Once processed what happens to my swine? Dr. Sylvain Fournaise DVM, M. Sc. Vice-President, Food Safety and Technical Services OLYMEL

Transcription

1 Once processed what happens to my swine? Dr. Sylvain Fournaise DVM, M. Sc. Vice-President, Food Safety and Technical Services OLYMEL

2 Presentation Outline How our pork is used in other countries. How we make ham. Main steps. Issues. Labelling. Shelf life.

3 United States Fresh pork Deli or retail Deli Retail or Food Service

4 Japan Loin Tonkatsu Tenderloin Tonkatsu Belly single rib Roman-style noodles Processing Retail

5 TYPICAL MENU found in a japanese restaurant

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8 Mexico Leg bone-inles Deli

9 Australia Leg Ham Loin Back bacon

10 South Korea Chilled butt or belly single retail Frozen butt thinly sliced BBQ pork Frozen bone soup

11 China Head Feet Shank stewed HRI Heart Liver Tongue HRI or retail Loin- Leg retail Trimmings sausage Food safety

12 Ham Production

13 The Origin of Ham No ham without salt Together with agriculture and animal husbandry, the discovery of the role of salt in food preservation led to the Neolithic Revolution. The rational use of salt came later, around the end of the Bronze Age (approx. 800 BC). Some historians claim that colonisation in Europe followed local salt stocks. By skillfully combining salting and smoking, early man learned that pig s meat was more easily preserved using these two techniques than any other meat. Legend has it that a boar was once discovered well-preserved in salt works close to Salies-de-Béarn after having drowned at the beginning of the winter. Translated from:

14 The Origin of Ham Ancient Egyptians and Romans as well as Europe s early settlers used salt (sodium chloride or table salt) containing sodium nitrate or small quantities of sodium nitrite to preserve meat. Know your nitrites:

15 Ham Production Definitions: To be called ham, a piece of pork meat can only include meat taken from the animal s leg. Muscles bigger than 25g must make up 80% of the ham. Cream makes up the remaining 20% and will serve to bind the muscles together. To be called ham the meat must also contain a minimum of 12% proteins. The same goes for ground ham. Pork meatloaf, on the other hand, is an emulsion (9.5% proteins).

16 Full Legs

17 Raw Material

18 Outside Round with Eye

19 Inside Round

20 Knuckle

21 Shanks

22 Trimmings - Cream

23 Ingredients Water Salt Nitrite Sodium phosphate, sodium bicarbonate and potassium chloride Sodium erythorbate Sweeteners Flavour Bacterial growth inhibitors

24 Water In terms of quantity, water ranks first among ingredients. Water solubilises the other ingredients added to the ham. Water is essential. It enables chemical reactions between the meat and other ingredients. Apart from water, two other ingredients are essential to ham preparation: salt and nitrites.

25 Salt Salt is so important that it could never be completely replaced in meats. One of salt s main functions is to help water enter meat proteins. Salt obviously gives the product its salty taste. Salt s function is also to limit microbial growth in meats.

26 Nitrites The main feature of ham is that it is cured. What is particular about ham? - its pink color and distinctive taste. This particularity is due to the reaction of sodium nitrites. The effect of sodium nitrites is so unique that it cannot be easily reproduced by other means. To make a long story short, sodium nitrites bind with the muscle s myoglobin and, while cooking, give the ham its pink color and distinctive taste.

27 Forms of Nitrites

28 Meat Color

29 Other ingredients We also use other non-mandatory ingredients that help with ham production or improve texture or flavour. Sodium phosphate, sodium bicarbonate and potassium chloride have functions that are similar to salt, except where taste is concerned. Sodium erythorbate is added to ham to help bind nitrites to myoglobin. It is also an antioxidant, which means it will help keep meat from turning rancid and losing flavour and color. Sweeteners: sugar, dextrose and glucose are mostly used because of their sweet taste. Flavour is added to our ham recipes. This flavour contains soy protein.

30 Role of Antioxidants

31 Role of Phosphates Phosphates act to increase meats water retention capacity by forcing protein separation, which enables water to move between and bind to protein molecules.

32 Other Ingredients Carrageenans belong to the same family as sugars, but do not taste sweet. Carrageenans have the same action as soy proteins, i.e. they improve texture and water retention. Spices are seldom added to ham. At home, cloves can be stuck in the surface of the ham to add flavour. California Ham Spice, a combination of seasonings of which cloves are dominant, is the most common spice used on ham. Growth inhibitors: sodium lactate, potassium lactate, sodium acetate, citric acid, acetic acid, etc. Following the 2008 events at one of our competitors, we integrated growth inhibitors in our listeria control program.

33 OLD FASHIONED LOW SALT NATURAL Pork Pork Pork Water Water Water Glucose extract Glucose extract Sea salt Salt potassium lactate Vinegar Potassium lactate Sea salt Cultured celeri powder* *Cultured celeri powder naturally contains nitrites. flavour Potassium chloride Lemon juice Sodium phosphate Sodium phosphate Spice Disodium acetate Disodium acetate Smoke Sodium erythorbate Sodium nitrite Smoke Sodium erythorbate Sodium nitrite Smoke

34 Nitrosamines

35 Deli meats are carcinogenic and so probably are red meats, according to the WHO Worldwide, 34,000 cancer deaths per year can be attributed to a high deli-meat diet. One million cancer deaths per year can be attributed to smoking. 600,000 can be attributed to alcohol. 200,000 can be attributed to air pollution.

36 Deli meats are carcinogenic and so probably are red meats, according to the WHO Each portion of 50 grams of processed meat consumed daily increases by 18% the risk of colorectal cancer. This risk could increase by 17% for each portion of 100 grams of meat consumed daily.

37 Numbers War Translated from: Alain Vadeboncoeur. Le salami, votre ennemi? Tout est relatif!, in L actualité (Oct ). The 18% relative risk is really a percent rate applied to the absolute risk, which must be known before drawing conclusions. The IARC tells us that if 1,000 people eat an extra 50g of processed meat daily, their risk of developing colon cancer will increase by 18%. What does that mean in practice? That the absolute risk increases from 7.2 to 8.5 per 1,000 over a 10 year period.

38 In pictures Alain Vadeboncoeur. Le salami, votre ennemi? Tout est relatif!, in L actualité (Oct ).

39 A bit of perspective According to the CDC, smoking increases by 15 to 30 fold the incidence of lung cancer, not by 15 to 30%. That is a 1,500 to 3,000% increase in the baseline risk of lung cancer, compared to 18% for processed meats. Globally, that amounts to approximately one million cancer deaths per year due to smoking, compared to 34,000 due to processed meat consumption. That is 29 times more. Translated from: Alain Vadeboncoeur. Le salami, votre ennemi? Tout est relatif!, in L actualité (Oct ).

40 Brine Preparation Water and dry ingredients are mixed together to make what we call brine.

41 Injection The injection is the first step in processing ham. Fresh meat is transported on a conveyor belt at a speed determined by the injector. Needles move up and down into the meat. When they pierce muscle, brine is injected under pressure in the flesh.

42 Injection

43 Tenderising Tenderising the meat is the next step. Muscles that have been injected move between two serrated rollers. The roller teeth act as small knife blades and enter the meat to cut meat fibers. There are two reasons for tenderising meat: First, tenderising is done to cut fibers called collagen. These fibers tend to contract during cooking and add stiffness to cooked meat. Tenderising also increases the brine s exposure to the surface of the meat to enable soluble protein extraction.

44 Tenderiser

45 Tenderised Meat

46 Maturation Maturation simply refers to a 24 to 48 hour aging period during which injected and tenderised meats are kept in a maturing bin. This period allows the nitrites and salt to act and enable soluble protein extraction. The maturation period also allows sodium nitrites to bind to the myoglobin, which as you ll remember gives the ham its color and distinctive taste.

47 Nitrites

48 Tumbling Tumbling follows the maturation period and is the last meat preparation stage. The tumbler rotates while the inside blades force to meat to rise to the top and fall to the bottom of the tub. Therefore, tumbling consists of a tumble and muscle rubbing motion. Muscle massaging also occurs during vacuuming. Tumbling has 3 functions: 1 st Sticky cream formation: The mechanical action enables soluble protein extraction. Mixed with the brine, these proteins will form the sticky cream, i.e. the glue that will enable muscles to bind to one another during cooking and ensure meat slices are of adequate quality. 2 nd : The machine s tumbling action will act as a muscle tenderiser. Finally, tumbling completes the brine s migration towards the inside of the cells.

49 Tumbling Room

50 Tumbling Tumbling can last from 4 to 8 hours depending on the injection level. Cream is added to the ham at the end of the tumbling process. The cream has the same muscle binding function as the sticky cream that formed on the meat. Therefore, approximately 1 hour before the end of the tumbling process, the cream is added and spread evenly around the muscles.

51 Ready for Stuffing

52 Filling Fibrous Casings Regular or pre-smoked fibrous casings can be used. With fibrous casings, the end product always has the same diameter, which is preferable for sliced meats. The meat is netted in a manner resembling the butcher s manual netting process. The net can be placed directly on the meat but it is more often separated from the meat by a collagen or cellulose film.

53 Filling Casings (stuffing)

54 Collagen and Cellulose Collagen Collagen is made from beef protein. Collagen is comestible and sticks to the finished product like a skin. Cellulose Cellulose resembles a permeable plastic coating, which smoke can penetrate. Cellulose is removed after the cooking stage.

55 Ready for Cooking

56 Cooking Cooking stabilises the meat in its final form. Extracted soluble proteins coagulate and form a gel. Cooking modifies the texture and taste of the meat. Heat destroys a large portion of microorganisms and increases the product s shelf life.

57 Smoking There are two types of smoked ham: naturally and liquid smoked. Naturally smoked Maple sawdust is used to generate smoke. The smokehouse is filled with smoke, which is in contact with the product throughout the cooking stage. Liquid smoked Liquid smoking is a concentrated form of natural smoking. The smoke produced is not artificial. Liquid smoke is atomized in the cooking chamber to create a blanket of smoke which comes into contact with the product. Atomisation lasts 30 minutes or so. The product is then cooked using dry or humid heat.

58 Kiln

59 Cooling Following the cooking stage, which can last up to 12 hours, all hams are cooled to 4 C as quickly as possible and then packaged.

60 Two Types of Netting

61 Packaging Packaging is an important ham preparation stage. Packaging has 3 main functions: Protecting finished products against external bacterial contamination. Sealing moisture in. Keeping oxygen out. Contact with oxygen would change the product s color and flavor.

62 Slicing Before Packaging

63 Vacuum Packing

64 Packaged Product

65 Shelf Life Shelf-life studies to validate best before date Reproduces distribution conditions At different temperatures Microbiological assessments Organoleptic evaluation: Purge Color Smell Taste VALIDATION STUDY (Challenge study) Listeria product inoculation 5 different strains according to a Health Canada approved protocol Growth for the life of the product and beyond

66 Together we feed the world!!!