Advanced Meat Processing

E
t

ADVANCED
1. Overview of the Meat Industry

PROCESSING

2. Role of Various Ingredients in Meat Processing

3. Slaughtering Techniques for
4. Processing of Various Meat Products

on Meat Quality

5. Quality Control Measures i n Processing 6. Packaging

7. Costing of Various Products
8. Hands on
I

9.

to a

Processing

INDUSTRY IN THE PHILIPPINES

Production of Livestock and Small Animals
1 . Hogs 2. Cattle 4. Goats

3 . Poultry (chicken, turkey, ducks)

Animals Movement From Production to Consumption

Production of Food Animals
(by Foot)

(Road transport) Livestock Auction market

I

Nearby

Slaughtering

I
Mortem meat Inspection

P o s t Mortem

Edibles

Principles of Meat Preservation

Meat preservation is principally concerned with he application of measures to delay meat spoilage which are caused by microbial, chemical and physical changes. Of these, microbial spoilage (caused by bacteria) is the most common Microbes thrive in moisture and since meat is 70% it spoils easily through microbial action. Meat, being a rich source of nutrients, also becomes an excellent food for bacteria. Methods of meat preservation, however different superficially, are alike in that they employ environmental conditions w h i c h discourage the growth of micro-organisms.
2

They may be grouped in the three broad categories based on: a. control by temperature, control of moisture, and c. by lethal agencies (bactericidal, fungicidal and fungistatic). Generally, the methods
1 . By exposing meat to high

discourage microbial growth can be divided into groups: 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 always keep in mind. These are the prevention or lessening of: a. Atmospheric oxidation c. a. Microbial bacteria,

and molds (micro-organisms which cause food spoilage). Thus these flourish in meat. Eliminating the growth requirements: a. temperrequirements, moisture contents, c. nutrient content and oxygen (for aero micro-organisms) micro-organisms are the most important considerations in the control of their growth. This can be achieved by removing one, two or all the required conditions for growth.

M e a t contains abundant nutrients required for the growth of

Oxidation. Meat fats are susceptible to oxidation when they are exposed to the molecular oxygen present in air. This results in the production of a strong disagreeable odor and in the cooked product. When these chemical reactions occur, they constitute a defect referred to as oxidation rancidity.
More popularly known as rancidity or maanta, this can be avoided by eliminating the factors required for its development. These factors are: a light, air and c. free fatty acids. While the entry of light and air can prevent free fatty acids easily form the meat fats. Anti-oxidants can be used to delay free fatty acid formation. can be used to delay fatty acid formation. Anti-oxidant are compounds which react with certain intermediary products necessary for the development of fatty acids.

c.

reaction. This is another cause of food spoilage. Enzymes are protein substances which help speed up chemical reactions. Enzymatic reaction may be reduced or totally if you subject the meat to a temperature below or above the temperature range needed for the activity of the meat enzymes.

Methods of Meat Preservation

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

natural sunlight is used to reduce the moisture content of

the 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 better quality and can be 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 deposition of acid on the the meat surface that acts as preservative and agent. H a r d w o o d ,saw dust, guava leaves or any of wood may be used. Artificial smoke flavor is incorporated in t h e pumping pickle for ham and bacon at the rate of

3 . Salting - a simple method of dehydration in which the salt causes the withdrawal of water the tissue of both the meat spoilage organisms, resulting to the shriveling and inactivation of the cells.
4.

is the application of salt, sugar, (potassium nitrate) and other preservatives and adjunct to prolong the keeping quality of the product. Other substances such as various sugar, spices, vinegar and wine m a y be used for different
Curing

types of cure, but in small quantities thus may have no preservative effect, although the essential 'oilsin spices do retard bacterial growth and vinegar has a similar action.
a. withsaltalone withsaltandsugar c. with salt sugar and salt pepper (sugar cure) sugar cure is either done dry or in sweet pickle brine. Because the dry method is faster, it is practical for use in tropical countries like the Philippines where warm weather makes spoilage a serious problem.
5. Refrigeration

and bacterial growth for a limited period only.

- is the exposure of meat to the temperature

- 40F to - 36F to
(1C

range of

to 50F

Home

Commercial refrigerator

6. Freezing is the exposure of meat to a temperature range of to resulting to crystallization of the water in the tissues, thus inactivating the enzymes and the bacteria present.

the hermetic o r air tight sealing of food in can or jars at and 10 - 15 pounds pressure for specific period of time.

Curing
1 .

and Their Functions

is the ingredients in meat curing. It makes up the bulk of the curing mixture because it is not only a good preservative but it provides the most desirable flavor.

As a preservative, it causes the dehydration of the tissues through osmosis, at

the same time withdraws water from the shriveling and inactivating their cells. of the spoilage organisms,

Salt also plays a role in the binding of meat products. It improves the ability of the meat protein to retain either the normal moisture content or added water and stabilize the fat-protein emulsion in sausages.
Three of salt are available

a. solar or coarse salt

c. refine salt most suitable for meat curing because it is the most concentrated and has the least amount of impurities.
2. Sugar

is a ingredient in the curing formula which counteracts the astringent quality of salt, enhances the flavor of the product and aids in lowering the of the cure.

Refined cane sugar is most suitable. The use of brown sugar is limited by the fact that it caramelizes at lower temperature and tends to darken the meat on cooking. Large sugar on prolonged curing promotes vigorous microbial growth which usually causes acid fermentation that effects palatability and color.
3. Nitrates and N i t r a t e s Potassium nitrate (genuine saltpeter), sodium nitrate (chile saltpeter) a m color fixation agents or substances responsible for the development of the proper color in cured meat products.

N i t r a t e s and nitrites have a pronounced effect on flavor. Without them, a cured ham 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. The nitrates

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

Nitrate in itself is not effective in producing the curing reaction until it is first broken down i n t o nitrite. This is a slow process and is usually dependent on bacterial action. With the need for rapid curing to meet todays modern processing schedules, nitrite is added directly.
Nitrites provide the ultimate source of the nitric oxide that combine with the pigment. The use level and residual levels are controlled as follows:

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

of meat

4 . Ascorbic These substances spend up curing reaction. accelerate the conversion of metmyoglobin and nitrite to myoglobin and nitric oxide and also suppress the reverse reaction. The residual amounts of also add stability to the cured meat pigment by reducing the determination the nitrisocrome and thus giving the longer shell life. The permissible level for this 7 of ascorbic acid or its pickle or lbs. sausage meat o r emulsion or meat.

to

of

5. Phosphates are adjuncts that are used to increase the water-holding and binding capacity of cured There is some evidence that they also reduce oxidate rancidity. With increased water-holding capacity, product yields increase, product surfaces are drier and firmer and emulsion are more stable at higher temperatures.

Phosphates are not easily soluble in most brines, once the salt has been added so the recommending practice is to dissolve the phosphates first. The use of phosphate is restricted to 1 dissolved in cup of meat.
6. Vinegar added for

but also has some antiseptic value. It therefore, aids in prolonging the shelf-life of the finished product. The acetic acid content be between 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 increase zest and product variety of the diet. These substances, though lacking in nutritional stimulate the flow of digestive secretions thereby materially aiding digestion. The Food and Drug Administration has defined spices as aromatic vegetable substances used for the seasoning of food. They are true to name, and from t h e m portion of any volatile oil or other flavoi-ing has been removed.

spices consist of leaves flowers, buds, fruits, seeds, barks, rhizomes, or plant parts which have been dried and are used either in the entry or after grinding to a pair. Example of these spices are pepper, onion, garlic, ginger, paprika, laurel, Little can be said general way about their composition. However, most spices owe their properties to their content of volatile oil, while in the flavor to be due to the intimate natural blending of the of a great number of different components like alcohol, esters, phenols and their derivatives, organic acids, containing compounds, alkaloids and resins.
8. Binders, Fillers, Emulsifiers The main reason for the popular use, of these intentional additives is one of economics. Flours, products and cereals when added proportionally do not cause any radical change in the quality of the product and in cases, actually improve its characteristics such as texture, appearance, slice ability and plumpness. They also prevent shriveling and shrinkage to a certain extent.
9. Other ingredients.

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I I

wine, monosodium glutamate (vetsin), soy sauce, are added to further improve the flavor of the product.

Selection of Packaging Materials for Meat and Meat Products

Basic Principles i n the
1 . Protecting the products against

of a Good Packaging Material:

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 H a n d l i n g the products during transport in the most hygienic way so as to maintain their quality. Characteristics of a Good Packaging Material The packaging requirements of frozen, and cured meats differ primarily due the chemical nature of the pigments that are present. However, they are also affected to some degree by the processing methods used, and the nature of the microorganisms that limit their shelf life.

Fresh Meat
For meat merchandising, the following are the characteristics of a good packaging material: must allow oxygen to pass through them t o maintain an optimum maintaining a predominantly oxymyoglobin

2 It must be moisture proof to

dehydration and surface discoloration. contamination during subsequent

3. It must protect the product storage, handling, and merchandising.

4. It must

flavors and

impart any or product and should retain the natural that are inherent to the product. to withstand

5 . It should

tensile strength and resistance to tearing and handling.

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

Meat
The packaging requirements for
1 . It should have moisture surface discoloration during storage. 2. It must possess pliability and

meat include the following:

to prevent product dehydration and

3 . It must possess strength which includes tear and puncture resistance, 'temperature resistance,
4. It m u s t be grease proof or grease resistant.

Cure Meat Products In contrast to fresh meat, the retention of a stable color in cured meat products depends on the absence of oxygen. to light also causes change known light fading.
the packaging material used for cured meat products must possess the follow characteristics:

impermeable. Some cured meat products are vacuum-packaged. Other are placed in opaque packages with only limited portion of the product visible through a "window"in the package to minimize light fading.

It must be proof so that the products remain moist or retain the characteristic juiciness during handling and storage.
3.
must the product further storage, handling and merchandising.

contamination during subsequent

4. It must not impart any

or to the product and the natural flavors and that are inherent tot he product must be retained. tensile strength and resistance to handling.
and scuffing to

It must have withstand

6. It must grease so that the meat fat w i l l not be absorbed and the strength o r moisture vapor transmission properties will not be reduced.

Recommended Packaging Materials for Fresh and Cured Meat Products

Fresh Meat Paper is still extensively used for wrapping fresh meats. Paper meat wrappers the following:

Bleached and unbleached

2. Oiled wet-strength bleached

Used for wrapping wholesale cuts of beef.

paper. Used for wrapping wholesale cuts of pork,

Plastic is the most popular packaging materials for fresh meats. It has desirable characteristics such light weight, inertness, clarify flexibility, rigidity and a wide range of barrier properties. Plastics include cellophane, polyethelene (PE), ypropylene nylon. Fresh meat cellophane is coated with a special nitrocellulose or coating on one side. The side is in direct contact with the moist, fresh meat to have continuous transmission of oxygen. The outside coating restricts transmission of moisture f r o m the meat to prevent shrinkage and desiccation. Polyethylene (PE). polyethylene film is used for both fresh and frozen It is particularly a packaging material for stored meat because it retains its flexibility at temperature as low as It is also used for laminating packaging for vacuum and gas packaging meats. Polypropylene (PP) has very good transparency, has fair resistance, but has very poor cold resistance. Thus, i t may only be used for fresh meats but not for frozen ones. Nylon is a polyethylene tubular stock used in the form of casings and contour bags for packaging frozen, and cooked boneless beef and other meats.

Meats
Paper
Paper packaging materials such as are for wrapping fat meats such as ham and
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Plastics
Plastics include regenerated cellulose, polyethelene (PE), polypropylene esters, nylon, saran, foil and laminate. Regenerated cellulose essed meats. poly-

is used as mold and containers of smoked and proc-

Polyethylene (PE). Low density polyethylene film is useful for packaging frozen stored meat and processed meats. Bio-oriented polyethylene film is used for shrink packaging meat products. Polyesters is suitable for packaging meat and ready-to-serve convenience foods. It is available in uncoated forms, heat shrinkable types, polymer coated types for heat-sealed packages, and polymer coated thermoformable and able types for vacuum packaging. Nylon is used for differentmeat packaging applications especially in thermoforming deep draw vacuum package of processed meats. Typical applications are packaging luncheon meat or frankfurters. Saran film is heat-sealed and tends to shrink on exposure to heat. Saran casings are resistant to moist heat up to They are used as heat processing package as well as consumer for liver sausage and other sausage products.

U
U

Aluminum foil is the most

used foil in meat packaging. It is opaque, has moderate dimensional stability and high degree of heat transfer. It is not also sensitive to moisture and has zero permeability t o water and gas vapors. Aluminum foil for packaging applications is available in gauges of a quarter mil to six mil. In gauge of less than one mil, the foil is generally laminated with paper, paperboards, cellophane, and plastic film to make flexible pouches for gas packaging, decorative and packages for cured, smoked, and processed meats. It gauges of one or more, the unsupported foil is pressure-formed into rigid trays.

Laminate is a combination of two or more single sheets of papers, films and foils w h i c h are bonded together. Lamination results in a number of possibilities to develop or wrapping material of greater durability for packaging. In addition to laminating paper, many coating processes are also employed to change the make-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 natural sealing properties, optical properties, release properties, and the durability of the film.

Metal Cans
Metal cans are containers utilized for thermal processing and for merchandising shelf-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 for preserved foods. is the principal material used for metal cans. It is mild steel coated on both sides with tin. The tin is normally applied in a very thin coating by electrolytes deposition.
cans. These replaced the tin cans for canned sausage and luncheon meat. can has lighter weight and greater resistance to chemical interaction w i t h products.

Glass Containers Glass, as a packaging material, has chemical inertness, clarity, rigidity, resistance to internal pressure, and resistance to heat. However, it is fragile (hazard to breakage) and heavy weight.

Advantages of
Combining packaging materials, e.g., advantages. These are the following:

Packaging Materials
foil and
have various

Improves the strength of the package. Improves the resistance to loss of volatile components of the packaged product. Reduces transmission of water oxygen, and other gases. Improves fat resistance. Provides heat-sealing. Eliminates fracture at low temperature and measures package integrity at high temperatures. 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 of Pork Carcass

ribs

buth

12

Part of Beef Carcass

I
chuck

fore

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MEAT
Meat Material. Pork lean ground, finely Ingredients:

1.0 kg.
Per kg. 1
lf4

Salt coarse curing Phosphate Water Sugar refined Nutmeg White pepper, ground Ascorbic 600 mg.(pulverized)

MSG

Water (to dissolve

1 tab. l f 2t 2T

Procedure:
1 .

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

2.

a l l ingredients. Mix salt, curing salt and phosphate with meat until tacky. Add the remaining ingredients u n t i l tacky. Add the remaining ingredients
u n t i l blended.

3. Put in a bowl and cure for 1 2 days in a

4. The next day,

for 5 -6 minutes then for 1

in a casing (nylon shrinkable

casings).
5. Cook in water

luncheon meat:

- 165F.

2 hours. Internal temperature of cooked

6. Cool and store in chiller or

7 .S l i c e if to be served.

MEAT LOAF
Meat Pork, ground Vienna sausage
Ingredients:
1.0 k

can

Salt, coarse salt Phosphate

sugar

Water Pickle relish Cheese grated Egg, slightly beaten Onion,chopped All purpose flour Raisins, chopped Ground blackpepper (dissolve in Procedure:
1. Prepare all ingredients needed.

1 t + 114 C water 4T 1 1 4

C water)

2 1 pc. 2T lf2 lf2 T t 2T

2 . Mix meat with the first three ingredients: salt, curing salt, phosphate dissolved i n

C water, until tacky.

3. Mix rest of the ingredients.

4. Place i n greased baking pan and bake at

for 30 minutes or until done.

Remove and let cool.

5. Slice before serving.
Note:

foil maybe used t o roll meat mixture arid steam f or

hour.

BOLOGNA
Meat
Beef brisket, ground finely Pork lean, ground finely
600 g

400

Ingredients:
Salt salt Phosphate Sugar Ascorbic acid, lf2 t t+ 2T tab. lf2 t t lf4 t t t 2T

C water

MSG

(pulverized)

Onion powder
Nutmeg Paprika G a r l i c powder (dissolve in water) Water

Procedure:
1 . Chill meat. Grind through

hole plate. C water. Cure overnight.

2. Mi x meat with Salt, curing salt, phosphate dissolved in

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

4. Pass through grinder together with ice (150 mix by hand until tacky

5. Stuff in nylon shrinkable casings. 6. Cook in hot

7

water with little salt, pepper and oregano,

Serve cold or store in freezer.

roll meat in foil or put in pan mold. Steam for one hour.

N o t e : In the absence of nylon shrinkable

1
Meat Material: Chicken, whole, dressed

RELLENO
1.2

1.5

(1

Marinade:

soy sauce

juice Ground blackpepper

112 c 114

MSG

F i l l i n g :(good for 1 . 2 1 . 6 kg,chicken)

Pork lean, ground
salt

Sugar refined Ground blackpepper

kg. 112 T 1 2T t

de bilbao, cubed Potato, cubed bell pepper, cubed Green peas

c c (2 c

R a i s i n

4 T (2 boxes) 2 2

boiled, medium fresh, medium Garlic, chopped finely Onion,chopped grated Pickle relish Water C

bar
2T
2 T (dissolved in water) C

Procedure:
1 . Marinate chicken overnight in the refrigerator

Saute garlic and onion till brown. Add the ground, the ingredients. 3. F i l l inside the debored chicken, then sew the cut side.

de bilbao, and the rest of

1
1
1

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 can be added to thicken sauce. Nob: Chicken Relleno maybe cooked in an oven at 350F for one hour.

I I I

1 l

EMBUTIDO
Meat Material: Pork lean, ground Pork fat, ground Textured Soy Protein
800 g.

200 g. 60 g. (U4 C + C water, hydrate for 3 minutes)

Ingredients:

Salt, coarse Phosphate curing salt Sugar Ground blackpepper Evaporated m i l k Bread Chorizo de bilbao, chopped coarsely Pickle relish Onion, chopped finely Raisin
boiled (optional) or quail eggs (6 pcs.) Vienna chopped chopped finely Butter (spread in foil)

2 t

t 6T
1/4

1 1pc.

1/4

box)

3T

2T
2T

Procedure:
1 . Hydrate

C water for 3 minutes or until soft

M i x until well blended.

2 . Combine

pork, raw eggs,

3 .

meat mixture in

foil (1cup per roll) and twist both ends

4. Prick foil with pin and steam for 1hour. Cool 5.

C h i l l in

unwrap and slice if to be served

E l

QUE
Meat Pork lean, coarsely ground Shrimp meat, cooked and chopped Ingredients:
s a l t Sugar Garlic, chopped shredded, pressed Onion,chopped Carrots, shredded Ground blackpepper powder powder Mix together Water
1

1.0 100 g

4T 2T
C
yc.,

C
2t 2T

pc., medium)

MSG

Eggs, medium

1 . C h i l l meat. Grind meat and chop shelled shrimps meat. 2. Combine all ingredients well and mix into meat and shrimp till
3 . Pack in taupee wrapper
4.

blended

per roll).

Fry in hot

oil. sauce.

5. Serve

Ingredients:
Water Brown Sugar Cornstarch

6T 2T
t
t

S i l i labuyo
Soy sauce Laurel Ground blackpepper

1small pc.

Meat

Pork, ground, coarsely Shrimp, cooked and chopped Ingredients:

1.0 kg. 100 g

salt

curing salt Phosphate

Water

c
6T

Garlic chopped Ground blackpepper Carrots, shredded

c
4

Cheese grated MSG Molo wrapper

Procedure:
1. Mix meat with the first three ingredients until 2. Then combine a l l ingredients thoroughly and wrap in 3. Steam for 30 minutes. 4. Serve with soy sauce and

c
t

wrappers.

Yield: 90 100

for every kg.

I'

Meat
Pork lean, ground, coarsely Beef lean, ground, coarsely Pork cubed
600

600 300 g

Ingredients:

salt
Sugar refined c ur ing salt White pepper Pepper corn Mustard seed
Phosphate Water

t
2t

U4 c

Procedure:
1 . Chill meat. Cube

and pass meat through a coarse plate of a grinder.

2. Mix by hand: fat cubes, meat, spices and other ingredients until tacky.

3 . Fill meat mixture i n t o casings. Afterwards, smoke for 45 minutes.

4. After

dry for 2 - 2

hours.

5.

Pack for storage.

before serving. maybe added and drying could done under the sun for 8

6. Slice and

N o t e : Smoke flavor (U4

hours.