Meat

Processing Dr. Salah Aboraya ,

Technology Cairo University Faculty of Agric.
Food Technol. Dept
EGYPT
Feb.2017
Introduction

Despite the growing preference in some

circles for meatless diets, the majority of
us will continue eating meat. It is
generally accepted that balanced diets of
meat and plant food are most effective
for human nutrition.
Nutritive Value

Animal foods are better sources of

protein than plant foods (except
soy bean products).
High Protein Content (20 22%)
High protein quality (BV)
Relatively high lipid content (4-6)
(9-11) (energy source )
Nutritive Value

meat, is rich in iron, which is of

utmost importance to prevent
anemia, especially in children and
pregnant women.
Meat is indispensable for children to
establish Vitamin B Complex
(B1,B2,B6,niacen and B12) deposits.
Advantage & Purposes of meat
processing

It fully utilizes meat resources (all edible

livestock parts) for human food
consumption.
Preservation by inhibiting or microbial
decomposition.
Resulted in flavorful and nutritious
products.
Providing both convenience and variety to
the meat portion of the diet.
Advantage & Purposes of meat
processing

Additives are used to enhance product

Flavor, appearance and to increase
product volume.
Meat processing can create different types
of product composition that maximizes
the use of edible livestock parts and are
tasty, attractive and nourishing.
For specific meat preparations, animal by-
products such as internal organs, are
also well suited for meat processing.
Advantage & Purposes of meat
processing

create low-cost products

many processed meat products
can be made shelf-stable.
Such shelf-stable meat products
can conveniently be stored and
transported without refrigeration
Meat processing adds value to
products (trimmings, connective
tissue, organs and casings)
Meat Technology

Includes all processes utilized in

altering fresh meat( except for
simple grinding, cutting, mixing
and packaging ).
This includes:
All the processes that inter into the
preservation and manufacture of
meat products which prolongs the
keeping quality of fresh meat.
Meat Technology

Irradiation treatment
freezing, dehydration and
production of intermediate-
moisture products.
Salting, curing, smoking, canning,
cooking
Use of certain additives such as
chemicals and enzymes.
Meat Sources

Animals (red meat)

Cattle
sheep
goats
Pigs
Hors
Birds (white meat)
Chickens
Turkeys
Ducks
geese
 Slaughtering
Animals:
Stunning, shackle, stick, bleed, head remove,
hang, eviscerate, remove skin washing, split
into sides, weigh, wash, chill, maturation
- Birds
Hanging, stunning, slaughter, bleeding,
scalding, defeathering, washing, hock
cutting, shank removal, evisceration,
washing, chilling, trussing, packaging,
Freezing
Meat Quality Characteristics

Color (pigments)
Juiciness, WHC , Marbling
Toughness (tenderness)
Flavor
Meat Quality Characteristics

Color
myoglobin.
Oxymyoglobin
Met myoglobin
Meat Quality Characteristics

Color
myoglobin.
Oxymyoglobin
Met myoglobin
Meat Quality Characteristics

Juiciness
- The water holding capacity (WHC)
Water bound to the muscle protein
affects the eating and processing
quality of the meat.
As the muscle tissue develops acidity
(decrease of pH) the water holding
capacity decreases
Meat Quality Characteristics

- Marbling (Fat distribution )

The adpose tissue located between

muscle fiber bundles in the perimysial
connective tissue (good quality meat)
Excessive fat surrounding major
muscles (poor quality)
Meat Quality Characteristics

Toughness (Tenderness)
- Muscle diameter
- Connective Tissue Content
- inter- and intramuscular fat
Meat conditioning (Aging)

Resoluton of rigor during storage

Protein changes
Increase tinderness
Skeletal muscle changes
Degradation of the z-disc
Disappearance and degradation of some
proteins
Proteolysis
Meat conditioning (Aging)

Resoluton of rigor during storage

Protein changes
Increase tinderness
Skeletal muscle changes
Degradation of the z-disc
Disappearance and degradation of some
proteins (nebulin- titin-desmin-troponin)
Proteolysis
Factors affecting meat quality

Pre-slaughter handling of animals

Slaughterhouse techniques
Post-slaughter processing of meat
Biochemical changes during maturation
Grading of meat
Packaging of meat
Hygiene practices
Spoilage detection and safety
criteria

Sensory evaluation
Physical tests
Chemical tests
Biological inspection
Meat Spoilage and preservation

Spoilage factors
Preservation :
Chilling , Freezing
Irradiation
Packaging
Bio preservation
Dehydration
Preservatives
EQUIPMENT USED IN MEAT
PROCESSING

Frozen meat cutter meat grinder (Mincer)

Mixer / blender
Bowl cutter (bowl chopper)
Filling machine (sausage stuffer)
Clipping machine
Smokehouses
Combined equipment
Brine injector
PRINCIPLES OF MEAT PROCESSING
TECHNOLOGY

EQUIPMENT USED IN MEAT

PROCESSING
Tumbler or Massager
Vacuum packaging machine
Emulsifying machine
Ice flaker
Processes

Physical
Preservation
Cooking
Smoking
Formulation
Packaging
Cleaning
etc
Curing - Salting

Curing Salting Process

Up to about 5% in lean meat:
adds to the taste of the final product.
Increasing the water holding capacity of
meat
conversion of the red meat pigment
myoglobin (Fe+2) to the brown
metmyoglobin (Fe+3).
water binding and texture formation in
certain meat products
 Curing Process
Meat mixed with common salt (sodium
chloride NaCl and curing agent NaNO2
Sodium or potassium nitrate (Na/K NO3)
(saltpetre)
Sodium nitrite in very small amounts has the
ability to react with the red meat pigment to
form the heat stable red curing colour
Levels of 150 mg/kg in the meat product,
which is 0.015%, are normally sufficient.
Meat Curing

Curing Process
beneficial properties of Nitrite in meat
processing:
- create a heat resistant red Colour
- inhibitory effect on the growth of bacteria.
- attributing a specific desirable curing
flavour
- an antioxidant effect for fat rancidity
Curing ingredients:

- Common salt (NaCl)

- Suger and sweeteners (corn syrup)
- Nitrite and nitrate, Phosphates
- Sodium ascorbate and erythorbate
- Sod. and pot. lactate
- Pot. Sorbate
- Mono sodium glutamate
Curing methods:
- Dry curing (conventional)
- 3-5 Ib salt/ 100 Ib of bellies
- At 48F 50 F for 3-5 days
- Wet curing (pickling)
- Artery pumping
- Soaking
- injection curing
- Single-needle stitch pumping
- Multiple-needle stitch pumping
- Thermal or hot cures using saline
solution 70 sal. At 135-140F for 0.5-1 hr
Smoking

Smoking Process:

Definition: Treatment of meat product by

exposing to the smoke produces from
incomplete combustion of special type of
wood sawdust (time and temp.)
Benefits of smoking:
Meat preservation through aldehydes,
phenols and acids (anti-microbial effect)
Antioxidant impact through phenols and
aldehydes (retarding fat oxidation)
Smoke flavour through phenols,
carbonyls and others (smoking taste)
Smoke colour formation through
carbonyls and aldehydes (attractive
colour)
 Formation of a protective skin on
emulsion-type sausages (Surface
hardening of sausages/casings through
aldehydes in particular for more rigid
structure of the casing)
Creation of new products
 Types of fuel:
Corncobs, hardwoods (alder, beech, oak,
poplar and birch),
Composition of smoke:

More than 300 different compounds

- Phenols
- Alcohols
- Organic acids
- Carbonyls
- Hydrocarbons
- gases
Smoke Houses Types :
Three types of smoke house
a) Old style county smokehouse
- (natural air circulation)
b) Modern smoking
2. Air-conditioned or forced air
3. Continuous (better control)
Smoking methods :
1- Cold Smoking
At 18C (up to 26C) which may take
several days but in intervals of a few
hours per day.
2- Hot Smoking
At 60 C to 80C from 10 min. up to 1 hr.
3- liquid smoking
Advantages of liquid smoke preparations
- Not require smoke generator
- Repeatable
- Can be remove the carcinogenic matters
- Little atmospheric pollution
- Can be applied easily
- Faster than the conventional
NON-MEAT ingredient additives

Most ingredients are functional Categories

of non-meat ingredients
- chemical substances (preservatives,
Antioxidants, MSG, Clouring)
- plant origin (spices, isolated soy protein,
wheat gluten)
- animal origin (Milk caseinate, Gelatine,
Eggs)
The functional properties of ingredients
include their impact on:
Taste, flavour, appearance, colour, texture,
water binding, counteracting fat
separation, preservation
The criteria for the utilization of functional
non-meat ingredients are:
safe for consumers
improve of processing technology.
sensory quality of the products.
Examples:
- meat extenders (Soy flour, Concentrate)
- Fillers (Starches, Vegetable, Cereal flours)
- Binder (polyphosphates, albumen,
skimmed milk)
- Flavour enhancer (MSG)
- Food colourings (natural sources,
orangeyellow beta-carotene, red
oleoresin from paprika)
- Sugar (sucrose1, dextrose2 or corn syrup)
Heat Treatments of meat products

High Heat Treatments :

meat products are heat treated during
manufacture and cooled down in a next
step
Purposes:
Reduction of microbial content
Enhancement of desirable texture,taste, flavor
and color,
High Temperature

Types of heat treatment :

Thermal treatment
a. Heat treatment at temperatures below 100C,
mostly in the temperature range of 60 to 85C,
also called pasteurization or simply cooking
then stored refrigerated (0-5C).
b. Heat treatment at temperatures of above 100C,
also called sterilization stored under
ambient temperature (shelf stable).
CATEGORIES OF PROCESSED MEAT
PRODUCTS :

Fresh and frozen meat products

chopped beef and hamburger
Cured meats (not smoked or cooked)
Smoked, dried and cooked meat
Curd, smoked, dried and cooked products
Basterma, corned beef, luncheon meat
Fermented Meat products
Canned meats products
Convenience foods (meat used)
Pizza-meat, pies-meat, dinners-meat, entrees-meat, other
Meat Products

Definition of some meat products :

Fresh processed meat products
These products are meat mixes composed of
comminuted muscle meat, with varying quantities of
animal fat. Products are salted only, curing is not
practiced.
Non-meat ingredients are added in smaller
quantities for improvement of flavour and binding,
in low-cost versions larger quantities are added for
volume extension.
Heat treatment (frying, cooking) is applied
immediately prior to consumption to make the
products palatable.
 Cured meat cuts

The meat pieces are treated with small amounts of

nitrite, either as dry salt or as salt solution in water.
Two groups of cured meats
Cured-raw meats
Cured-cooked meats,
Cooked meat products

Precooked-cooked meat products

Precooked-cooked meat products contain mixes of

lower-grade muscle trimmings, fatty tissues, head
meat, animal feet, animal skin and other edible
slaughter by-products and heat treated:
precooking of raw meat materials
cooking of the finished product mix
 Raw-fermented sausages:

Raw-fermented sausages are uncooked meat

products and consist of more or less coarse
mixtures of lean meats and fatty tissues combined
with salts, nitrite (curing agent), sugars and spices
and other non-meat ingredients filled into casings
then fermented for short or long ripening phases
combined with moisture reduction (drying)
The products are not subjected to any heat
treatment during processing
 Dried meat products:

Dried meat products are the result of the simple

dehydration or drying of lean meat in natural
conditions or in an artificially created environment
CATEGORIES OF PROCESSED MEAT
PRODUCTS
FRESH PROCESSED MEAT PRODUCTS:

This group comprises meat mixes composed of

finely comminuted, minced or sliced muscle meat,
with varying quantities of animal fat and filled in
casings.
Flavouring is done by adding salt and spices
non-meat ingredients are added in smaller
quantities
meat and nonmeat ingredients are added fresh
The heat treatment (frying, cooking) is only applied
immediately prior to consumption
 Patties, Kebab, etc. :
Patties are formed from minced meat (beef, mutton,
chicken) (with fats, connective tissue/tendons)
usually in a disc-like shape with diameters of 80-
150mm and 5-20mm height (Fig. 140, 411). In
commercial fast-food outlets the common name is
hamburgers or simply burgers.
Salt, spices, herbs, garlic or onions, textured soy
protein are added.
Burgers are stored frozen and individually pan-fried
before consumption.
 Fresh sausages:

Fresh meat and fat are mixed with salt and spices
and stuffed into natural casings derived from small
intestines of slaughter animals.
In some low-cost formulations non-meat extenders
are also used.
 RAW FERMENTED SAUSAGES :

Raw-fermented sausages receive their characteristic

properties (tangy flavour, in most cases chewy
texture, intense red curing colour) through
fermentation processes, which are generated
through physical and chemical conditions created in
raw meat mixes filled into casings.
 RAW-COOKED MEAT PRODUCTS :

The product components muscle meat, fat and non-

meat
ingredients, are processed raw (raw=uncooked)
by comminuting and mixing in a first phase. The
resulting viscous mix/batter, upon portioning in
sausages or otherwise, is thereafter submitted to
heat treatment or cooking, in order to obtain a
firm-elastic texture typical for ready-to eat raw-
cooked products and to achieve palatability and a
certain degree of bacterial stability.
 The most common are the small-calibre
Frankfurters and Vienna sausage and the large
calibre Bologna and Lyoner.
Others can be classified as extended raw-cooked
meat products as they contain higher amounts of
low-cost non-meat ingredients mostly of plant origin
for cost-reduction. Some typical representatives of
this group are hotdogs or luncheon meat
Principles of sausage manufacture

Extract and dissolve solid muscle proteins

(chopping and salting)
Establish a network structure of liquid or
gelatinous muscle proteins (emulsion)
Stabilise the muscle protein network through
heat coagulation by cooking.
Cool products (immediately after cooking, pass
quickly temperature range from +40C to +20C,
store in refrigerated rooms)
Principles of sausage manufacture

The chopping process

Step 1 : The lean meat portion is pre-minced and
kept chilled (0C).
Step 2 : The lean meat is placed in the bowl cutter
with the salt and additives for the whole batch.
The mixture is chopped for 5- 10 rounds without
ice. This step is called dry-chopping.
Step 3 : Ice is added and the chopping continued at
fast bowl chopper speed until the ice is evenly
incorporated and a sticky lean batter is
achieved. Now also the spices are added.
Principles of sausage manufacture

Step 4 : The fat (pre-minced and

chilled) is added and the mixture
chopped at high speed until a
homogeneous batter made of lean
and fatty tissues is achieved.
Step 5 : The final temperature of the
batter should not exceed +12C
Principles of sausage manufacture

Filling the product mixture into casings or

other containers
Casings can be natural or made of different
materials and are available in different shapes
and calibres. Most casings require pre-
treatment before being used
Principles of sausage manufacture

Reddening after filling

the sausages are hung on sticks and allowing for
air circulation around the individual pieces.
pre-heated smokehouse and exposed to modest
heat treatment (hot air) in a first phase without
smoke at approximately +50C
Colour was changed from grey to red (from 15
minutes for calibre 22 to one hour for calibre 90).
The presence of cure accelerators (ascorbic acid,
sodium ascorbate) in the batter enhances this
curing reaction.
Principles of sausage manufacture

Hot-smoking
Raw-cooked sausages are hot-smoked at
temperatures of +65 to 70oC until a desired
product colour is achieved (30-60 minutes).
Principles of sausage manufacture

Cooking
After the hot-smoking is completed the sausages
are taken for further heat treatment (cooking,
scalding) in order to achieve complete protein
coagulation.
cooking in a vat and submerged in hot water of
+74 to +80C for a certain period of time until a
core temperature of at least +72C is achieved
(1 minute of heat treatment at +70C per 1 mm of
sausage diameter is required)
Principles of sausage manufacture

Cooling of cooked products

Products should never be kept or stored in the
temperature range of +20oC to +40o
The rapid cooling is practically achieved by
immersing the products in a container of cold
water or in modern cooking chambers by
showering with cold water
the products must be immediately transferred into
chillers where they can be stored for a few days
to a few weeks
PRECOOKED-COOKED MEAT
PRODUCTS

Two heat treatment procedures used

1. precooking of most of the raw meat materials
at temperatures in the range of 80C.
2. cooking of the finished product mix at the
end of the processing stage at 80C for
sausages filled in natural and artificial
casings (above 100C) canned products are
filled in glass jars, tin or aluminium cans or
similar (not require refrigeration)
 The raw meat materials used for
precooked-cooked products are lower-
grade muscle trimmings, fatty tissues, head
meat, animal feet, animal skin, blood, liver
and other edible slaughter by-products.
Corned beef varieties

Corned beef with jelly :

is produced from cured pre-cooked beef. The
pre-cooked lean beef should be shredded in
order to maintain the fibrous structure of the
muscle tissue to some extent.
Cutter knives fitted in the reverse way to avoid
sharp cutting of the tissues and operated in
slow gear can also serve for this purpose.
Cooking broth liquid enriched with gelatin
(from boiled lean meat), spices and additives
were added to shredded precooked beef
Corned beef varieties

Corned beef with jelly

filled either in synthetic casings and
pasteurized (cooked below +100C to core
temperatures of +74C)
or filled in cans and sterilized
lower price products beef or buffalo meat
trimmings are used with higher fat and
connective tissue content, some also contain
meat extenders
CURED MEAT CUTS

Curing is the treatment of muscle meat

with common salt (NaCl) and sodium
nitrite1 (NaNO2) for larger pieces of meat
applied to achieve a pinkred colour as
well as a typical flavour and taste in
processed meat products
two groups of cured meats
Cured-raw meats
Cured-cooked meats,
Processed chicken meat products :

chicken ham
chicken breast
Other chicken meat products

Coated / breaded products

Chicken nuggets (ground meat mix),
chicken sticks or fingers (muscle strips)
chicken schnitzel (breast muscle slices).
Chicken burgers,
chicken longganisa
MEAT PRODUCTS WITH HIGH LEVELS
OF
EXTENDERS AND FILLERS

Traditional extended meat products

Italian Mortadella and breakfast sausage
Moo-Yoh (Asia), Kilishi (Africa)
Extended Western style meat products
Fresh coarsely ground meat products -
extended
Hamburgers
Chicken burgers
Meat balls (coarse)
Meat rolls, ground kebabs
 Extended Western style meat products
Rawcooked meat products - extended
Hot dogs, Vienna sausages
Chicken viennas, Chicken hotdogs
Luncheon meat
Cooked ham
Corned beef
Sausage and sliced products

Fresh sausages
Dried and semi-dried sausages
Frankfurters
Bologna (regular, with extenders, with
variety meats
Miscellaneous sausages
Liver sausages
Meat loaves-cured
Other formulated products
Luncheon meat

Canned product :
usually manufactured from pork and/or
beef, luncheon meat may also contain
other meat types. Cheap luncheon meat
products often contain mechanically
deboned meat (MDM), mostly from
chicken, as part of the lean meat
ingredients.
Cylindrical shape without canning
product
Sausage and sliced products

Sliced products Pepperoni

Bockwaurst Scrapple
knockwurst Souse
Braunschweiger Mortadella
Capicola Meat potted
Cervelat,dry Beef
Luncheon meat chicken

salami
Sausage and sliced products

The USDA classification of sausages :

1. fresh
2. Uncooked and Cooked smoked
3. Cooked
4. Dry and semi-dry
5. Luncheon meat
6. loaves and jellied products
Sausage

One of the oldest forms of processed foods

The term sausage is derived from the
Latin word salsus meaning salt, or
literally translated, refers to chopped or
minced meat preserved by salting
Sausages are salted, seasoned, chopped
meat products that are generally but not
always cylindrical in shape
Sausage

Sausage mixtures were encased in

Animal intestines or stomachs in cylindrical
shape
Synthetic casing
Sausage Classification

No single classification system is

completely satisfactory so it may be
classified according to the followings:

Degree of chopping
Coarsely ground
Emulsion or finely chopped
Amount of cooking
Uncooked- cooked
Sausage Classification

Amount of smoking
Unsmoked
Smoked (natural smoke, smoke flavoring
isolated smoke components)
Amount of curing
Uncured cured
Amount of fermentation
Unfermented- fermented
Sausage Classification

Amount of moisture in the final product

Fresh (unsmoked or smoked)
Smoked (fresh and cured)
Cooked (fresh and cured-smoked and
unsmoked)
Cured (smoked and unsmoked)
Meat loaves and specialty items
Dried (semidry and dry)
Spoilage
Cooked Meat Products
Meat Emulsion
Dried Meat
Cured Meat
Luncheon Meat
Casing materials

Natural casing
Synthetic casing
MEAT DRYING

In physical terms, drying is the lowering of

the water activity aw in meat and meat
products. Water activity is the measure of
free unbound water available for microbial
growth. Microorganisms need certain
amounts of free water for growth, and their
growth is halted below defined minimum
levels of moisture. Minimum levels vary from
species to species of microorganisms.
Dried meat products

Jerky
dehydrated lean meat, which contains salt and
spices. (Thin dried strips of meat)
Bastirma
is salted cured and dried beef muscle from
mature animals coated with spices and garlic.
Pemmican
A mixture of dry and semidry meat pounded
together with dried fruits and vegetables
covered with milted fat.
Cured Dried
Packaging Materials
Thank You

See you latter