Fat incorporation

Abstract: A process for preparing meat containing meat trimmings therein which comprises fermenting meat trimmings with a starter culture, freezing the fermented meat trimmings and incorporating a frozen suspension of the meat trimmings in a brine, marinate or pickle into chilled meat characterised in that fat is added to the meat trimmings.

Description: The present invention relates to a process for incorporating meat trimmings and fat into meat. Meat trimmings are obtained by removal from the meat during the standard preparation of whole cuts of meat in the meat industry. The trimmings are usually but not always of low quality and usually contain some fat (about 10-12% by weight) and some muscle tissue. It is possible, by using technology introduced onto the market in recent years, to incorporate suspensions made of meat trimmings into whole cuts of like meat to increase the weight using a multi-needle injector. By controlling parameters such as the amount of trimmings injected, the meat/fat ratio and the quality of the meat, this technology enables the production of cooked ham or other marinated meat products without affecting the standard quality with regard to flavour, shelf-life and lack of visibility of the suspension, and in some cases improving it, for instance, with regard to binding and yield. Such a process is described in US-A-4,960,599. The cost saving of injecting trimmings is considerable when the trimmings are of low value compared to whole cuts of meat. In order to impart a specificity to the flavour and to improve the microbiological stability, it has been proposed to ferment the raw marinated meat by using a starter culture in the brine or marinade prior to cooking to produce bacteriocins. However, since the raw marinated meat can under no circumstances be allowed to ferment at a temperature higher than about +8°C prior to cooking, the biggest problem is to find a starter culture that can produce bacteriocins and a specific flavour at low temperature. We have tested some commercially available cultures but the effect on the final quality of the product regarding flavour and microbiological stability is minimal. In addition, the production time before the cooking step must be prolonged considerably. We found that by applying the fermentation step with a starter culture in the meat trimmings prior to incorporation into meat, it was possible to adapt the fermentation parameters such as temperature, time, humidity and ingredients, etc. to their optimal values. Accordingly, in our co-pending EP-A-95202882.7 there is provided a process for preparing meat containing meat trimmings therein which comprises incorporating a frozen suspension of meat trimmings in a brine, marinate or pickle into chilled meat characterised in that before freezing, the meat trimmings are fermented with a starter culture. Although, as stated above, meat trimmings usually contain about 10-12% by weight of fat, we have found surprisingly that, by incorporating extra fat into the meat trimmings, the final flavour intensity of the meat can be significantly improved. According to the present invention there is provided a process for preparing meat containing meat trimmings therein which comprises fermenting meat trimmings with a starter culture, freezing the fermented meat trimmings and incorporating a frozen suspension of the meat trimmings in a brine, marinate or pickle into chilled meat characterised in that at least 10% by weight of fat is added to the meat trimmings, based on the weight of the mixture of fat and meat trimmings. The amount of fat added to the meat trimmings may depend on the requirements but usually to obtain an improvement in flavour, preferably at least 20% by weight of fat based on the weight of the mixture of fat and meat trimmings is added. Typically for optimum improvement of flavour, the amount of fat added is from 25 to 75%, preferably from 30 to 70% and especially from 40 to 60% by weight of fat based on the weight of the mixture of fat and meat trimmings is used. It should be understood that since meat trimmings normally contain about 10-12% fat, the total amount of fat in the mixture is about 10-12% more than the fat added. The fat used for adding to the meat trimmings is preferably that removed from the thick fat layer of the actual piece of meat to be treated but it is also possible to use fat from the thick fat layer of the same type of meat as the meat to be treated. It is also possible to use fat from the thick fat layer of a type of meat other than the type of meat to be treated, although this is generally less preferred. The fat is preferably pork fat but other food acceptable fats such as animal fats or vegetable oils may be used, if desired. The fat is preferably added to the meat trimmings before or during fermentation. The meat used in the process may be obtained from all types of meat such as pork, beef, lamb, poultry and fish. For example, raw whole cuts of meat may be chilled, e.g. to a temperature from -2° to 12°C, preferably from 2° to 10°C and especially from 3° to 8°C, deboned and the trimmings removed in the usual manner. The meat trimmings used are preferably those removed from the actual piece of meat to be treated but it is also possible to use meat trimmings from the same type of meat as the meat to be treated. It is also possible to use meat trimmings from a type of meat other than the type of meat to be treated, although this is generally less preferred. The mixture of fat and meat trimmings may be incorporated into trimmed whole meat cuts as such or into smaller portions of meat formed by dividing the whole meat cuts into pieces having an average diameter of from 0.5 to 10 cm, more conveniently from 1 to 5cm. When the mixture of fat and meat trimmings is incorporated into whole cuts of meat, this may be carried out conventionally by injection, using for instance a multi needle injector. When the mixture of fat and meat trimmings is incorporated into smaller portions of meat, this may be carried out by mixing the mixture of fat and meat trimmings with the smaller portions of meat, e.g. with agitation such as stirring or tumbling. For example, a suspension of the mixture of fat and meat trimmings may be added directly to a tumbler. Before fermentation, the mixture of fat and meat trimmings is conveniently ground until the majority of the particles have a size of less than 30mm diameter and their average particle size is from 1mm to 5mm, preferably from 2mm to 4mm diameter. Before, during or after the addition of the starter culture, the ground mixture of fat and meat trimmings is preferably mixed with a brine, pickle or marinate. As is well known, a pickle is used for preserving meat and may contain brine, vinegar or other salt or acid liquor while a marinate is used for flavouring meat and may contain brine, vinegar or wine, oil, spices and herbs, etc. Black pepper may advantageously be added. For instance, the mixture of fat and meat trimmings may be mixed with sugar and a nitrite salt such as sodium nitrite. The pH of the mixture is usually in the range of from about 5.2 to 6.3, preferably from 5.5 to 6.0. Suitable starter cultures may be obtained from Lactobacillus, Streptococcus, Pediococcus or Staphylococcus species and preferable strains are lactobacillus sake (L.saki), Pediococcus acidilati (P.acidilati) and Staphylococcus carnosus. The starter culture may be mixed in water as is conventional before adding to the meat trimmings. The amount of starter culture used may be from 0.1 to 10ml, preferably from 0.5 to 5ml and especially from 0.75 to 2.5ml per kg of ground fat and meat trimmings. The mixture of ground fat and meat trimmings and the starter culture in the brine, pickle or marinate is advantageously packed in a vessel or bin suitable for fermentationsuch as a plastic bag or pouch within which fermentation is allowed to proceed. The cell concentration before fermentation is preferably from 10 6 to 10 7 cells /g. The fermentation may take place at a temperature of from 0° to 55°C, preferably from 8° to 45°C and more preferably from 15° to 40°C over a period of from about 12 hours to about 7 days, preferably from 18 hours to 5 days. During the early stages of the fermentation, e.g. after a period of from about 6 to 30 hours and more usually after a period of from 12 to 24 hours, the pH falls, for instance to pH 5.2 or 5.3 or below. The cell concentration after fermentation is preferably from 10 8 to 10 9 cells/g. After the fermentation, the fermented mixture of ground fat and meat trimmings is frozen, e.g. to a temperature from -5° to -30°C, preferably from -15° to -25°C. After freezing, the fermented ground meat trimmings are advantageously flaked, e.g. to particles having a maximum volume of about 2cc, preferably a maximum volume of 1cc. After freezing, a frozen brine, pickle or marinate may be mixed with the fermented mixture of ground fat and meat trimmings to form a suspension. The mixing may be performed by emulsifying one or more times, e.g. up to four times. The ratio of brine, pickle or marinate to the fat may be from 1:1 to 20:1, preferably from 1.5:1 to 15:1 and more preferably from 2:1 to 9:1. For example a brine may consist of a mixture of nitrite salt, sugar, ascorbate and water. The nitrite and ascorbate salts are conveniently the sodium salts. The frozen suspension of the mixture of fat and meat trimmings in a brine, marinate or pickle is then warmed to a temperature of not greater than +1°C, for instance about -2° to -10°C, preferably from -4° to -8°C and incorporated into the chilled meat. Although it is possible to warm the suspension to a temperature up to 5°C if the suspension contains less than 25% meat, especially less than 10% meat, there is no clear advantage to do so. The temperature of the suspension should preferably not exceed +1°C otherwise proteins would be extracted which would cause the suspension to thicken rapidly and this may cause subsequent clogging of the needles when the mixture of fat and meat trimmings is injected into the meat with needles. The amount of mixture of fat and meat trimmings incorporated into the meat may vary, e.g. up to 15%, conveniently from 1 to 10% and preferably from 2 to 6% by weight based on the weight of the meat. During the incorporation of the suspension of the mixture of fat and meat trimmings into the meat, especially by injection, a portion of the suspension is squeezed out of the meat and may be returned to the batch containing the mixture of fat and meat trimmings with brine where it is chilled down again. Any portion of the suspension returned is preferably emulsified at least once, more preferably at least two or three times, with the next batch because it may contain small meat particles which are disrupted from the muscles during injection and which could cause clogging of the needles. When the mixture of fat and meat trimmings is incorporated by injection, a part of the suspension of the mixture of fat and meat trimmings is preferably added separately so that some may be absorbed during tumbling since it is not usually possible to incorporate the exact desired percentage of suspension by injection. After the injection, the meat may be processed conventionally. The meat product may be a chilled product which is either non-cooked or cooked, or it may be frozen, preferably marinated, or dried. Examples of non-cooked chilled meat products are Lardon, bacon, cold smoked ham, etc. An example of a cooked and chilled meat product is cooked ham. For a cooked, chilled product such as cooked ham, the meat may undergo tenderisation, tumbling, moulding, cooking, chilling, storage, slicing and packaging by conventional methods such as are well known in the art. Advantageously, for a meat product which is cooked, such as cooked ham, the meat may be fermented prior to the cooking process. The process of the present invention may provide protection against undesirable bacteria such as Listeria in chilled products and improved flavour in frozen and dried products. The following Example further illustrates the present invention. Parts and percentages are by weight. Example 1 A whole ham was chilled to 5°C and trimmed by removing fat, sinews, etc. before separating into different whole meat cuts. The trimmings removed from the whole ham were mixed with an equal amount of pork fat obtained from the thick fat layer of the same ham and ground in a Kilia grinder to an average particle size of 3mm, mixed in a Hobart mixer with 1% dextrose, 2% nitrite salt and 1.0% of a starter culture of L.sake containing 10 6 to 10 7 bacteria per gram of the mixture of fat and trimmings. The mixture was packed under soft vacuum into plastic pouches and fermented at 25°C for 36 hours. The pH fell rapidly during the first day from an initial value of pH6 to pH5 and the cell count increased to 10 8 to 10 9 cells/g. After fermentation, the fermented mixture was packed into whole bags and frozen to -20°C, flaked in a magurit flaker to particles having dimensions of 0.5 x 0.5 x 0.5cm and warmed to -15°C. A brine at -8°C composed of 10.08% sodium nitrite, 0.18% of sodium ascorbate, 2.28% of dextrose and 87.46% of water (corresponding to an injection level of 40.5% and a 7% level of the mixture of fat and trimmings in the final product) in a ratio of 3 parts brine to 1 part of salami. The mixing was carried out by emulsifying three times to form a suspension. The suspension was then injected at -6°C into one of the whole cuts of ham through a multi-needle injector and the ham containing the mixture of fat and trimmings was then subjected to tenderisation, tumbling, moulding, cooking, chilling, storage, slicing and finally packaging by conventional methods. The chilled cooked ham had a significantly enhanced ham flavour when compared with a similar product containing meat trimmings which had been fermented in a similar but in the absence of added fat. Example 2 A similar process to that described in Example 1 was followed except that the injection level of the suspension was only 23% instead of the 40.5% level used in Example 1 giving an addition of only 4% of the mixture of fat and trimmings in the final product instead of 7% in Example 1. The chilled cooked ham had had a significantly enhanced ham flavour when compared with a similar product containing meat trimmings which had been fermented in a similar but in the absence of added fat.

Claims: A process for preparing meat containing meat trimmings therein which comprises fermenting meat trimmings with a starter culture, freezing the fermented meat trimmings and incorporating a frozen suspension of the meat trimmings in a brine, marinate or pickle into chilled meat characterised in that at least 10% by weight of fat is added to the meat trimmings, based on the weight of the mixture of fat and meat trimmings. A process according to claim 1 wherein the amount of fat added to the meat trimmings is at least 20% by weight of fat based on the weight of the mixture of fat and meat trimmings is added. A process according to claim 1 wherein the fat used for adding to the meat trimmings is that removed from the thick fat layer of the actual piece of meat to be treated or the thick fat layer of the same type of meat as the meat to be treated. A process according to claim 1 wherein the fat is added to the meat trimmings before or during fermentation. A process according to claim 1 wherein the meat trimmings used are those removed from the actual piece of meat to be treated. A process according to claim 1 wherein the meat trimmings used are trimmings from the same type of meat as the meat to be treated. A process according to claim 1 wherein the incorporation of the mixture of fat and meat trimmings into whole cuts of meat is carried out by injection using a multi needle injector. A process according to claim 1 wherein, before fermentation, the mixture of fat and meat trimmings are ground until the majority of their particles have an average particle size of less than 30mm diameter. A process according to claim 1 wherein, before, during or after the addition of the starter culture, the mixture of the ground fat and meat trimmings are mixed with a brine, pickle or marinate. A process according to claim 9 wherein the pH of the mixture is in the range of from about 5.2 to 6.3. A process according to claim 1 wherein the starter culture is obtained from Lactobacillus, Streptococcus, Pediococcus or Staphylococcus species. A process according to claim 1 wherein the ratio of brine, pickle or marinate to the fermented mixture of fat and meat trimmings is from 1:1 to 20:1. A process according to claim 1 wherein the frozen suspension of fat and meat trimmings in a brine, pickle or marinate at a temperature no greater than +1°C is incorporated into the chilled meat. A process according to claim 1 wherein the amount of the mixture of fat and meat trimmings incorporated into the meat is up to 15% by weight based on the weight of the meat. A process according to claim 1 wherein after the incorporation, the meat is chilled, frozen or dried. A process according to claim 15 wherein the meat is cooked before being chilled. A process according to claim 16 wherein, prior to cooking, the meat is fermented.

Inventors: BODENAS LARS GOERAN, HALDEN JONAS PETER, OLSSON KJELL, BODENAS, LARS GOERAN, HALDEN, JONAS PETER, OLSSON, KJELL, Bodenas, Lars Göran
Applicants: NESTLE SA, SOCIETE DES PRODUITS NESTLE S.A.
Application year: 1996
Main classification: A23L1
IPC codes: A23L1, A23B4