234.

COMHERCIAL PROCESSING PROBLEMS OF MOST CONCERN TO

NE I L WEBB

THE ECKERTPACKING COMPANY DEFIANCE.OHIO

INTEEODUCTION :

The xeat industry is in greater need of scientific and technical assistance in all areas of processing than ever before. Applied research is in extremely high demand, and, if this trend continues, there will be a dearth of good basic research information within a very short time. Thus, we must develop basic research information to meet the demands of applied research and . I feel the and USDA experiment stations can be of invaluable assistance in supplying basic research information to the industry. Most companies of medium to large size are putting an increased percentage of their budgets into applied research and technology. Also, many of the larger companies are developing extensive research programs.

I would like to point out that, at present, many of the medium size companies do not have personnel formally trained in science. How- ever, many of these companies have personnel who have an extremely good understanding of the practical processing techniques and they are certainly of great value. However, my thesis and ideas presented at this conference are for a more sophisticated type of technical program than can be con- ducted by personnel with only practical training. I think there is still a large gap remaining between the viewpoints of what is commonly referred to as practical plant operating personnel and technically trained personnel. I believe this is a viewpoint without sound basis. It is merely a degree of desired precision in which both individuals are atteqting to attain the same thing. Thus, neither can function effectively without some under- stending and assistance from the other. The conpatability of diverse types of individuals is a major problem which must be comprehended by top manage- ment in order to solve many of the major processing problems. We lrust integrate personnel throughout the industry who have good technic a1 train- ing and a good knowledge of principles. If technical personnel are integrated with personnel having many years of practical experience, a strong tecBnical and management team should result.

The long range progress of any firm is highly de- pendent upon sound basic research. Sound basic principles must be estab- lished in order to have a well run manufacturing operation. I have listed nine basic problem areas which I consider to be of present and immediate importance to meat processing companies. I wish to state that these basic problem areas are not mentioned because they have any direct relationship to the specific problems of the Eckert Packing Company. Rather, these are broad areas that I believe are of lcost vital concern to the manufacturing 235. process from the standpoint of controlling manufacturing operations in a precise and scientific manner. The importance of these problem areas will vary with the location and stage of development of a particular company.

THE CONTROL OF RAW WERIALS: The development of new methods of evaluation and mre rapid procedures in obtabing objective data on raw materials is needed for meat processing operations. For example, we need rapid methods of analysis for the quality of raw materials such as: , nonfat dry milk, meat triromings, et cetera. By the time analyses can be completed on many raw materials, the data is of limited value. Thus, a great deal of subjective evaluation is presently used in ascertaining the quality of raw materials used in meat processing. With due respect to sub- jective analyses of materials, this type of evaluation reduces our ability to ascertain the true quality of the and consequently the quality of the finished product. The pre-blending of various emulsion com- ponents for operations has a very promising future if further basic is done on instrumentation and materials handling . In fact, this is one of the most promising areas of applied technology in sausage manufacture. However, it would be very unwise to adapt a system costing approximately 50,000 dollars unless a great deal more basic and applied research is done. I think we learned such a lesson with the advent of computers. The area of pre-blended emulsion mixtures has some application with computer systems if more is learned about binding capacity and behaviour of various under manufacturing conditions. When mre basic principles are elucidated, further application of elaborate engineering systems can be made. As another example, in many cases with the present methods of analyses, it would be very difficult to determine the bacterial content of raw materials in time to modify or eliminate contaminated materials prior to processing.

WERIALS HANDLING SYSTEMS: We need to obtain a closer coordi- nation between equipment manufacturers and food science research and tech- nology groups. Proper coordination of equipment units used within each operating department is extremely important in relation to efficiency, product quality, and long range plans. The trend has too often been to pur- chase equipment from a manufacturer and the company spend considerable time and effort in mdifying the equipment to suit individual operations. It is very important that -her research be conducted on basic principles of materials handling. This would give a more comn basis for the development of specific items of equipment which would blend in with the entire processing system in relation to plant , product quality and flow rate. In materials handling systems further study is needed on the principles of checking uniformity and flow rates as incorporated with automatic equipment and man power. Fromthe viewpoint of one involved in food science work, it seems imperative that certain basic criteria for the control of product quality must be stated prior to the development of sophisticated materials handling systems. For example, the development of a system of cooking wieners by electronic units or electron transfer systems is of very little value if it is impossible to formulate an acceptable wiener for the consumer. Also, the use of analytical instmentation in connection with flow rate of materids processed through automatic equipment systems must be considered in future design of materials handling equipment. These examples require basic quality and mechanical concepts set forth prior to development of systems. 236.

CONTROL OF FLAVOR COMPONEWS: Since there has been a large amount of basic research done on the components of flavors and aromas, I will not dwell on this subject at length. However, it is extremely important that more basic research be conducted on methods of approach for the control or development of flavors and aromas. We need more elaborate systems to obtain accurate analyses of flavor levels. I am speaking of flavor components to be added to processed meats to either impart an additional flavor response or to cover 811 undesirable flavor component in the basic meat material. There are some very desirable factorial arrangements for approaching this area of technology, but mre systems need to be applied to the flavor research area. Also, we need to establish more thresholds for many flavor ingredients and components. As an example, the type of work which h8S been conducted on and sugar levels in meats at Michigan State University is extremely beneficial. Other areas of tremendous importance are the "cooked" or "left over" flavor characteristics of meats and the failure of basic flavor- ing components to retain desirable flavors over a sustained period of time. Processed meats do not retain their initial warm cooked flavor during shelf- life storage. Since a large portion of the meat dollar is in pre- cooked meats and meat products, we need to retain the initial flavors de- veloped at the time of cooking to fully satisfy our customers. INWSPRIAL COOKERY METHODS: We have a long way to go in the development of better methods of large scale meat cookery and heat process- ing. Present methods allow too much loss in the transfer of heat energy to products and the variation in internal temperature at the end of the cooking cycle is too great. Naturally, these problems can result in high bacterial numbers, color differences, and poor scheduling of production. All of these difficulties add up to a variation in quality of the find product as well as ineffective supervision in plant processing. There are many principles which need to be nore thoroughly elucidated to establish better methods of heat transfer for product cookery. For example, the principles of heat energy transfer as applied to changes in protein structure are of basic importance to industry. One might ask, how does heat affect the protein structure and final product quality at various relative humidities, pressures, temperatures, rates of application, rates of aj.r flow, and in vacuum systems? Another area of major concern is the method in which the product is prepared for cookery. One inovation is cookery of luncheon meats by the use of metal molds. These molds are prelined with polyeth- ylene bags, stuffed with emulsion, sealed, and the product cooked in water or steam, chilled, remved and sliced. This method is effective, but is expensive, cumbersome, and, as you can perceive, involves many steps in the transfer of equipment and the utilization of man power. The capital in- vested by a company in such equipment can be fantastic. In some cases, an automatic washer unit may be used to clean the molds which will cost as much as 10,000 dollars and 8,000 dollars additional per year to operate the washer. Certainly there are Fossibilities of improvement in this area.

PKIDUCT IlYVEFiTORY CONTROL: The control of meat product inventories is a serious problem with all processors. In many cases, production shcedules must be written as much as four to five days ahead of anticipated sales. Thus, the regulation of inventory of perlshable products is very difficult and may result in distressed product or in a shortage to customers. A reduction in processing time would be of significant value in meeting rapid inventory turnover. Admittingly increased shelf-life and packaging 237. techniques have assisted greatly in controlling the inventories. However, the retention of maximum flavor, aroma, juiciness, and color demands that the product be held a minimum of time at the processor level. Therefore, methods which can reduce the time of holding of product after the process- ing operation is initiated will be of tremendous value. For example, inventory control would be improved if bologna could be cooked, chilled, firmed, sliced and packaged for shipment in eight hours.

BEEF PROCESSING SYSTEMS: I think the operation is the most unorthodox mmuf'acturing system of all the areas of the meat industry. The beef operation is very difficult to document into a workable system. The operation of a successful beef department requires extensive on-the-job training of individuals even though the personnel may have spent atremen- dous amount of time training at the college level. Each company has a specific philosophy and group of customers. The meat industry needs more specific information on yields, shrink, and methods of testing to allow for the many vaxiations in types of and the particular demands of customers. Thus, close specifications of beef cuts and carcasses are re- quired. This calls for Eore refinement within the USDA Grades. We need basic principles developed on a mre sophisticated level for merchmdising beef. For example, if basic principles were developed, the use of computer systems could be of primary importance in the selection and evaluation of available beef cuts on inventory for specific customers.

THE RELATION OF THE MEAT INDUSTRY TO THE MEAT INSPECTION DIVISION, USDA: There does not appear to be enough effort being made on the develop- ment of better methods of analysis and control in relation to meat process- ing regulations. Naturally, such research should not be conducted at the processing plant level. I would suggest that there be a continuous research program functioning to obtain better methods of analysis. These methods 170Uld assist the goverment inspectors in assuring better control and more objective evaluation of quality for the consumer. This, of course, would be of mutual benefit to the processor in assisting in the development of consistency and uniformity. As a st& in such a program, I would suggest that the MID employ a meat scientist as a research liason person to work throughout industry in the development and review of problems which are most pertinent in laboratory methods. A system to allocate research funds should be developed.

DEVELOPMENT OF IN-PW ME;THODS OF ANALYSES AND CONTROL: We need more extensive methods of in-plant objective analyses for the control of production. For exemple, rapid and quantitative tests for nitrite content, color, product rmisture, bacterial content, the free fatty acid content, degree of doneness in certain process end-point measurement, et cetera, would be of great value in controlling production. The test methods and analytical. systems utilized by many industries indicEcte that we have a long way to go in precisely controlling meat processing operations. We have been too content to accept wide variations and fail to take the time to precisely control these vaxiations and, in turn, charge the price required to accomplish this precision.

bTILIZATION OF SCIENTIFICALLY TRAlCNED PERSONNEL IN IWWFACTUFUNG OPEWIONS: There is no area that is of Eore concern to industry todw than the proper integration of well trained personnel in the manufacturing operation. In fact, most of our major problems concern the ingenuity and 238. initiative of management personnel. We still have a long way to go in properly utilizing well trained scientific people in manufacturing opera- tions. In many cases, the scientifically trdned person desires to work entirely in the research laboratory. There is definitely a need for the scientifically trdned person to be actively involved in meat manufacturing operations. However, it is very important th& this technical person be fortified with sufficient management principles to give the personnel with whom he is working good leadership. The college trained students who are interested in manufacturing operations need a tough combina- tion of science, logic, psychology, humanities, , and communica- tions. Unless the meat science student has training i.n these latter areas, he will be limited in his use to industry. Therefore, personnel who are to be utilized in the companies of the future will need to have a sufficient scientific knowledge to utilize the methods and techniques that basic re- search will elucidate,but, in addition, he must be able to manage opera- tions and allocate personnel. IN CONCLUSION: It is imperative that the industry work very closely with basic research groups in developing methods and techniques which will more precisely control the manufacturing and processing opera- tions. The intergration of quality control, engineering, production analysis, operations research, analytical instrumentation with man power and manufacturing equipment will be mandatory in meat processing operations duriq the next decade. Meat science students must be trdned in communi- cations and management as well as science in order to efficiently serve the meat industry.

DR. WELLINGTON: Thank you very much, Neil, and I hesitate to withhold questions at this time, but I think we can discuss questions at the close of our program. Our next topic has to do with the work at Cornell on Sausage Emulsion Stability Under Pilot Plant Tests. As a word of introduction we think it's a big step fromthe textbook theories on the behavior of crude emulsions to what actually happens, for instance, in processing a frankf'u&er or a bologna type product. Last year you will re- call that Cliff Swifi end his group reported on their work which is published, together wlth other reports similar to this by the same group, in the Journal. of Food Technology. Those reports cover some very interesting studies that have to do with emulsions, their formation and with breaking these emulsions in laboratory experitrents .

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