RESTRUCTURED MEAT PRODUCTS* ROGER W. MANDIGO U n i v e r s i t y of Nebraska

Transcription

1 403 RESTRUCTURED MEAT PRODUCTS* ROGER W. MANDIGO U n i v e r s i t y of Nebraska Restructuring beef, pork and lamb i n t o p o r t i o n c o n t r o l l e d meat products o f f e r s a l a r g e new area f o r merchandising meat. If through r e s t r u c t u r i n g, pork could capture a g r e a t e r portion of t h e i n s t i t u t i o n a l market, pork consumption could be increased. Check a r e s t a u r a n t menu and see haw seldom pork appears. Pork has not captured t h e same s t a t u r e as beef i n t h e i n s t i t u t i o n a l market. This i s important as t h e i n s t i t u t i o n a l market accounts f o r approximately 40$ of t h e meals e a t e n d a i l y. C a f e t e r i a s, h o s p i t a l s, a i r l i n e s, f a s t food o u t l e t s and r e s t a u r a n t s want meat products uniform i n both s i z e and q u a l i t y. Explanations o f f e r e d f o r t h e poor showing of pork i n t h e s e food operations have been: (1) r e l i g i o u s and medical reasons; ( 2 ) p r e s t i g e and stature; ( 3 ) l a c k o f uniform p o r t i o n c o n t r o l ; ( 4 ) l a c k of uniform q u a l i t y t o include j u i c i n e s s, tenderness and f l a v o r ; and ( 5 ) proper preservation t o preserve q u a l i t y. The l a s t t h r e e items on t h e l i s t o f f e r o p p o r t u n i t i e s f o r t h e meat s c i e n t i s t t o make s u i t a b l e refinements. Research has been under way i n our l a b o r a t o r y f o r over t h r e e years t o develop r e s t r u c t u r e d pork products. This research has been funded by t h e National Pork Producers Council tbmugh t h e i r n i c k e l f o r p r o f i t check-of f program, t h e U n i v e r s i t y of Nebraska Agriculture Experiment S t a t i o n and equipment g r a n t s from Bettcher I n d u s t r i e s of Vermilion, Ohio, and Urschel Laboratories of Valparajso, I n d i a n a. The r e s u l t s of t h i s combined team e f f o r t a r e discussed i n t h i s paper. Restructured f r e s h pork products,as w e l l as cured and smoked pork products, have been developed ( p l a t e s 1 and 2 ). The t o t a l concept involves t h e i n t a c t pork muscles. Boneless pork loins and o t h e r l e a n masses such as boneless hams can be used i n t h i s phase, 6s shown in f i g u r e 1. These c u t s are removed f r o m t h e c a r c a s s, boned and trimmed of excess f a t, frozen, tempered t o 24 t o ~,pressed i n t o uniform "logs" and c u t on a power cleaver i n t o uniform p o r t i o n c o n t r o l l e d f r e s h pork products from i n t a c t muscles (Goldner e t al., 1974). Also shown i n f i g u r e 1 a r e t h e other pork cuts, such as bacon, spare r i b s and neck bones which a r e removed and processed in a conventional m n n e r. Shown i n a shaded c o l o r i n f i g u r e 1, i s t h e flow diagram f o r t h e f r e s h pork products t o be flaked-formed-sectioned. * Presented a t t h e 27th Annual Reciprocal Meat Conference of t h e American Meat Science Association, 1974.

2 404 P l a t e 1 FFS Cured and Smoked Ham Plate 2 Pork Chops and FFS P o r k

3 405 PR- OTHER PACKAGI NG I 1 Y TRIFMING I FREEZING TEMPERING c 5 CLEAVING I PACKAGING PESTRUCTUPED PORK PROCESSIrlG FlGURE 1 - FLON DIAGP,AF!

4 A wide array of meat ingredients have potential use in restructured meat products. Pork trimmings can be used based on their visual or chemical composition. Blending of more than one type of trimmings is possible. Pork shoulders could be boned and used as a sole source of meat for the products. By-products from the slaughter and breaking operations offer considerable potential for use in restructured pork products where final costs can be reduced by their inclusion. The research has shown that the use of two different temperatures of meat ingredients offers certain advantages over a single temperature. The 36"~ tempered meats are excellent for the emulsion component of the flaked-f ormed-sectioned product. This temperature would usually be used for the fat source component and would be used with the finer flake sizes. The colder tempered meat, 24OF, is used for the leaner meat components as well as the coarses flake sizes. By combining the two temperatures, different fat levels and flake sizes, texture, fat visibility, color and overall appearance can be changed and controlled, Following flaking through the Comitrol high speed cutter (Urschel Leiboratories, plate 3) the meat ingredients are mixed. Additives such as water, salt, sugar, phosphates, cure, soy and flavorings can be added at this time. Mixing time is very important and is currently receiving considerable attention in our laboratory. After mixing, the products are removed and retempered at 22 to 24OF before pressing. Retempering is necessary to have the proper temperature for pressing and forming. Salt content will dictate the temperature needed. Pressing (plate 5) is done in a hydraulic press (Bettcher Industries) at pressures between 250 and 400 psi. A variety of shapes can be used as long as sharp, narrow pbints are avoided. Several diameters of any one shape can be used so thickness can remain constant while portion weight can be varied. Immediately following pressing, the ''logs" of pressed meat are placed in the Power Cleaver (plate 6--Bettcher Industries) and cut to portion controlled weights. The upright hoppers hold the "logs" of meat and rotate into a circular knife. The conveyor carries the meat away from the cutting edge for packaging. Fresh restructured pork products will be distributed in a frozen state for cooking in a partially defrosted state. Temperature and Blending The temperature of the trimmings and meat ingredients as they are flaked are extremely important with respect to the texture and appearance of the finished products. Cold flakes (24OF) are important in providing the "bi,te" or t&x%iare of the finished product. One of the original criteria placed on this process is that the cooked finished products should have textures and consistencies as near to the intact muscle products as possible. The system has no particular appeal if the finished products have the texture and eating qualities of ground meat.

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6 Plate 5 Press Plate 6 Cleaver

7 409 Blending ingredients of d i f f e r e n t f a t contents permits c o n t r o l of t h e v i s i b i l i t y of f a t and lean. When t h e f a t component i s flaked through f i n e f l a k i n g heads, t h e f a t content i s not r e a d i l y discernable i n t h e f i n i s h e d product. Conversely, should t h e marbled e f f e c t be desired, f a t flaked through coarser heads a t colder temperatures (24O vs ~ ) w i l l accomplish t h i s o b j e c t i v e. Additionally, t h e lean component can be flaked through coarser heads and w i l l increase t h e mouth f e e l c)r t e x t u r e o f t h e product. P l a t e 7 i l l u s t r a t e s the v i s u a l d i f f e r e n c e s between products made with 10% of t h e meat component flaked a t 25'F and P l a t e 8 i l l u s t r a t e s t h e response t o blends of 25O and ~ a t 35'3'. meat components. P l a t e s 9 and 11 show two of t h e f r e s h pork products made using t h e r e s t r u c t u r e d pork concept. The Pork B r o i l i s a 6 ounce pork chop shape product s u i t a b l e f o r b r o i l j n g o r g r i l l i n g. The Fresh Pork Roast i s a v a r i a t i o n made i n f o i l pans and weighs 2 pounds. This i s an oven roasted product. Cured and Smoked Restructured Pork Products The cured and smoked v a r i a t i o n of flaked-formed-sectioned pork i s shown i n f i g u r e 2. A t t h e p o i n t i n t h e flow diagram during mixing, t h e necessary curing ingredients are added. Following mixing, t h e meat i s s t u f f e d i n t o f i b r o u s casings and cooked and smoked using a t y p i c a l processing cycle. After cooling, t h e s e products can be s l i c e d and used as Breakfast Bacon ( p l a t e 10) similar t o Canadian S t y l e bacon, Pizza Dollars, Boneless Buffet S t y l e Hams or t h i n s l i c e d f o r t h e ham and cheese sandwich ( p l a t e 1 2 ). Current Research Several s t u d i e s a r e i n progress which w i l l answer s p e c i f i c questions on s e v e r a l phases of t h e t o t a l program. (1) Shelf l i f e study on cured and smoked pork p r o d u c t s - - s t a b i l i t y and panel evaluations. ( 2 ) Mixing time studies--to determine t h e impact of mixing time on physical and chemical measurements. ( 3 ) Shelf l i f e and s t a b i l i t y study on f r e s h products--evaluation of a long term frozen s h e l f l i f e study. ( 4 ) Cooking performance--wide a r r a y of cooking devices and conditions w i l l be evaluated w i t h respect t o performance of t h e product. (5) Mechanical t e n d e r i z a t i o n and portion c o n t r o l of boneless f r e s h pork loins.. ( 6 ) E f f e c t of by-products and non-meat ingredients on product performance

8 4 10 OTHEt? POPK I I 1 7 FREEZER FEEEZI NG TVIPEPING CLEAW NG I PACKAGING I PACMG I NG RESTRUCTU P.ED PORK PROCESSIlG FIGUHE 2

9 411 Plate 7 Comparison 25' vs 35' F Plate 8 Comparison of Blends

10 412 Plate 9 Pork Broil Plate 10 FFS Canadian Style Bacon

11 Plate 11 Fresh Pork Roast Plate 12 Shaved Ham and Cheese

12 summary Flaking temperature of 22OF is more desirable than 36OF based on product perf omnce and chemical analysis (Popenhagen and Mandigo, 1974 ) 2. Blends of flake size and temperatures are more desirable than single sizes or temperatures (Chesney and Mandigo, 1974; Popenhagen and Mandigo, 1974). 3. Medium size flakes are preferred over very fine or coarse in nonblended samples (Chesney and Mandigo, 1974). 4. Panelists prefer flaked over ground pork products (Chesney and Mandigo, 1974 ). 5. Panelists prefer salted formulations (Mandigo et al., 1972). 6. Flaked products have greater water-holding capacity and cohesiveness (Chesney and Mandigo, 1974). 7. No effect of flaking on proximate analysis (Mandigo et al., 1972; Chesney and Mandigo, 1974; Popenhagen and blandigo, lr4t 8. Flaking temperature effects water-holding capacity and emulsion stability (Hansen and Mandigo, 1972; Chesney and Mandigo, 1974). 9. Mixing time effects water-holding capacity and emulsion stability (Belohlavy and Mandigo, 1974.). 10. Increasing salt and tripoly phosphate increases texture and appearance of cured products (Neer and Mandigo, 1974). 11. A wide array of fresh and cured products can be produced. 12. Portioned Pork Products with predictable performance.

13 BIBLIOGRAPKY Belohlavy, R. G. and R. W. Mandigo Influence of mixing time on chemical and physical properties of flaked, formed and sectioned meat. Abstr. for 66th ASAS. Chesney, M. S. and R. W. Mandigo Chemical, physical and organoleptic properties of formed and sectioned pork muscle as influenced by size, temperature and comminution method. J. Food Sei. (In press). Goldner, W. J., R. W. Mandigo and W C. Schwartz Effect of mechanical tenderization on fresh and tempered boneless pork lains. Abstr. for 66th ASAS. Hansen, K. R. and R. W. Mandigo The effect of pre-chill pork on flaked, formed and sectioned pork products. J. Anim. Sei. 35:1096. Mandigo, R. W., K. R. Hansen and M. S. Chesney Effect of salt content and flaking temperature on flaked, formed and sectioned meat products. J. Anim. Sci. 35:19. Neer, K. L. and R. 11. Mandigo. salt on flaked, cured pork Effect of tripolyphosphate and Abstr. for 66th ASAS. Popenhagen, G. R. and R. W. Mandigo Influence of flake size, flake temperature, and blend combinations on the chemical, physical and organoleptic properties of fabricated pork. J. Food Sei. (In press).

14 4 16 H. F. Bernholdt: W i l l all the speakers come forward. Do we have any questions for any of these gentlemen? Dale Huffman: A question for Mr. Peoples. Are you troubled by yellow fat covering? J. Peoples: No, not really; not lately. If you mean, do my customrs accept it--no, they don't. They don't like it. It is no-t acceptable to them, I'll put it that way. It is not desirable, but I am not currently plagued with it and I don't think we have had as much trouble in this area with yellow fat as we have had in years past. Question: I have a question for Max Judge. Have you done any work on acceptable levels of these soy products through taste panels, and so forth? M. D. Judge: No, we use the levels that the manufacturer recommended on these products and we haven't gotten into the question of flavor which you may be thinking of particulariy, and I have a Peeling that that could be a problem--mafie at the high level we were working at here. We have no data to talk about. Question: I have a question for Roger. Do you have any advice on the binding properties of these various flaked products and,if so, what standpoint are you looking at for texture--is it coherence or bite, amount of fat percentage? R. Mandigo: To get at the texture problem we called it cohesiveness, I don't know if it is the right word or not--but the overriding criteria for all of the products that we have made--particularly the fresh ones-- we don't want you to put a fork on it and crumble it or break it like you would a pork sausage patty for breakfast. We are after a product that you have to put a knife on and have to cut and when you get through cutting it, we want it to look like intact muscle. As far as the binding properties go, that is a real can of worms. The slightest variation in formulation can change binding properties of these products considerably. We are getting to the point now where every time we try and make a particular product it comes out essentially the same. At one point in time you got something different every time--mixing time, mixing temperature, level of salt, all of the various additives are going to affect this bind very much. We are working, I shouldn't, say it that way, we are in the process of setting up a study to go into the soy products and look at those things, with that in mind also. I'm not sure I answered your question really though. Question: You kept using the word emulsion in your slides, is it an emulsion? Roger Mandigo: We have one fraction that is definitely an emulsion. There is no way around it, and this is the fraction that makes part of the texture come out the way it really is.

15 G. H. Wellington: Max, your s l i d e s appear t o be printed and I was wondering if' t h i s m a t e r i a l i s a.vailable o r do we have t o wait f o r them t o come out i n t h e appropriate journal? M. D. Judge: It i s published i n t h e Journal of Food Science i n 1974 Q u e s t i m : Max, you i n d i c a t e i n your s l i d e t h a t you got a decrease i n shrinkage when you added soy f l o u r. Did you determine whether it was due t o decreased l o s s of moisture or decreased loss of weight i n t h e soy product compared t o t h e all-meat product? M. D. Judge: No, w e d i d n ' t look a t t h a t and afterward we wished w e had--but w e had no reason t o say that we could see any d i f f e r e n c e i n thickness or i n t h e apparent change i n t h e weight. Question: Were t h e products containing soy f l o u r dryer? 14. D. Judge: I w o u l d say t h e r e was a t e x t u r a l d i f f e r e n c e and y e t I don't t h i n k you could characterize t h a t it was dryer--in f a c t, some of t h e panelists--not panelists--some of t h e workers f e l t t h a t they seemed a l i t t l e more Juicy, and I t h i n k t h e y were, because of t h e bind t h a t t h e f l o u r gave us. We did not do t a s t e p a n e l work on these, s o I c a n ' t be very d e f i n i t e on t h a t. D. H. Kropf: I have a question f o r Roger Mandigo. You i n d i c a t e 22OF. w a s b e s t f o r f l a k i n g. Under commercial conditions you may not get 223F. I s t h e r e a c r i t i c a l temperature above which you g e t lousy results? R. W. Mandigo: We g e t a l o t of lousy r e s u l t s. No, seriously, we say 22 o r w e say 24--we use most of t h a t range. The r e a l problem you g e t i s a s you g e t up i n t o t h e range, you s t a r t g e t t i n g a l o t of smearing, c a l l it smearing i n t h e f l a k e s. Again, one p a r t of t h e f r a c t i o n, we want t h i s t o happen. The other s i d e of t h e t h i n g i s t h a t you get down t o around 21O and i n s t e a d of f l a k i n g, you g e t explosions. Think of it a s l i k e snow. This p a r t i c u l a r f l a k i n g machine--one way you clean i t - - i n f a c t one recommended way t o clean it i s t o put i c e i n i t. And it j u s t makes snow cones l i k e crazy and j u s t a r e a l high f l u f f y f l a k e. So you can make l e a n trimming explode and t o answer your question I t h i n k you were saying O i n t h e way of a range. D. H. Kropf: t h e y be? You a l s o i n d i c a t e medium s i z e f l a k e. What s i z e would R. W. Mandigo: Well, t h e problem we have with it i s t h a t t h e nomenclature o f t h e machinery i s a l l in thousandths. That head t h a t you s a w t h e r e i s a.oo5 thousandths head. They run i n t h e ones w e have--we have a l l the way from.030 thousands up t o 1600 and some odd thousandths. When you t r y and convert t h e s e over t o some o t h e r system-you d o n ' t g e t t h e same measurements. Put it i n millimeters. Help m e. They don't want t o h e l p m e today. Okay. You are going t o l e t me d i e on my own up h e r e.

16 4 18 Question:,Do you use just one head? R. hr. Mandigo: Do you use just one head? I want ym to use a relatively coarse head for the frozen meat, the colder meat. And I want you to use a very fine head for the fatter meat, because that is what I want, I want to hide the fat and I want to make the emulsion come out of that part too. Question: Roger, on that product where you add 3/4% salt, how does this affect shelf life stability Df that product as compared to normal fresh product? R. W. Mandigo: Of course its bound to reduce shelf life. No alternatives. Now the fresh pmducts that we are working with which is where the 3/4 of 1% is at, they are vacuum packed and they, well we don't know how long they are going to hold up. We have some indications in some of the products that we have 8 months to a year already in them. There was some problems at the outset with color, but some technology changes, and I'm not even sure I can identify a couple of the technology changes that we must have done plus vacuum changes has remmed that problem essentially. We upped the pressure on the press-- we changed the mixing time amund and we got rid of metmyoglobin we were looking at in some of the earlier products. We have a cured study we are looking at right now, frozen cured products, they are in their 16th week and many of the formulations are being evaluated by the taste panel just as good as they were the first time. Some of them, of course, have deteriorated. We have s3me fresh products now that have been laying around the freezer for over a year; some of them are good and some of them aren't. So I think we have no great problem of shelf life with these products. You get to packing them a lot sloppier and you are going to cut shelf life down quickly. H. F. Bernholdt: Apparently, there is a lot of interest in the Comitrol and the reason we are getting these terms is in thousandths of inches is that Joe Urschel is an engineer basically, and I would comment that if you are interested in the equipment, contact Joe Urschel. It is a fine piece of equipment. We use it not only in meat products but also in peanut butter manufacture. It is quite a versatile piece of equipment. * * *

17 R. J. Eplex: The Educational S1:rvices Committee was charged with a triplicate role, not necessarily limited to extension education, but also me that could cover, if we so desired, resident instruction as well as other programs. I would like to thank the members of my committee for their excellent cooperation and suggestions as to program content: Jim Acton, Clemson University; John Grossbeck, The State University of New York; Ken Johnson, the National Livestock and Meat Board; Quin Kolb, University of Wisconsin; Don Kropf, Kansas State University; Rod Plimpton, The Ohio State University; Bob Reddish, University of Florida; BDb Rogers, Mississippi State University; and Bill Stringer, University of Missouri. As I am sure most of you are aware, Educational Service is a very, very broad topic and we did have many, many topics suggested for coverage at this session. We had well over 120 topics, every one of them very important, so it was a very difficult task for the Committee to decide exactly what we would like to present. We would, of course, have liked to have more time to go into more areas. Nonetheless, we have two excellent speakers that will cwer the two topics indicated in your programs. First with us is Dr. Billy Powell from Auburn University. Dr. Powell received his B.S. from Auburn University and his Ph.D. from Auburn, and Billy is in charge of all Food Science Extensim wxk at Auburn University. The title of his presentation is "Successful, Industrial Education Objectives and Methods."