HPP for Enhanced Meat Quality

Transcription

1 HPP for Enhanced Meat Quality MINTRAC National Meat Retail Trainer s Conference - Melbourne Anita Sikes 18 November 2015 FOOD AND NUTRITION

2 Overview High pressure processing.what is it? High pressure processing (HPP) technology Benefits Current applications Shelf-life and safety Meat quality Tenderisation Salt reduction in processed meats Industry opportunities 2 Meat Retail Trainer's Conference Anita Sikes

3 High pressure processing - HPP What is it? 3 Meat Retail Trainer's Conference Anita Sikes

4 What is HPP? What pressures are involved? For preservation MPa For tenderisation, MPa Barrel eye 4100 m MPa Source: Hiperbaric 4 Meat Retail Trainer's Conference Anita Sikes

5 How does it work? elephants x 3000 kg each on a CD = 600 MPa (6000 bar or 90,000 psi) Piston Size CD High Pressure Chamber 5 Meat Retail Trainer's Conference Anita Sikes

6 Industrial HPP machines 160 L vessel 420 L vessel Avure Technologies 350 L vessel 6 Meat Retail Trainer's Conference Anita Sikes

7 How does HPP work process steps Source: Hiperbaric 7 Meat Retail Trainer's Conference Anita Sikes

8 HPP systems at CSIRO 2 ml kinetic 700 MPa & temp 2 L, 500 MPa L 900 MPa & temp Meat Retail Trainer's Conference Anita Sikes 3 L 800 MPa & temp 35 L 690 MPa & temp

9 Benefits and Applications 9 Meat Retail Trainer's Conference Anita Sikes

10 Benefits of HPP Preservation / extension of shelf-life Packaged, sliced, cooked meats Alternative method to heat treatment; no thermal degradation Preservative-free clean label Increased food safety Flavour, colour, nutritional value minimal effects Maintain quality attributes Improving functional properties 10 Meat Retail Trainer's Conference Anita Sikes

11 Commercial application of HPP pressure range 11 Meat Retail Trainer's Conference Anita Sikes

12 HPP Commercial Products Guacamole Wet salads RTE vegetable meals Pathogens-free sliced cooked meats Preservative-free deli meats Listeria-free dry-cured products Raw beef products Preservative-free sausages Oysters shucking Lobster meat extraction Clams & mussels shucking RTE seafood meals Fruit juices Smoothies Vegetable juices Toll processing Cheese / Eggs products Global HPP food production estimated in 2014 : million kg Source: Hiperbaric 12 Meat Retail Trainer's Conference Anita Sikes

13 HPP industrial machines Source: Hiperbaric Total machine number in production (Hiperbaric & competitors): Meat Retail Trainer's Conference Anita Sikes

14 Current HPP processors in Australia 14 Meat Retail Trainer's Conference Anita Sikes

15 HPP Meat Value-Adders 15 Meat Retail Trainer's Conference Anita Sikes

16 Packaging requirements Flexible packaging (>15% volume contraction) Extra tight seals Rounded and reinforced edges Minimal head space MAP possible Tear strength, puncture resistance, surface smoothness generally not affected by HPP Often flexible pouches or bottles are inserted in secondary cardboard containers or sleeves after processing 16 Meat Retail Trainer's Conference Anita Sikes

17 Conventional HPP processing of typical MAP products Delamination of packaging film Micro defects ( white spots ) Bending and delamination of packaging film Damage can occur when insufficient packaging and processing is used In particular, modified atmosphere packs (MAP) Micro defects ( white spots ) Source: Tobias Richter, Multivac 17 Meat Retail Trainer's Conference Anita Sikes

18 Estimating Costs of HPP Factors to consider Processing conditions (pressure, temperature, time) Cycle time Capital Costs (size of plant, manufacturer) Depreciation period (note: number of cycles is limited) Vessel filling efficiency Labour costs Energy/water costs Factory overheads Exchange rates COST FACTORS VALUE UNITS Exchange rates EUR:USD a $/ AUD:USD a $/AUD JPY:USD a $/ General factors Electric power 0.11 AUD/kWh Water 2.74 AUD/m³ Factory overheads 13 % Depreciation period 10 years Interest rate per period 10 %/a Production parameters Process pressure 600 MPa Starting temperature 5 C Yearly days of production 216 d/a Production hours per day 24 h/d Cycle time 9.0 min Pressure come up time 3.0 min Vessel filling estimate 60 % Product density b 1.0 kg/l Labour Engineer(s) per shift Worker(s) per shift 2 - Annual costs per Engineer(s) AUD/a Annual costs per Worker(s) AUD/a Hours per shift 8 h 18 Meat Retail Trainer's Conference Anita Sikes

19 Shelf-life and Safety 19 Meat Retail Trainer's Conference Anita Sikes

20 Shelf-life extension Cold pasteurisation in the final package Increased shelf life Destruction of pathogens Listeria, Salmonella, coliforms Stabilisation of preservative-free or low salt content products 20 Meat Retail Trainer's Conference Anita Sikes Country Year Products Spain 1998 Sliced cooked ham and tapas USA 2001 Sliced cooked products and proscuitto ham USA 2001 Poultry products USA 2002 Pre-cooked chicken and beef strips Spain 2002 Sliced cooked meats products, Serrano cured ham Italy 2003 Proscuitto ham, salami & pancetta Germany 2004 Cured and smoked sliced and diced ham Japan 2004 Nitrites-free bacon, sausages and sliced meat USA 2005 Ready-to-eat meat based products Spain 2005 Cured meat products & Serrano ham Canada 2006 Cured & cooked meat products USA 2006 Whole roasted chicken USA 2006 Sliced cooked turkey and chicken Canada 2006 Ready-to-eat meat meals USA 2007 Chicken sausages USA 2008 Cooked pork & beef sliced products USA 2008 Pet food Canada 2008 Sausages and bacon Canada 2009 German style cooked meat products USA 2009 Sliced RTE meats Canada 2010 Proscuitto ham and cured meats Australia 2010 Sliced and diced preservative free poultry products Switzerland 2011 Cooked pork sliced products and sausages USA 2011 Proscuitto ham and cured meats USA 2011 RTE sliced meats Rumania 2011 RTE pork products Spain 2011 Serrano ham and cured meats Source: Carole Tonello, Hiperbaric

21 Effect of pressure on micro organisms Before 250 MPa 600 MPa After High pressure can kill microorganisms by interrupting their cellular function without the use of heat that can damage the taste, texture, and nutrition of the food. 21 Meat Retail Trainer's Conference Anita Sikes

22 In-pack pasteurisation by HPP Ready-to-eat meats processed at 600MPa for 180s Approx. 4-log reduction of L. monocytogenes Extension of refrigerated shelf-life from days to > 98 days CFU/ml Time (s) Hayman et al Meat Retail Trainer's Conference Anita Sikes

23 CSIRO Chill-stable meals concept products 23 Meat Retail Trainer's Conference Anita Sikes

24 Meat quality HPP for tenderisation 24 Meat Retail Trainer's Conference Anita Sikes

25 Pressure-heat treatment neck muscle 200 MPa / 60 C / 20 min improvement in texture Peak Force (kgf) x Beef neck muscle (tongue root) M. Sternomandibularis High connective tissue content muscle 2 0 Control Heat HPP / Heat 25 Meat Retail Trainer's Conference Anita Sikes

26 Tenderisation at high temperature retail muscles 200 MPa / 60 o C / 20 min varying connective tissue content Raw 10 8 Heat HPP-Heat Peak Force (kgf) Heat treatment 60 C, 20 min P-H treatment 200 MPa, 60 C, 20 min 0 Topside SM Silverside ST Striploin LD Muscle 200 MPa / 60 C / 20 min 70 C / 30 min tender meat 26 Meat Retail Trainer's Conference Anita Sikes

27 Effect of high pressure on meat colour Turkey breast (M. pectoralis superficialis) after 1 min at MPa and 25 C. 25 C Ref MPa Chicken breast (M. pectoralis superficialis) after 1 min at MPa and 25 C. 25 C Ref MPa Pork meat (M. longissimus dorsi) after 1 min at MPa and 25 C. 25 C Ref MPa 27 Meat Retail Trainer's Conference Anita Sikes

28 Colour change in minced meat Minced Meat Ref. 0.5 s 15 s 30 s 0.5 s 10 s 20 s 30 s 0.5 s 10 s 20 s 30 s 28 Meat Retail Trainer's Conference Anita Sikes

29 One-step pressure-heat process Topside 150 g, 20 mm thick steak One-step P-H process 200 MPa for 20 min at C No further cooking Measure texture and yield 29 Meat Retail Trainer's Conference Anita Sikes

30 Texture and yield of P-H treated steaks One-step process Peak shear force (kgf) Heat only 200 MPa 60 o C / 20 min then cooked 200 MPa then cooked Overall weight loss (%) Heat only 200 MPa 60 o C / 20 min then cooked 200 MPa then cooked Temperature ( o C) Temperature ( o C) 200 MPa / 76 C / 20 min tender meat + increased yield 30 Meat Retail Trainer's Conference Anita Sikes

31 Concept products Lamb Tagine Goat Curry Beef Short Rib Beef Chuck Soft Taco Search YouTube high pressure processing / MLA / red meat 31 Meat Retail Trainer's Conference Anita Sikes

32 Salt reduction in processed meats 32 Meat Retail Trainer's Conference Anita Sikes

33 Effect of pressure and salt content on cook loss Cook loss (%) % NaCl 0.8 % NaCl 0.6 % NaCl pressure range MPa salt content 0 2% 10 o C, 2 min optimal for cook loss MPa, 1% salt MPa 200 MPa Pressure (MPa) Cook loss (%) NaCl (%) 33 Meat Retail Trainer's Conference Anita Sikes

34 Textural differences and acceptability Control Hardness (N) MPa 200 MPa NaCl (%) At 1% salt, all of the sensory parameters were improved by HPP (informal sensory panel) Texture was firmer with a more appealing bite HPP (200 MPa), 1% salt Optimal at 200 MPa 34 Meat Retail Trainer's Conference Anita Sikes

35 Significance for industry 35 Meat Retail Trainer's Conference Anita Sikes

36 Opportunities Extension of shelf life ready-to-eat (RTE) meat products : sliced/diced cooked meat products, readyto-eat meals, marinated meats, dry cured products Enhance quality of low-value cuts (value addition) HPP combined with heat can tenderise low-value whole meat cuts one-step process can significantly improve yield Provide healthy, convenient, alternative processed meat products HPP at low temperature improves the functional properties (binding, texture) of meat batters using reduced salt content Commercialisation opportunities business models (toll manufacturing) product types (meal solutions, smallgoods) 36 Meat Retail Trainer's Conference Anita Sikes

37 Thank you Anita Sikes t e anita.sikes@csiro.au Project team: Tomas Bolumar Joanne Hughes Janet Stark Aarti Tobin Ron Tume FOOD AND NUTRITION