MEAT PROCESSING TECHNOLOGY

THIS PRESENTATION DESCRIBES MEAT PRODUCTION. MEAT PROCESSING, VALUE ADDED PTODUCTS FROM MEAT , BASIC PROCESSES FOR PROCESSING OF MEAT, ROLE OF NON MEAT INGREDIENTS IN MEAT PROCESSING IN A VERY EFFICIENT MANNER. THIS PRESENTATION CONTAIN IMAGES SO YOU CAN UNDERSTANDEASILY.

1. WELCOME TO PRESENTATION ON PRESENTED BY- ANKIT BIHOLA PRESENTED TO – G. GOPIKRISHNA SIR

2. INTRODUCTION Meat is the edible portion of animal tissues. The common meat animals are cattle, buffaloes, sheep, goat, pigs and poultry. The advantage of meat processing is the integration of certain animal tissues like, muscle trimmings, bone scrap, skin parts or certain internal organs in to the food chain as valuable protein rich ingredients. The basic meat product processing technologies; cutting and mixing are accomplished by various additional treatments like curing, seasoning, smoking, filling in to rigid containers, vacuum packaging, canning. This treatment depends upon the type and quality of the final product. The main objective of processing is to prevent it by inhibiting microbial decomposition. Processing technologies for meat products will not deliver satisfactory results, if there is no adequate meat hygiene in place. All the slaughtering equipments used during processing should be made of stainless steel or plastic and should be rust resistant and easily cleaned & sterilized.

3. Suspension by hind limb Cattle Receiving Bleeding Skinning Removal of Head Evisceration Carcass splitting and Sizing Chilling Cutting and Boning Meat ready for processing Stunning Flow Chart for Production of Meat

4. Slaughtering Procedures Stunning It is a process to inactivate animals so that it is not able to move. It is an obligatory process with large animals. Stunning ensures that the animal is unconscious before it is slaughtered in order to eliminate pain, discomfort and stress from the procedure. Many countries have legislation that requires pre-slaughter stunning. Care should be taken not to affect the heart and it should function normally to ensure complete bleeding which ensures better meat quality. Stunning is done in special stunning pan (box with movable side wall).

5. Stunning methods 1.Most common method employed is striking on the head with a wooden hammer or captive bolt. However blow should not damage the frontal bones as it may cause brain hemorrhage. 2. Electrical stunning: An electric current of 75-120 volt is passed for 15-70 seconds through the hind part of the animal head in the regions of parietal boxes by puncturing the skin. This causes unconsciousness of the animals which may last for 5 min and it is enough to transfer the animal from stunning pan to bleeding runway. 3. Anesthetization : Anaesthetization may be carried out on swine using a mixture of CO2 and air in equal volume with 0.18% chloroform and the inhalation period may last for one min.

6. Stunning with Striking (Captive Bolt)

7. Stunning with electric stunner

8. Slaughtering methods The most common methods of slaughter practiced worldwide are the Halal (Islamic), the Kosher (Jewish) and the Jhakta (Sikh) methods. Halal: Halal is one of the most popular method of slaughter. This method prescribes slaughtering of animals with a sharp knife to make a swift, deep incision that cuts the front of the throat, the carotid artery and jugular veins but leaves the spinal cord intact. The animal is then hung upside-down and left for drainage of blood. The Halal slaughter requires that the name of Allah (or God) should be mentioned at the initiation of the operation. This method of slaughter ensures that the blood flows out completely from the animal.

9. Slaughtering methods

10. Slaughtering methods Jhatka: It is an instant decapitation process limited mostly to sheep and goats and practiced in countries like India by few religious sects. The animals are killed by a single strike of a sword or axe by severing the head. Jewish Slaughter (Kosher): “Kosher” is the term applied to the procedures and techniques of slaughter practiced under the Jewish faith. In Hebrew language, Kosher means fit to be used as food. Under this method of slaughter, the animals in fully conscious state are killed and bled thoroughly by one clean stroke of the knife. Animals are however hoisted and shackled first. A 16-inch (40.6 cm) razor-sharp steel knife called the chalaf is stuck into the throat by a trained slaughterer, in an operation the animal is killed and bled at the same time. Skinning is made from the chest down to the level of the belly, and the chest is cut open first for inspection and later evisceration.

11. Slaughtering methods Jhatka Jewish Slaughter (Kosher)

12. Bleeding Bleeding is a procedure in the slaughter process which is performed by cutting jugular vein in the neck and carotid artery in order to allow blood to drain from the carcass, resulting in the death of the animal from cerebral anoxia. The bleeding knife should be continuously sharpened as a blunt knife may prolong the incision and damage the cut ends of the blood vessels. This may result in premature clotting and blockage of the vessels thus delaying the bleeding process. A prolonged delay in bleeding could result in the animal regaining consciousness. The delayed bleeding may also result in an increase in blood pressure causing the blood vessels to rupture and hemorrhage of muscle. The extra blood in the tissues may lead to meat getting decomposed quickly. Incisions should be therefore swift and precise. In poultry, sheep, goats and ostriches, the throat is cut behind the jaw.

13. Skinning After successful bleeding, first the head is skinned, separated from the body, then hung on hook for post mortem examination. ‘Skinning’ is a term mostly used for small ruminants and the method of skinning is known as “case-on”. The skinned materials are called as “skins”. Skin is the most valuable byproduct economically. In sheep and goats, skin is first cut around the leg to expose and loosen the tendon of the hock and used for hanging the carcass. This process is called legging. The second step that follows is called skinning which involves removal of the entire skin and preparation of the animal body for evisceration. Skinning can be done either in the horizontal or hanging position depending on the convenience and available facilities.

14. skinning If animal body is in hanging position, legging is generally started at the back of the free leg by removing the skin around the hock and continued towards the toes. This exposes the tendon on the back leg and the foot is cut off at the joint above the toe. The body skin is removed by making an opening in the front legs, cutting towards the jaw and continuing over the brisket. Once the brisket has skinned, knife is seldom used to protect the “fell” (a fine membrane between the skin and the carcass). This helps in improving carcass appearance and reducing surface shrinkage. This is largely accomplished by using hand . After the skin has been removed, the carcass is washed and placed on a hook. In horizontal skinning the animal is placed on its back on a flat raised surface and similar process repeated. This operation is absent in pigs, because skin is a part of the carcass. In the case of large ruminants (cattle and buffaloes) Skinning are employed. Skinning of large ruminants is known as “flaying” and the incisions made on the skins are known as “ripping lines”. The deskinned materials are called as “hides”.

15. Evisceration It should be carried out without damaging the internal organs or disturbing the internal surface of the carcass. Damage to the gastro- instestinal tract (GIT) may contaminate the carcass with the microorganisms. The first step in evisceration is to cut around the tied bung or rectum and free it completely from all attachments. The breastbone is then cut. Another cut is made from the cod. Then the ureter connections to the kidneys are severed and the intestines loosened. The stomach and intestinal mass are removed. The lever could be detached from its connecting tissues and then pulled out along with the contents of the abdominal cavity. The gall-bladder is carefully removed from the liver so that its content does not spill out and contaminate the carcass. The pluck consisting of heart, lungs, trachea and esophagus can be pulled out as a unit. The carcass is then washed and carried manually or mechanically to the inspection area.

16. Carcass splitting and sizing In the slaughterhouses, carcasses of small ruminants are not split into sides or quarters; carcasses of large ruminants are split into four quarters; and carcasses of pigs are split into two sides. Therefore, at the retail meat stalls selling buffalo meat, pork and mutton, we find quarters, sides and whole carcasses of respective animals. Carcasses are sawed by electric or pneumatic saws starting from the hind part to the central vertebrae. This facilitates transport, storage and efficient refrigeration.

17. Role of Nonmeat Ingredients in Meat Processing SALT Salt is used for three broad purposes in foods: processing, sensory (taste) and preservation. The addition of salt to raw lean meat products increases their water-holding capacity and cooking yield. Salt helps to extract meat proteins that effectively form “cement” between the individual pieces of meat. Even though salt increases the solubility of muscle proteins and improving their emulsifying, binding capacities in meat products, it encourages oxidative and rancidity changes in fats and accelerates metmyoglobin formation in raw meat. The main preservative effect of salt is by reduction of water activity (aw) and altering osmotic pressure which inhibits bacterial growth. Salt in solution binds some of the water, leaving a reduced level for the microorganism. Salt at 3.5 % level in the aqueous phase is the minimum level for shelf-stable canned cured meats.

18. Role of Nonmeat Ingredients in Meat Processing POLYPHOSPHATES Use of polyphosphates like Sodium acid pyrophosphate (SAPP), tetra sodium pyrophosphate (TSPP), sodium tripolyphosphate (STPP) and sodium triphosphate (STP) is practiced widely in meat product formulations. Phosphates function in food processing by their ability to enhance moisture retention, inhibit oxidation, stabilize emulsions and modify pH. Salt and phosphates have a synergistic effect on altering meat properties. Alkaline polyphosphates increase the water binding and fat emulsifying capacity of the myofibrillar proteins by increasing the pH level. Maximum permissible limit for phosphates is 0.5%. Pyrophosphates, tripolyphosphates and hexametaphosphates have effective antioxidant properties. Use of phosphates decreased off flavour and rancidity development in meat products and also masked the pro-oxidant effect of NaCl by the antioxidant properties of polyphosphate. Incorporation of phosphate in pork sausage patties decreased off flavour and development of oxidative rancidity. Salt and polyphosphate treatments of buffalo meat had significantly enhanced functionality. The functionality of phosphates is greatly affected by the addition of 0.5% sodium acid pyrophosphate (SAPP) in low salt (2-3%) meat product delayed microbial growth and extended shelf life due to decline in pH . SAPP delayed Clostridium botulinum toxin production in mechanically deboned turkey meat emulsion while sodium hexametaphosphate was found to be ineffective.

19. Role of Nonmeat Ingredients in Meat Processing NITRATE/NITRITE Sodium nitrite is most commonly used for curing. Maximum permissible limit of nitrite is 200 ppm . Nitrite plays a key role in cured meat as a bacteriostatic and bacteriocidal agent. The lethal oral dose for human beings is 22–23 mg nitrite/kg body weight. It is strongly inhibitory to anaerobic bacteria, most importantly Clostridium botulinum and contributes to control of other micro organisms such as Listeria monocytogenes . Nitrite is a highly reactive compound that can function as an oxidizing, reducing or a nitrosylating agent, and can be converted to a variety of related compounds in meat including nitrous acid, nitric oxide and nitrate. Up on addition to meat nitrite is reduced to nitric oxide which accounts for most of the functions of nitrite. This nitric oxide binds with iron atom within the myoglobin to form a heat stable nitrosylhaemochrome which imparts attractive pink colour to product. The nitrite reaction sequences involved with cured color development probably also play a key role in the strong anti-oxidant function of nitrite in cured meat, because proposed mechanisms for the antioxidant effect of nitrite include reaction with heme proteins and metals, and formation of nitroso - and nitrosyl -compounds that have antioxidant properties. Nitrite is also responsible for the production of characteristic cured meat flavor.

20. Role of Nonmeat Ingredients in Meat Processing SWEETENERS / SUGAR The sugar is added to cures primarily for flavor. Sugar softens the products by counteracting the harsh hardening effects of salt especially at high levels. Sugar also interacts with the amino groups of the proteins and, when cooked, forms browning products through the Maillard reaction that enhances the flavor of cured meats. Sugar substitutes have been used in bacon cures to prevent excessive browning during cooking. Non-reducing sugars are necessary to prevent browning. Corn syrup, dextrose and other natural sugar substitutes are sometimes used in place of sugar. Corn syrup and corn syrup solids are frequently substituted for sugar. Sugar, also, is an effective preservative at high levels. However, the level used in meat curing is so low it is doubtful that sugar has any major influence on the bacteria. In long cures, particularly dry cures, the sugar provides food for reducing bacteria, yeasts and molds. Sugar (dextrose) also provides food for some of the lactic acid fermenting bacteria that provide the characteristic flavor of some dry cured and fermented sausage products.

21. Role of Nonmeat Ingredients in Meat Processing BINDERS Binders plays diverse role in meat processing. Generally binders are rich in protein. Binders can be obtained from plant, animal or vegetable sources. Some of the functions are to improve meat batter stability, to improve texture/ flavour, to minimize cooking losses and to improve the slicing characteristics.

22. Role of Nonmeat Ingredients in Meat Processing Soya Proteins are used considerably for their nutritional and functional properties. Due to their unique properties in meat system, widely used to replace part of the animal proteins, particularly in comminuted meat products. Moreover, the increasing utilization of soy proteins in comminuted meat products is due to their contribution to desirable texture, water binding, and good nutritional properties. These are available in the form of soya flour (30-50% protein), soya protein concentrate (70% protein) and soya protein isolate (90% protein). Soya products are generally limited to the extent of 3% and isolated soya protein to 2.5% level in meat products.

23. Role of Nonmeat Ingredients in Meat Processing Textured vegetable protein (TVP) prepared by simultaneous cooking and extrusion of mixture of soya flour, flavour and coloring agents can also be used as extenders. TVP made from soy flour contains 50% soy protein and needs to be rehydrated before use, at a weight ratio of 1:2 with water. However, TVP when made from soy concentrate contains 70% protein and can be rehydrated at a ratio of 1:3. It can be used as a meat replacement or supplement. TVP can replace ground beef in most recipes, completely or partly. It is high in protein and low in fat and sodium. It is also a good source of fibre and isoflavones .

24. Role of Nonmeat Ingredients in Meat Processing Refined wheat flour (Maida) is being used as binder for a long time. It improves the firmness of the product and reduces cooking loss. Emulsion stability and cooking yield improved because of incorporation of maida . Hydrocolloids/gums are effective water binders and texture modifiers. Gum refers to group of long-chain polysaccharides having ability to form highly viscous solution at lower concentration. They have been used in low-fat meat products for their ability to form gels and retain water and to provide desirable texture. Carrageenan , xanthan gum or locust bean gum can be used in product processing. Carrageenan interacts with proteins, binds water to improve sliceability and increases tenderness in low fat meat products and have excellent functionality in low fat meat products. These can be used in rather low (0.1 to 0.5%) concentrations.

25. Role of Nonmeat Ingredients in Meat Processing MONO SODIUM GLUTAMATE MSG is the sodium salt of glutamic acid. When MSG is added to foods, it provides a flavoring function. When dissolved in water (or saliva) it rapidly dissociates into free sodium and glutamate. MSG is known to enhance flavour and are recognized as the “umami” (pronounced: oo-marmi ) taste. MSG contributes a delicious umami taste to foods. It is also used in low fat foods to make up the flavor that lost when fat is reduced or eliminated. MSG is generally added to foods before or during cooking. It enhances the natural flavors of meats, poultry, seafood, and many vegetables. It can be found in most soups, meat-based sauces, salad dressings, processed meats, and snack foods.

26. Role of Nonmeat Ingredients in Meat Processing SEASONINGS Spices and condiments are products of plants, mostly used for seasoning, flavouring and thus enhancing the taste of foods and beverages. In addition to imparting distinctive flavours , spices contain antioxidant properties and inhibit rancid flavour development due to lipid oxidation. Antioxidant properties of spices are due the presence of flavanoids , terpenoids , lignans and polyphenolid . CURED COLOUR ACCELERATORS Cured colour accelerators such as sodium ascorbate , sodium citrate and sodium erythorbate are added to promote the formation of cured colour ( nitrosyl hemochrome ). Sodium citrate and sodium ascorbate also exert antioxidant property and help in maintaining the colour and flavour of the cooked product. Sodium erythorbate is used at 550 ppm or a combination of sodium erythorbate 275ppm and sodium citrate 275 ppm are used in cured meat products.

27. Role of Nonmeat Ingredients in Meat Processing ANTIOXIDANTS Antioxidants are the substance which retards oxidation thereby prolonging the wholesomeness and palatability of foods containing fat. Cooked meats are prone to lipid oxidation as compared to raw meats. The lipid oxidation can be minimized or prevented by using chemical/synthetic antioxidants. Butylated hydoxyanisole (BHA), Butylated hydroxy toulene (BHT), Propyl gallate (PG) and Tertiary butyl hydroquinone (TBHQ) are synthetic antioxidants.

28. BASIC PROCESSING PROCEDURES FOR MEAT Canning Canning is a thermal process that employs heat (steam) to sterilize the product placed in a sterilized container (can). The major reason for canning meat is to provide safe products that have desirable flavour, texture and appearance during storage for sufficient long time. In canning, meat or meat products are subjected to heat treatment to kill spoilage microorganisms. The heat treatment is generally , given after packing the products in cans or in retort pouches. The machine used for heat treatment is called retort. The heat treatment is scheduled in such a way so that it either commercially sterilize the product i.e. destroys all viable microorganisms or pasteurize the product i.e. destroy most of the microorganisms (not all). Steps of Canning Cooked or raw meat and gravy are filled into cans. Cans shall not be completely filled. Some of the space must be left. Air present in cans is removed mechanically and seaming is done with the help of machine. The cans are subjected to high temperature under pressure as per requirements. Immediately after thermal processing, cans are cooled to 30-40°C.

29. BASIC PROCESSING PROCEDURES FOR MEAT Enrobing Enrobing is the coating of surface of product with edible materials. The ingredients used in enrobing (coating) are wheat flour, corn flour, rice flour, gram flour, proteins. e.g. milk powders, egg albumen, cereal flours, soya proteins, seasonings, spices, salt, sugar, fat and hydrogenated oils etc. Enrobing of any product is advantageous because of improved appearance, taste, juiciness , flavour, tenderness, nutritive value, cooking yield and shelf life of the product Example :- Ground meat products e.g., enrobed nuggets, enrobed patties.

30. Method of Preparation of Enrobed - Products Preparation of enrobed products generally consists of three steps: battering, breading and frying. A thin suspension of different ingredients called batter is applied on the surface. Some times, before batter application, pre-dusting with dry flours is done to ensure better adhesion of batter. Coated product is then dusted with dry material like dried breadcrumbs. This is called breading. Battered and breaded product is then deep fat fried.

31. BASIC PROCESSING PROCEDURES FOR MEAT Fermentation Fermented meat product's are prepared by microbial fermentation and dehydration to develop specific flavour and texture. In the production of fermented meat products, we add selected bacterial culture to the minced meat. These are called 'starter culture'. Starter cultures are available commercially. These contain microorganisms like Lactobacillus, Pediococcus , Lactococcus and Micrococcus . After addition of starter culture to minced meat, mixture is kept at specific temperature and humidity for a specified period. This allows maximum growth of added bacteria. This process is called 'fermentation' . During fermentation bacteria utilize sugar and produce lactic acid, which causes decrease in pH. After completion of fermentation, product is dried to specific moisture level. After drying, products are cooked or smoked. Longer shelf life of fermented meat products is due to creation of adverse conditions for bacterial growth as, Lower pH Competitive bacteria (large number of lactic acid bacteria prevents growth of spoilage bacteria).

32. BASIC PROCESSING PROCEDURES FOR MEAT Cooking/Heat Processing Dry heat cooking: When meat is cooked by surrounding hot air, it is called as dry heat cooking. Relatively tender cuts of meat are cooked by dry heat cooking. Roasting, broiling and frying are different dry heat cooking methods. Roasting: Tender cuts like veal shoulder, pork shoulder, leg of lamb, veal leg, ribs of beef etc. are roasted generally. The meat cuts (at least 2 1 /2 inches thick) are placed in an open roasting pan with fat and then placed in a hot air oven at a temperature of 250°-350° F. Higher temperature can also be used for browning effect and increased flavour of the product. It may be used in preparing precooked frozen beef.

33. Cooking/Heat Processing Broiling: Tender steaks of beef, chops of lamb and cured ham steaks are generally cooked by broiling. In this method of cooking, meat cuts are supported by wire grill and heat is either supplied from above as in a gas/ electric oven or may be from below as with a charcoal oven. Time required for cooking depends upon the desired attributes of the products. Frying: Frying may be of two types: shallow pan frying and deep-fat frying. When the meat cuts are fried in a small amount of fat in a frying pan, it is called as shallow pan frying. In deep-fat frying, meat cuts are fried in large amount of fat in a deep-fat fryer. Generally small meat cuts like sliced steaks, veal chops, lamb chops etc. are cooked by this method.

34. BASIC PROCESSING PROCEDURES FOR MEAT Moist heat cooking: In this method hot liquid or steam is used for cooking the meat. Water is added during cooking and the container is covered with a lid to condense the steam for most effective cooking. Stewing, braising, pot-roasting, simmering and pressure cooking are commonly used moist heat cooking methods. Stewing: Usually less tender small meat cuts are covered with water or tomato juice and then cooked at a simmering temperature after covering the container with a lid. Stew may be or may not be browned in fat. Vegetables may also be added. Consistency of the stew must be slightly thick.

35. Moist heat cooking Braising: This method is also suitable for less tender cuts like breast of lamb, chuck roast of beef, veal and pork chops etc. Here dry and moist heat- both are used. The meat cuts are browned by dry heat cooking in a small amount of fat, then cooked by moist heat by adding water, vegetable stock, milk or gravy etc. The container is covered and simmered at a temperature just below the boiling. Vegetables may be added and must be sufficiently cooked. Pressure cooking: Tough meat cuts like breast of lamb, chuck roast of beef etc. are cooked by this method. This method uses higher cooking temperature and minimum time to make the tough meat cuts tender in a short time by means of pressure. In pressure coking, meat cuts may lose their normal texture. Simmering: Meat cuts or products are cooked in water at a temperature considerable below the boiling temperature (160°- 170°F). Generally meat cuts are cooked in casings or bags to avoid excess shrinkage loss.

36. BASIC PROCESSING PROCEDURES FOR MEAT Curing Dry curing: Dry curing is a traditional method. In this method, dry ingredients are rubbed over the external surface of meat. This is a slow method. Completion of curing may take months. In dry salt curing, common salt along with nitrite or nitrate is used. Pickle curing: In this type of curing, water is used as a medium for dissolving the curing ingredients and the product is placed in a vat containing brine solution (solution containing cure ingredients). The curing process is accomplished by diffusion of brine into the tissue at refrigerated temperature. Curing process completes within 2 to 3 days.

37. BASIC PROCESSING PROCEDURES FOR MEAT smoking Traditionally fire pits or cabins were used for smoking of meat. Now-a-days automatically controlled chambers called Smoke Ovens are used for smoking. The meat products are placed in the sealed smoking chamber. Smoke is generated outside of this chamber by controlled combustion of Wood or sawdust and allowed to go inside the chamber. Meat products are smoked continuously for many hours. Control of temperature, air velocity and relative humidity inside the chamber are very important for quality of smoked products.

38. VALUE ADDED PRODUCTS FROM MEAT

39. COMMINUTED MEAT PRODUCTS Comminution involves subdividing the raw meat, so that the product consists of small meat pieces. Most common comminuted meat products may be classified as sausages. Sausages are comminuted, seasoned meat products that may also be cured, smoked, molded and heat processed. The degree of comminution varies in salami, pork sausages and summer sausages. There are also many comminuted products that are not classed as sausages. Meat patties, nuggets, hamburger and ground beef are the most common. Many commercial products begin as ground meat or meat chunks, pieces or slices that are then formed into patties by machines using sufficient pressure to force the meat tightly together. These products are often marketed under the general titles of "burgers" or "steaks".

40. Ingredients used for Comminuted Meat Products Raw meat: Meat from different species of animals, low value cuts, meat trimmings, mechanically separated meats are used for production of comminuted meat products. Fat: Generally 10 per cent external fat is added. Maximum limit of fat in the final product is 30 per cent. Based on initial fat content of meat, added fat can be decided. Chilled water/ice: Generally 10 per cent chilled water is added. Combination of fat (maximum 30 per cent) and added water shall not exceed 40 per cent. Salt: Salt is added @ 1.5 to 2 per cent. Alkaline phosphate: Generally added @ 0.3 per cent. Maximum limit is 0.5 per cent in the finished products. Sodium nitrite: Generally added @ 150 mg/kg (ppm). Sugar: Can be added up to 1 per cent. Binders and extenders: Generally added to improve functional properties and volume of meat products e.g. milk powders, whey proteins, cereal flours (added up to 3.5 per cent), modified starches, soy proteins (added up to 2 per cent of formulation) etc.

41. Basic Processing Steps for Comminuted Meat Products Chilled meat and fat are ground (minced) separately in the meat grinder/ mincer . Meat is placed in bowl chopper and chopped after addition of salt, sugar, phosphate, nitrite and water. Fat, binders/extenders, condiments and spices are added during further chopping respectively, In between rest of 1 to 2 minutes is given. Sequence of adding ingredients is very important. Chopping is continued till batter (emulsion) is formed. Generally it takes 5-6 minutes. No meat particle should be visible in emulsion. Emulsion is taken out from bowl chopper and stuffed into casings for preparation of sausages or molded into patties or nuggets. For preparation of meat blocks, emulsion is filled in blocks. Meat balls, patties and many other products can be prepared from emulsion by using different types of molds/machines. The prepared products are then smoked or roasted or steam-cooked or fried depending upon type of product .

42. MEAT MINCER/GRINDER AND MEAT CHOPPER MEAT MINCER/GRINDER MEAT CHOPPER

43. Sausages Sausages are meat products that are salted & usually seasoned or spiced and are an example of comminuted meet products that are generally recognized as emulsified, stuffed, linked, smoked, and cooked meat products. Based on the product characteristics and processing methods, they are broadly divided into three categories: fresh sausages, cured sausages and fermented sausages. In all cases meat is communited to reduce meat and fat particle size (grinding, mincing , chopping), mixing with ingredients, stuffing into specific casing, linking to obtain specific lengths and finally, packaging. Sausages might be of ground and emulsion type. In the ground variety of sausages discrete particles of meat are seen on the other hand, in emulsion type sausages fat is emulsified & stabilized by lean component. Sausages were developed to utilize low- quality meats such as trimmings head, shoulder & by- products of the meat.

44. Typical composition of sausage Ingredients Quantity Lean meat Fat Salt Sugar Sodium nitrite Alkaline phosphate Water/crushed ice Binder (Refined wheat flour) Dry spices mix Wet spice mix (Onion : Garlic: ginger=3:1:1 ) 70 - 85 % 15 - 30 % 2% 1 % 120 - 200 ppm 0.4 - 0.5 % 10 - 15 % 2.5 - 3 % 1.5 % 3%

45. Adding minced or ground fat and chopping to facilitate emulsion formation (1-2minutes) Grinding of meat and fat separately with 8mm plate followed by 4mm plate Addition of binder, seasonings (wet and dry) in sequence and chopped for 1 minute. Remove emulsion or dough from bowl chopper Stuffing into casings (artificial or natural casing) Linking and tying Cooking or smoking (80°C for 15-20 minutes) Showering and chilling (after cooking the product is showered or dipped in cold water and then chilled by refrigeration to an internal temperature of 2-4°C) Peeling and packaging (the casing peeled off in case of artificial casings of non edible nature) Packaging Mixing and chopping (addition of salt and curing ingredients) along with added water / ice for about 2-4 minutes - to facilitate extraction of proteins Processing steps for preparation of sausage

46. Processing steps for preparation of sausage 1) Selection of ingredients: Good quality lean meat, fat, salt, other curing ingredients and seasonings are carefully selected. 2) Grinding: Meat and fat are ground separately with 8mm plate followed by 4mm plate (meat mincer) and kept at low temperature. 3) Mixing and chopping: Curing and other ingredients are mixed thoroughly. Minced meat mixed with curing ingredients are transferred to a bowl chopper and chopped to facilitate extraction of protein. Usually meat is chopped for about 2 to 3 minutes. Chilled water or ice is added to maintain low temperature. 4) Emulsifying: The minced fat is added to the contents in the bowl chopper. The bowl chopper is run for 1-2 min to allow the fat to emulsify. A proper emulsion is now formed. Then other ingredients like binder, dry spice mix and condiments are added to it and chopping is continued for one more minute till completely uniform sausage batter is formed. The batter is taken out of the bowl chopper. If it is not used instantly it must be stored in the refrigerator.

47. 5) Stuffing/Filling: The dough/emulsion is then transferred to sausage filler. Then the emulsion is filled or stuffed into either natural or artificial casings. Stuffing should be done with great care and control to prevent formation of air pockets as well as to prevent breaking up of casings due to over stuffing. 6) Linking and tying: After stuffing, the sausages are linked and tied to uniform size. Linking is done at a uniform length of about 10 cm to give it a cylindrical shape. 7) Thermal processing (smoking and cooking) : The stuffed and linked sausages are cooked either by using water at a temperature of 80°C for about 20 minutes to internal temperature of 70-75ºC. The sausages also can be cooked by steam. Alternately the sausages are smoked and cooked simultaneously in smoke house. 8) Chilling: Immediately after removing from cooking the sausages are showered with cold water and chilled at 0-4ºC. 9) Peeling and Packaging: The cooked smoked and chilled sausages are packed into suitable consumer packs. If artificial casings are used, then sausages are packed into consumer packs after removing the casings. Processing steps for preparation of sausage

48. meat patties Formulation for meat patties Ingredients Quantity Lean meat Fat Salt Texturised soy protein Condiments Dry spices 70% 10% 2% 10% 6.5% 1.5%

49. Meat Patties Meat patty (singular form of patties) is one of the most popular products among the comminuted meat items and is generally used as a filling for sandwiches or burgers. Some times they are consumed as such with tomato sauce or chutney. This product has a very good demand in big towns and cities in India. Patties are partially or completely emulsion based products. Different meat based by-products namely organ meats, and low value cuts are used along with regular lean as the raw material for patties. Meat (lean meat and by-products) is mixed/ground using a meat mincer. Minced meat is then added ( blend) with salt (2%), sodium phosphate, sodium nitrate along with water and chopped for 1 minute in a bowl chopper, so as to extract the protein. Fat is added and chopped for 1 minute to get proper emulsion. To the meat and fat mixture of condiments, spices and binder are added in sequence and chopped for 1 more minute the dough is ready for molding / shaping. The patties are prepared by molding 80 to 100 grams of batter in a 70 to 80 mm diameter and 15 to 20 mm thick aluminum or stainless steel or glass Petri-plate mold. Raw patties may be frozen for future use or broiled in a preheated oven at 180°C for 20 minutes. The internal temperature must reach 70 to 75°C. These are deep fat fried in many commercial establishments. The patties are cooled and packed.

50. Meat Nuggets Ingredients Quantity (%) Raw Lean meat Cooked meat Fat Salt Sugar Alkaline phosphate Water / ice Whole egg liquid Condiments Dry spices 55 10 10 2 1 0.4 10 5 5 1.5

51. Meat Nuggets These are ready-to-eat convenience products which are made by utilizing, beef, pork, mutton and chicken. These are mainly comminuted and emulsion type product. For the preparation of nuggets meat ingredients are minced and then chopped in a bowl chopper along with ice, salt, and other curing ingredients. Fat is then added and emulsion is made in the chopper. After emulsion is formed binders, spices, condiments, are added in sequence and the dough is prepared for stuffing into molds to obtain blocks. The filled or stuffed molds are then cooked in water maintained at 80°C for 40 minutes. After cooking the molds are taken out and cooled promptly and chilled. The cooled blocks are removed and sliced into uniform dimensions of 4cm x 1.5cm x 1.5cm or as desired. For the preparation of the nuggets some portion of raw meat can be substituted with, cooked meat.

52. HAM Ham with Bone Ham without Bone

53. Ham The leg portions of the pig and the cured product made of that portion are known as ham. The leg portions of pigs are trimmed to obtain a regular shape. Then they are cured by injecting brine/pickle containing salt, sugar, sodium nitrite and phosphate. In addition sodium ascorbate or sodium erythorbate are also used frequently. In general salt is used usually between 2.5 to 3 per cent of the brine. Phosphates used are alkaline phosphates and are incorporated at levels not exceeding 0.5%. Sodium ascorbate or sodium erythorbate is used at levels of 550 ppm. Nitrite is incorporated at the rate of 200 ppm in the finished product. Pickle is prepared by dissolving 250 grams of salt (sodium chloride), 100 grams of sugar, 2 grams of sodium nitrite, 5 grams of tetra sodium pyrophosphate and 5 grams of sodium ascorbate in warm distilled/ deionized water. Then the brine/pickle is cooled and filtered using muslin cloth. This facilitates removal of undissolved substances. Then the filtered or clarified pickle is kept under refrigeration. The pickle thus prepared will have strength of 65 - 70° salinometer.

54. Trimmed ham Ham (Leg portion of pig) Pickle (65° Salinometer) injecting into hams @ 10% weight of green hams (This will give about 2% salt, 150 ppm NaNO2 and 250ppm sodium ascorbate in the pickle injected hams.) Pickled ham Keeping in the chilling room for 24 hours Immersion in cover pickle for 3 - 7 days Smoking and cooking Slicing and packaging Cutting and trimming Preparation of Commercial Ham

55. Ham To achieve highest quality hams on processing, the pickled/ injected/pumped hams are placed in cover pickle for 3 to 7 days at 4 to 5°C. Hams cured in cover pickle have better colour development and better flavour stability. They have very few uncured spots, more uniform distribution of salt, better flavour and improved water binding. Hams are subjected to natural wood smoke. The smoking schedule starts at 60°C raised to 70°C after 2 hours. Further, it is increased to 82°C after another two hours. The relative humidity of the smoke house is maintained at 30 to 40 per cent. Fully cooked ready-to-eat ham should be cooked to an internal temperature of 65°C. The length of time hams remain in the smoke house depends on size of the ham, the final internal temperature desired, air velocity in the smoke house and the cooking schedule employed.

56. Bacon Pig bellies are used for bacon preparation. The bellies are cleaned and cured either by dry curing or pickle curing. In dry curing, mixture of curing ingredients viz. sodium chloride, sugar, sodium nitrate, phosphate and cure accelerators are rubbed on all surface of green bellies. The bellies are placed in the cooler (2 - 4°C) for curing for 10 to 14 days. After curing they are cooked. The rind is removed and the bacon is sliced and packed.

57. Bellies are combed - pierced with multipoint hangers, Cured for 10-14 days Bellies are injected with pickle Smoking and cooking Chilling and removal of rind Further cooling to internal temperature of (3°C) Pressing Slicing 1. Thin-1/32“ 2. Regular - 1/16” 3. Thick - 1/8" Packaging Commercial bacon production

58. Smoking and cooking Three stages cooking schedule: In the first stage the bacon is subjected to 48 -51°C for 2 hours. In the second stage, the temperature is raised to 56°C and bacon is smoked and cooked for 2 hours, In the third stage the temperature of the smoke house is increased to 60°C and the cooking is continued till the internal temperature of the bacon reached to 55°C. Single stage cooking schedule: The bacon is subjected to smoking and cooking in smoke house maintained at 55-56°C till an internal temperature of 55°C is attained in the bacon. The relative humidity of the smoke house is maintained at 25-40% on either of the cooking/smoking schedules. Cooling of the smoked bacon to an internal temperature of 3°C helps to allow bacon to retain its shape when it is subsequently pressed. This will facilitate slicing.

59. Fermented meat products Definition: The product obtained from the microbial fermentation of the meat followed by dehydration to develop specific flavour and texture. Selected bacterial culture known as 'starter culture' is added to the minced meat for fermentation of the product. Classification of Fermented Products Based on pH, fermented products can be divided into two groups: low acid and high acid products. Low acid products: These have a final pH of about 6.0. In these products either low temperature drying is done along with fermentation to decrease water activity or high temperature drying is done after fermentation to lower water activity and inactivate bacteria. High acid products: These have a final pH of 5.3 or lower. These products are generally produced by simultaneous fermentation and dehydration. Based on moisture content, fermented products can also be divided into two groups — dry or semi-dry. Dry fermented products: In dry fermented products, average moisture content varies between 30 to 40 per cent. Semi-dry fermented products: In semi-dry fermented products, average moisture content varies between 40 to 50 per cent.

60. Ingredients Used for Fermented Meat Products 1. Meat 2. Fat 3. Salt and curing agents 4. Starter culture: Different bacteria, yeasts and molds are used for the production of fermented meat products. (Generally lactic acid producing bacteria are used). 5. Carbohydrates: Generally used at the level of 0.4 to 0.8%. These are added to provide medium for growth of bacteria. 6. Acidulates: Added to increase rate of pH fall. 7. Other ingredients e.g. spices, meat extenders etc.

61. Steps for Preparation of Fermented Meat Products 1. Inoculation Minced meat and different ingredients are mixed and then lactic acid bacteria (starter culture) are added. 2. Fermentation After inoculation, meat mix is stuffed into casings and allowed to ferment for 1 to 4 day at 18°C to 43°C temperature and 70% to 80% relative humidity. The controlled temperature and relative humidity is obtained in an equipment called humidity chamber. This allows sufficient acid production and development of colour. Monitoring of temperature, relative humidity and pH is important to get good product.

62. Steps for Preparation of Fermented Meat Products 3. Drying After fermentation is complete, products are dried to the desired moisture level. Semi-dry sausages (having moisture content between 40 to 50 per cent) require ageing or drying up to 5 days. But dry sausages (having moisture content between 30 to 40 per cent) are placed in drying chamber up to 10 days or even more to achieve desired moisture : protein ratio. After drying, products are cooked and/or smoked as per requirements. 4. Storage Dry sausages do not require refrigerated temperature for storage. Lower moisture content, lower water activity and low pH do not allow spoilage bacteria to grow. However, semi-dry sausages require refrigeration temperature to prevent microbial spoilage during storage.

63. Salami Salami refers to a family of sausages. It is of Italian origin, but found in other parts of Europe as well. Most of the salamis are made from pork and have a coarse ground texture. Beef is also used as a regular constituent of the raw material. Garlic is the main spice used along with other spices. Salami is a type of fermented sausage and is not an emulsion type sausage. It is more or less a semi-dry sausage. The salami contains approximately 50% moisture .

64. Salami Ingredients Quantity ( %) Lean beef Regular pork trimmings Pork jowls (glands removed) Starter culture Salt Sugar Sodium nitrate White pepper Garlic powder 40 20 35 0.5 3 1.3-1.5 0.02 0.15-0.2 0.1

65. Mixing of all the ingredients except salt Grinding of pork trimming and pork jowls separately using 1 /2 inch grinder plate and grinding of beef through a 1/4 inch plate Chopping in a bowl chopper for 1 to 2 minutes Addition of salt during the last 30 seconds of chopping Stuffing of mix into hog bung casings or artificial casings Transferring to a room maintained at controlled conditions Holding for 2 - 4 days to facilitate desired fermentation Smoking or cooking of salami after attaining desired pH Flow diagram of salami preparation

66. MEAT PICKLE Meat pickle is generally prepared by using organic acid mainly acetic acid or vinegar and or edible oil, table salt, spices and condiments. These ingredients impart special flavour and shelf stability to the product. Requirements Meat (beef/ mutton/ chicken/ pork-bone or boneless). Different ingredients used in meat pickle preparations like, salt, dry spice mix, green condiments (onion, garlic and ginger in the ratio of 3:1:1), mustard oil, vinegar etc.

67. MEAT PICKLE - recipe Ingredients Quantity ( %) Meat Salt (4%) Dry Spice mix Green Condiments Meat Broth Acetic Acid (1%) Mustard Oil (20%) 1kg 40g 40g 100g 200ml 10ml 200ml

68. Meat pickle- Procedure Bone-in or boneless meat can be utilized for pickle preparation. Collect meat and trim off the excess connective tissue, excess fat, ligaments and tendons. Cut the meat into 2-3 cm size chunks. Pre-salt the meat pieces with total salt required in the recipe. Pressure cook the meat chunks with addition of 100ml of water for 5- 10 minutes and cool it to ambient temperature. Separate the meat broth and the meat chunks and keep separately. Adjust the volume of meat broth to 200ml as and when required. Deep fat fry the cooked meat chunks in heated mustard oil till they develop a light golden brown colour. Strain out the fried chunks. Fry the green condiments to golden brown colour and add dry spice mix and fry in the same oil. Add the meat broth to the oil containing fried dry and wet spices and heat till boiling with constant stirring. Transfer the fried meat chunks to the cooking broth and spices and boil for 2-5 minutes. Remove/stop the flame. Lastly add 10 ml of acetic acid and mix it thoroughly. Allow it to cool to room temperature on its own for packaging.

69. Thank you