organisms.

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They may be grouped in the three broad categoriesbased on: a. control by temperature,control of moisture, and c. by lethal agencies (bactericidal, fungicidal

and fungistatic).

Generally, the methods discourage microbial growth can be divided into groups:

1. By exposing meat to high or or low or temperature

2. By treating meat with substances (e.g. salt, nitrate, other chemical preservatives)which will or delay microbial actions.

There are three general principles of meat preservation that you should alwayskeep in mind. These are the prevention or lessening of:

a.Atmospheric oxidation

c.

a.Microbial Meat contains abundant nutrients required for the growth ofbacteria, andmolds (micro-organismswhich cause food spoilage). Thus these

flourishin meat. Eliminating the growth requirements: a. temper-requirements, moisture contents, c. nutrient content and oxygen (for aero

micro-organisms) micro-organisms are the most important considerations in the control of their growth. Thiscan be achieved by removing one, two or all the re-quired conditions for growth.

Oxidation.Meat fats are susceptible to oxidation when they are exposed to themolecular oxygenpresent in air. Thisresultsin the production of a strong disagree-able odor and in the cooked product. When these chemical reactions occur,

they constitute a defect referred to as oxidation rancidity.

More popularly knownas rancidity ormaanta,this can be avoidedby eliminat-i ng thefactors requiredfor its development. These factors are: a light, airand c.free fatty acids. While the entry of light and air canprevent free fatty acids easilyform the meat fats. Anti-oxidants canbe used to delay free fatty acid forma-tion. can be used to delay fatty acid formation. Anti-oxidant arecompounds which reactwith certain intermediary products necessary for the devel-opment of fatty acids.

c. reaction.Thisis another causeof food spoilage. Enzymes are

protein substances whichhelp speed up chemical reactions. Enzymatic reaction maybe reduced or totally if you subject themeat to a temperature below orabove thetemperature range needed for the activity of the meat enzymes.

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Methods ofMeat Preservation

1 Drying removal of meat. The method involves the reduction of theoriginal water content (70% of the meat to about 15%).There are 2ways of drying:

a. Natural sundrying natural sunlight is used to reduce the moisture content ofthe meat.

Artificial drying - a chamber equipped with heating elements main tained at a

temperature of - 120Fand a relative humidity of 85% is used for drying.This is more expensive than sundrying but its dried products have a betterquality and canbe sold at a higher price.

2. -there are 2 methods of smoking:

a. Natural -is the exposure of the meat to wood smoke which causes the depositionof acid on the the meat surface that acts as preservative and

agent. Hardwood,saw dust, guava leaves or any of wood maybeused.

Artificial smoke flavor is incorporated in thepumping pickle for ham and baconattherateof

3. Salting - asimple method of dehydration in which the salt causes the withdrawalofwater the tissue of both the meat spoilage organisms,resulting to theshriveling and inactivation of the cells.

4. Curing -istheapplication of salt, sugar, (potassium nitrate) andotherpre-servatives and adjunct to prolong the keeping quality of the product. Other sub-stances such asvarious sugar, spices, vinegar and winemay be used for differenttypes of cure,but in small quantities thusmay have no preservative effect, althoughthe essential 'oilsin spices do retard bacterial growth and vinegar has a similaraction.

a. withsaltalonewithsaltandsugar

c. with salt sugarand saltpepper (sugar cure) sugar cure is either done dryor insweet pickle brine. Because the dry method is faster, it is practical for use intropicalcountries like the Philippines where warm weather makes spoilage a

serious problem.

5. Refrigeration- is the exposure of meat to the temperature range of to 50Fand bacterial growthfor a limited period only.

Home -40F toCommercial refrigerator -36Fto (1C

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6. Freezing is the exposure of meat to a temperature range of toresulting to crystallization of the water in the tissues, thus inactivating the

enzymes and the bacteria present.

thehermeticorairtightsealingoffoodincanorjarsatand 10 - 15poundspressure for specific period of time.

Curing and Their Functions

1. is the ingredients in meat curing. It makes up the bulk of thecuring mixture because it isnot only a good preservative but it provides the mostdesirable flavor.

Asa preservative, it causes the dehydration of the tissues through osmosis, atthe same time withdraws water from the of the spoilage organisms,shrivelingand inactivating their cells.

Salt alsoplays a role in the binding of meat products. It improves the ability ofthe meat protein to retain either the normal moisture content or added water andstabilize the fat-protein emulsion in sausages.

Three of saltare available

a. solaror coarse salt

c. refine salt -most suitable for meat curing because it is the most concentratedand hasthe leastamount of impurities.

2. Sugar is a ingredient in the curing formula which counteracts theastringent qualityof salt, enhances the flavor of the product and aids in loweringthe of thecure.

Refined cane sugar is most suitable. The use of brown sugar is limited by thefact that it caramelizes at lower temperature and tends to darken the meat on

cooking. Large sugar on prolonged curing promotes vigorous microbialgrowth which usually causes acid fermentation that effects palatability andcolor.

3. Nitrates andNitrates - Potassium nitrate (genuine saltpeter), sodium nitrate(chile saltpeter)am color fixation agents or substances responsible for the develop-

ment of the proper color in cured meatproducts.

Nitrates and nitrites have a pronounced effect on flavor. Without them, a curedham would simply be a salty pork roast. They further effect flavor by acting as

antioxidants.

are very effective inhibitor of the growth of Clostridia,the bacteria that causes botulism. Thenitrates


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change the anaeribic condition of .the meat to aerobic, so that Clostridiumlinum and other putrefactive bacteria can not grow.

Nitrate in itself is not effective in producing the curing reaction until it is firstbroken down into nitrite. This is a slow process and is usually dependent on bacte-rial action. With the need for rapid curing to meet todays modern processing sched-ules, nitrite is added directly.

Nitrites provide the ultimate source of the nitric oxide that combine with thepigment.

The use level and residual levels are controlled as follows:

nitrates or nitrites -500 of meatnitrates and nitrites (in combination) 200 of meat

4.Ascorbic These substances spend up curing reac-tion. accelerate the conversion of metmyoglobin and nitrite to myoglobinand nitric oxide and also suppress the reverse reaction. The residual amounts of

also add stability to the cured meat pigment by reducing t h edetermination thenitrisocrome and thus giving the longer shell life.

The permissible level for this 7 of ascorbic acid or its to ofpickle or lbs. sausage meat or emulsion or meat.

5. Phosphates are adjuncts that are used to increase the water-holding and bindingcapacity of cured There is some evidence that they also reduce oxidaterancidity.With increased water-holding capacity, product yields increase, product

surfaces are drier andfirmer and emulsion are more stable at higher temperatures.

Phosphates are not easily soluble in most brines, once the salt hasbeen addedso the recommending practice isto dissolve the phosphates first. Theuse of phosphate is restricted to 1 dissolved in cup of meat.

6.Vinegar- added for but also has some antiseptic value. It therefore, aidsin

prolonging the shelf-life of the finished product. The acetic acid content bebetween 4.5% and 5.0%.

7. Spices- Although flavoring materials are naturally prescribed in many foodstuffs,

palatability is enhanced by the addition of various substances which in-crease zest and product variety of the diet. These substances, though lacking innutritional stimulatethe flow of digestive secretions thereby materially aid-ing digestion. The Food and Drug Administration has defined spices a s aromaticvegetable substances used for the seasoning of food. They are true to name, andfrom themportionof any volatile oil or other flavoi-ing has been removed.

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spices consist of leaves flowers, buds, fruits, seeds, barks, rhizomes, orplantparts which have been dried and are used either in the entry or

after grindingto a pair. Example of these spices are pepper, onion,garlic, ginger,paprika, laurel, Little canbe said general way about their composi-tion. However, most spices owe their properties to their content of volatileoil, whilein the flavor to be due to the intimate natural blending of the

of a great number of different components like alcohol, esters, phenols andtheir derivatives, organic acids, containing compounds, alkaloids and resins.

8. Binders, Fillers,Emulsifiers The main reason for the popular use, of these in-tentional additives is one of economics. Flours, products and cereals whenadded proportionally do not cause any radicalchange in the quality of the productandin cases, actually improve its characteristics such astexture, appearance,slice ability and plumpness. They alsoprevent shriveling and shrinkage to a certainextent.

.I 9. Other ingredients. wine, monosodium glutamate (vetsin), soy sauce,are added to further improve the flavor of theproduct.

Selection of Packaging Materials forMeat and Meat Products

I BasicPrinciplesin the of a Good Packaging Material:1. Protectingthe products against damage, chemical changes and the micro-

contamination.

Presenting the products to the consumers in the most attractive manner to display,promote, motivate, and glamorize.

3 Handlingthe products during transport in the most hygienic way so asto maintaintheir quality.

Characteristicsof a Good Packaging Material

The packaging requirements of frozen, and cured meats differ primarily duethe chemical nature of the pigments that are present. However, they arealso af-

fected to some degree by the processing methods used, and the nature of the microor-ganisms that limit their shelf life.

FreshMeat

For meat merchandising, the following are the characteristics of a goodpack-agingmaterial:

must allow oxygen topass through them tomaintain an optimummaintainingapredominantlyoxymyoglobin

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2 It must be moisture proof to dehydration and surface discoloration.

3. It must protect the product contamination during subsequentstorage, handling,and merchandising.

4. It must impart any or product and should retain the naturalflavorsand that are inherent to the product.

5 . It should tensile strength and resistance totearing and to withstandhandling.

6 . It grease proof to prevent the absorption of fat that will reduce the strengthand moisture transmission properties of the material.

Meat

The packaging requirements for meat include the following:

1. It shouldhave moisture toprevent product dehydration andsurface discoloration during storage.

2. Itmustpossesspliabili ty and

3. It mustpossessstrengthwhich includes tear and puncture resistance, ' temperatur eresistance,

4. Itmust be greaseproof orgrease resistant.

Cure Meat Products

In contrast to fresh meat, the retention of a stable color in cured meat productsdepends on the absence of oxygen. to light also causes change knownlight fading.

the packaging material used for cured meat products must possess the followcharacteristics:

1 impermeable. Some cured meat products are vacuum-packaged. Otherare placed in opaque packages with only limitedportion of the product visiblethrough a "window"in the package to minimize light fading.

It must be proof so that the products remain moist or retain the character-isticjuiciness during handling and storage.

3. must the product further contaminationduring subsequentstorage, handling and merchandising.


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4. It must not impart any or to the product and the natural flavors and

thatare inherent tot heproduct must be retained.

It must have tensi le strength andresistance to and scuf f ing towithstand handling.

6. Itmustgrease sothatthemeatfatwillnotbeabsorbedandthestrengthormoisture vapor transmission properties will not be reduced.

RecommendedPackaging Materials forFresh and CuredMeat Products

Fresh Meat

Paper is still extensively used for wrapping fresh meats. Paper meat wrappersthe following:

Bleached and unbleached Used for wrapping wholesale cuts ofbeef.

2. Oiled wet-str ength bleached paper. Used for wrapping wholesale cutsofpork,

Plastic is the most popular packaging materials for fresh meats. It has desir-able characteristics such light weight, inertness, clarify flexibility, rigidity and awide range of barrier properties. Plastics include cellophane, polyethelene (PE),ypropylene nylon.

Fresh meat cellophane is coated with a specialnitrocellulose or coatingon one side. The side is in direct contact with the moist, fresh meat tohave continuous transmission of oxygen. The outside coating restricts transmissionof moisture from the meat to prevent shrinkage and desiccation.

Polyethylene (PE). polyethylene film is used forbothfresh and frozenIt is particularly a packaging material for stored meat because

itretains its flexibility at temperature as low as It is also used for laminatingpackaging for vacuum and gas packaging meats.

Polypropylene (PP) has very good transparency, has fair resistance, but has verypoor cold resistance. Thus, i t may only be used for fresh meats but not for frozen

ones.

Nylon is apolyethylene tubular stock used in the form of casings and contourbagsforpackaging frozen, and cooked bonelessbeef and other meats.

PaperMeats

Paperpackagingmaterialssuchas

are for wrapping fat meats such asham and

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Plastics

Plastics include regenerated cellulose, polyethelene (PE),polypropylene poly-

esters, nylon, saran, foil and laminate.

Regenerated cellulose is used as mold and containers of smoked and proc-

essedmeats.

Polyethylene (PE). Low density polyethylene film is useful for packaging frozenstored meat and processed meats. Bio-oriented polyethylene film is used for shrink

packaging meat products.

Polyesters issuitable forpackaging meat and ready-to-serve convenience foods. It isavailable in uncoated forms, heat shrinkable types, polymer coated types forheat-sealed packages, and polymer coated thermoformable andable types for vacuumpackaging.

Nylon is used for differentmeatpackaging applicationsespecially in thermoformingdeep draw vacuumpackage of processed meats. Typical applications are packagingluncheon meat or frankfurters.

Saran film isheat-sealed andtends to shrink on exposure to heat. Saran casings areresistant to moist heat up to They are used as heat processing package aswellas consumer for liver sausage and other sausage products.

Aluminum foil is the most used foil in meat packaging. It is opaque, hasmoderate dimensional stability and high degree of heat transfer. It is not alsosensitive to moisture and haszero permeability t o water and gas vapors. Aluminum

foil forpackaging applications is available in gauges of a quarter mil to six mil. Ingauge of less thanone mil, the foil is generally laminated with paper, paperboards,cellophane, and plastic film to make flexiblepouches for gas packaging, decorative

and packages for cured, smoked, and processed meats. It gauges of oneor more, the unsupported foil ispressure-formed into rigid trays.

Laminate is a combination of two or more single sheets of papers, filmsand foilswhich are bonded together.Lamination results in a number of possibilities to de-

velop or wrapping material of greater durability for packaging. In addition tolaminatingpaper,many coating processes are also employed to change themake-up of films to improve their packaging qualities. Coating is used to increase

the protective of wrapping materials against water, water vapor, gases,odors, greases, chemicals, or organic solvents. It also increases the naturalsealing properties, optical properties, release properties, and the durability of thefilm.


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Metal Cans

Metal cans are containers utilized for thermal processing and for merchandisingshelf-stable, heat-processed meat products. The two types of metal cans are tin and

cans:

Tin cans. These are the most rigid and most protective containers produced forpreserved foods. is the principal material used for metal cans. It is mildsteel coated onboth sides with tin. The tin is normally applied in a very thin coatingby electrolytesdeposition.

cans. These replaced the tin cans for canned sausage and luncheon meat.can has lighter weight and greater resistance to chemical interaction

with products.

Glass Containers

Glass, as apackagingmaterial,has chemical inertness, clarity, rigidity, resistance

to internal pressure, and resistance to heat. However, it is fragile (hazard tobreakage)and heavy weight.

U Advantages of PackagingMaterials

Combining packaging materials, e.g., foil and have variousadvantages. Theseare the following:

Improves the strength of thepackage.Improves the resistance to loss of volatile components of the packaged product.Reduces transmissionof water oxygen,and other gases.

Improvesfat resistance.Provides heat-sealing.Eliminatesfracture at low temperature and measures package integrity at hightemperatures.Improves flex endurance.Improves packaging machine performance.Provides sandwich printing and other graphics improvement.Improves the package appearance.Supplies merchandising and convenience features.

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Part ofPork Carcass

ribs

buth

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Part ofBeef Carcass

I

chuck

fore

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MEAT

Meat Material.

Pork lean ground, finely

Ingredients:

SaltcoarsecuringPhosphateWaterSugarrefined

NutmegWhite pepper, groundAscorbic 600 mg.(pulverized)MSG

Water (todissolve

Procedure:

1.0kg.

Per kg.

1

lf4 c

1 tab.lf2 t2T

c

1. meat before grinding, Grind pork lean using a coarse plate.

2. allingredients. Mix salt, curing salt and phosphate with meat untiltacky. Add the remaining ingredients untilt acky . Add the remaining ingredientsuntil blended.

3.Putinabowlandcurefor1 2daysina

4. The next day, for 5 -6 minutes then in a casing (nylon shrinkablecasings).

5 . Cook in water for 1 2 hours. Internal temperature of cookedluncheonmeat: 165F.

6.Coolandstoreinchilleror

I 7.Slice if tobe served.


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MEAT LOAF

Meat

Pork,groundVienna sausage

1.0 kcan

Ingredients:

Salt, coarsesalt

PhosphatesugarWaterPickle relishCheese gratedEgg,slightly beatenOnion,choppedAll purpose flourRaisins,choppedGround blackpepper

(dissolvein C water)

1 t + 114 C water4 T114

cc

21 pc.2 T

lf2 clf2 T

t2 T

Procedure:

1. Prepare all ingredients needed.

2. Mix meatwith the firstthree ingredients: salt,curing salt,phosphate dissolved i n

C water, until tacky.

3. Mix rest of the ingredients.

4. Place in greasedbaking pan and bake at for 30 minutes or until done.Remove and let cool.

5. Slicebefore serving.

Note: foil maybe used to roll meat mixture arid steam for hour.

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BOLOGNA

Meat

Beef brisket, ground finelyPork lean, ground finely

600 g

400

Ingredients:

Saltsalt lf2 t

PhosphateSugarAscorbic acid, (pulverized)MSGOnionpowderNutmegPaprika

Garlic powder(dissolve in water)

Water

Procedure:

t + C water2 T

tab.lf2 t

tlf4 t

t

t2 T

c

1. Chill meat. Grind through hole plate.

2. Mix meat with Salt, cur ing salt,phosphate dissolvedin C water. Cure overnight.

3. To the cured mixture, add the prepared spices and condiments

4. Passthroughgrinder together with ice (150 mixbyhand until tacky

5. Stuffin nylon shrinkable casings.

6. Cook in hot water with little salt,pepper and oregano,

7 Servecold or store in freezer.

Note:In the absence of nylon shrinkable roll meat in foil orput inpan mold. Steam for one hour.


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RELLENO

Meat Material:

Chicken, whole, dressed 1.2 1.5 (1

Marinade:

soy saucejuice

112c114

Ground blackpepperMSG t

Filling:(good for 1.2 1.6kg,chicken)

Pork lean, groundsalt

0

Sugar refined

Ground blackpepper

de bilbao, cubedPotato, cubed

bellpepper, cubedGreen peasRaisin

boiled, mediumfresh, medium

Garlic, chopped finelyOnion,chopped

gratedPickle relishWater C

kg.112 T1

2 T

t

cc (2 c

4 T (2boxes)

22

bar2 T

2 T (dissolved in Cwater)

Procedure:

1.Marinatechicken overnight in the refrigerator

Saute garlic and oniontillbrown. Add the ground, de bilbao, and the rest ofthe ingredients.

3. Fill inside the debored chicken, then sew the cut side.

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4. Place the chicken inside the turbo broiler and cook for 45 minutes at 350F.

5. Serve with sauce (extracted From the chicken when cooked in turbo, comstarch canbe added to thicken sauce.

Nob: Chicken Relleno maybe cooked in an oven at 350F for one hour.

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EMBUTIDO

Meat Material:

Porklean, groundPork fat, ground

Textured Soy Protein

Ingredients:

800g .200 g .60 g. (U4 C +

C water, hydratefor 3minutes)

Salt,coarse 2 tPhosphatecuringsalt tSugarGround blackpepperEvaporatedmilkBreadChorizo de bilbao, chopped coarselyPickle relishOnion, chopped finelyRaisin

boiled (optional)or quaileggs (6pcs.)

Vienna choppedchopped finely

Butter (spread in foil)

Procedure:

1. Hydrate C + C water for 3minutesor until soft

2. Combine pork,raw eggs, Mix until well blended.

6 T

C1/4 c

1 1/4

box)1pc.

3T2T2 T

3. meat mixture in foil (1cupper roll) and twistbothends

4. Prick foil withpin and steam for 1hour.Cool

5 . Chill in unwrap and slice if to be served

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QUE

Meat

Pork lean, coarsely groundShrimp meat, cooked and chopped

1.0100g

Ingredients:

salt

SugarGarlic, chopped

shredded, pressedOnion,choppedCarrots, shreddedGround blackpepper

powder

powderMix together

1

4 T2T

C yc.,C pc., medium)

2t

2 T

WaterMSG tEggs, medium

1. Chillmeat. Grind meat and chop shelled shrimps meat.

2. Combine all ingredients well andmixinto meat and shrimp till blended

3. Pack in taupee wrapper per roll).

4. Fry in hot oil.

5 . Serve sauce.

Ingredients:

WaterBrownSugarCornstarch

Sili labuyo

Soy sauceLaurelGround blackpepper

6 T2 T

t

t

1smallpc.t


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Meat

Pork, ground, coarselyShrimp,cooked and chopped

Ingredients:

saltcuringsaltPhosphateWater

GarlicchoppedGround blackpepperCarrots,shredded

Cheese gratedMSGMolo wrapper

I Procedure:1. M i xmeatwiththefirstthreeingredientsuntil

1.0 kg.100 g

1t

c6 T

c4

ct

2

2. Then combine all ingredients thoroughlyand wrap in wrappers.

3. Steamfor 30minutes.

4. Servewithsoysauceand

Yield: 90 100 for every kg.


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'Meat

Pork lean, ground, coarselyBeef lean, ground, coarselyPork cubed

600

600300g

Ingredients:

salt 2Sugar refined

curingsalt tWhitepepper

Pepper corn

Mustardseed 2 tt

Phosphate

Water U4cProcedure:

1. Chill meat. Cube and pass meat through a coarseplate of a grinder.

2. Mixbyhand: fat cubes, meat, spices and other ingredients until tacky.

3. Fill meat mixture into casings. Afterwards, smoke for 45 minutes.

4. After dryfor 2 -2 hours.5. Pack for storage.

6. Slice and before serving.

Note: Smoke flavor (U4 maybe added and drying coulddoneunder the sunfor 8hours.

Advanced Meat Processing

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