Understanding Smoke Color

Transcription

1 Understanding Smoke Color Chad Anderson Sales Manager Red Arrow Products Bob Hanson VP of Research & Technology ALKAR -RapidPak

2 Why do we cook meat? Primary goal: Secondary goal: Kill bacteria Quality characteristics

3

4 Smoked Sausage, natural casing, 32-34mm, traditional smoke Step Time Dry-Bulb Wet-Bulb R.H. Dampers Smoke 1 10 min 110º F 100º F 68% Auto 2 90 min 120º F 0º F --- Auto 3 30 min 120º F 0º F --- Closed On 4 30 min 145º F 120º F 47% Auto On 5 30 min 165º F 140º F 50% Auto On 6 to 158º F core 170º F 160º F 78% Auto

5 Smoke Composition Phenols Carbonyls Acids

6 Smoke Color Carbonyls + amines + dry heat Hot, dry conditions promote Maillard browning

7 Maillard Reaction Reducing Sugar + Schiff s Base The Amadori Rearrangement Yield Several Products including 5 Hydroxymethyl 2 Furaldehyde Brown Pigments Melanoidins Different pathways based on the ability to dehydrate Protein (N) R E V E R S I B L E N O T R E V E R S I B L E

8 Factors Affecting Smoke Color Concentration of browning components Surface temperature Surface dryness

9 Factors Affecting Smoke Color Concentration of browning components Absorption of liquid smoke Application method Atomized or drenched Concentration of drench solution Liquid smoke or Maillose Atomization time Surface dryness Absorption of traditional smoke Surface dryness Smoke density

10 Factors Affecting Smoke Color Surface Temperature & Surface Dryness Air velocity Dry heat Humidity Surface drying before smoke application Surface drying after smoke application Product formulation Water content influences surface dryness Product shape

11 Test Equipment and Procedures Batch Oven Air velocity = fpm Dry-bulb = o F Used typical processes Belt Oven Air velocity = 1800 fpm Dry-bulb = 400 o F Accelerated color development

12 Test Equipment and Procedures Batch Oven Air velocity = fpm Dry-bulb = o F Used typical processes Belt Oven Air velocity = 1800 fpm Dry-bulb = 400 o F Accelerated color development

13 Factors Affecting Smoke Color Concentration of browning components Absorption of liquid smoke Application method atomized or drenched Concentration of drench solution Liquid smoke or Maillose Atomization time Surface dryness Absorption of traditional smoke Surface dryness Smoke density

14 15% 30% 45% Effect of liquid-smoke concentration -- molded hams Pre-cooked hams: 10-min pre-dry, drench, 10-min final dry Air velocity = 1800 ft/min Dry-bulb = 400 o F

15 15% 30% 45% Effect of Maillose concentration -- Turkey breast Pre-cooked turkey: 5-min pre-dry, drench, 5-min final-dry Air velocity = 1800 ft/min Dry-bulb = 400 o F

16 Factors Affecting Smoke Color Surface Temperature & Surface Dryness Air velocity Dry heat Humidity Surface drying before smoke application Surface drying after smoke application Product formulation Water content influences surface dryness Product shape

17 900 ft/min 1800 ft/min Effect of air velocity on browning Pre-cooked turkey: 5-min pre-dry, drench, 5-min final-dry Dry-bulb = 400 o F Concentration = 30% Maillose

18 Factors Affecting Smoke Color Surface Temperature & Surface Dryness Air velocity Dry heat Humidity Surface drying before smoke application Surface drying after smoke application Product formulation Water content influences surface dryness Product shape

19 200 o F 300 o F 400 o F Effect of dry heat on smoke color -- molded hams Pre-cooked ham: 10-min pre-dry, drench, 10-min final-dry Air velocity = 1800 ft/min Dry-bulb = 400 o F Liq smoke = 30%

20 200 o F 400 o F Effect of dry heat on smoke color -- turkey breast Pre-cooked turkey: 5-min pre-dry, drench, 5-min final-dry Air velocity = 1800 ft/min Dry-bulb = 400 o F Maillose = 30%

21 Effect of Heat Treatment on Surface Temperatures of Hams Pre-cooked molded hams, Virginia molds, 6.0"dia x 15.0", lb Surface temperature 400 o F process Temperature o F Surface temperature 200 o F process Process 1. Pre-Dry = 200 or 400 o F dry-bulb temperature 2. Drench = 30-sec in 30% liquid smoke, 90-sec drip-off 3. Final-Dry = 200 or 400 o F dry-bulb temperature Time - Minutes Effect of dry heat on smoke color -- pre-cooked hams

22 Effect of Heat Treatment on Surface Temp of Turkey Pre-cooked turkey breast, 4.5"x 8"x 10", 9-10 lb 220 Temperature ( o F) Process: Pre-dry = o F dry-bulb temperature Drench = 30 sec in 30% Maillose, drip-off = 90 secs Final-dry = o F dry-bulb temperature Time (min) Surface temperature 400 o F process Effect of Dry Heat on Smoke Color -- Turkey Breast

23 Factors Affecting Smoke Color Surface Temperature & Surface Dryness Air velocity Dry heat Humidity Surface drying before smoke application Surface drying after smoke application Product formulation Water content influences surface dryness Product shape

24 Pre-smoked casings Oven Cook Time DB WB RH% 90 min to min shower Steam Cook Time DB WB RH% 60 min to min shower Effect of humidity on smoke color -- boneless hams Pre-smoked fibrous casings -- steam vs dry cook

25 Factors Affecting Smoke Color Surface Temperature & Surface Dryness Air velocity Dry heat Humidity Surface drying before smoke application Surface drying after smoke application Product formulation Water content influences surface dryness Product shape

26 Effect of pre-drying on smoke color--atomized smoke Natural-casing sausage, 32mm, batch oven, atomized liquid smoke No pre-dry 30-min pre-dry 60-min pre-dry Time DB WB RH% 0, 30, 60 min min Atomization with Supreme 15 min to min shower

27 Effect of pre-drying time on smoke color Atomized vs traditional smoke -- natural-casing sausage Liquid smoke Traditional smoke No pre-dry 30-min pre-dry 60-min pre-dry

28 Effect of pre-drying time on smoke color -- drenching Skinless smoked sausage, 28mm, cellulose casing, drenched liquid smoke No pre-dry 15-min pre-dry 30-min pre-dry Time DB WB RH% 0, 15, 30 min min Drench (30% liquid smoke) 15 min to min shower

29 Factors Affecting Smoke Color Surface Temperature & Surface Dryness Air velocity Dry heat Humidity Surface drying before smoke application Surface drying after smoke application Product formulation Water content influences surface dryness Product shape

30 Process Steps 1) Drench 2) 10-minute final-dry 1) Drench 2) 20-minute final-dry Concentration = 15% 30% 45% Surface drying after smoke application--pre-cooked ham Air velocity =1800 fpm Dry-bulb =400 o F

31 Process Steps 1) Drench 2) 10-minute final-dry 1) 10-minute pre-dry 2) Drench 3) 10-minute final-dry Concentration = 15% 30% 45% Effect of surface drying -- pre-dry vs no pre-dry Air velocity = 1800 fpm Dry-bulb = 400 o F (pre- and final-dry)

32 Factors Affecting Smoke Color Surface Temperature & Surface Dryness Air velocity Dry heat Humidity Surface drying before smoke application Surface drying after smoke application Product formulation Water content influences surface dryness Product shape

33 4.6 10% Ham % Ham % Ham Time DB WB RH% 2 min Drench (30%) 60, 90, 120 min to Drying time after smoke application boneless ham Process: 60, 90, and 120-minute post-dry, batch oven

34 Factors Affecting Smoke Color Surface Temperature & Surface Dryness Air velocity Dry heat Humidity Surface drying before smoke application Surface drying after smoke application Product formulation Water content influences surface dryness Product shape

35 2 20% Ham % Ham Time DB WB RH% 2 min Drench (30%) 60, 90,120 min to Effect of product shape on smoke color Process: 60, 90, and 120-minute post-dry

36 Effect of product shape on temperatures of boneless hams 2.0" vs 4.6" diameter, fibrous casings, 20% water-added formula 200 Dry-bulb 160 Temperature ( o F) Surface, 2" hams Surface, 4.6" hams Wet-bulb time (hours) Effect of product shape on smoke color -- hams

37 Factors Affecting Smoke Color -- Process Variables Surface dryness Pre-dry Humidity Air velocity Post-dry Concentration

38 Influence of Equipment Design Batch Oven Large cabinet cross-section Variation in three dimensions Variable air velocity and drying Readily over-loaded Continuous Ovens Higher airflow and drying Fixed loading prevents over-loading Less variable air velocity and drying Variation in only one or two dimensions