Patent Abstract:
An apparatus and method for macerating raw meat pieces includes two sets of rotating arbors, each having a different primary function. More particularly, the first arbor set is primarily configured to flatten and roughly tenderize the meat. The second arbor set is primarily configured to increase the surface area and tenderness of the meat without breaking the meat apart, though the second arbor set may also further reduce the thickness of the meat pieces. The second arbor set is positioned downstream of the first arbor set by a conveyor such that the meat pieces advancing through the macerator are only macerated by one of the arbor sets at any give time. Each arbor set has a pair of counter rotating shafts.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application No. 61/479,672, filed Apr. 27, 2011, which is hereby incorporated by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     This invention relates generally to meat processing, specifically to an apparatus and method for macerating meat or meat-type products prior to further processing. 
     BACKGROUND 
     Macerating raw whole muscle meat pieces prior to further processing can improve the water holding capacity and the texture of the final meat product. Further, maceration increases the surface area of whole muscle meat pieces and may increase the rate of absorption of non-meat ingredients such as salt and flavorings. To increase the surface area, macerators use implements such as rotating blades, spiked teeth, or other protrusions to produce slight cuts, ruptures, or tears, or to stretch the surface. The protrusions may open up or stretch the whole muscle meat pieces merely by protruding into the muscle without aggressively working the meat or otherwise causing significant structural degradation to the whole muscle meat. The increase in surface area is, nonetheless, a physical action that results in increased protein solubility and improves the water holding capacity by exposing more binding sites for water molecules. As used herein, the term “raw whole muscle meat” describes meat that has not undergone significant processing and includes not only whole muscles but also smaller pieces or chunks. Some pieces are about the size of a fist, for example. The term “raw whole muscle meat” does not include ground meat or other meat of which the structural integrity has been substantially compromised by mechanical action. 
     It is well know to flatten meat, such as through pressing or pounding operations. In addition to macerating the meat by tenderizing and increasing the surface area, such flattening operations also resize the meat to provide a relatively uniform and consistent thickness, which helps ensure proper cooking of the meat. In other operations, meat pieces may be fed between a pair of counter-rotating shafts that have projections that press into the meat as the meat passes through the space between the shafts. 
     While the counter-rotating shafts are suited for processing meats of a similar size, such equipment is not typically suited to process meat pieces having a wide variety of sizes and configurations. Meat pieces are often divided among their relative sizes and then processed with similarly sized meats. This processing is done after the maceration equipment is calibrated to the size of meat pieces in a batch by adjusting the counter-rotating shafts. Alternatively differently sized meat pieces are sometimes processed together, then meat pieces requiring additional maceration are run through the counter-rotating shafts again. These approaches can be time consuming, inefficient, and impractical when working with certain large batches of meat. 
     SUMMARY 
     The illustrated apparatus provides a more efficient system for macerating raw meat pieces to increase surface area and absorption of ingredients such as salts and flavorings, while avoiding excessive tearing. The illustrated apparatus includes two sets of rotating arbors, each having a different primary function. The first arbor set is primarily configured to flatten and roughly tenderize the meat. The first arbor set also may reduce the thickness of the meat pieces, crush or squeeze the meat pieces and/or create or puncture holes or openings in the meat pieces. The second arbor set is primarily configured to increase the surface area and tenderness of the meat without breaking the meat apart, though the second arbor set may also further reduce the thickness of the meat pieces. For example, the second arbor set may crush the meat muscle cells while retaining the overall appearance of the whole muscle meat. Each arbor set has a pair of counter rotating shafts and, therefore, the macerator has at least four arbor shafts. The raw meat is passed between the counter-rotating arbors at the first and second maceration stations. 
     The maceration apparatus has a first conveyor positioned to receive raw meat and deliver the meat to a first arbor set. The first arbor set has upper and lower rotatable arbors and is positioned upstream of the second arbor set. The first upper and lower rotatable arbors have a first distance between them. A second conveyor is positioned at the exit of the first arbor set and receives the raw meat pieces as they exit the first arbor set. The second conveyor then delivers or transports the raw meat pieces to the second arbor set. The second arbor set has upper and lower rotatable arbors that have a second distance between them. The second distance is smaller than the first distance. The distance between the first and second maceration stations is preferably long enough that the meat advancing through the apparatus is not engaged by the first and second stations simultaneously. 
     Each arbor is preferably an integral one-piece sleeve or shaft that has projections formed thereon. The integral sleeve may have a central cavity extending therethrough. By another approach, the integral sleeve may have central cavities that extend through portions of the arbor adjacent the ends thereof. The central cavities at the ends of the arbor may receive respective drive shafts and other mounting elements such as idler gears. In another embodiment, the arbor may include individual projection elements that can be individually mounted onto a drive shaft. Individual discs having projections and recesses thereon may be secured together to form an arbor. By one approach, the axial dimension of each individual disc is about equal to the axial dimension of one recess or projection. Alternatively, one disc may include a projection and a recess, or possibly several projections or recesses. 
     So configured, the illustrated apparatus provides a desired degree of maceration for whole muscle meat pieces having a wide range of dimensions without requiring the meat pieces to be divided based on size or to be processed through the macerator a second time with differently calibrated settings, and without the excessive tearing or breakdown of muscle fibers that can occur under certain circumstances, such as where large pieces are drawn through a very small gap. This apparatus, is useful where meat pieces are more varied in size, e.g., due to increases in animal muscle mass. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a partial schematic view of an embodiment of the invention; 
         FIG. 2  is a more detailed side view of another embodiment thereof; 
         FIG. 3  is a partial schematic cross sectional view of portions of the embodiment of  FIG. 1 ; 
         FIG. 4  is a plan view of  FIG. 2 ; 
         FIG. 5  is an end view of  FIG. 2 ; 
         FIG. 6  is a detail top view of one of the first stage arbors of  FIG. 2 ; 
         FIG. 7  is a side view of a portion of  FIG. 6 ; 
         FIG. 8  is a detail top view of one of the second stage arbors of  FIG. 2 ; 
         FIG. 9  is a side view of a portion of  FIG. 8 ; 
         FIG. 10  is a flow diagram; and 
         FIGS. 11 to 14  are partial perspective views of portions of arbors. 
     
    
    
     Elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. 
     DETAILED DESCRIPTION 
     Referring to  FIG. 1 , an illustrative maceration apparatus  10  has a first maceration station  12  and a second maceration station  14 . A first conveyor  16  delivers raw whole muscle meat to the first maceration station  12 . The second maceration station  14  is separated from the first maceration station  12  by a second conveyor  18 . The distance between the two maceration stations is preferably greater than the lengths of the largest raw meat pieces to be macerated and, therefore, each meat piece will only be macerated by one maceration station at a time. Preventing a single meat piece from being simultaneously macerated by two macerations stations helps the meat pieces remain largely intact or whole, and prevents them from being broken apart, overly worked and otherwise damaged. The distance between the first and second arbor maceration stations may depend on the type of meat being macerated. For example, chicken and turkey whole muscle meat pieces will generally be smaller than beef whole muscle meat pieces. The second conveyor  18  may provide a distance of between 12 inches and 6 feet from the first and second maceration stations. For example, a 12 inch conveyor may be used for certain chicken and turkey meats, whereas for beef the second conveyor  18  may be, e.g., at least 1.5 feet. 
     Each of the first and second maceration stations  12 ,  14  has a pair of counter-rotating shafts or arbors that are generally parallel to each other. The first maceration station  12  or first arbor set has upper and lower arbors  20 ,  22 . The second maceration station  14  or second arbor set has upper and lower arbors  24 ,  26 . As shown in  FIG. 4 , each arbor is supported by a drive shaft—on one end and an idler shaft—on the other end. Each arbor has an integrated assembly of radially projecting and axially extending teeth members or projection portions  28  and narrow spacers, or recess portions  30  in alternating rows. The rows of projections  28  are positioned on the arbors in an offset arrangement such that the projections  28  of one arbor are positioned opposite the recesses  30  on the other arbor in each maceration station. 
     The projections  28  have an outer portion that penetrates into the raw meat pieces passing through the counter-rotating arbors in the axial plane. While the projections of the first maceration station may be identical or nearly identical to the projections of the second maceration station, it is also contemplated that the projection size and geometry may be different such that the projections of the first maceration station are larger or otherwise different than the projections of the second maceration station. For example, the projections and recesses may have a variety of widths. In one illustrative embodiment, the first maceration station  12  may have projections with a width of about 0.18 to 0.5 in. and recesses with a width of about 0.2 to 1.0 in., while the second maceration station  14  may have projections with a width of about 0.18 to 0.37 in. and recesses with a width of about 0.2 to 0.5 in. 
     A tote, bin, or other container  118  may be positioned at the exit of maceration apparatus  10  to receive the meat pieces exiting from the second maceration station  14 . Furthermore, a slide or extension  120  may guide the meat pieces from the second maceration station  14  to the container  118 . The extension  120  may also be connected to a stripper comb  54 , which helps remove the meat from the projections as discussed below. In another embodiment, the extension  120  may be connected to a frame of the apparatus. 
     Turning now to  FIG. 2 , the first and second maceration stations  12 ,  14  and first and second conveyors  16 ,  18  may be mounted on a single frame  70  as illustrated. However, other embodiments may have independent frames for the maceration stations  12 ,  14  and may be connected by a conveyor that may be connected to one of the frames for the stations  12 ,  14  or may be connected to another independent frame. The overall design of the frame or frames, along with the various elements mounted thereon, may depend on the desired uses or the installation space for the apparatus  10 . 
       FIG. 2  illustrates maceration apparatus  10  having a first maceration station  12  and a second maceration station  14 . Arrow  32  illustrates the product flow that the raw meat pieces will adopt once placed on the first conveyor  16 . As illustrated, conveyor  16  delivers the whole muscle meat to the upper and lower arbors  20 ,  22  of the first maceration station  12 . A first distance  34  between the upper and lower arbors  20 ,  22  is illustrated and is larger than a second distance  36  between the upper and lower arbors  24 ,  26  of the second station  14 . Indeed, the second distance  36  may be a negative distance such that the projections of the second maceration station  14  intermesh, as discussed below.  FIGS. 2 and 3  also illustrate how the second conveyor  18  is located below the first conveyor  16 . The elevation difference between the two maceration stations  12 ,  14  may help advance the meat pieces from the first maceration station  12  to the second maceration station  14 . 
     In one illustrative embodiment, the first and second maceration stations  12 ,  14  are adjustable. For example, the first distance  34  between the arbors  20 ,  22  may be adjusted, which may be helpful for macerating different types of meat. In addition to adjusting the first and second distances  34 ,  36 , the operational parameters of the arbors may be adjusted. For example, the operational speed or the rpm of the arbors in the first and second maceration stations  12 ,  14  may be adjustable. In one example embodiment, the rate of rotation of the second maceration station  14  may be faster than the first maceration station  12 . As discussed below, the second stage arbors  24 ,  26  may have smaller diameters and, therefore, even if the throughputs in the first and second maceration stations  12 ,  14  are equal to one another, the second stage arbors  24 ,  26  will run at a higher rate than the first stage arbors  20 ,  22 . 
     As shown in  FIG. 3 , the raw meat pieces  38  advance from upstream of the first maceration station  12  and between the upper and lower arbors  20 ,  22 , as shown by product flow  32 . While passing between the upper and lower arbors  20 ,  22 , the arbor projections contact the surface of the raw meat piece  38 . Projections  28  and recesses  30  may be generally uniform between the two macerations stations, or alternatively, the projections  28  and recesses  30  ( FIG. 5 ) of the two maceration stations  12 ,  14  may be tailored for the different functions of the particular maceration station. For example, the projections  44  on the arbors of the second maceration station  14  may be smaller or may have a different geometry or configuration that the first stage projections  40 . The projections illustrated in  FIG. 3  include upper and lower projections  40  at the first maceration station  12  and upper and lower projections  44  at the second maceration station  14 . 
     As illustrated in  FIG. 3 , it is anticipated that each arbor  20 ,  22 ,  24 ,  26  may have a comb or stripper blade  48 ,  50 ,  52 ,  54  associated therewith. The stripper blades assist in removing the raw meat pieces from the arbors. By one approach, each stripper blade  48 ,  50 ,  52 ,  54  has a body  56  (shown in  FIG. 3 ) that is mounted at one end on the frame  70  and tines  55  or  58  that extend from the body  56  and into the recesses  30  of the associated arbor and in between the projections  28 . 
     There are primarily two tine configurations  55 ,  58 , both of which are illustrated in  FIG. 3 . By one approach, the tines  58  can wrap partially around the arbor, thereby filling portions of the spaces that would otherwise receive portions of the meat pieces, as with the second stage arbors  24 ,  26  of  FIG. 3 . More particularly, the tines  58  may extend from the exit side of the arbor to the in-feed side of the arbor, where the meat pieces enter the arbor so that the meat pieces are not compressed deeply into the recesses. Thus, the meat is more gently macerated, thereby helping to preserve the whole muscle character of the meat and may be more easily removed from the arbor. 
     By another approach, the tines  55  can extend only slightly around the arbor in the recesses, as illustrated in the first stage arbors  20 ,  22  of  FIG. 3 . The shorter tines of the first stage arbors  20 ,  22  permit the meat to be more aggressively worked by allowing the full depth of the arbor recess  30  to be used and reached by the meat pieces. 
     The first and second conveyors  16 ,  18  are typically endless conveyor belts that wrap around at least two rollers. The conveyors  16 ,  18  may have smooth surfaces or the conveyors  16 ,  18  may further include logs, spikes, or projections  60 . The projections  60  provide additional traction on the conveyors  16 ,  18  for the meat pieces and prevent sliding of the meat in relation to the conveyor belt. By one approach, the projections  60  extend across the width of the conveyors  16 ,  18 . The projections  60  may be positioned perpendicular to the product flow and are generally used to prevent sliding. Projections  60  may be employed only on the first conveyor  16  as shown, or on both conveyors. For some meat types a smooth belt will adequately convey the meat such that no projections  60  are necessary. For other types of meat the addition of projections  60  may be necessary to provide additional traction. 
     The conveyors  16 ,  18  may be horizontal, or one or both may be slightly sloped to increase the flow of the product to the maceration stations. By one approach, the slope may be 30° or less. In another example, the slope of conveyor  16  may be more than 30°, depending on the application and the type of meat being processed. Such a slope may assist in feeding the meat through the apparatus  10 , while also retaining control of the movement of the meat. The first conveyor  16  may have a more significant slope than the second. 
     A photoelectric sensor (photo eye) or other similar device may be mounted between the first and second maceration stages  12 ,  14  to monitor the volume of meat passing on the conveyor  18 . Such a device may be able to detect and help prevent meat from piling up and assuring even throughput in both stages. Based on the data gathered by the photo eye, the rotation of arbors of the first or second maceration stations may be adjusted e.g., in response to accumulation of meat pieces, or in response to a decrease in accumulation. 
     As shown in  FIG. 5 , the arbors of the first maceration station  12  are spaced from one another by a first distance  34  and the arbors of the second maceration station  14  are spaced from one another by a second distance  36 . The arbors of the second maceration station  14  may not have such a space between the projections  44  of the two arbors  24 ,  26 . Instead, the projections  44  of the upper arbor  24  may intermesh with the projections  44  of the lower arbor  26  at the second maceration station  14  such that the projections  44  extend into the recesses  64  of the corresponding arbor. Thus, the second distance  36  may be thought of as a negative distance or a lack of space between the arbors. 
     In other embodiments, both the first stage arbors  20 ,  22  and the second stage arbors  24 ,  26  intermesh, and the arbors  24 ,  26  of the second maceration station  14  intermesh or overlap more than the arbors  20 ,  22  of the first maceration station  12 , such that the projections  44  of the second maceration station  12  extend further into their corresponding recesses  64  than those of the first maceration station  12 . In this configuration, both distances  34 ,  36  may be thought of as a negative distance or an intermeshing of the projections. By yet another approach, both the first and second distances  34 ,  36  may provide gaps or spaces between the arbors of both stages  12 ,  14 . The second distance  36  may be smaller than the first distance  34  and the projections  40  of the first maceration station  12  may be farther apart than the projections  44  of the second maceration station  14 . 
     The size, geometry, and configuration of the projections on the two sets of arbors may be the same or may be different. Since the functions of the two maceration stations  12 ,  14  are differently focused, the arbors may be tailored toward those different functions. In the embodiment of  FIG. 5 , the width of the first stage projections  40  is greater than the width of the second stage projections  44 , and the width of the first stage recesses  62  is larger than the width of the second stage recesses  64 . Due to the smaller size of the projections  44  and recesses  64 , the second stage arbors  24 ,  26  may have more projections and recesses than the first stage arbors  20 ,  22 . The two arbor sets  12 ,  14  may also be operated in a different manner. 
     In one illustrative embodiment, the first stage arbors  20 ,  22  may have a central working area  66  and the second stage arbors  24 ,  26  may have a central working area  68 . The width of the central working areas  66 ,  68  is between about 12 to 30 in. The width chosen for the working areas  66 ,  68  may depend on the desired throughput. Furthermore, the width of the central working areas  66 ,  68  is about equal to the width of the conveyors  16 ,  18 . A set of guides may be positioned on the sides of the conveyors  16 ,  18  to keep the meat pieces on the conveyor and within the working width. 
     A variety of overall arbor configurations may be employed. In one illustrative embodiment, each of the first and second stage arbors  20 ,  22 ,  24 ,  26  has the exact same geometry and sizing such that only one arbor configuration is manufactured for the apparatus. In such an embodiment, the ends of the lower arbor will be reversed relative to the upper arbor when installed into the frame  70 . In another embodiment, while the upper and lower arbors within each station  12 ,  14  are identical, the arbors of the first maceration station  12  are different from those in the second maceration station  14 . In yet another embodiment, each of the arbors  20 ,  22 ,  24 ,  26  is specifically designed such that no two arbors are the same. In such a configuration, four separate arbors are manufactured. 
       FIG. 6  illustrates the upper arbor  20  of the first maceration station  12 . The rows of projections  40  of the first stage may have a projection width  82  of about 0.18 to 0.5 in. and the recesses  62  of the first stage may have a recess width  82  of between about 0.2 to 1.0 in. By one approach, the width  82  of each projection  40  and recess  62  is about 0.44 in. with the recesses are slightly larger than the projections. The width of projections  40  generally is slightly less than the width of the recesses  62  to enable the rows of projections  40  to extend into the recesses  62 . For example, if the width of recesses  62  is about 0.5 in., the row of projections  40  may be about 0.438 in. This slight difference helps accommodate intermeshing. In other configurations, the recesses can be significantly wider than the projections. 
     In one illustrative embodiment, the bottom arbor  22  of the first maceration station  12  is similar to the top arbor  20 , except for a few adjustments so that the arbors may cooperate together to counter-rotate and more effectively macerate the meat passing between the arbors. For example, the bottom arbor  22  has a series of recesses  62  that are aligned opposite the projections  40  of the top arbor  20  such that the arbors can intermesh together and the projections  40  of the bottom arbor  22  are aligned opposite the recesses  62  of the top arbor  20 . Other minor differences between the upper and lower arbors may include the orientation (or angling direction) of the projections  40  and the attachment of the stripper blades  48 ,  50 . 
     The width of central working areas  66 ,  68  corresponds to the first and second conveyors  16 ,  18 , which also may have a width of about 12 to 30 in. By one approach, the width of the central working areas and the width of the conveyors are about 26 in. By another approach, the width of the central working area and the width of the conveyors are about 16 in. The arbors  20 ,  22 ,  24 ,  26  may have end portions  72 ,  74  on either end of the central working areas  66 ,  68 . By one approach, the entire length of the arbors  20 ,  22 ,  24 ,  26  including the central working areas  66 ,  68  and the end portions  72 ,  74  may be about 30 to 35 in. In one illustrative approach, the entire length of the arbors is about 31.2 in. By another approach, the entire length of the arbors  20 ,  22 ,  24 ,  26  may be about 21 to 26 in. The overall length of the arbors depends on the width of the central working areas and it is anticipated that the overall length of the arbors may be about five inches larger than the width of the working areas. 
     The outer diameter  80  of first stage arbors  20 ,  22  may be between about 2.5 and 7.0 in. By one approach, the outer diameter  80  may be about 3.8 in. By yet another approach, the outer diameter  80  may be about 5.5 in. The diameter of the arbor  20  at the recesses  40  may vary depending on the type of meat to be processed, the type of processing desired, and the other parameters and configuration of the arbors. In one illustrative embodiment, the radial dimension of the recess is about 0.75 in. and extends around the shaft such that the outer diameter is about 5.5 in. and the inner diameter at the recess is about 4.0 in. 
     Referring to  FIG. 6 , the end portions  72  of the first stage arbor  20  have central cavities  76 ,  78 . The central cavity  76  is configured to engage a drive shall that rotates the arbor  20 . Furthermore, the end portion  72  with central cavity  78  is configured to act as a spindle, which rotatably mounts onto an idler gear or a portion of the apparatus frame. By one approach, the end portions  72  may have an outer diameter  84  of between about 1.75 to 2.75 in. In one illustrative embodiment, the outer diameter  84  of the end portions  72  is about 2.4 in. By one approach, the inner diameter  92  may be between about 1.5 and 6.25 in. In one illustrative embodiment, the inner diameter  92  may be about 2.0 in. 
       FIG. 7  illustrates a portion of one row  28  of projections  40 . Each row  28  includes a plurality of individual teeth  88  and a space  86  between each pair of adjacent teeth. By one illustrative approach, each tooth  88  has a sharp edge  90  that is pressed into the meat passing between the arbors  20 ,  22 . One side of each tooth may comprise a first surface  94  extending inward and rearward behind edge  90  to angle or bend  96 . The teeth  88  are configured to allow the meat pieces to be easily removed from the teeth by the stripper blades  48 ,  50  (illustrated in  FIG. 3 ) without doing unnecessary damage or tearing of the meat pieces. In addition to the angled portion, it is anticipated that the individual teeth  88  may include a wave or curved portion configured to permit easy removal of the meat from the projections  40 . 
     The second stage arbors  24 ,  26  may have central working areas  68  that correspond to the working areas of the first stage arbors  20 ,  22  and the conveyors  16 ,  18 . The upper arbor  24 , shown in  FIG. 8 , includes rows of projections  44  and recesses  64 . As mentioned above, the projections  44  and recesses  64  may be smaller than the projections  40  and recesses  62  of the first maceration station  12 . The rows of projections  44  and recesses  64  may have a width  98  of about 0.18 to 0.5 in. By one approach, the width of the rows of projections  44  and recesses  64  may be about 0.28 in. Further, the width of the rows of projections  44  may be slightly smaller than the width of the rows of recesses  64  such that the rows of projections  44  can extend into the recesses  64 . For example, the recesses  64  may be about 0.28 in. and the projections  44  may be about 0.22 in. A slight difference in the widths helps accommodate the intermeshing of the elements. For example, by one approach, the projections are about 0.18 to 0.37 in. and the recesses may be about 0.2 to 0.5 in. 
     The bottom arbor  26  of the second maceration station  14  is similar to the top arbor  24 , except for a few adjustments so that the arbors may cooperate together to counter-rotate and macerate the meat passing between the arbors. For example, the bottom arbor  26  has a series of recesses  64  that are aligned opposite the projections  44  of the top arbor  24  such that the arbors can intermesh together. Other minor differences between the upper and lower arbors may include the orientation (or angling direction) of the projections  44  and the attachment of the stripper blades  52 ,  54 , to note but a few differences between the upper and lower arbors  24 ,  26  of the first maceration station  14 . As suggested above, in one embodiment, the upper and lower arbors of the second set  24 ,  26  are the same when manufactured and then, when installed, the ends of one of the arbors are reversed relative to the other arbor, which permits intermeshing of the two arbors. 
     As shown in  FIG. 8 , the outer diameter  102  of the upper arbor  24  extends from the projections  44  on one side of the arbor to the projections  44  on the other side of the arbor. By one illustrative approach, the outer diameter  102  of arbors  24 ,  26  may be between about 2.5 and 4.5 in. By one approach, the outer diameter  102  may be about 3.6 in. An inner diameter  104  of the arbor  24  is the diameter of the arbor  24  at one of the recesses  44 .  FIG. 8  illustrates the end portions  74 , which, like those shown in  FIG. 6 , have central cavities  76 ,  78  adapted to engage a drive shaft and to mount the arbors. 
       FIG. 9  illustrates a detailed sectional view of a portion of one row  28  of projections  44 . Each row  28  includes a plurality of individual teeth  110  and a space  108  between each tooth. By one approach, each tooth  110  has a sharp edge  112  that is angled to be pressed into the meat passing between the arbors. One side of each tooth may include a surface  114  that begins at a slight angle or bend  116  in the face of the individual tooth  110 . The angling of a portion of the projections  44  assists the stripper blades  52 ,  54  with removing the meat from the teeth  110  such that the meat pieces are not unnecessarily damaged. 
     While projections  40  and  44  are illustrated as individual teeth having sharp edges, it is also anticipated that the projections may have a variety of configurations, sizes, and geometries. For example, in addition to a tooth shaped projection, a square or rectangular shaped projection, a frustoconical shaped projection, a projection with a curve or waved profile, and/or a cone shaped (spiked) projection may be employed. 
       FIGS. 11 to 14  illustrate four configurations of the individual teeth.  FIG. 11  shows a single individual tooth  288  and a plurality of individual teeth  288 . One side of the tooth  288  may comprise a first surface  294  that includes an angle or bend  296 . The axial dimension or width ‘l’ of the individual teeth  288  may be about 0.1 to 0.3 in., i.e., about 0.2 in. and the length of the sharp edge  290  also is equal to the width ‘l’.  FIG. 12  illustrates individual teeth  388 , which are similar to individual teeth  288 . Each of those individual teeth  388  has a width that is approximately double that of the individual teeth  388 , i.e., about 0.4 in. The double width individual teeth  388  may be used on a larger system that has wider arbors and provides additional throughput. In other configurations, the double width individual teeth  388  may be employed on the first stage arbors  20 ,  22  of the first maceration station  12 , whereas the single width individual teeth  288  may be employed on the second stage arbors  24 ,  26 . 
     In another configuration shown in  FIG. 13 , each of the individual teeth  488  may have a curved portion  496  on a first surface  494  such that a portion of the individual tooth has a curved profile. The curved portion  496 , similar to angled portion  296 , permits the meat to be more easily removed from the arbors with the stripper blades.  FIG. 14  illustrates individual teeth  588  having a curved portion  596  in a double width configuration. 
       FIG. 11  illustrates ρ as the distance from the face of one tooth to a corresponding face of another tooth. Though distance ρ is approximately equal in  FIGS. 11 through 14 , apparatus  10  may be configured with different distances ρ between the teeth on the first stage arbor and the teeth on the second stage arbor. For example, if the diameter of a first stage arbor is larger than the second stage arbor and the number of teeth disposed on the two arbor sets is the same, then the distance ρ is larger on the first stage arbors than the second stage arbors. On the other hand, if the diameter of the two arbor sets is different and the distance ρ of the two arbors sets is equivalent, then the number of teeth disposed upon one of the arbor sets is greater relative to the other arbor set. 
       FIG. 10  presents one process  200  for using the above-described apparatus. The raw meat may be any of a variety of meats including chicken, beef, pork, and turkey, among others. Further, the configuration of the arbors including, for example, the projections  28 , recesses  30 , and distances  34 ,  36  between the arbors, may be adjusted depending on the type of raw meat being processed and the desired final meat product. For some meat products, the geometry and projections of the arbors can be different between the first and second maceration stations. In addition, the projections in the first maceration station may be bigger and spaced father apart on the circumference, in the arbor axis direction, than the projections in the second maceration station. Further, as discussed above, the distance or gap between the projections on the arbors of the first stage may be larger than the distance between the projections of the second stage. The distance between the arbors of the second stage may not only be smaller, but also may be a negative distance such that the projections intermesh with one another. As used herein, raw whole meat pieces may include raw whole muscle meat and raw whole muscle portions that are still largely intact but may be less intact than a complete whole muscle. 
     As mentioned, whole muscle meat macerated with the illustrative maceration apparatus  10  undergoes an increase in surface area without excessive tearing and has an improved water holding capacity. By crushing the cells of the whole muscle meat as described herein, individual cell membranes are ruptured, however, the overall structure of the whole muscle meat is retained, thereby maintaining its overall appearance. By rupturing the cell walls, ingredients including, for example, salt, spice, water, cure accelerator, nitrite, and other preservatives, are more quickly absorbed into the whole muscle meat. Rupturing the cell membranes may occur by causing the cell walls to burst or become weak, porous, and/or leaky. 
     In addition to providing for rapid absorption, it is desirable that the maceration provide for relatively uniform absorption of the ingredients. Uniform absorption of the ingredients helps ensure proper color development. For example, if portions of a ham muscle have not undergone sufficient absorption of ingredients, they may be somewhat gray in color once cooked, as opposed to the desired pink color. Proper color development can indicate that the meat has been properly cured. 
     It is also desirable that the maceration and subsequent curing provide for protein extraction, which occurs when the salt solution reaches salt-extractable proteins. The curing process can be performed in a variety of ways. For example, the whole muscle meat may be collected in containers and stored in a cooler while the ingredients diffuse through the whole muscle meat, which can take a day or more. This is called a cover pickle or a cover brine. Indeed, the pickle cure time may range from 48 hours to 7 days, depending on whether the meat also has undergone pickle injection. If the whole muscle meat is not injected with the brine solution, the pickle cure time typically may range from 5 to 14 days. 
     To accelerate the curing process, the whole muscle meat may be sent through a pickle injector that employs hypodermic-type needles to puncture the meat and to inject pickle solution through the needles and into the meat, as it travels through the pickle injector on a conveyor. This injection step helps diffuse the cure or pickle solution through the meat and also serves to tenderize the meat. Also, reducing the size of the whole muscle meat pieces can accelerate the cure process. 
     To shorten the cure time, the whole muscle meats are typically injected with the curing mixture including water and other ingredients to accelerate the diffusion of the ingredients, however, macerating the whole muscle meat, as described herein, may also accelerate the diffusion of the ingredients and the cure process without requiring the pickle injector or a significant reduction in the size of the whole muscle meat pieces. 
     The apparatus  10  accelerates the cure process such that uniform color development may occur within 24-48 hours, whereas certain prior art processes may require, e.g., about 72 hours or more. The apparatus  10  provides for rupturing a significant percentage of cells. For example, between 10-90% of the cell membranes may be ruptured in the whole muscle meat processed by apparatus  10 . By one approach, about 45-75% of the cells are ruptured. By another approach, 50-60% of the cells are ruptured. These percentages may be different depending on the type or section of whole muscle meat. These percentages are averages over the entire piece of whole muscle meat being macerated. 
     A stable protein matrix employs protein bonds to suspend fat and water. In this process, salt soluble or salt-extractable and heat coagulable proteins such as myosin, actomyosin, and actin bind water, swell, and become tacky as a result of working or blending of the meat in the presence of a salt or a salt solution. The proteins are subsequently set when heated to create a bond. Other myofibrillar proteins, as well as sacroplasmic or water soluble or extractable proteins, may also play a role in bonding. 
     Whole muscle meat products such as ham with natural juices and ham with water added often comprise about 18% and 17% protein, respectively. A typical raw ham whole muscle meat has about 20% protein, whereas the protein in the final product is about 17-18% after maceration and incorporation into a finished consumer product. Thus, a significant amount of water is absorbed into the whole muscle meat pieces. Indeed, whole muscle meat may have about 70-77% water once formed into a consumer food product. Processed consumer products typically have non-meat ingredients (including added water and flavorings) that dilute the meat protein, however, the percentage of water in the raw and processed consumer product remains generally similar because the addition of the water is accompanied by the addition of other, ingredients. As another example, a raw turkey breast has a protein amount of about 20.7%, whereas the amount of protein in the final turkey breast is about 16 to 17%, i.e., 16.6%, after maceration and incorporation into a finished consumer product. As another example, lean beef muscle denuded may have a protein amount of about 21.5% and an amount of protein after maceration of about 17% in the final product. In sum, maceration may improve the water holding capacity for these raw whole muscle meats as they are processed into a final consumer product. 
     The apparatus  10  and the process  200  can be employed to provide different degrees of maceration. In some embodiments, the degree of maceration may be described by the inequality:
 
τ/ P   1 &gt;5,000  P   2   /P   3 ,
 
where τ is the cure time (in hours) required to achieve uniform color development after maceration using a curing process; P 1  is the decrease in protein as a percentage of total weight due to absorption of water and other ingredients during the curing process, over period τ; P 2  is the percentage of muscle cells ruptured during maceration; and P 3  is the weight percentage of protein in the whole muscle meat pieces prior to maceration. In addition, the units for value 5,000 may be considered to be hours. As further outlined below, the following parameters may apply: 0&lt;τ&lt;72; 1%&lt;P 1 &lt;5%; 10%&lt;P 2 &lt;90%; and 15%&lt;P 3 &lt;25%.
 
     Maceration decreases the amount of time needed to cure the raw whole muscle meat pieces. Indeed, the apparatus  10  typically reduces cure time by a factor of about 2 to 5, depending on the meat species. In some embodiments, the cure time to achieve uniform color development after maceration τ e  may be described by the inequality, where τ a  is the cure time to achieve uniform color without maceration:
 
τ e &lt;τ a /μ and μ=2  to  5.
 
     Maceration affects the absorption of water and other ingredients and the degree of maceration may be represented, in part, by the change in protein after maceration and the percentage of muscle cells ruptured during maceration. The percentage decrease in protein after maceration, P 1 , may by represented as:
 
 P   1 =( P   a   −P   e )/ P   a ,
 
where P a  is the percentage of protein prior to maceration where no additional water is added; P e  is the percentage of proteins subsequent to maceration and addition of the cure mixture.
 
     The percentage of muscle cells ruptured during maceration, which may be represented by P 2 , may be represented as follows:
 
 P   2   =X   e   /X   2 ,
 
where X e  is the number of cells ruptured during maceration and X 2  is the total number of muscle cells.
 
     P 3  is the weight percentage of protein in whole muscle meat prior to maceration and may be represented as:
 
 P   3   =P   a   /P   x  
 
As noted above, P a  is the weight percentage of protein prior to maceration where no additional water is added and P x  is the total weight of the whole muscle meat.
 
     A wide variety of modifications, alterations, and combinations can be made with respect to the above described embodiments without departing from the scope of the invention, and such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept.

Technology Classification (CPC): 0