Patent Publication Number: US-9848631-B2

Title: Home-style meat product and method of producing same

Description:
RELATED APPLICATION 
     This application is a continuation-in-part of co-pending and co-owned U.S. patent application number, entitled Ser. No. 12/267,356, entitled Method and Apparatus to Mechanically Reduce Food Products Into Irregular Shapes and Sizes, filed Nov. 7, 2008, which is incorporated by reference in its entirety herein. 
    
    
     FIELD 
     This disclosure relates generally to a method and apparatus for producing a home-style meat product, specifically mass producing a home-style meat product. 
     BACKGROUND 
     Processing systems for various food products like vegetables, fruits, and meat products are known. When focused on meat products, the systems in the art are typically directed to producing uniform slices and cuts. In fact, the art exhibits a systematic progression to achieve greater and greater uniformity. This is true whether the system is producing a diced product, where the squareness of the final product is the desired trait, or producing a sliced product, where uniformity of thickness, size, and shape is preferred. These systems produce a final meat product that is packaged and presented to the consumer with each piece looking generally the same as the next. 
     An important factor in a consumer&#39;s selection is the visual appearance of the cut food product. If put off by the uniformity normally on display by mass produced meat products, consumers may instead desire “home-style” products with an appearance similar to meat cut from a home cooked turkey or ham. Meat products that are irregular in shape and size can solve this need without requiring the consumer to spend hours preparing a home cooked meat product. However, the known processing systems for producing slices of meat with irregular shapes and sizes do not provide a sufficient solution this problem. 
     When applied on a mass scale, manual cutting and slicing is simply not cost effective, requiring tedious processing and excessive manual labor. Accordingly, there have been other attempts at producing irregular shaped and sized slices. One method known in the art involves using molds to shape the meat in casing to give them an irregular shape. These molded slices of meat are then put through a traditional cutting or slicing system, which produces a product where consecutive slices appear different from one another, but also with a pattern of repeating shapes, uniform thickness and size. Another method uses a technique of skimming the bottom of a cooked meat product to produce slices with a roughed up appearance. A final method to produce slices with an irregular shape and size involves simply taking slices from several different sticks of meat and packaging them together. However, all of these techniques still result in slices of meat that have an overall uniform appearance and/or a lack of a cost-effective technique. 
     Therefore, a method and apparatus is needed to mass produce high quality slices of meat of irregular shape and size in a cost effective manner. The disclosed method and apparatus produces high quality, unique slices of meat that have irregular edges, natural meat grains, and natural color variation. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a flow diagram of a method for producing meat slices of irregular shape and size; 
         FIG. 2  is a side elevation view of an apparatus for producing meat slices of irregular shape and size; 
         FIG. 3  is a front elevation view of an apparatus shown in  FIG. 2 . 
         FIG. 4  is a perspective view of the apparatus of  FIG. 2  with the optional front panel open. 
         FIG. 5  is a side elevation view of the impeller and knife assembly of the apparatus of  FIG. 2 ; 
         FIG. 6  is a perspective view of an optional circular knife assembly for use in the apparatus of  FIG. 2 ; and 
         FIG. 7  is a flow diagram illustrating a process as described below. 
     
    
    
     DETAILED DESCRIPTION 
     With reference to the drawings, a method and processing machine is provided for use in producing irregularly shaped and sized food products and, in particular, for use in producing irregularly shaped and sized meat slices. The processing machine is generally referred to by reference numeral  10  in  FIGS. 2-4 . 
     With reference to  FIGS. 2-5 , the rotary processing machine  10  comprises a support frame  12  and a housing  14 . Prepared meat products  46  are fed into a rotary impeller  34 , which is rotatably attached in the housing  14 . The impeller  34  comprises a plurality of equally spaced paddles  40  and is encircled by a stationary cylinder  48 . A motor  42  drives the rotation of the impeller  34 . As the impeller  34  rotates, the paddles  40  catch the meat product  46  and carry it along an inner surface  50  of the stationary cylinder  48 . The stationary cylinder  48  includes an opening  54 . On one side of the opening  54 , a slicing knife  56  is attached. As the impeller  34  drives the meat product  46  around the inner surface  50  of the stationary cylinder  48 , the meat product  46  approaches the opening  54  and impacts the slicing knife  56 . The meat products  46  are able to tumble in the impeller so that different sides are engaged by the slicing knife  56 . This process produces meat slices  46   a  of irregular shape and size. 
     The rotary processing machine  10  can further include a circular knife assembly  62 . The circular knife assembly  62  is positioned proximal to the opening  54 , but downstream of the slicing knife  56 . The circular knife assembly  62  is oriented generally parallel with the slicing knife  56 . The circular knife assembly  62  may then further reduce the size of the meat product  46 , while still producing meat slices  46   a  of irregular shape and size. The circular knife assembly  62  would have at least one circular, rotating cutting blade  68 . The blade  68  preferably is dulled to produce rough cutting edges. 
     The rotary processing machine  10  can further include a cross cut knife assembly  76 . The cross cut knife assembly  76  is positioned proximal to and downstream of the circular knife assembly  62  and the slicing knife  56 . The cross cut knife assembly  76  is oriented generally parallel with the slicing knife  56 . The cross cut knife assembly  76  may then further reduce the size of the meat product  46 , while still producing meat slices  46   a  of irregular shape and size. The cross cut knife assembly  76  would have at least one cross cut blade  78 . The blade  78  preferably is dulled to produce rough cutting edges. 
     The rotary processing machine  10  can be made to be highly space efficient. For example, in one embodiment, the rotary processing machine  10  may have a height in the range of 50 inches to 72 inches, and preferably in the range of 54 inches to 69 inches. In addition, the rotary processing machine  10  may weigh in the range of 1,400 pounds to 1,600 pounds, and preferably about 1,500 pounds. 
     The frame  12  provides the support for the rotary processing machine  10 . In one embodiment, the frame  12  may have a length in the range of 26 inches to 38 inches and a width in the range of 25 inches to 37 inches. In the preferred embodiment, the frame  12  has a length of about 32 inches and a width of about 31 inches. These embodiments are designed to utilize a relatively small area while still allowing the rotary processing machine  10  to operate in a high-speed commercial environment. 
     The small area allows the rotary processing machine  10  to seamlessly integrate with existing operations. The frame  12  may further comprise numerous legs  16 . In the preferred embodiment, each of the legs  16  has casters  18  at their terminal end to allow for greater mobility of the rotary processing machine  10 . At least one caster  18  preferably has a locking mechanism  20  that an operator can engage to prevent the rotary processing machine  10  from moving when movement is not desired. 
     The frame  12  is attached to and supports the housing  14 . In one embodiment, the housing  14  may have a length in the range of 37 inches to 67 inches, and preferably in the range of 47 inches to 62 inches, and more preferably about 57 inches. The housing  14  may enclose any or all of the motor  42 , the impeller  34 , the stationary cylinder  48 , the knife assembly  52 , and an electrical component box  32 . The housing  14  may also include access to the devices enclosed within it. In one embodiment, this access comprises a front panel  22 . The front panel  22  may be hinged to provide the operator access to the impeller  34 , the stationary cylinder  48  and the knife assembly  52 . This feature provides the user with easy access to these devices as needed, for example, for maintenance or cleaning. In another embodiment, this access may include a back panel  24 . The back panel  24  may be hinged to provide the operator access to at least the electrical component box  32 , as needed. 
     The housing  14  includes a hopper  26 . The hopper  26  is positioned to receive the prepared meat product  46  and feed it into the stationary cylinder  48 . The hopper  26  is positioned adjacent to the stationary cylinder  48 , and preferably centered with the stationary cylinder  48 . In the preferred embodiment, the hopper  26  has an opening directed upwards for loading of the prepared meat product  46  and urging of the prepared meat product  46  into the stationary cylinder  48  by gravitational force. The diameter of the hopper  26  where it provides access to the stationary cylinder  48  may be in the range of 13.5 inches to 14.8 inches, and preferably about 13.5 inches. The hopper  26  may preferably be positioned on the front panel  22  to provide access to the stationary cylinder  48  and the impeller  34  as needed, for example, for maintenance or cleaning. 
     In the preferred embodiment, the housing  14  also comprises a feeder chute  28 . The feeder chute  28  is attached to the hopper  26  to provide an extended and more covered access route for the prepared meat product to reach the stationary cylinder  48 . The access opening of the feeder chute  28  may be vertically aligned or preferably facing generally upwards. In one embodiment, the feeder chute  28  is generally circular with an opening generally equal to that of the hopper  26  at its distal end where the chute  28  meets the hopper  26 . Alternatively, in the preferred embodiment, the feeder chute  28  starts with a generally square opening, preferably about 13.5 inches on each side, and ends with an opening generally equal to that of the hopper  26  at its distal end where the chute  28  meets the hopper  26 . 
     The housing  14  also may include a discharge chute  30 . The discharge chute  30  is positioned below the knife assembly  52  to direct the discharge of the meat slices  46   a  from the rotary processing machine  10 . The discharge chute  30  may be downward facing. The distal end of the discharge chute  30  may be in the range of 10 inches to 20 inches above the floor, and preferably about 15 inches. This preferable height from the floor provides the discharge chute  30  with a sufficient height to accommodate larger slices produced by the processing machine  10 . It may be of a generally rectangular shape with a width equal to or larger than the width of the stationary cylinder  48 , and preferably in the range of 13 inches to 15 inches, and more preferably about 13.7 inches. The length of the distal end of the discharge chute  30  may be in the range of 5 inches to 15 inches, and preferably about 10 inches. In one embodiment, the discharge chute  30  is attached to the housing  14  directly below the knife assembly  52  and angles away from the rotary processing machine  10 , so that the distal end of the discharge chute  30  is spaced from the frame  12  in the range of about 4 inches to 12 inches, and preferably in the range of 8 inches to 9 inches. In addition, the discharge chute  30  preferably does not contain any obstructions in order to provide an easier discharge path for the meat slices  46   a.    
     The impeller  34  includes a pair of rotating end discs  36 ,  38  interconnected by the paddles  40 . The paddles  40  are equally spaced around the interior circumference of the end discs  36 ,  38 . The impeller  34  is rotatably attached in the housing  14 . The paddles  40  are preferably attached perpendicular to the end discs  36 ,  38 . The paddles may be orientated generally radially, or alternatively, they may be angled toward the direction of rotation of the impeller  34 . This angle can be between 0 and 55 degrees from radial in the direction of rotation of the impeller  34 , and preferably about 30 degrees. The paddles  40  may preferably start at the outer edge of the impeller  34  or, alternatively, start in a range up to 1 inch from the edge. The paddles  40  have a length in the range of 3 inches to 6 inches, and preferably 4 to 5 inches. This preferable length allows the meat product  46  to tumble and present different oriented slicing surfaces to the slicing knife  56 . In one embodiment, the impeller  34  has between two and six paddles  40 , and preferably between three and five paddles  40 . In the most preferred embodiment, the impeller  34  has four paddles  40 . 
     The motor  42  drives the rotation of the impeller  34 , such as in a direction indicated by the arrow  44 . The motor  42  can operate at any feasible hertz level, and preferably in a range from 60 to 75 hertz, and more preferably 75 hertz. In addition, the motor  42  can operate at any feasible horsepower, and preferably at 10 horsepower. The motor  42  may preferably be supplied voltage across the line or, alternatively, by a variable frequency drive. 
     As the motor  42  causes the impeller  34  to rotate, the paddles  40  contact the prepared meat product  46  and cause it to rotate along with the impeller  34  in the direction of the arrow  44 . As a result of the rotation, centrifugal force presses the prepared meat product  46  against the inner surface  50  of the stationary cylinder  48 . The paddles  40 , in turn, drive the prepared food product  46  around the inner surface  50  of the stationary cylinder  48 . Because the rotary cutting machine  10  does not restrain or control the position of the prepared meat product  46  beyond the application of centrifugal force, the prepared food product  46  can tumble and fall within the impeller  34 . As a result of this process, the prepared meat product  46  is pressed against the inner surface  50  of the stationary cylinder  48  in random and different orientations as it is driven by the paddles  40  of the impeller  34 . 
     The degree of random and different orientations can be increased depending upon the amount of meat product  46  present in the impeller  34 . For example, having more meat products  46  in the impeller  34  than the number of paddles  40  can advantageously result in the excess meat products  46  accumulating in a lower region of the cylinder  48 . After a meat product  46  has been sliced, the meat product  46  can continue to rotated toward the lower region where the accumulated meat products  46  can cause the just-sliced meat product  46  to become dislodged from adjacent the paddle  40 . Another meat product  46  can then take the place of the just-sliced meat product  46 . When the just-sliced meat product  46  is subsequently advanced by the same of a different paddle  40 , it can be in a different orientation than if it had continued to rotate by the same paddle  40 , and thereby the next time it is sliced, a differently shaped slice can be cut. 
     As the prepared meat product  46  is driven around the inner surface  50  of the stationary cylinder  48 , it encounters the knife assembly  52 , as shown in  FIG. 5 . The knife assembly  52  includes the opening  54  and the slicing knife  56 . 
     The opening  54  is formed in the stationary cylinder  48  by spacing the side of the opening  54  positioned earlier in the path of rotation of the impeller  34  from the outer periphery of the impeller  34 . The opening  54  can be formed anywhere on the stationary cylinder  48 , and preferably is formed at a position of the stationary cylinder  48  where the rotation of the impeller  34  is in a generally downward direction and, more preferably, where the velocity of the prepared meat product  46  is generally perpendicular with the floor. The opening  54  preferably spans the width of the stationary cylinder  48  and is preferably generally horizontal. Alternatively, the opening  54  may be formed in the stationary cylinder  48  at an angle in the range of 45 degrees above or below horizontal. 
     In the preferred embodiment, the width of the opening  54  can be adjusted by a control knob  58 . The control knob  58  is preferably adjacent to the opening  54  and attached to the side of the opening  54  spaced from the outer periphery of the impeller  34 . To adjust the width of the opening  54 , the control knob  58  can adjust the distance the side of the opening  54  is spaced from the outer periphery of the impeller  34 . The control knob  58  can vary the width of the opening  54  in a range from 1/16 inch to 1 inch, and preferably the opening  54  is set between ⅛ inch and 3/16 inch. The width of the opening  54  set by the control knob  58  determines the maximum thickness of the meat slices  46   a  produced by the rotary processing machine  10 . 
     The slicing knife  56  is positioned at the side of the opening  54  that extends along the outer periphery of the impeller  34 . In the preferred embodiment, the slicing knife  56  is removably positioned at the opening  54 . The removably attached slicing knife  56  may then be removed and inserted as needed, for example, to select a different type of the slicing knife  56 , with a scalloped blade being preferred, to repair or maintain the slicing knife  56 , or to- replace -the slicing knife  56 . The slicing knife  56  preferably spans the length of the opening  54  and is positioned to provide the first point of contact for the meat product  46  as it is driven into the opening  54  by the impeller  34 . As the paddles  40  drive the meat product  46  to the opening  54 , the meat product  46  is driven beyond the outer periphery of the impeller  34  due to the spacing of the opening  54 . As the paddle  40  continues to rotate, the meat product  46  is driven into the slicing knife  56  which is positioned at the outer periphery of the impeller  34 , producing meat slices  46   a  of thickness determined by the width of the opening  54 . 
     The slicing knife  56  may further comprise a guide surface  60 . As the slicing knife  56  cuts into the prepared meat product  46 , meat slices  46   a  are produced, and the guide surface  60  can direct the meat slices  46   a  away from the knife assembly  52  and towards the discharge chute  30 . 
     The knife assembly  52  may further comprise the circular knife assembly  62 , as shown in  FIG. 6 . The circular knife assembly  62  comprises at least one circular blade  68  mounted on a rotatable shaft  64  and is positioned in a direction that is generally parallel to the process feed direction. The circular knife assembly  62  is rotatably mounted to the housing  14  to preferably rotate in a direction as indicated by the arrow  66 . The circular knife assembly  62  is preferably downstream and proximal to the slicing knife  56 . As the meat slices  46   a  are produced, they may travel down the guide surface  60  of the slicing knife  56 . While on the guide surface  60 , the at least one circular blade  68  may then further reduce the size of the meat slices  46   a.    
     In the preferred embodiment, the circular knife assembly  62  has dulled circular blades  68 . The circular blades  68  may be artificially dulled by any method, or preferably, the circular blades  68  may be allowed to dull naturally and are not sharpened. The dulled circular blades  68  may then reduce the meat slice  46   a  size while still producing meat slices  46   a  with irregular edges consistent with the appearance of “home-style” carved meat. The dull circular blades  68  provide a natural cut by pulling the muscle fibers of the sliced meat product  46 a. 
     The circular knife assembly  62  may alternatively contain feed discs  70  to assist in advancing the meat slices  46 a. The feed discs  70  may be mounted on the rotatable shaft  64  in place of any number of the circular blades  68 . 
     The circular knife assembly  62  may consist of between one and fifteen circular blades  68 , and preferably one circular blade  68 , depending on the size of the prepared meat product  46  being used and the size of the meat slices  46   a  desired. The chosen number of blades  68  having different spacings therebetween to cut the meat slices  46   a  into further reduced sizes of varying widths. As illustrated in  FIG. 6 , a first spacer  72  creates a gap or space of length ‘a,’ and a second spacer  74  creates a gap of length ‘b.’ The spacers  72 ,  74  can be alternated every other one, such that the spacing between the blades  68  is also alternating between a space of length ‘a’ and ‘b,’ or, alternatively, may be placed in any other suitable combination. The blade  68  spacing may be varied from ⅛ inch to 1 inch. For any number of the circular blades  68  not used, the feed discs  70  may be positioned on the rotatable shaft  64  instead. Preferably, the circular knife assembly  62  is composed of two circular blades  68  spaced apart by 3 inches and centered on the rotatable shaft  64  having ¾ inch spacers  72 ,  74  running the length of the rotatable shaft  64 . The remaining spaces between the spacers  72 ,  74  on the rotatable shaft  64  preferably have feed discs  70 . 
     The knife assembly  52  may also comprise the cross cut knife assembly  76 . The cross cut knife assembly  76  is positioned in a direction that is generally parallel to the process feed direction. The cross cut knife assembly  76  can be comprised of a number of cross cut blades  78  in the range of 1 to 14, and preferably 2. The cross cut blades  78  preferably run the length of the cross cut knife assembly  76  and are positioned generally parallel to the process feed direction. The cross cut knife assembly  76  is rotatably mounted to the housing  14  to preferably rotate in a direction as indicated by the arrow  80 . The cross cut knife assembly  76  is preferably downstream and proximal to the slicing knife  56 . As the meat slices  46   a  are produced, they may travel down the guide surface  60  of the slicing knife  56 . As the meat slices advance beyond the end of the guide surface  60 , the cross cut blades  78  may then further reduce the size of the meat slices  46   a.    
     In the preferred embodiment, the cross cut knife assembly  76  has dulled cross cut blades  78 . The cross cut blades  78  may be artificially dulled by any method, or preferably, the cross cut blades  78  may be allowed to dull naturally and are not sharpened. The dulled cross cut blades  78  may then reduce the meat slice  46   a  size while still producing meat slices  46   a  with irregular edges consistent with the appearance of “home-style” carved meat. The dull cross cut blades  78  provide a natural cut by pulling the muscle fibers of the sliced meat product  46   a.    
     With reference to the diagram of  FIG. 1 , a bulk meat product is first selected for processing by the processing machine. The bulk meat product can be selected from any variety of meat product, including, for example, ham, turkey, chicken, or beef. Once the bulk meat product is selected, it can then be prepared for processing. This preparation can first include chilling the bulk meat product to the required temperature. This may include storing the bulk meat product at the desired temperature or instead chilling the bulk meat product further to reach the desired temperature. The meat product should be kept at a temperature below 40 degrees Fahrenheit for food safety purposes, and preferably, the meat product should have a temperature in the range of 30 to 35 degrees Fahrenheit when processed by the processing machine. Alternatively, the bulk meat product can be cooked or heated prior to processing. This may include cooking the meat product by any suitable means. This preparation can also include removing the bulk meat product from any casing or wrapping used to store and ship the product. This preparation may ensure that the meat product is free of any foreign material to keep any foreign material out of the final sliced product. Another option for preparation includes breaking down the bulk meat product prior to processing. The bulk meat product may be broken down by hand or other suitable means. However, it has been found that breaking down formulated turkey into smaller portions before processing can create a good, but small end product. In any case, the prepared meat product is preferably about 10 inches in any dimension or less. Finally, the total amount of meat product may be selected. The amount of meat product selected is dependent on the amount of output slices desired and can be in a range of one meat product to more than 20 with each load into the processing machine. 
     A next step can include selecting a slicing knife. The slicing knife can have any type of edge, including, for example, a scalloped or a wavy edge. Once the slicing knife is selected, it may then be inserted into the processing machine. As disclosed above, inserting the slicing knife into the processing machine positions the knife at the opening formed in the stationary cylinder. 
     Next, a desired slice thickness can be determined. As disclosed above, the slice thickness may be in the range of 1/16 inch to 1 inch. The desired slice thickness may vary depending on the selected type of meat or the application of the desired output. Once selected, the slice thickness may then be represented on the processing machine. To alter the thickness of the slices produced by the processing machine, the width of the opening can be adjusted. The control knob is operably attached to the opening to adjust the width thereof. The slice thickness corresponds to the distance between the slicing knife and the side of the opening spaced from the outer periphery of the impeller. 
     The following step may include determining a desired slice width. This width may be as large as the selected bulk meat product or the broken down selected meat product, or as small as ⅛ inch as disclosed in the discussion of the circular knife assembly above. The desired slice width may vary depending on the type of the selected meat product or the application of the product intended to be produced by the processing machine. Once the desired slice width is determined, it can then be determined whether a circular knife assembly is needed. If the desired slice width is less than any dimension of the prepared meat product, the circular knife assembly may be used to further reduce the width. If the circular knife assembly is required, its setup must then be determined. This includes choosing the number of pre-dulled circular blades desired and the spacing between the pre-dulled circular blades. After the desired number of blades and spacing is determined, then the type of spacers and number of feed discs can be ascertained. Once all of the circular knife assembly materials are chosen, they may be mounted on a rotatable shaft. The assembled circular knife assembly may then be rotatably attached to the housing of the processing machine proximal to and downstream of the slicing knife. 
     Another step may include determining a desired slice height. This height may be as large as the height of the selected bulk meat product or the broken down selected meat product, or instead, a smaller slice may be desired. If a smaller slice height is desired, a cross cut knife assembly may be used. If the cross cut knife assembly is required, its setup must then be determined. This includes choosing the number of pre-dulled cross cut blades desired and the spacing between the pre-dulled cross cut blades, and preferably two evenly spaced dulled cross cut blades. The cross cut knife assembly may then be rotatably attached to the housing of the processing machine proximal to and downstream of the slicing knife. 
     Next, the processing machine may be started. A desired speed of rotation of the impeller may then be determined. The speed of the rotation of impeller influences the magnitude of the centrifugal force applied on the prepared meat product while in the impeller and, similarly, it may also influence the tumbling and orientation of the meat products while in the impeller. This process determines the edge of the meat product from which the slices are produced. If a desired speed is determined, the speed of rotation of the impeller may then be set. The available speeds may vary with the type of motor operating the processing machine, and preferably the motor can operate at 75 hertz. 
     The processing machine comprised of a housing, a motor, an impeller, and a knife assembly may then use the impeller having at least one paddle to rotatably drive the prepared meat product around the housing, the prepared meat product held to the housing by centrifugal force, to impact the knife assembly to create irregularly shaped meat slices. 
     The selected and prepared meat product can then be loaded into the processing machine. The machine operates as detailed above to output mass-scale “home-style” slices of meat of irregular shape and size. As the slices of meat are output by the processing machine, they can be collected. This may be done by placing a bag or collection bin under the discharge chute. Finally, the collected slices can be packaged. 
     EXAMPLES 
     The following examples illustrate presently preferred methods and should be understood to be illustrative of, but not limiting upon, the scope of the apparatus and method which are set forth in the appended claims. 
     For the following tests, the processing machine had an impeller with four equally spaced paddles, a ten horsepower motor operating at sixty hertz across the line, and a scalloped slicing knife with a 3/16 inch slice thickness. Two bags of bulk meat product, removed from the plastic casing, were used in the tests. 
     
       
         
           
               
               
               
               
               
             
               
                   
               
               
                 Test 
                 Meat 
                 Temp. 
                 Prep. 
                 Result 
               
               
                   
               
             
            
               
                 1 
                 Ham Loaves 
                 32° F. 
                 Whole 
                 Very Good Slices of 
               
               
                   
                   
                   
                   
                 Irregular Shape and Size 
               
               
                 2 
                 Ham Loaves 
                 35° F. 
                 Broken into 
                 Very Good Slices of 
               
               
                   
                   
                   
                 pieces by hand 
                 Irregular Shape and Size 
               
               
                 3 
                 Ham Loaves 
                 35° F. 
                 Whole 
                 Very Good Slices of 
               
               
                   
                   
                   
                   
                 Irregular Shape and Size 
               
               
                 4 
                 Formulated 
                 30° F. 
                 Whole 
                 Very Good Slices of 
               
               
                   
                 Turkey 
                   
                   
                 Irregular Shape and Size 
               
               
                 5 
                 Formulated 
                 30° F. 
                 Broken into 
                 Very Small Slices of 
               
               
                   
                 Turkey 
                   
                 pieces by hand 
                 Irregular Shape and Size 
               
               
                 6 
                 K Butt Tumbled 
                 32° F 
                 Broken into 
                 Very Good Slices of 
               
               
                   
                 Ham Loaves 
                   
                 pieces by hand 
                 Irregular Shape and Size 
               
               
                 7 
                 K Butt Not 
                 32° F. 
                 Broken into 
                 Very Good Slices of 
               
               
                   
                 Tumbled 
                   
                 pieces by hand 
                 Irregular Shape and Size 
               
               
                   
                 Ham Loaves 
               
               
                   
               
            
           
         
       
     
     For the following tests, the processing machine had an impeller with four equally spaced paddles, a ten horsepower motor operating at sixty hertz across the line, a scalloped insert knife with a 3/16 inch slice thickness, and a circular knife assembly. The circular knife assembly had one circular blade at 5¼ inches and feed discs positioned at the remaining spaces between the ¾ inch spacers. Two bags of bulk meat product, removed from the plastic casing, were used in the tests. 
     
       
         
           
               
               
               
               
               
             
               
                   
               
               
                 Test 
                 Meat 
                 Temp. 
                 Prep. 
                 Result 
               
               
                   
               
             
            
               
                 8 
                 Formulated 
                 38° F. 
                 Whole 
                 Good Slices of Irregular 
               
               
                   
                 Turkey 
                   
                   
                 Shape and Size 
               
               
                 9 
                 Ham Loaves 
                 34° F. 
                 Broken into 
                 Very Good Slices of 
               
               
                   
                   
                   
                 pieces by hand 
                 Irregular Shape and Size 
               
               
                   
               
            
           
         
       
     
     For the final test, the processing machine had an impeller with four equally spaced paddles, a ten horsepower motor operating at seventy five hertz across the line, a scalloped insert knife with a ⅛ inch slice thickness, and a circular knife assembly. The circular knife assembly had one circular blade at 5¼ inches and feed discs positioned at the remaining spaces between the ¾ inch spacers. Two bags of bulk meat product, removed from the plastic casing, were used in the test. 
     
       
         
           
               
               
               
               
               
             
               
                   
               
               
                 Test 
                 Meat 
                 Temp. 
                 Prep. 
                 Result 
               
               
                   
               
             
            
               
                 10 
                 Ham Loaves 
                 34° F. 
                 Whole 
                 Very Good Slices of 
               
               
                   
                   
                   
                   
                 Irregular Shape and Size 
               
               
                   
               
            
           
         
       
     
     For the following tests, the processing machine had an impeller with four equally spaced paddles, a ten horsepower motor operating at 75 hertz across the line, a scalloped slicing knife with a 3/16 inch slice thickness, and a circular knife assembly. The circular knife assembly had two dulled circular blades one 3 inches from either end of the rotatable shaft and feed discs positioned at the remaining spaces between the ¾ inch spacers. Four pieces of bulk meat product were used in the tests. 
     
       
         
           
               
               
               
               
               
             
               
                   
               
               
                 Test 
                 Meat 
                 Temp. 
                 Prep. 
                 Result 
               
               
                   
               
             
            
               
                 11 
                 Chicken - Slit 
                 31° F. 
                 Whole, drained 
                 Very Good Slices of 
               
               
                   
                 casing 
                   
                 juices 
                 Irregular Shape and Size 
               
               
                 12 
                 Chicken 
                 31° F. 
                 Whole, drained 
                 Very Good Slices of 
               
               
                   
                   
                   
                 juices 
                 Irregular Shape and Size 
               
               
                 13 
                 Turkey - Slit casing 
                 31° F. 
                 Whole, drained 
                 Very Good Slices of 
               
               
                   
                   
                   
                 juices 
                 Irregular Shape and Size 
               
               
                 14 
                 Turkey 
                 31° F. 
                 Whole, drained 
                 Very Good Slices of 
               
               
                   
                   
                   
                 juices 
                 Irregular Shape and Size 
               
               
                 15 
                 Ham - Split Top 
                 31° F. 
                 Whole, drained 
                 Very Good Slices of 
               
               
                   
                   
                   
                 juices 
                 Irregular Shape and Size 
               
               
                 16 
                 Ham 
                 31° F. 
                 Whole, drained 
                 Very Good Slices of 
               
               
                   
                   
                   
                 juices 
                 Irregular Shape and Size 
               
               
                 17 
                 Beef - Split Top 
                 31° F. 
                 Whole, drained 
                 Very Good Slices of 
               
               
                   
                   
                   
                 juices 
                 Irregular Shape and Size 
               
               
                 18 
                 Turkey Breasts 
                 31° F. 
                 Halved, drained 
                 Very Good Slices of 
               
               
                   
                 Halved 
                   
                 juices 
                 Irregular Shape and Size 
               
               
                 19 
                 Chicken Breasts 
                 31° F. 
                 In 12 pieces, 
                 Very Good Slices of 
               
               
                   
                   
                   
                 drained juices 
                 Irregular Shape and Size 
               
               
                   
               
            
           
         
       
     
     For the following tests, the processing machine had an impeller with four equally spaced paddles, a ten horsepower motor operating at 75 hertz across the line, a scalloped slicing knife with a ½ inch slice thickness, a circular knife assembly, and a cross cut knife assembly. The circular knife assembly had dulled circular blades at every 1½ inches and feed discs positioned at the remaining spaces between the ¾ inch spacers. Four pieces of bulk meat product were used in the tests. 
     
       
         
           
               
               
               
               
               
             
               
                   
               
               
                 Test 
                 Meat 
                 Temp. 
                 Prep. 
                 Result 
               
               
                   
               
             
            
               
                 20 
                 Beef 
                  97° F 
                 Whole, drained 
                 Chunk style shreads 
               
               
                   
                   
                   
                 juices 
               
               
                 21 
                 Ham 
                 125° F. 
                 Whole, drained 
                 Chunk style shreads 
               
               
                   
                   
                   
                 juices 
               
               
                 22 
                 Ham 
                 120° F. 
                 Whole, drained 
                 Chunk style shreads 
               
               
                   
                   
                   
                 juices 
               
               
                 23 
                 Beef 
                 135° F. 
                 Whole, drained 
                 Chunk style shreads 
               
               
                   
                   
                   
                 juices 
               
               
                   
               
            
           
         
       
     
     For the following tests, the processing machine had an impeller with four equally spaced paddles, a ten horsepower motor operating at 75 hertz across the line, a scalloped slicing knife with a 3/16 inch slice thickness, a circular knife assembly, and a cross cut knife assembly. The circular knife assembly had dulled circular blades spaced 3¾ inches from each end of the rotatable shaft and feed discs positioned at the remaining spaces between the ¾ inch spacers. The cross cut knife assembly had two dulled cross cut blades positioned on opposite sides of the assembly. Two pieces of bulk meat product were used in the tests. 
     
       
         
           
               
               
               
               
               
             
               
                   
               
               
                 Test 
                 Meat 
                 Temp. 
                 Prep. 
                 Result 
               
               
                   
               
             
            
               
                 24 
                 Ham 
                 33° F. 
                 Whole, drained 
                 Very Good Slices of 
               
               
                   
                   
                   
                 juices 
                 Irregular Shape and Size 
               
               
                 25 
                 Ham 
                 33° F. 
                 Whole, drained 
                 Very Good Slices of 
               
               
                   
                   
                   
                 juices 
                 Irregular Shape and Size 
               
               
                 26 
                 Ham 
                 33° F. 
                 Whole, drained 
                 Very Good Slices of 
               
               
                   
                   
                   
                 juices 
                 Irregular Shape and Size 
               
               
                 27 
                 Ham 
                 33° F. 
                 Whole, drained 
                 Very Good Slices of 
               
               
                   
                   
                   
                 juices 
                 Irregular Shape and Size 
               
               
                 28 
                 Turkey 
                 33° F. 
                 Whole, drained 
                 Very Good Slices of 
               
               
                   
                   
                   
                 juices 
                 Irregular Shape and Size 
               
               
                 29 
                 Turkey 
                 33° F. 
                 Whole, drained 
                 Very Good Slices of 
               
               
                   
                   
                   
                 juices 
                 Irregular Shape and Size 
               
               
                   
               
            
           
         
       
     
     For the foregoing, it will be appreciated that apparatus and methods are described herein for manufacturing irregularly shaped and sized food products. While the figures and description herein are illustrative of certain aspects of methods and apparatus for manufacturing irregularly shaped and sized food products, the apparatus and methods are not limited to the aspects illustrated in the figures and described hereinabove. For example, while the description generally refers to meat as the product being produced in irregular shapes and sizes, it is understood that a process according to the present description may be used for other suitable products. 
     Turning now to the preparation of the sliced meat,  FIG. 7  illustrates a process  200  for producing a shaped home-style meat product having an irregular appearance. Such home-style meat products may have a variety of irregular shapes, sizes, and textures, to note but a few of the varied characteristics. By one approach, a package of such home-style meat products may have individual meat slices or pieces with irregular shapes, sizes, textured surfaces, and density. Further, it is anticipated that although each of the individual slices is varied from one slice to the next, the various parameters of each of the slices may fall within a predetermined range. For example, though the shape of the meat slices may be irregular, the shape may nonetheless, fall into a range such that a majority of the slices in a package may have a small, diced configuration or all of the slices in a package may be flat with a relatively thin depth compared to the width, to note but a few shape options. 
     To produce such varied slices, the rotary processing machine  10 , as discussed above, may be employed to mass produce slices of meat having an irregular appearance. Process  200  also may be used to that end. Further, process  200  may be used to produce such a home-style meat product having an irregular appearance with conventional slicing equipment. Indeed, process  200  may be used, either in combination with the rotary processing machine  10  discussed above or in combination with other slicing equipment such as a reciprocating-carriage slicer, among others. Thus, if a high degree of irregularity between the meat slices is desired, the rotary processing machine  10  may be used to slice meat prepared according to process  200 . 
     Prior to slicing the whole muscle meat, process  200  formulates a whole muscle meat mixture having a low-salt, no-phosphate solution mixed therein such that when the meat mixture is cooked and chilled, this formulation produces a whole muscle meat structure characterized by individual meat fibers that bind modest amounts of water and fat. Further, such a mixture may be loosely stuffed, as detailed below. Thus, when such formulated meat products are sliced, such as by the rotary processing machine  10  or other slicing equipment, the cut surface of the whole muscle meat is typically fractured along the lines between weakly bound fibers, thereby resulting in a sliced meat product having a rough irregular surface that displays the natural structure of the meat. Such an irregular surface is commonly found in whole muscle meats that have been prepared in the home. 
     Alternatively, in conventional meat processing applications, product formulations are designed to maximize protein functionality and when such a formulation is combined with conventional slicing technology, a meat product with smooth, regular surface cuts is produced. To create such a standardized product, conventional processing indicates that once the deboned whole muscle meat is supplied, it is then mixed with a pickle solution having a relatively high salt concentration and phosphates to increase functionality. Phosphates function like ATP in the muscle structure. They temporarily break the chemical bonds between protein bundles and allow the protein structure to open up and hold water. By one approach, the deboned whole muscle meat is treated in a pickle injector that injects pickle solution into the meat. The injector uses hypodermic-type needles to puncture the meat and to inject a pickle solution through needles into the meat, as the meat travels through the pickle injector on a conveyor. The injection step helps diffuse pickle solution through the meat and also serves to tenderize the meat. Various pickle solutions may be employed for meat processing. Conventional pickle solutions include a mixture of: water, salt, nitrite, phosphate, ascorbate, erythorbate, and sugar to note but a few ingredients. A typical curing solution contains 10% salt, 2.3% sodium phosphate, 62% water, 0.3% sodium ascorbate, 0.09% sodium nitrite, 3.5% sugar, 20% sodium lactate. In a typical product, such as a deli-shaved meats, we add around 20 lbs of pickle to 100 lbs of meat. This will result in having 2 lbs of salt per 100 lbs of meat. 
     Additional pickle solution may be added to the whole muscle meat after the injector step if desired. Once the meat has been combined with the solution, the conventional batch is mixed for a specified period of time, typically about 60 minutes. Once mixed, the meat mixture is allowed to cure for between approximately 24-48 hours. 
     Once the meat has cured, the conventional meat is tightly stuffed into casings. Conventional wisdom encouraged stuffing the casings tightly to avoid creating void spaces inside the casings, which resulted in excess moisture being expelled from the meat. Once stuffed, the meat is cooked just above 155° F., anywhere from between 3 and 6 hours. Then, the meat is cooled, and sliced. Such conventionally prepared meat may be sliced in a variety of slicing equipment including the rotary processing machine  10  discussed above. Slicing such conventionally prepared meat on conventional slicing equipment produced a meat product having regular, standardized appearance. Such a meat product typically has little variations between shape, surface, and texture of the slices or pieces produced. Alternatively, if the conventional meat product is sliced using the rotary processing machine  10 , the resulting product exhibits a moderate degree of irregularity between the meat pieces and avoids the meat product having the standardized regular appearance typically resulting from meat processing. 
     In another embodiment, to mass produce a home-style product having an intentionally differentiated texture and appearance with a high degree of irregularity between the meat pieces, process  200  may be employed with the rotary processing machine  10 . Further, as discussed below, process  200  may also be employed with other slicing equipment to provide a moderate degree of irregularity between the meat pieces. In determining how to prepare and slice the whole muscle meat, the desired product including the desired level of irregularity and differentiation between the various meat slices should be considered. 
     As illustrated in  FIG. 7 , process  200  includes receiving or providing  201  deboned whole muscle meat at a processing plant. Further, the whole muscle meat is combined  203  with a mixture or solution having a small amount of salt and having no phosphates. By one approach, the whole muscle meat provided  201  undergoes a pickle injection step  202 . Such a pickle injection step, as discussed above, delivers the pickle solution to the whole muscle meat via hypodermic-type needles. However, unlike the conventional process, the whole muscle meat is not combined with phosphates in process  200 . Thus, the pickle solution of process  200  has no phosphates and, further, has a limited amount of salt therein. By one approach, the pickle solution added to the whole muscle meat will be less than 2 lbs. of salt per 100 lbs. of meat. In one illustrative embodiment, approximately half the amount of salt used in a conventional product is added to the whole muscle meat in process  200 . For example, about 10 lbs. of pickle solution having a 10% salt concentration may be added to 100 lbs of meat to end up with 1 lbs of salt in 100 lbs. of meat. Once the pickle injection step is complete, the whole muscle meat may be further combined with additional pickle solution having a small amount of salt and lacking any phosphates. 
     Once the whole muscle meat has been combined  203  with the low-salt, phosphate-free solution, the combination may be mixed  204  together such as in a tumbler or other mixing apparatus. The combined whole muscle meat may be mixed  204  for a specified of time period. By one approach, the mixing step is approximately 30 minutes or less. Alternatively, the mixing step may be between 30 and 60 minutes, depending on the desired end product. However, it is important that the meat not be over mixed and, thus, it is desirable to have the mixing extend no longer than 60 minutes and preferably closer to 30 minutes. Significant mixing promotes binding of the muscle structure such that the structure binds more tightly. In turn, the cut surface of the meat slices will not fracture along the irregular protein strand seams but will slice smoothly and have a more conventional sliced meat appearance. Once the whole muscle meat has undergone sufficient mixing, the meat is collected in a vat for a period of time to permit the salt and other ingredients to diffuse uniformly throughout the meat pieces. The length of the cure time may depend on the desired final product. In one illustrative embodiment, the whole muscle meat is retained in a cooler for between 24 and 48 hours. 
     The whole muscle meat may then be stuffed  206  into casings in which the meat is cooked. Unlike conventional processing where the meat is tightly packed into the casing, however, process  200  loosely stuffs  206  the meat product into the casings. As used herein, the term loosely stuffs indicates that the whole muscle meat is stuffed into the casings such that voids are permitted to occur between the individual whole muscle meat pieces and between the pieces and the casing. Further, such voids create irregularities in the meat product during the cooking phase via moisture expulsion. The low-salt, no-phosphate solution is a relatively poor water binder and thereby encourages water loss through evaporation and expulsion, similar to what occurs in home-style cooking. Comparatively, a conventional product having a higher salt solution and phosphates is relatively a good water binder, which results in a higher product yield. However, such a product produces a very regular appearance. By allowing the water to escape form the system, irregularities in the final product are further introduced. 
     Since the low-salt, no phosphate solution does not promote significant water binding, the casing is relied upon to retain some of the moisture within the meat structure. However, certain casings may retain too much water or may not permit expansion of the product, thereby unduly increasing the pressure inside the casing, while others may permit too much water loss. The meat cooked in the average home-oven produces a significant amount of steam and meat juices collect in the pan, which is the result of moisture evaporation and expulsion from the meat. Thus, the casing used in process  200  typically permits significant amounts of moisture loss. 
     As mentioned, the water loss occurs through the casings, which may be comprised of a variety of natural or synthetic materials. For example, a thin mesh fabric or wire mesh may be used, to note but a few. Whatever the material, it is desirable for the casing to permit some expansion of the meat product and also permit loss of water, both of which relieve some of the pressure created in the product. By one approach, the casings are pre-stuck casings that have openings, such as slits or holes, created therein prior to stuffing and cooking. These openings allow the water to escape from the casing. 
     In sum, some void space is deliberately left within the casing once it is filled with the meat product. This void space permits moisture expulsion and keeps the pieces from “gluing” together to thereby help create a meat product with a home-style appearance by creating surfaces with an irregular texture. To that end, the casings selected also encourage some amount of water loss. Thus, the manner of stuffing the casings and the casings themselves contribute to the irregularities in the final cooked product. 
     Further, once the casings have been loosely stuffed  206 , the casings may be thermally processed  207  such as through cooking at a temperature of at least 155° F. In one illustrative embodiment, a series of temperature steps are employed, where the temperature gradually increases to reach the final temperature, just over 155° F. For example, by one approach, the final product temperature at the end of the cooking cycle is approximately in between the 155°-170° F. range, whereas and the air temperature in the final cook step is in the range of approximately 180°-210° F., depending on the product. Comparatively, such temps are a bit higher than those conventionally used and this drives off more moisture by evaporation. A loss of between 22-28% of the total ingoing product weight is targeted. For example, for 100 lbs. of product that is introduced into the smokehouse, approximately 72-78 lbs. of product will exit the smokehouse after cooking. Such loss, as described above, results from evaporation and expulsion. This is quite different from conventional products, where as much water as possible is retained. 
     The cook process takes about 6 hours, while conventional cook times range from 3 to 6 hours. Thus, the cook time of process  200  is at the long end of the spectrum. Further, as mentioned above, the cook temperature is at the higher end, as well. Thus, water loss is encouraged, which contributes to the final product&#39;s varied texture. Encouraging such water loss is possible because the solution does not have a high salt concentration or phosphates that bind the water. 
     After the meat produce has been cooked, the casings of meat products are cooled  208 . By one approach, such cooling occurs by showering the casings with chilled water. By yet another approach, the casings and meat product are permitted to chill by removing the casings from the heat source and exposing the outside of the casings to chilled air. The water shower, if used, will expose the casings to water at approximately 34-38° F. for about 30 minutes. The air chill takes about 7 hours and uses 18-25° F. air to reduce the product temperature to the desired slicing temperature of 29-31° F. 
     Once the casings and meat product have cooled, the prepared meat may undergo slicing  209  to produce the home-style meat with individual pieces have an irregular appearance. Such slicing  209  may occur in a variety of slicing equipment. Since process  200  prepares the whole muscle meat in a manner such as to purposefully create irregularities in the final product, such a prepared meat mixture may be sliced in a conventional slicer and may still exhibit a degree of irregularity between the sliced pieces. In addition, if a high degree of irregularity is desired the whole muscle meat prepared according to process  200  may be sliced in the rotary processing machine  10 . As discussed above, the rotary processing machine has an impeller  34  with equally spaced paddles  40  that rotate and carry the meat product to be sliced by slicing knife  56  having a dulled cutting edge. Such a configuration wherein the chunks of whole muscle meat are exposed to the stationary slicing knife from different angles creates further irregularities in the low-salt, phosphate-free meat product. Alternatively, a slicer with a less random and varied manner of slicing would still produce an irregularly textured meat product if process  200  were employed to prepare the meat. 
     For example, a slicer with a reciprocating carriage and a stationary blade typically orients the meat relative to the slicing knife based on the manner of delivery of the meat, such as through a feed tube or hopper. The orientation of the meat product in such a feed tube does not widely vary as the whole muscle meat does not have room to rotate or significantly shift around. Instead, the whole muscle meat slowly advances toward the slicing knife as leading portions of the whole muscle meat are sliced from the unsliced portion. Such a slicer typically produces a sliced meat product having standardized, highly regular characteristics, however, such equipment may be used to produce irregularly textured and shaped meat slices if the sliced meat is prepared according to process  200 . 
     Thus, a home-style carved meat product having intentionally irregular and controlled variations, which are within certain parameters including size, shape, texture, and density, may be produced by slicing on a rotary processing machine  10  or by preparing the whole muscle meat according to process  200 . Further, a home-style carved meat product having a high degree of irregularity may be produced by preparing whole muscle meat according to process  200  and then slicing the prepared meat in the rotatry processing machine  10 . 
     While process  200  illustrated in  FIG. 7  may occur in order of the steps listed, such as combining  203  the whole muscle meat with a small amount of salt and without phosphates after the boneless whole muscle meat has been provided  201  to the meat processing plant. It is also contemplated that the steps of process  200  may occur in a variety of other orders as well For example, combining  203  the whole muscle meat with the low-salt, phosphate-free solution may occur prior to providing  201  the whole muscle meat at the processing plant. Further, in such a configuration, curing  205  of the whole muscle meat may occur during several of the other steps. Thus, it is contemplated that the steps of process  200  may occur in a variety of sequences. 
     Sliced meat having a home-style appearance preferably will have increased irregularities in the slice surface, such as an increase in surface roughness, as compared to conventionally prepared meat. In addition, the range of irregularities is higher, such as the range of surface roughness is also larger. 
     To demonstrate the increased surface irregularity, test samples of ham processed according to process  200  were compared with samples of conventionally processed ham. As discussed below, five samples of conventionally produced ham and seven test samples of ham produced according to the invention described herein were examined. 
     To examine the differences between the two samples, digital images of the samples were taken and then the images were evaluating by examining the difference in the contrast between pixels to determine a surface irregularity value. The images were captured by scanning the samples with an EPSON Pro 750 instrument at 300 dpi and then analyzed using Image-Pro Plus Version 5.1. The texture (surface roughness) was examined by comparing the intensity of the light reflected off the surface. Elevated portions of the sample were indicated by a darker pixel and lower portions of the sample were indicated by a lighter pixel. For example, a sample, with a high degree of variation included many high spots (dark) and low spots (light) within a certain area indicated. This variations in pixels indicated that the sample had a rough surface. 
     To evaluate the images, a portion of the image (7 pixel by 7 pixel area) was examined for the variation in brightness, which was interpreted as texture (surface roughness). These 7×7 pixel areas were compared with other 7×7 pixel areas. By one approach, the mean brightness of the various areas was compared with mean brightness of other 7×7 pixel areas. The surface irregularities value listed below refers to local variation in brightness from one area to the next. Both the range (difference between the maximum and minimum brightness values in a neighborhood) and the variance (statistical variance of pixel values in any particular area) were examined. 
     
       
         
           
               
               
             
               
                   
               
               
                 VARIANCE 7 × 7 IMAGE 
                 SURFACE IRREGULARITIES VALUE 
               
               
                   
               
             
            
               
                 Conventional Ham Sample #1 
                 55.65 
               
               
                 Conventional Ham Sample #2 
                 44.60 
               
               
                 Conventional Ham Sample #3 
                 60.81 
               
               
                 Conventional Ham Sample #4 
                 53.91 
               
               
                 Conventional Ham Sample #5 
                 57.67 
               
               
                 Test Ham #1 
                 75.82 
               
               
                 Test Ham #2 
                 76.56 
               
               
                 Test Ham #3 
                 94.16 
               
               
                 Test Ham #4 
                 73.55 
               
               
                 Test Ham #5 
                 68.13 
               
               
                 Test Ham #6 
                 76.35 
               
               
                 Test Ham #7 
                 58.64 
               
               
                   
               
            
           
         
       
     
     The five samples of conventionally produced ham had surface irregularity values falling between approximately 44.60 and 60.61. In contrast, images of the seven samples of the test ham had surface irregularity values ranging from approximately 58.64 to 94.16. The mean variance for the conventional ham was 54.53, whereas mean variance for the test ham was 74.74. Thus, the test ham showed significantly more variation in the surface (increased amount of difference between the light and dark pixels). In short, ham according to process  200  has noticeable surface irregularities that help create the home-style appearance desired by many consumers. Thus, in one embodiment, the home-style meat product has a surface irregularity value of above  61 . In one example, the home-style meat product has a mean variance surface irregularity value of greater than about 70. In another embodiment, the home-style meat product has a mean variance surface irregularity value of greater than about 75. By yet another approach, the meat produced according to the invention herein has a mean variance of at least 25% more than conventionally produced meat products. 
     In addition, it will be appreciated by those skilled in the art that other modifications to the foregoing preferred embodiments may be made in various aspects. The present invention is set forth with particularity in any appended claims. It is deemed that the spirit and scope of that invention encompasses such modifications and alterations to the preferred embodiment as would be apparent to one of ordinary skill in the art and familiar with the teachings of the present application.