Global trends in ingredients for processed meat
Jesper Kampp Danisco World tour of ingredients
2 Ingredient trends in Europe
E number concern No definition of ”Natural ” Strong GMO concern Focus on removal of allergens
3 Europe is not a homogeneous market
4 Low/No/Reduced allergens New products launched in 2009
Allergens that require specific labelling:
Gluten Crustaceans Egg Fish Peanuts Soybeans Milk Nuts Celery Mustard Sesame seeds Sulphite Lupin Molluscs
5 Naturalness of texturants
Ingredient Very Natural or Natural [%]
Wheat Flour 90.2
Rice Flour 86.0
Gelatin 56.3
Proteins Locust Bean Gum = St. John’s bread flour [German]54.0
Locust Bean Gum, E 410 44.1 Carboxymethylcellulose Guar Gum, E 412 20.8 Xanthan Gum Carrageenan,Diacetyl E 407 Tartaric and Fatty Acid Esters of Glycerol1.2
Modified Starch,Polyoxyethylene e.g. E 1442 (20) Sorbitan Monostearate 1.9
Source: GfK, Germany 2009 (Food Marketing & Technology, Aug. 2009)
6 Alginate How can it be used in fat and oil emulsions?
Linear, unbranched polysaccharide Extracted from various seaweeds Cold gelation with calcium ions Strong, cohesive and heat-stable gels
7 Alginate gelation
8 Fat emulsions
A gelled, stabilised emulsion of water, fat/oil/skin
A typical fat emulsion is a 1:10:10 emulsion (Stabiliser system : Water : Fat) Can replace fat 1:1
Ingredients Ratio % Pork fat 10 47.62 Water 10 47.62 Stabiliser system 1 4.76 Total 100.00
Potential benefits of fat emulsions Improved texture Improved water binding Potential fat reduction Potential replacement of animal fat
9 Production of fat emulsions based on alginate
Add water (0°C) to bowl chopper
Spray stabiliser into water, start to chop, slow speed for a few rounds
Increase speed, chop until a smooth and homogeneous paste is obtained
Add ground fat or oil (slowly)
Stop chopping when a homogeneous and creamy texture is obtained
10 Fat emulsion for fat reduction and improved yield
The fat emulsion will build a gelled structure
The gel can be chopped or ground
Gel pieces and fragments to be added to the meat batter as fat substitute
11 Confocal laser scanning microscope photo of a fat emulsion
Fat
Alginate matrix
150 µm
12 Confocal laser scanning microscope photo of an oil emulsion
Vegetable oil
Alginate matrix
150 µm
13 Reduced cooking and storage loss - even with 1:10:10 emulsions (stabiliser:water:fat)
Soy isolate – 1:5:5 Stabiliser system – 1:5:5
Stabiliser system – 1:10:10
14 Oil emulsions as alternatives to standard fat
Fat addition can easily be reduced by 50% without altering product characteristics Fully stable oil emulsions – firm texture • Opportunity to add vegetable fat instead of animal fat • Addition of unsaturated fat • Reduction in cholesterol • Example: 1:10:5 oil emulsion (stabiliser:water:oil)
15 Oil emulsions in pepperonis
Ordinary pepperonis Pepperonis with oil emulsion
48% less fat 35% less cholesterol No fat separation during baking
16 Fibres for extension of ground meat
Very popular in the Middle East Includes e.g. beef, mutton and poultry Up to 35% added water Blends of fibres and hydrocolloids bind water
17 Cost reduction in minced meat with fibre/hydrocolloid blends
Recipe for minced meat
Ingredients Control Test 1
Ground beef meat 60.00% 50.00% TVP 10.00% 10.00% Water 30.00% 39.00% Fibre/hydrocolloid blends 1.00% Total 100.00% 100.00%
Drip loss after 1 hour at 12 ºC:
5
4 % 3
2
1 Control Stabiliser System
18 Syneresis control with fibre/hydrocolloid blend
After 1 hour at 12 ºC:
Syneresis after 1 hour at 12 ºC:
5,00% 4,50% 4,00% 3,50% 3,00% 2,50% 2,00%
% Syneresis 1,50% 1,00% 0,50% 0,00% Control Stabiliser system, 5% Stabiliser System - Stabiliser System - less meat 10% less meat 15% less meat
19 Functionality of fibre/hydrocolloid blend in burgers
Control recipe for medium/high-quality burger
80% beef meat 20% water, salt, spices, etc.
Recipe with fibre/hydrocolloid blend :
79% beef meat 1% fibre/hydrocolloid blend 20% water, salt, spices, etc.
20 Naturally cured cooked meat - how does it work?
Current curing process
Nitrite salt (E 250...) NO 2
Na Ascorbate NO (E 301...) Myoglobin
Nitrosometmyoglobin
Nitrosomyoglobin Upon cooking
Cured colour (Nitrosoheme + Globine)
21 Naturally cured cooked meat - how does it work?
Natural curing VegetablesVegetables process containing NO 3 containing NO 3
ductase Starter culture with Nitrate re Starter culture with Nitrite salt nitrate reductase NO tivity nitrate reductase (E 250...) 2 Ac activity d activity n n a io e t s p Na Ascorbate NO a m l u Myoglobin ta s (E 301...) a n C o c 2 O Nitrosometmyoglobin
Nitrosomyoglobin Upon cooking
Cured colour (Nitrosoheme + Globine)
22 “Naturally cured” ham – with and without culture with high nitrate reductase activity
Control With vegetable
with NO 2 juice and culture
No colour development
With vegetable juice but without culture
23 Emulsifiers in meat products
Traditionally used in liver sausages • Reduced liver content • Improved stability • Improved spreadability
24 Spreadable textures
Spreadable, cooked sausages
• Denaturation of meat proteins due to heat treatment or blocking by other additives.
No texture building during cooking
• Emulsion created by the addition of emulsifiers
25 RUSSIA: Semi-smoked sausages
• Made with large, coarse fat particles
The use of emulsifiers provides:
• Reduced greasiness • Improved flavour release • Added at the beginning of the process
26 CHINA: Traditional Chinese sausages
27 Chinese sausages
Typical recipes: Basic ingredients for 100 kg 60–74 kg lean pork or lean pork trimmings 25–40 kg pork backfat 10 kg water 1.5 kg Chinese wine (“Mei Kwei Lo” etc.) 20 g nitrite salt 10-50 g sugar MSG, soy sauce, cinnamon Emulsifier blend
28 Manufacture of Chinese sausages
GrindingGrinding MixingMixing StuffingStuffing
DryingDrying and and smoking: smoking: •• 48 48 – – 50ºC 50ºC (118-122ºF) (118-122ºF) for for 72 72 hours hours •• 60 60 – – 65ºC 65ºC (140-149ºF) (140-149ºF) for for 24 24 hours hours •• Weight Weight loss loss 40 40 – – 45% 45%
Emulsifiers: • Prevent fat from melting during drying • Increase yield • Extend shelf life
29 Time for questions
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