Purveyor. Hotel Restaurant Institution. & forequarters. Fabricate to primal cuts. Fabricate to subprimals

Transcription

1 Overview of Meat Life Cycle from Harvest to Consumer American Society of Animal Science Annual Meeting, San Antonio, TX July 9, 2007 Overview Meat processing distribution channels Preservation techniques Define and contrast freshness and safety Changes in retail meat case - implications for industry 1

2 Meat Industry Organization Packer Export Processor Retail Distributor Purveyor Fast Food Chain Distributor Retail Store Hotel Restaurant Institution Fast Food Chain Store Beef Carcass Processing hour chill Grading & Sorting Transfer rail to fab Separate hind & forequarters Fabricate to primal cuts Fabricate to subprimals Trim and cut to specifications Vacuum package boxing Weigh and label Chilling Ship to distribution 2

3 History of meat preservation Salt Refrigeration Improved sanitation Improved packaging (canning, aseptic packaging) Preservatives / antimicrobials Vacuum packaging (fresh and processed) Modified atmosphere packaging The Conundrum of Fresh Trimmings for Ground beef and Further processing Combo packed ~1 6 days 1 6 days Retail Over-wrap ~10-12 days Case Ready High Oxygen ~21-35 days Case Ready Low Oxygen Primals for Steaks / Chops / Roasts Vacuum packaged (2 ~ 75 days) ~30-45 days ~ >180 days Case Ready Vacuum Frozen hr carcass chill ~ >180 days Further processed ALL PRODUCTS HAVE SIMILAR SAFETY PROFILE Which process is likely to produce the freshest product? 3

4 Fresh =??? Just harvested? Never frozen? Great appearance / taste? Safe to eat? Not spoiled? Or. Just a marketing buzzword? Major causes of safety concerns Growth / presence of pathogenic bacteria Presence of chemical hazards Presence of physical hazards HACCP systems are designed to eliminate, or reduce to an acceptable level, food safety hazards. Shelf life determination of a given product assumes that HACCP and prerequisite programs are functioning to ensure safety. 4

5 Major causes of spoilage Growth of spoilage bacteria Oxidation of lipids Enzymatic activity In contrast, the causes of spoilage are mostly unrelated to factors that influence product safety. Indicators of safety Human observation (subjective measures) Implementation e of HACCP and prerequisite equ control programs in the process Visual observation of the process for physical hazards and nodes of potential introduction of microbiological or chemical hazards. Instrumental measures (objective measures) Pathogen testing of ingredients, raw materials, finished products, etc. Chemical testing of ingredients, raw materials, finished products, etc. Metal detection, x-ray, etc. 5

6 Indicators of spoilage Human measures (subjective sensorial changes) Smell -- odors Touch visual texture, or feel Sight -- color or texture Instrumental measures (objective measures) Spoilage bacterial enumeration Texture analysis Color analysis Factors affecting meat shelf life Animal production factors Genetic differences Temperature Muscle chemistry Muscle ph Muscle-to-muscle differences Postmortem age Ground vs. Whole muscle Oxygen & other atmospheres Packaging Other factors??? 6

7 Valued traits for meat processing and packaging Fresh raw materials Sanitation, Sanitation, Sanitation Low spoilage bacteria loads Normal meat ph Temperature control Minimize exposure to O2 Control of these factors is critical to preserving product and extending shelf life Current state of fresh meat packaging National Meat Case Study Conducted twice, 2002 and retail stores 43 metro markets in 29 states 29,000 linear feet of display case Over 117,000 packages sampled Sponsored by: Cryovac Sealed Air Corporation, National Cattlemen Beef Association and National Pork Board 7

8 National Meat Case Study % of linear feet devoted to fresh Styrofoam tray, PVC overwrap, 51% 49% of fresh meat packages were case ready 9% MAP % 4% 63% of linear feet devoted to fresh Styrofoam tray, PVC overwrap, 47% 60% of fresh meat packages were case ready 13% MAP Case Ready Penetration Increased for Each Major Specie Based on Package Counts 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 23% 15% Beef 66% 56% Ground Beef 37% 50% 28% 37% 38% 47% 95% 95% 83% 85% 60% 49% Pork Veal Lamb Chicken Turkey Total

9 In-Stock Position Was Better in Case- Ready than Store-Wrap Packaging 100% 90% 84% 80% 69% 70% 62% 63% 60% 50% 50% 48% 40% 30% 20% 10% 0% Beef Ground Beef 81% 70% 71% 61% 44% 46% 53% 54% 54% 50% 35% 34% Pork Veal Lamb Chicken Turkey 2002 Total Store Wrap Case-Ready 2004 NMCS Research, All Rights Reserved 2004 Total In-Stock is 5 or more packages per SKU displayed. Sausage was excluded. Current State: Fresh meat retail packaging Evolution to case ready continues at a measured pace Driven largely by economic influence Fresh Meat case continues to shrink Driven largely by need for consumer convenience 9

10 Progression of MAP Innovations High Oxygen as an industry standard Has worked well for a number of years Some retailers successful in implementation of this format; others find limited shelf life to be a challenge Downside is the rapid development of oxidation The ultimate in low oxygen packaging: g Vacuum packaging Consumer acceptance is still an issue due to appearance and color Low Oxygen-CO Innovations Consumer benefits of low- oxygen packaging with carbon monoxide Major benefit is control of oxidation Superior flavor over oxygenated product Removing oxygen prevents pre-mature discoloration 10

11 Summary Meat processing and distribution systems are complex, and are designed to meet the needs of a demanding and increasingly global marketplace. Product safety and product freshness (or spoilage) are measured by different factors and should be treated independently. Management of meat shelf life requires a balance between science, sanitation and packaging. g Innovative packaging and processing technologies will continue to evolve and change the way the industry delivers fresh product to consumers. Acknowledgements Dr. Darren Cornforth -- Utah State University Dr. Melvin Hunt Kansas State University Scott Eilert, Tim Freier, Brad Down, Anne Rojas -- Cargill Meat Solutions Phil Minerich, Kevin Meyers -- Hormel Foods Brian McFarlane, Dean Danilson -- Tyson Foods Mark Franzreb, Charles Barmore, Jerry Kelly, Jim Belcher Cryovac-Sealed Air Corporation 11

12 Thank you. 12