FLEISCHWIRTSCHAFT international_04_2018
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Volume 33 _D428<strong>04</strong> F<br />
Journal for meat production,<br />
processing and research<br />
<strong>international</strong><br />
4_<strong>2018</strong><br />
Alternative Products<br />
Seasoning new protein sources<br />
Pork<br />
China‘s boom has<br />
peaked recently<br />
Storage<br />
Packaging ensures<br />
meat quality<br />
Research<br />
Plant materials in<br />
mutton patties<br />
Topics<br />
Additives and Ingredients<br />
Packaging and Labelling
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
3<br />
Trade fairs need <strong>international</strong>ity<br />
Only action across national borders can secure the supply of safe food worldwide<br />
Editorial<br />
At the moment it looks as if national protectionism<br />
is slowing down <strong>international</strong> trade. A<br />
number of large and important trading nations<br />
are using political means to advance their own<br />
interests, relying on their own power and<br />
strengths at the expense of previous market<br />
partners. Politicians' ideas are being implemented,<br />
for example, by increasing customs<br />
duties on important trade goods like meat. The<br />
response to this is usually not long in coming<br />
and previous market partners respond in a<br />
similar way. This "build-up" leads to severe<br />
political restrictions in trade. As a result, the<br />
environment for this year's <strong>international</strong> trade<br />
fairs in the autumn does not seem as favorable<br />
as in previous years.<br />
One of these fairs is FachPack. Over a compact<br />
three-day schedule in Nuremberg, Germany,<br />
from 25 to 27 September <strong>2018</strong>, it will<br />
present its extensive range of solutions for the<br />
packaging process chain for industrial and<br />
consumer goods. Alongside the 1,500 exhibition<br />
booths, the more than 40,000 trade visitors can<br />
look forward to an attractive supporting programme<br />
with numerous presentations on the<br />
hot trends in the industry.<br />
From 30 September to 4 October Poland offers<br />
the visitors of Polagra Tech in Poznan a good<br />
opportunity to get acquainted with the latest<br />
solutions in food technology.For years, the fair<br />
has been supporting the development of trade on<br />
the <strong>international</strong> level. This allows primarily to<br />
acquire new, reliable business partners. Additional<br />
conferences and lectures accompanying<br />
the fair are also conducive to this target.<br />
Some days later – from 8 to 12 October –<br />
Agroprodmash <strong>2018</strong>, an important event for<br />
Russian food manufacturers and global and<br />
local developers of solutions for the food processing<br />
industry, will open its doors at the Expocentre<br />
Pavilions in Moscow. The Salon of<br />
Equipment for Meat Processing is one of Russia’s<br />
largest showcases and offers equipment for<br />
the whole meat industry.<br />
This year, 50 industry associations have come<br />
together to support Pack Expo International<br />
<strong>2018</strong> which will be held from 14 to 17 October at<br />
McCormick Place, Chicago, USA. The trade<br />
associations serve as an on-site resource for the<br />
50,000 attendees expected at the event. Many of<br />
these partners bring a specific vertical market<br />
focus and will host pavilions, sponsor networking<br />
lounges and offer educational sessions.<br />
Health concerns predominantly underlie the<br />
success of “Alternative Food”. This term covers all<br />
about concocting healthier food, respect to nature<br />
and animal well-being. After the major food crises<br />
of the '90s and early 2000's, consumers are turning<br />
toward food that is perceived, rightly or<br />
wrongly, as healthier and more ethical. As a<br />
result, the number of innovations based on meat<br />
substitutes now exceeds the number of meatbased<br />
innovations. Sial <strong>2018</strong>, which takes place<br />
from 21 to 25 October at Paris-Nord Villepinte, is<br />
giving this food category the space it deserves.<br />
All these fairs aim at a distinct <strong>international</strong><br />
trade and exchange. The times of limited trade<br />
horizons must be over in order to ensure the<br />
supply of safe food worldwide.<br />
Michael Weisenfels<br />
Editor<br />
<strong>FLEISCHWIRTSCHAFT</strong><br />
<strong>international</strong><br />
Advertisement
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4<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
Content<br />
14 22<br />
26<br />
Columns<br />
Meat chain<br />
Topics<br />
3 Editorial<br />
5 News<br />
13 Industry News<br />
39 Calendar<br />
40 Advertisers, Credits, Subscriptions<br />
8 Pork<br />
China‘s boom appears to have peaked.<br />
The global pork industry barometer<br />
shows calm and sound growth for <strong>2018</strong>.<br />
22 Hygiene<br />
Detection assures food safety. State-ofthe-art<br />
microbiological tests help to<br />
reduce the risk of human illness cases –<br />
Part 2.<br />
38 Legislation<br />
Smoking Technologies. Assessment<br />
under the European food law.<br />
14 Alternative Products<br />
Seasoning new protein sources. Tapping<br />
into the latest consumer trends regarding<br />
vegan and vegetarian products.<br />
17 Combined Proteins<br />
Meat extensions – products with animal<br />
and vegetable components. Products<br />
with reduced meat content as alternatives<br />
to vegetarian and vegan meat<br />
analogues.<br />
26 Marking<br />
Food packaging and labeling. Driving<br />
efficiency in meat and poultry coding.<br />
30 Storage<br />
Packaging assures quality. Modified<br />
atmosphere packaging is the most<br />
commonly packaging method used in<br />
poultry marketing.<br />
Additves<br />
Ingredients notably influence the<br />
characteristics of meat products.<br />
Photo: Valerii Dekhtiarenko/fotolia<br />
Research & Development<br />
41 Quality characteristics and<br />
shelf life evaluation of<br />
functional mutton patties<br />
– Investigations on<br />
incorporated combinations<br />
of plant materials<br />
By Om Prakash Malav,<br />
Brahm Deo Sharma, Rajiv<br />
Ranjan Kumar, Suman Talukder,<br />
Sakeh Rafeh Ahmed and<br />
Irshad A. Dahsri<br />
41
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
5<br />
News<br />
Omron<br />
New General Manager<br />
Central Eastern Europe<br />
Previously Dr. Klaus Kluger was<br />
Managing Director Europe at Omron<br />
Adept Technologies. After the<br />
merger of Omron Adept Technologies<br />
into Omron He started as<br />
General Manager Central Region at<br />
Omron in April 2017. Since May <strong>2018</strong><br />
he is now active as General Manager<br />
Central Eastern Europe, which<br />
includes Germany, Austria,<br />
Switzerland, Poland, Hungary, the<br />
Czech Republic, Slovakia, and<br />
Romania.<br />
In <strong>2018</strong> Omron concluded that it<br />
would be more beneficial for the<br />
development of the markets in<br />
Central and Eastern Europe to<br />
reside under the same management.<br />
He now leads the newly<br />
formed organisation as General<br />
Manager Central Eastern Europe.<br />
//www.omron.co.jp<br />
Tyson<br />
Food giant<br />
to acquire Keystone<br />
Tyson Foods, Inc. announced it has<br />
reached a definitive agreement to<br />
buy the Keystone Foods business<br />
from Marfrig Global Foods for<br />
$2.16 bn. in cash. The acquisition<br />
of Keystone, a major supplier to the<br />
growing global foodservice industry,<br />
is Tyson Foods’ latest investment<br />
in furtherance of its growth<br />
strategy and expansion of its<br />
value-added protein capabilities.<br />
The aquisition helps to expand the<br />
<strong>international</strong> presence. Headquartered<br />
in West Chester, Pennsylvania,<br />
Keystone supplies chicken,<br />
beef, fish and pork to some of the<br />
world’s leading quick-service<br />
restaurant chains, as well as retail<br />
and convenience store channels.<br />
Its value-added product portfolio<br />
includes chicken nuggets, wings<br />
and tenders, beef patties, and<br />
breaded fish fillets.<br />
The acquisition includes six<br />
processing plants and an innovation<br />
center in the US. It also includes<br />
eight plants and three<br />
innovation centers in China, South<br />
Korea, Malaysia, Thailand and<br />
Australia. Keystone, which employs<br />
approximately 11,000 people,<br />
generated annual revenue of<br />
$2.5 bn. and adjusted EBITDA of<br />
$211 mill. in the last 12 months<br />
ending 30 June, <strong>2018</strong>.<br />
//www.tyson.com<br />
Marel<br />
Global provider agrees to buy Maja<br />
Marel has agreed to acquire Maja,<br />
a German food processing equipment<br />
manufacturer. The transaction<br />
is subject to anti-trust approval<br />
and customary closing<br />
conditions, and is expected to<br />
close in the third quarter of <strong>2018</strong>.<br />
The acquisition is in line with<br />
Marel’s strategic objective to be a<br />
full-line supplier of advanced food<br />
processing solutions and standard<br />
equipment, and further<br />
strengthen Marel’s global market<br />
presence.<br />
Marel is a global provider of<br />
advanced processing systems and<br />
services to the poultry, meat and<br />
fish industries with annual revenues<br />
of € 1,038 mill. in 2017.<br />
Marel invests around 6% of revenues<br />
in research and development<br />
annually, which translated<br />
into around € 60 mill. in 2017.<br />
Marel’s full-line approach includes<br />
standalone equipment, individual<br />
systems and full production lines<br />
all controlled and integrated with<br />
Innova, Marel’s overarching software<br />
solution.<br />
Maja’s technological leadership<br />
and strong market position is a<br />
good fit to Marel’s commitment to<br />
innovation and extensive global<br />
presence. With Maja’s innovative<br />
product offering and complementary<br />
geographical reach, Marel is<br />
better positioned to offer full-line<br />
solutions for the meat industry<br />
globally and advance market<br />
penetration. Marel also aims to<br />
utilize Maja’s high-quality innovation<br />
and manufacturing site as an<br />
addition to existing production<br />
sites. Maja’s experienced management<br />
team will stay on board<br />
and continue to lead Maja.<br />
//www.marel.com<br />
Since its founding<br />
Maja has been<br />
specializing in<br />
skinning and<br />
portioning with main<br />
focus on the meat<br />
market.<br />
Advertisement
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6<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
News<br />
Miratorg<br />
Company plans to invest<br />
in pork production<br />
Miratorg informs it invests 1.5 bn<br />
rubles to extend pork production in<br />
Pristenskiy district of Kursk region –<br />
a new farm with a capacity of 12,000<br />
t per year will be open at the beginning<br />
of 2019.<br />
Miratorg will extend pork<br />
production in Kursk region.<br />
The company has been developing<br />
a large-scale project to double<br />
its current pork production capacity<br />
to 1 mill. t in live weight. The company<br />
builds the vertically integrated<br />
production chain: plant growing,<br />
feed mill plants, livestock ranchos<br />
and the largest slaughtering and<br />
processing complex in Russia located<br />
in Chernitsino settlement,<br />
Kursk region. Kursk region with 20<br />
pig farms already holds a 25% share<br />
in Miratorg production – 109,000 t of<br />
pork in live weight in 2017. "The new<br />
farm plans means 52 new jobs for<br />
local people. Employees of the<br />
pig-breeding site will be provided<br />
with stable job, benefits and decent<br />
salary in average higher than in<br />
region and industry”, the comment<br />
says.<br />
//www.miratorg.ru<br />
FAO<br />
Food Price Index<br />
drops in July<br />
Global agricultural food commodity<br />
prices fell sharply in July, as all the<br />
major traded items posted notable<br />
declines, led by dairy and sugar.<br />
The FAO Food Price Index averaged<br />
168.8 points, 3.7% below their<br />
June level, the biggest monthly drop<br />
since late last year. The index had<br />
been steadily rising in <strong>2018</strong> until<br />
June. The FAO Food Price Index is a<br />
measure of the monthly change in<br />
<strong>international</strong> prices of a basket of<br />
commodities. The FAO Meat Price<br />
Index averaged 170.7 points in July,<br />
down 3.3 points (1.9%) from its<br />
revised value for June. The June<br />
upward revision primarily reflects a<br />
sharp rise in bovine meat prices<br />
from Brazil, caused by a decline in<br />
exports following logistical problems<br />
due the prolonged truck drivers’<br />
strike. In July, the Index shed<br />
few points, in part due to a gradual<br />
normalization of meat exports from<br />
Brazil. Overall, price quotations for<br />
bovine meat fell, while those of pig<br />
and poultry meat also weakened.<br />
However, ovine meat prices increased<br />
marginally on strong import<br />
demand, especially from China and<br />
the United States.<br />
//www.fao.org<br />
Advertisement<br />
Advertisement<br />
Expo chosen for Program<br />
The International Production & Processing Expo (IPPE) has<br />
again been selected to participate in the 2019 U.S. Department<br />
of Commerce International Buyer Program. The program brings<br />
trade delegations together from around the world and helps<br />
match <strong>international</strong> attendees with American suppliers. The<br />
program also provides export counseling, market analysis and<br />
more.The next IPPE, comprised of three integrated trade<br />
shows, will be held Tuesday through Thursday, 12 to 14 February,<br />
2019, at the Georgia World Congress Center in Atlanta.<br />
//www.ippexpo.com<br />
UK Government<br />
ASF in China<br />
The Chinese authorities reported an outbreak of ASF in domestic pigs in<br />
Liaoning region, north east China in the beginning of August. According<br />
to the disease report clinical signs were first observed on the 1st August<br />
in 47 animals, however, the exact number of animals on farm is unclear<br />
as different reports state between 300 and 8,000 pigs.<br />
This is the first time that ASF has been reported in China. Disease<br />
control measures are in place including culling affected and susceptible<br />
animals. ASF has caused a small number of isolated outbreaks in central<br />
Russia, north of Kazakhstan and Mongolia, approximately 1,000 km from<br />
the border with China.<br />
//www.gov.uk<br />
Plukon<br />
Polish poultry processor acquired<br />
Plukon Food Group and the Polish<br />
Wyrebski family received approval<br />
from the competition authority<br />
regarding this transaction. The<br />
deal was officially closed last<br />
week. The family Wyrebski is producing<br />
high quality fresh and<br />
frozen poultry products for the<br />
food service, retail and food industry<br />
under its own brand and under<br />
private label. Its main markets are<br />
Poland and north-western Europe.<br />
With the closing of the deal Plukon<br />
Food Group gets a majority interest<br />
in Wyrebski‘s new slaughterhouse<br />
project. The transaction enables<br />
Plukon Food Group to enter the<br />
Polish market and will expand<br />
Plukon’s position going forward in<br />
Europe.<br />
Peter Poortinga, CEO of Plukon<br />
Food Group, commented: “With this<br />
transaction Plukon Food Group is<br />
able to continue to grow in Europe<br />
and create a fifth production country<br />
in Europe. I am pleased that<br />
Plukon Food Group and Wyrebski<br />
will jointly build a solid position on<br />
the Polish poultry market. The<br />
parties will develop a greenfield<br />
slaughterhouse in the center of<br />
Poland.”<br />
//www.plukonfoodgroup.com
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
7<br />
News<br />
Westfleisch<br />
Growing again in 2017<br />
Westfleisch-Group closed the<br />
business year 2017 with records<br />
regarding turnover, sales and<br />
slaughter volume.<br />
These positive results were<br />
announced by the members of the<br />
Executive Board Carsten Schruck,<br />
Steen Sönnichsen and Johannes<br />
Steinhoff at Westfleisch SCE´s<br />
General Assembly. The Managing<br />
Board led through the event in this<br />
three-member constellation for<br />
the first time. Sönnichsen, responsible<br />
for production and sales of<br />
fresh meat, just started at Westfleisch<br />
in December 2017.<br />
Schruck announced that the<br />
group will pay a dividend of 4.2 %<br />
to shareholders plus special<br />
bonuses in the amount of €3 mill.<br />
for agricultural members.<br />
“Our turnover grew by 11.4% to<br />
€2.75 bn.“, he declared. The EBITDA<br />
was up by 16% to €71.3 mill. in<br />
2017. Westfleisch slaughtered<br />
8.26 mill. pigs – 2.7% more than in<br />
2016. For cattle, i.e. bulls, dairies<br />
and heifers, the volumes increased<br />
by 1.5% to about 424,000 animals.<br />
Westfleisch sold about 44% of<br />
its meat and meat products<br />
abroad. The target markets include<br />
the European states as well as<br />
overseas markets. But there were<br />
differences compared to the previous<br />
year: After the `Asia-Boom´ –<br />
above toward the PR of China – the<br />
The company sucessfully closed<br />
the business year 2017.<br />
demand in third countries decreased<br />
by 4.8%. On the other hand<br />
the exports to the EU-markets<br />
have risen significantly up to 10.5%<br />
and could partially compensate the<br />
losses.<br />
Westfleisch is the No. 3 meat<br />
marketer in Germany and ranks<br />
amongst the Top 5 in Europe. The<br />
<strong>international</strong> company, based in<br />
Münster, slaughters, cuts, processes<br />
and refines meat. In 2017<br />
the company sold 980,000 t of<br />
meat and generated turnovers of<br />
€2.75 bn. Westfleisch is owned by<br />
about 4,300 farmers in North West<br />
Germany and the Netherlands. On<br />
the basis of cooperation contract,<br />
they breed pigs, cattle and calves.<br />
Westfleisch has approximately<br />
5,000 employees.<br />
//www.westfleisch.de<br />
USDA<br />
US poultry gains market<br />
access in Marocco<br />
US Trade Representative Robert<br />
Lighthizer and US Secretary of<br />
Agriculture Sonny Perdue announced<br />
that the government of<br />
Morocco has agreed to allow commercial<br />
imports of poultry meat<br />
and products into Morocco for the<br />
first time.<br />
The United States is the world’s<br />
second largest poultry exporter,<br />
with global sales of poultry meat<br />
and products of $4.3 bn. last year.<br />
US exports of agricultural products<br />
exceeded $12 bn. Initial estimates<br />
indicate that Morocco would be a<br />
$10 mill. market, with additional<br />
growth over time. Morocco had<br />
prohibited imports of US poultry.<br />
Officials from the Office of the<br />
Trade Representative and the<br />
Department of Agriculture worked<br />
with the Moroccan government to<br />
provide assurances on the safety.<br />
//www.usda.gov<br />
Provisur<br />
Aquisition of Hoegger<br />
Provisur Technologies, Inc., a<br />
global leader in innovative food<br />
processing technologies announced<br />
that it has acquired<br />
Hoegger AG, a privately-held leading<br />
provider of form pressing,<br />
separation and cook & chill equipment.<br />
Based in Flawil, Switzerland,<br />
Hoegger serves leading food processors<br />
globally.<br />
Hoegger is the recognized global<br />
leader in meat press technology<br />
and is known for continuous innovation<br />
and uncompromising quality.<br />
This acquisition further expands<br />
Provisur’s growing global<br />
footprint and provides the company<br />
with added sales, service and<br />
production capacity in Europe.<br />
“The acquisition of Hoegger<br />
strengthens our position in the<br />
slicing and portioning markets and<br />
complements our cooking portfolio.,”<br />
said Cohen.<br />
//www.provisur.com<br />
Advertisement<br />
UK Government<br />
British pork export to Taiwan<br />
British farmers and food producers<br />
are set to benefit from a valuable<br />
new market as Taiwan prepares to<br />
welcome British pork exports for<br />
the first time. UK pork exports were<br />
worth £290 mill. to the economy<br />
last year, reaching over 80 export<br />
markets. This new agreement is<br />
expected to be worth more than<br />
£50 mill. over the next five years.<br />
The eagerly awaited deal has<br />
been secured by the UK government,<br />
working with the Agriculture<br />
and Horticulture Development<br />
Board (AHDB) and UK Export Certification<br />
Partnership (UKECP). Exporters<br />
can take advantage of the<br />
market as soon as the administrative<br />
listing process is completed<br />
and export certification is made<br />
available. The deal also means UK<br />
exporters can further tap in to the<br />
overseas demand for parts of the<br />
pig carcass that are not commonly<br />
purchased in the UK. This means UK<br />
farmers and pork processors will<br />
be able to generate income for the<br />
whole carcass. It follows a number<br />
of recent successes for UK food<br />
and drink exports, which reached a<br />
record level of £22 bn. in 2017.<br />
China lifted its two-decade long<br />
ban on UK beef exports following<br />
the BSE outbreak. The agreement<br />
will allow official market access<br />
negotiations to begin, estimated<br />
to be worth over £250 mill. in the<br />
first five years alone.<br />
//www.gov.uk
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8<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
Pork<br />
China‘s boom appears to have peaked<br />
The global pork industry barometer indicates calm and sound growth for <strong>2018</strong><br />
The world economy can look back<br />
on asuccessful year 2017.Ona<br />
global basis the gross domestic<br />
product (GDP) grew by 3.6%. With<br />
few exceptions, most countries have<br />
overcome the recession and in<br />
advanced national economies<br />
economic growth was boosted. In<br />
<strong>2018</strong> the economy will pick up<br />
distinctly in many emerging<br />
economies, while the upswing in<br />
established economies is set to<br />
weaken alittle. Altogether the<br />
worldwide GDP is likely to grow by<br />
3.7%, and the meat industry too will<br />
profit from this.<br />
By René Maillard<br />
Looking back over aperiod of<br />
three years, it can be established<br />
that in 2015 the global meat<br />
industry was dominated by radical<br />
changes in foreign exchange rates,<br />
above all by the strong US Dollar.<br />
In the following year the industry<br />
was subjected to tough price<br />
competition that was brought<br />
about by clear increases in the<br />
volumes of poultry and pork on<br />
the growing world market. For<br />
2017/<strong>2018</strong> the industry barometer<br />
Source:GIRA, adaptation by Belgian Meat Office <strong>FLEISCHWIRTSCHAFT</strong> <strong>international</strong> 4_<strong>2018</strong><br />
Fig. 2: Russia is expectedtoincreasethe volume of its pork production<br />
permanentlyfrom2006 to 2022.<br />
Source: GIRA, adaptation by Belgian Meat Office <strong>FLEISCHWIRTSCHAFT</strong> <strong>international</strong> 4_<strong>2018</strong><br />
Fig. 1: The restructuring of China’spig farming is downsizing global stocks.<br />
forecasts calm, sound growth that<br />
will be driven by firm import<br />
demand from China. An increase<br />
in production is expected worldwide<br />
for all types of meat and this<br />
will be set against increased demand.<br />
The meat industry profits from<br />
the growing world population that<br />
has higher income levels at its<br />
disposal and is increasingly consuming<br />
proteins of animal origin.<br />
On the other hand, the industry is<br />
ever more becoming the focus of<br />
criticism in society,particularly in<br />
the richer,industrialised countries.<br />
Furthermore vegetarianism,<br />
veganism and flexitarism movements<br />
are on the advance.<br />
The low feed prices supported<br />
the meat industry in 2017 too. In<br />
<strong>2018</strong> prices are only likely to increase<br />
slightly –atany rate up to<br />
the next harvest.<br />
The global pork market<br />
One factor stands out particularly<br />
clearly in an analysis of the global<br />
pork market –in2017 producer<br />
prices for pork dipped dramatically<br />
by 14.8% by comparison with<br />
the previous year due to the turbulences<br />
in China. Ayear before,<br />
China was still being celebrated as<br />
the lifeline for global producer<br />
prices because of the exceptionally<br />
high import volumes of pork. The<br />
peak of the probably unique China<br />
boom of 2016 appears to have<br />
passed. In <strong>2018</strong> the global producer<br />
prices are expected to remain<br />
under pressure and this<br />
time too it will be the Middle<br />
Kingdom that tips the scales. Pig<br />
herds worldwide shrank with a<br />
moderate cutback of 1.8% to<br />
905 Mill. animals in 2017.The<br />
(mainly) government-steered<br />
restructuring measures in China<br />
that downsized the stocks by<br />
comparison with the year before<br />
by 16.1 Mill. to 435 Mill. animals, a<br />
drop of 3.6%, had amajor impact.<br />
Because the People’s Republic is<br />
home to just under half of the<br />
global pig population, effects of<br />
this are naturally felt around the<br />
world.<br />
With 147.2 mill. animals, Europe<br />
represents agood 16%ofthe<br />
global pig population, followed by<br />
the USA with 71.4 mill. animals (=<br />
8%). The depletion of the European<br />
pig population was stopped<br />
temporarily in 2017.<br />
The rise in demand from China<br />
the year before had apositive<br />
effect on world prices and also
.....................................................................................................................................................................<br />
10<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
Pork<br />
China's boom appears to have peaked<br />
opened up better prospects for<br />
European pig farmers. This situation<br />
has inspired farms struggling<br />
with financial problems to carry<br />
on. At the same time it increased<br />
the willingness of more efficient<br />
farms to invest. The optimistic<br />
mood in the context of the low<br />
feed prices brought distinct<br />
growth momentum to the North<br />
American processing industry. In<br />
<strong>2018</strong> the reduction of the global<br />
pig population will continue at a<br />
slightly slower rate. China is likely<br />
to reduce its stocks again by<br />
15 mill. animals or 3.4%. As herd<br />
sizes are increasing in many<br />
countries, above all in the USA,<br />
the global downsize will only<br />
amount to 1.3%. Altogether the<br />
global pig population will then be<br />
quantified at just under 893 mill.<br />
animals. All in all we are moving<br />
towards a smaller but more efficient<br />
global herd (Fig. 1).<br />
In Russia the state promotion,<br />
in combination with the protectionist<br />
strategy, is bearing fruit. It<br />
remains to be seen whether the<br />
Source: GIRA, adaptation by Belgian Meat Office <strong>FLEISCHWIRTSCHAFT</strong> <strong>international</strong> 4_<strong>2018</strong><br />
Fig. 3: The volumes continue to increase following the rise in imports by 11% in 2016.<br />
national demand can keep pace<br />
with this development and absorb<br />
the more abundant supply, or<br />
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whether larger amounts will flood<br />
the world market. Since the embargo<br />
entered into force in the<br />
year 2014, the Russian pork industry<br />
has concentrated on its own<br />
strengths and grown massively.<br />
While in 2014 production was<br />
quantified at 2.8 mill. t, it broke<br />
the 3.5 mill. t barrier for the first<br />
time in 2017. The growth curve is<br />
pointing upwards in <strong>2018</strong> as well.<br />
The carcass weights, which are<br />
increasing continuously, are an<br />
outstanding feature here.<br />
In <strong>2018</strong> the carcasses will weigh<br />
on average a good 90 kg. The<br />
Russian production system is<br />
permanently expanding its capacities,<br />
gaining points through a<br />
higher degree of efficiency and<br />
profiting from low feed prices.<br />
Furthermore the relatively<br />
stronger Rouble is cutting the<br />
comparative costs of imports<br />
serving for pig production. The<br />
large conglomerates are investing<br />
strongly. In the Kursk region for<br />
example, Miratorg is investing<br />
$1.2 bn. in the annual production<br />
of 4.5 mill. piglets. Cherkizovo has<br />
invested in new farms in<br />
Voronezh and expanded its capacity<br />
by 13%.<br />
The firm Agroeco, also based in<br />
the Voronezh region, constructed<br />
six new complexes in the past year.<br />
And last but not least Rusagro<br />
should be mentioned.<br />
They have topped up their<br />
capacity in the Tambov region by<br />
35,000 t (Fig. 2).<br />
However, all this cannot hide<br />
the fact that the African Swine<br />
Fever is hanging over the pork<br />
industry like the sword of Damocles.<br />
Extreme vigilance is necessary,<br />
for the virus is spreading ever<br />
further throughout Eastern Europe<br />
and Russia and heading<br />
unstoppably for Western Europe.<br />
Production has increased<br />
Last year some 1,425 mill. pigs<br />
were slaughtered worldwide.<br />
Global pork production increased<br />
by around 1% to 116mill. t. This<br />
trend will continue in a slightly<br />
higher form in <strong>2018</strong>: +1.3% to<br />
118mill. t.<br />
The fact is that the herds are<br />
characterised by a higher productivity<br />
rate. The average weight of<br />
the carcasses is also increasing<br />
permanently (+0.4%/year). In<br />
2017 a global carcass weight of<br />
82 kg per slaughter swine was<br />
calculated. The trend is rising. The<br />
industry is in a very dynamic state<br />
and is responding by topping up<br />
capacity. The production stage is<br />
moving with the times and increasing<br />
the supply of raw materials<br />
for the finishing farms accordingly.<br />
The further vertical coordination<br />
and integration is also<br />
having a positive effect on pork<br />
production. Export business will<br />
play a key role for future developments<br />
in the industry.<br />
In the global context pork consumption<br />
is increasing. A plus of<br />
1% was noted already in 2017,
.....................................................................................................................................................................<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
11<br />
Pork<br />
Source: GIRA, adaptation by Belgian Meat Office <strong>FLEISCHWIRTSCHAFT</strong> <strong>international</strong> 4_<strong>2018</strong><br />
Fig. 4: Europe and the USA each represent one third of the global foreign trade.<br />
corresponding to a volume of<br />
1.2mill. t. This growth is due to<br />
the more extensive supply. Altogether<br />
116mill. t pork were consumed<br />
in the past year. The market<br />
leaders are logically the Chinese<br />
with 56.7 mill. t. They are<br />
followed by the Europeans with<br />
21.1 mill. t and the USA with<br />
9.6 mill. t. In <strong>2018</strong> global meat<br />
consumption is set to increase<br />
again by 1.1% or 1.3mill. t to<br />
117.4 mill. t.<br />
While pork is by far the most<br />
popular type of meat in many<br />
European and Asian countries, in<br />
other countries it never comes<br />
onto the table for religious reasons.<br />
Furthermore, the price<br />
advantage by comparison with<br />
beef will probably allow pork to<br />
climb further up the popularity<br />
scale among consumers. A large<br />
share of the pork produced is<br />
offered in refined form.<br />
The global per capita consumption<br />
of pork is growing constantly.<br />
Within a period of ten years a rise<br />
of 1.1 kg has been achieved to a<br />
current level of 19.2 kg. In the<br />
long term very moderate growth<br />
rates are expected. This development<br />
is accompanied by the increasingly<br />
negative discussion in<br />
society to which pork is repeatedly<br />
exposed.<br />
Global trade with pork increased<br />
in the past year by 1.5% to<br />
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............................................<br />
12<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
Pork<br />
China's boom appears to have peaked<br />
8.2 mill. t. An increase of 1.3%<br />
taking us up to 8.3 mill. tisexpected<br />
for <strong>2018</strong>.<br />
China (including Hong Kong) is<br />
and remains the world’s capital for<br />
pork imports. The country with<br />
the highest population in the<br />
world was responsible for around<br />
28% of global imports in the<br />
record year 2016.Ayear later the<br />
Middle Kingdom “only” absorbed<br />
an import volume of 1.9 mill. t,<br />
equivalent to 22.8% of the global<br />
total. Any percentage shiftinthe<br />
Chinese market, be it ever so<br />
small, causes alarge wave on the<br />
global market.<br />
Accordingly,the root of the<br />
global price volatility is clearly to<br />
be sought in China. Chinese<br />
import demand will probably be<br />
downsized further by 1mill. tin<br />
<strong>2018</strong> to around afifth of theglobal<br />
import volume. Europe will defend<br />
its role as the most important<br />
pork supplier to China, followed<br />
by the USA and Canada.With<br />
1.4mill. t,Japan –which primarily<br />
procures its products from the<br />
Source: GIRA, adaptation by Belgian Meat Office <strong>FLEISCHWIRTSCHAFT</strong> <strong>international</strong> 4_<strong>2018</strong><br />
Fig. 5: The gap between total exports and total imports illustrates the global potential for crises.<br />
USA, Europe and Canada –isthe<br />
second most important importer<br />
in the world. It is followed by<br />
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Mexico with nearly 1mill. t, and<br />
the USA which imported around<br />
590,000 tpork, chiefly from<br />
Canada and the EU.<br />
Despite an increase in domestic<br />
production, Russia –greatly to the<br />
joy of Brazil –increased itsimport<br />
volumes by 18.8% to 366,000 tin<br />
2017 (Fig. 3).<br />
In export business the USA is<br />
slightly ahead of the field with<br />
2.6 mill. t. The main destinations<br />
are Mexico, Japan and China. In<br />
2017 altogether 2.5 mill. tofEuropean<br />
pork crossed the borders of<br />
the Union, primarily in the direction<br />
of China and Japan. The third<br />
in the league is Canada with<br />
1.3mill. t, exported chiefly to the<br />
USA, China and Japan. With<br />
737,000 t, Brazil remains at the<br />
same level as the year before.<br />
Brazilian pork scores chiefly in<br />
Russia, China and Sub-Saharan<br />
Africa (Fig. 4).<br />
Outlook for the global sector<br />
up to 2022<br />
In 2022 the global pig population<br />
will probably total 888.6 mill.<br />
animals. By comparison with 2017<br />
that would be adropof0.4%. The<br />
driving motor behind this development<br />
is once again China,<br />
which will probably reduce its<br />
stocks in afive-year comparison<br />
by 1.7% to 400 mill. animals.<br />
By comparison with 2017,the<br />
European herd size is likely to<br />
increase minimally to 147.7 mill.<br />
pigs.<br />
Global pork production in 2022<br />
is quantified at 123.67 mill. t. By<br />
comparison with the reference<br />
year 2017,this is aplusof1.2%.<br />
This growth in the pork industry<br />
is affected primarily by the main<br />
stakeholders China, Europe and<br />
the USA.<br />
The global boosting of production<br />
will not be without effects on<br />
foreign trade, which will probably<br />
generate growth of 2% by comparison<br />
with 2017 (Fig. 5).<br />
According to the forecast, global<br />
pork consumption in 2022 will<br />
rise to 122.62 mill. t, aplus of 1.1%<br />
by comparison with the reference<br />
year 2017.<br />
René Maillard<br />
has been working in the<br />
meat sector for 35 years,<br />
including more than 20 years<br />
as Managing Director of the<br />
Belgian Federation of the Meat Industry<br />
(BIVEX). Since 2003 he has been Manager of<br />
the Belgian Meat Office in Brussels. Maillard<br />
participates in the Gira Meat Club every year.<br />
Author’s address<br />
René Maillard, Manager VLAM –Belgian Meat<br />
Office, Koning Albert II-laan, 1030 Brussels,<br />
Belgium.
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
13<br />
Industry News<br />
Detectamet<br />
Totally detectable ink refills<br />
In its drive for total detectability<br />
Detectamet from York, The United<br />
Kingdom, has introduced a new<br />
specification for ink refills designed<br />
by this company. Its latest<br />
improvement has finally resolved<br />
its search for the totally detectable<br />
pen refill. The standard<br />
ball point ink cartridge used by pen<br />
manufacturers around the world is<br />
made of detectable metal. The<br />
small end stop has, until now,<br />
been made of undetectable plastic.<br />
Detectamet’s Chairman Sean<br />
Smith recently announced “To<br />
resolve this challenge we have<br />
developed our own standard ink<br />
refill and it is now being fitted only<br />
to Detectamet pens.”<br />
The first batch of pens containing<br />
these refills were fitted with<br />
black or blue ink. These new cartridges<br />
will also be available to<br />
customers as refills. Writing trials<br />
of the new cartridge have proved<br />
Complete detectability reduces<br />
risks of product contamination.<br />
that it matches the old standard<br />
refill. The recently proposed<br />
amendment to the BRC Global<br />
Standards (Issue 8) proposes that<br />
“pens used in open product areas<br />
shall be controlled to minimize risk<br />
of physical contamination (e.g.<br />
designed without small parts and<br />
detectable by foreign body detection<br />
equipment)”.<br />
//www.detectamet.co.uk<br />
Sæplast<br />
Container for food processing<br />
Sæplast from Dalvik, Iceland, has<br />
extended its range of rugged and<br />
hygienic reusable plastic containers<br />
for the food processing industry<br />
with the introduction of a further<br />
size. The new type 300PE is a<br />
square 800x800 mm container with<br />
a height of 770 mm giving it a net<br />
volume of 268 litres. This can be<br />
increased to 298 litres with the<br />
removal of the handle openings.<br />
For ease of access and transportation,<br />
the container features fork lift<br />
entry on all four sides.<br />
Like all Sæplast containers, the<br />
300PE offers important hygiene,<br />
safety and convenience benefits<br />
to ensure the highest food processing<br />
standards. The one piece,<br />
seamless triple-wall design and<br />
closed cell core provides excellent<br />
durability, meaning Sæplast PE<br />
containers last on average between<br />
five to seven times longer<br />
than single wall bins.<br />
The container features fork lift<br />
entry on all four sides.<br />
The solid inner core prevents<br />
absorption of liquid and the tubs<br />
do not have easily broken joints or<br />
hard-to-clean crevasses, preventing<br />
the harbouring of harmful<br />
bacterial growth and making them<br />
easy to clean, maintain and repair.<br />
This delivers safe and easy handling<br />
for users.<br />
//www.saeplast.com<br />
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14<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
Alternative Products<br />
Awider variety of plant protein options are entering the market – for example beans.<br />
Seasoning new protein sources<br />
Tapping into the latest consumer trends regarding vegan and vegetarian products<br />
In recent years, the popularity of<br />
vegetarian and vegan products has<br />
soared globally, as consumer interest<br />
to reduce or eliminate meat<br />
from their diets continues to grow.<br />
In fact, data from Innova Market<br />
Insights has shown a 60% rise in<br />
the number of global food and<br />
beverage launches using a vegetarian<br />
claim between 2011 and 2015.<br />
The vegetarian/vegan sector is now<br />
one of the fastest-growing segments<br />
in the European food and<br />
drink industry, exemplified by high<br />
levels of new product development<br />
in meat alternatives and substitutes.<br />
sustainable and environmentally<br />
friendly products are also considered<br />
to be major drivers.With more<br />
choices for great-tasting alternative<br />
meat options, consumers now<br />
benefit from meat-free retail aisles<br />
stocked with a wide selection of<br />
products to fit their needs. As a<br />
result, sales of plant-based meat<br />
substitutes have made steady gains<br />
in developed markets, as they move<br />
away from being the preserve of<br />
vegetarians to becoming popular<br />
among mainstream shoppers<br />
seeking to reduce their meat intake.<br />
In parallel, the growing trend<br />
toward vegetarianism is driving a<br />
new wave of plant protein-centric<br />
innovation across the food industry.<br />
The global plant protein market<br />
’New’ formats of<br />
protein are increasingly<br />
appearing in food and<br />
drink products for<br />
everyday meal<br />
occasions.<br />
By Roland Snel<br />
This trend is thought to be<br />
strongly driven by an increased<br />
focus on health and wellness, with<br />
particular opportunities around<br />
so-called ‘flexitarian’ consumers.<br />
Ethical topics, such as concerns<br />
about factory farming and food<br />
safety, and the growing demand for
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
15<br />
Alternative Products<br />
is predicted to grow at a CAGR of 8.29% during<br />
the period 2017-2021 via Research & Markets:<br />
Global Plant Protein Market, with many<br />
new ‘types’ of proteins emerging. These include<br />
pea protein, rice protein and hemp<br />
protein, to name just a few. Derived from<br />
sustainable vegetable sources, these proteins<br />
can offer a range of benefits over animal-based<br />
proteins, including reduction in total and<br />
saturated fats and lowering formulation costs.<br />
However, formulating with plant proteins<br />
can present a variety of challenges. For instance,<br />
plant proteins have their own, unique<br />
tastes that do not always appeal to meat-eating<br />
consumers and can therefore require the use<br />
of flavour modifying systems. In addition,<br />
plant protein ingredients often require supplemental<br />
ingredients to provide the moistness/<br />
hydration required in a formulation. This<br />
ultimately has an impact on overall product<br />
texture which, if not addressed, can result in<br />
products that are seen as unappetising by<br />
consumers. In comparison to whole muscle<br />
meat, vegetable proteins also deliver a noticeably<br />
different appearance and mouthfeel,<br />
impacting the perceived quality and acceptance<br />
of the end product. One of the main obstacles<br />
to meat substitutes being regularly eaten by<br />
meat-eating adults, for example, is the absence<br />
of the ‘meat-like’ taste and texture, which these<br />
consumers typically prefer. The challenge for<br />
formulators therefore is to meet increasing<br />
consumer demand for vegetarian, vegan or<br />
meat-free products that are not only nutritious,<br />
but also successfully mimic the texture, appearance<br />
and taste qualities of real meat.<br />
Unlocking the value of soya protein<br />
With consumption rising annually around the<br />
world, soya is currently one of the most utilised<br />
non-meat protein ingredients. According to<br />
WWF Global containing up to 38% protein,<br />
soya beans offer a great source of high-quality<br />
protein comparable to regular meat, fish or<br />
dairy protein, with a complete amino acid<br />
profile, and also deliver healthier, unsaturated<br />
fats and valuable phyto-nutrients. As such,<br />
soya is already regularly used to enhance the<br />
nutritional profile of a multitude of food and<br />
beverage products.<br />
Available in a wide variety of formats, including<br />
textured and concentrated proteins that<br />
include a high protein content as well as fibre,<br />
soya proteins offer enhanced functionality for a<br />
wide range of applications. Besides its role as a<br />
nutritional enhancer, soya is also favoured by<br />
formulators as a low-cost gelling and emulsifying<br />
agent, making it ideally positioned to<br />
improve texture in place of meat proteins. They<br />
also have highwater-binding capabilities,<br />
allowing manufacturers to simulate the texture<br />
of real meat in emulsified applications such as<br />
vegetarian “hot dog” and “mortadella” type<br />
products. For example, functional soya protein<br />
concentrates which are available in powder<br />
format, allow the functional replacement of<br />
lean meat components in ground-meat products<br />
such as patties, meatballs or kebabs and<br />
can be injected into whole muscle meat.<br />
With formulation advancements, different<br />
soya protein ingredients can now be used in<br />
combination to create a variety of meat profiles<br />
including allowing manufacturers to mimic a<br />
specific meat reference. Ingredient suppliers<br />
are increasingly experimenting with different<br />
processing techniques in order to develop<br />
on-trend applications from vegetable proteins.<br />
An innovative example of this is using the<br />
process of extrusion to create a pulled-pork<br />
analogue made from 100% fibrous soya. The<br />
resulting product mimics the texture of real<br />
slow-cooked pork, which can then be used to<br />
develop sandwich fillings or ready meals to<br />
meet consumers’ continuing enthusiasm for<br />
pulled meat products.<br />
When purchasing meat products, appearance<br />
is considered to be a key indicator of meat<br />
quality and can often influence a shopper’s<br />
decision on whether to buy a product or not.<br />
Achieving a light colour for chicken analogues<br />
is therefore important when it comes to attracting<br />
consumers, as they are likely to relate a<br />
darker colour to lack of freshness. Soya ingredients<br />
are naturally light coloured, allowing<br />
formulators to meet demand for the fresh light<br />
look that is usually associated with poultry<br />
products, helping to ensure consumer acceptance.<br />
Furthermore, with its neutral flavour<br />
profile, soya products such as ADM’s textured<br />
soya protein concentrates can be incorporated<br />
into meat products with limited need to mask<br />
off-flavours, which often creates further formulation<br />
challenges. In fact, manufacturers can<br />
easily add their own flavours and spices to<br />
differentiate their offering and develop attention-grabbing<br />
variants.<br />
Next-generation soya applications<br />
Capitalising on the growing appeal of plantbased<br />
foods, the industry is now going one step<br />
further by not only offering ingredients that<br />
replicate the properties of skeletal muscle<br />
meat, but entire dishes. For instance, ADM’s<br />
textured soya protein concentrates are increasingly<br />
being used to create entirely vegetarian or<br />
vegan versions of traditionally meat-based<br />
dishes. Popular examples include meat-free<br />
versions of chilli con carne, spaghetti bolognese,<br />
meat pies, tacos, burgers and burritos,<br />
which can be created by combining soya protein<br />
with vegetable preparations in the form of<br />
sauces, dips and marinades to offer an all-inone,<br />
ready-to-use solution. The characteristics<br />
of ADM’s soya proteins mean that the difference<br />
in taste, colour and texture is virtually<br />
imperceptible.<br />
New forms and sources of protein<br />
As the current popularity of plant proteins<br />
converges with heightened consumer interest<br />
in flexitarian, vegetarian and vegan lifestyles,<br />
other consumer trends – such as growing<br />
preferences towards minimally processed,<br />
natural and wholesome products – are driving
16<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
Alternative Products<br />
innovation of protein ingredients to<br />
new levels. A wider variety of plant<br />
protein options are entering the<br />
market, with wholefood ingredients<br />
such as legumes, nuts, seeds<br />
and grains coming to the forefront.<br />
Using the example of Mintel<br />
GNPD, grains (such as rice and<br />
Quinoa) and legumes (such as pea)<br />
are the preferred non-traditional<br />
protein sources for many consumers<br />
in Germany (56% and 49%,<br />
respectively). Such ingredients can<br />
be labelled as gluten-free, clean<br />
label and high in protein and fibre,<br />
meeting increasing consumer<br />
demand for ‘real’ foods.<br />
Beans are also increasingly being<br />
incorporated into recipes by formulators<br />
and well-known chefs alike<br />
in order to pack in the nutrients<br />
that have been found to be deficient<br />
in some vegetarian diets.<br />
As wholefood ingredients, bean<br />
varieties including pinto, black,<br />
small red, navy, great northern and<br />
chickpeas contain 20 to 27% protein<br />
and 9 to 29% fibre, depending<br />
on the individual bean type. Available<br />
in a range of formats, beans<br />
can also be used to create different<br />
sensory characteristics in the end<br />
application. Grits for example<br />
provide a crunchy bite, while powder<br />
formats can help manufacturers<br />
achieve a creamier, paste-like<br />
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texture. Furthermore, they can be<br />
declared on labels as bean powder<br />
or grits, satisfying consumer demand<br />
for simple ingredients lists,<br />
as well as meeting the growing<br />
requirements for vegan, non-GMO<br />
and gluten-free products.<br />
Unlike conventional beans,<br />
ADM’s pre-cooked bean portfolio is<br />
available in whole, grit or powder<br />
formats and also undergoes an<br />
additional washing step, which<br />
provides a clean and clear flavour<br />
profile, reducing the need for<br />
masking agents.<br />
Meanwhile, as consumer interest<br />
grows, whole food protein sources<br />
are expanding into non-traditional<br />
applications. ’New’ formats of<br />
protein are increasingly appearing<br />
in food and drink products and<br />
target mainstream consumers for<br />
everyday meal occasions.<br />
Examples include chickpea<br />
spaghetti, smoothies blended using<br />
pea protein, wholegrain brown rice<br />
protein, chickpea powder and lentil<br />
protein and even a chocolate<br />
flavoured lupine drink, thus creating<br />
opportunities to satisfy consumer<br />
demand for natural and<br />
wholesome products in fresh and<br />
exciting ways.<br />
Versatile source<br />
With the trend towards<br />
vegetarian and vegan<br />
continuing to grow,<br />
manufacturers are<br />
faced with new<br />
alternatives for<br />
popular food.<br />
market has to offer. At the same<br />
time, there is a significant opportunity<br />
for manufacturers to reformulate<br />
their product lines using ‘new’<br />
and increasingly popular whole<br />
food protein sources.<br />
As product development challenges<br />
become more complex and<br />
multi-faceted, ADM’s wide-ranging<br />
plant protein offering and knowhow<br />
can support manufacturers in<br />
bringing differentiated, on-trend<br />
products to market.<br />
The company has a broad portfolio<br />
of plant-based ingredients, from<br />
its extensive range of soya proteins<br />
– including soya protein concentrates<br />
and textured concentrates,<br />
isolated soya proteins, customisable<br />
protein crisps –to its edible<br />
bean ingredients, a range of wheat<br />
proteins and a number of organic<br />
options.<br />
References<br />
1. Innova Market Insights (2017) –<br />
2. Research & Markets (2017): Global<br />
Plant Protein Market 2017-2021 –<br />
3. WWF Global (8.08.2017): Soy is everywhere.<br />
http://wwf.panda.org/<br />
what_we_do/footprint/agriculture/<br />
soy/facts/. – 4. Mintel GNPD (2017):<br />
Consumers may be sceptical of new<br />
sources and forms of emerging proteins<br />
With the trend towards vegetarian<br />
and vegan continuing to grow,<br />
manufacturers are faced with an<br />
array of opportunities to tap into<br />
the plant protein movement. As a<br />
high-quality source with a neutral<br />
taste profile, soya protein is one of<br />
the most versatile ingredients<br />
available and can help manufacturers<br />
to capitalise on the potential the<br />
Author’s adress<br />
Roland Snel<br />
is senior technical<br />
manager, WILD Flavors and<br />
Specialty Ingredients, ADM.<br />
Roland Snel, ADM International Sàrl, A One<br />
Business Center, 1180 Rolle, Switzerland
.......................................<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
17<br />
Meat extensions –products with<br />
animal and vegetable components<br />
Products with reduced meat content as alternatives to vegetarian and vegan meat analogues<br />
Combined Proteins<br />
Meat extensions containing components of both animal and vegetable<br />
origin have convincing sensory characteristics, and offer benefits in terms<br />
of animal welfare, environment, climate, sustainability and health. As a<br />
result, it can be assumed that in the future they will gain importance in<br />
this country as well as elsewhere. In formulations, this means using less<br />
meat and more plant protein and vegetable ingredients; the technical<br />
possibilities provided by additives also come into play.Inthe growing<br />
segment of alternatives to conventional meat products, the meat extensions<br />
discussed in this article are astepinthe right direction. They are<br />
also an alternative to other meat analogues currently being researched.<br />
By HerbertWeber<br />
Among the important concerns facing modern society are CO2 reduction,<br />
resource conservation, raw material scarcity,climate change and<br />
environmental protection. The resulting developments will cause changes<br />
in society in the coming years, and influence processes and products in<br />
business.<br />
Changes are always engines for dynamic growth markets. The implementation<br />
of new concepts also affects the viability of companies, since<br />
innovation creates growth. The world belongs to those who innovate. This<br />
is true in all industries, not just engine and automotive technology but<br />
also in food. Nothing is more constant than change, as the ancient Greek<br />
philosopher Heraclitus said.<br />
Market analysis<br />
“Meat is strength” –thisslogan from 1967 by agriculture marketing company<br />
CMA reflected the attitude of many consumers for decades, especially<br />
in Germany.But now there seems to be ashift. Meat production and<br />
consumption are coming under criticism, and perceptions of animal<br />
products have changed. People are looking for alternatives to current meat<br />
Source: Innova NPD <strong>FLEISCHWIRTSCHAFT</strong> <strong>international</strong> 4_<strong>2018</strong><br />
Fig. 1: Product launches in Europe (excluding Germany) in the substitute<br />
category, like meatless sausages and other alternative products.<br />
production methods, especially in view of the growing world population.<br />
Forsome years the vegan and vegetarian product category has been growing.<br />
The trend to eating exclusively vegan or vegetarian started in EU<br />
countries outside Germany(Fig. 1),but has now reached Germany.Since<br />
2014 these products have seen steady growth (Fig. 2), while meat eating<br />
has stagnated in some parts of Europe. From June 2016 to May2017 sales<br />
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18<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
Combined Proteins<br />
Source: Innova NPD <strong>FLEISCHWIRTSCHAFT</strong> <strong>international</strong> 4_<strong>2018</strong><br />
Source: Gartner Inc. <strong>FLEISCHWIRTSCHAFT</strong> <strong>international</strong> 4_<strong>2018</strong><br />
Fig. 2: Product launches in Germany in the substitute category.<br />
Fig. 3: The five phases of the Hype Cycle according to Gartner Inc.<br />
of meat substitute products in Germany totalled €209.1mill., per market<br />
research institute IRI. In this country,establishedmeat producers have<br />
brought movement to the market. Among the pioneers of meatless products<br />
are companies that formerly made only meat products. Todaythey<br />
have alead in meat analogues. Earlier,meat-free was aniche category and<br />
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the products mostly did not have the requisite sensory properties; they<br />
were sold almost exclusively in health food retail. Buttoday supermarkets<br />
and other food retail offer vegetarian and vegan meat analogues, often<br />
placed right next to meat products. These meatless alternatives are typically<br />
integrated into normal meat product lines without much structural<br />
change. They are generally additions to existing product lines, and in<br />
advertising are often presented in the same way as conventional meat<br />
products –although they are far removed from traditional German<br />
sausage culture. In addition to the pioneer and market leader Rügenwalder,there<br />
are other companies that have jumped on the vegetarian and<br />
vegan bandwagon. Canthisbesustained or will it only be temporary? It<br />
remains to be seen how this development will pan out.<br />
The “Hype Cycle” is often cited in the context of new technology or<br />
product introductions. The term comes from the IT industry and was<br />
coined in 1995 by Jackie Fenn. The basic hype cycle has five phases, based<br />
on the amount of attention anew product gets. The cycle is shown in<br />
Figure 3and explainedinTable 1.<br />
Trend analysis and further development<br />
Following their successful start, vegetarian and vegan meat substitutes<br />
seem to be experiencing amarket saturation. Die Welt and Spiegel Online<br />
reported that in Germany the market has been shrinking since the summer<br />
of 2016,based on the latest figures from the consumer research firm<br />
Gesellschaftfür Konsumforschung(GfK). The initial euphoria seems to<br />
have worn off, and repeat sales are not brisk. Obviously,the desire for<br />
meat is not that easy to switch off. Vegan sausage doesn’t taste as good as<br />
many consumers expected. So hasthe veggie boom peaked? If so, why?<br />
Obviously,meat substitutes have not been able to come up to expectations<br />
in terms of flavour and texture. What’s next? What trends are on the horizon?<br />
Are there alternatives? Might there be amiddle way?<br />
Meat extensions as alternatives to<br />
vegetarian and vegan products<br />
Accordingtofoodtrendresearcher Hanni Rützler,meat substitutes are a<br />
helpful transition, but not the solution. The meat extensions category is an<br />
alternative to vegetarian and vegan products that have reached acertain<br />
market share and then stagnated. Meat extension products contain both<br />
animal and plant-origin components. They have better sensory qualities<br />
than vegetarian and vegan products, since there is acertain amount of<br />
meat in them. They are not yet addressed in guidelines, and there are as<br />
yet no regulatory mandates. They are their own product category.Products<br />
with reduced meat and added vegetable components can be considered<br />
hybrids. In technology,ahybrid is asystemthat combines two technolo-
................................................................................................................................................................<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
19<br />
Combined Proteins<br />
The Hype Cycle<br />
Tab. 1: Hype cycle phases, and what happens in them<br />
No. Phase Description<br />
1 Technology Trigger A potential technology breakthrough kicks things off. Early proof-of-concept stories and media<br />
interest trigger significant publicity. Often no usable products exist and commercial viability is<br />
unproven.<br />
2 Peak of Inflated Expectations Early publicity produces a number of success stories – often accompanied by scores of failures.<br />
Some companies take action; most don't.<br />
3 Trough of<br />
Disillusionment<br />
4 Slope of<br />
Enlightenment<br />
5 Plateau of<br />
Productivity<br />
gies. There are successful examples in all kinds of industries. For example,<br />
for a long time metal and plastic were considered competitors in industrial<br />
products, but those days are over and today the different strengths of<br />
metal and plastics are combined. At the same time, there is room for<br />
further innovation. “The best of both worlds” is the tenor of the advertising<br />
for such products. As another example, mixed products combining<br />
butter and vegetable oil are an established and growing category in<br />
spreads. Table 2 shows other examples of innovation with hybrid products<br />
outside the food industry.<br />
Meat extensions are right for consumers who have a moderate attitude<br />
towards eating meat. They don’t want to go entirely without meat or meat<br />
products, but would still like to do something for animal welfare and their<br />
own health. Market researchers term this group “flexitarians”.<br />
Nuremberg market research firm GfK is of the opinion that there are<br />
about seven times as many flexitarians as there are households with at<br />
least one vegetarian. According to market research firm TNS Infratest,<br />
56% of Germans said they eat flexitarian, i.e. more than half of Germans<br />
are flexitarians. This would appear to indicate that flexitarians will have<br />
much more influence on the market success of meat alternatives than will<br />
true vegetarians or vegans. According to GfK, flexitarians buy four times<br />
as many substitute products than non-flexitarians. Food with both meat<br />
and plant components harmonises with the recommendations of the<br />
German Nutrition Society (DGE), which recommends a reduced meat and<br />
sausage consumption of no more than 300 to 600 g per week.<br />
For many consumers, including flexitarians, the flavour of food is<br />
clearly a decisive criterion for repeat purchase and appreciation. And this<br />
is where current meat substitute products disappoint many customers.<br />
The sensory profile may also be unaccustomed. According to TNS Infratest,<br />
27% of Germans have considered reducing the amount of meat they<br />
eat, but have not followed through on it. Meat extensions are a possibility<br />
for this relatively large group as well. The manufacture of these mixed<br />
products was promoted at IFFA 2010. The possibility of more sustainability<br />
was mentioned as a benefit, with the use of more plant and less animal<br />
protein. In this context, it was mentioned that in 2050 there will be about<br />
30% more people on the earth, that alternatives to animal protein are a<br />
part of EU policy in the area of sustainable food production, and that less<br />
greenhouse gas is emitted in the production of these foods (WEBER, 2010).<br />
Many children and adults don’t like vegetables and eat much less of them<br />
than the German Nutrition Society recommends. Making meat extensions<br />
with vegetables is an attractive way to increase the consumption of vegetables<br />
and thereby fibre. This is positive from a health perspective, as is the<br />
Interest wanes as experiments and implementations fail to deliver. Producers of the technology<br />
shake out or fail. Investment continues only if the surviving providers improve their products to<br />
the satisfaction of early adopters.<br />
More instances of how the technology can benefit the enterprise start to crystallise and become<br />
more widely understood. Second- and third-generation products appear from technology providers.<br />
More enterprises fund pilots; conservative companies remain cautious.<br />
Mainstream adoption starts to take off. Criteria for assessing provider viability are more clearly<br />
defined. The technology's broad market applicability and relevance are clearly paying off. If the<br />
technology has more than a niche market, it will continue to grow.<br />
Source: Gartner Inc. <strong>FLEISCHWIRTSCHAFT</strong> <strong>international</strong> 4_<strong>2018</strong><br />
added value of using plant protein. Meat extensions are also an alternative<br />
to other meat substitute products currently being researched, mostly with<br />
ground meat as inspiration. At this year’s Green Week in Berlin, burger<br />
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20<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
Combined Proteins<br />
Hybrid products<br />
Tab. 2: Examples of innovations with hybrid products outside the food category<br />
Hybrid piano<br />
Hybrid car<br />
Hybrid rocket motors<br />
Hybrid heating<br />
Metal-plastic<br />
Car bumpers<br />
General<br />
A musical instrument that combines the advantages of the acoustic and electric or digital keyboard. It brings<br />
together two different sound sources in the truest sense of the word.<br />
Hybrid drive systems combine two different energy storage and propulsion systems. As a rule, hybrid cars have<br />
a petrol engine and an electric motor. The first hybrid vehicles were steamships with sails.<br />
Mix of solid and liquid fuel propulsion.<br />
Combination of two heaters, such as gas or gas-oil burner plus electric heat pump.<br />
Components made of both plastic and metal, used successfully in the automotive industry, communications,<br />
electronics and electrotechnics, and dental technology.<br />
Combinations of plastics and metals for more efficient production, weight savings, and better handling.<br />
In technology, a hybrid system is one in which two technologies are combined.<br />
Source: WEBER <strong>FLEISCHWIRTSCHAFT</strong><strong>international</strong> 4_<strong>2018</strong><br />
patties made of insects aroused great interest at the booth of the Federal<br />
Association of the German Food Industry. Numerous visitors tasted these<br />
meat alternatives made of ground beetle larvae and vegetables. In many<br />
Asian countries insects like grasshoppers, mealworms, larvae and tarantulas<br />
are on the menu. Insects are protein-rich and also inexpensive. It<br />
remains to be seen whether these multilegged creatures will join algae as<br />
part of the western diet. The situation is similar with “in vitro” meat,<br />
which is meat grown in a laboratory from animal stem cells. Here again it<br />
is an open question whether the burgers on our plates will come from<br />
petri dishes. Philosopher Richard David Precht is optimistic. At Meat<br />
Vision Day 2017 in Frankfurt, he predicted that in twenty years meat<br />
production will have changed dramatically, saying that the meat industry<br />
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faces profound shifts. He is convinced that mass production at cheap<br />
prices does not have a future (PRECHT, 2017). That we are in a time of<br />
change is evident from the fact that companies are being founded with the<br />
goal of minimising the negative consequences of meat production for the<br />
environment. Microsoft founder Bill Gates and Google Ventures have<br />
invested in the US startup Impossible Foods, which develops vegetable<br />
foods in a lab that taste like meat and bleed like real ground beef. The<br />
company gives as a reason the fact that current meat production methods<br />
are not viable in the long term. The company examines animal products at<br />
the molecular level and then selects specific proteins and nutrients from<br />
plants to reproduce the flavour of meat and dairy products. The future of<br />
meat-eating was also discussed at this year’s world economic summit in<br />
Davos. The business and political elite determined that today’s meat<br />
production is not sustainable. Possible ways to improve it are to replace<br />
animal protein with plant protein, use artificial lab-grown meat, and<br />
implement precision farming in large scale.<br />
Current world meat production is 229 mill. t. According to a report by<br />
the UN agriculture organisation, by 2050 that will climb to 456 mill. t.<br />
FAO experts fear that this will bring major environmental problems. Meat<br />
extensions with components of animal as well as plant origin are not just<br />
high in sensory quality, but also positive in terms of animal welfare, the<br />
environment, the climate, sustainability and health.<br />
As regards protein content, meat extensions are absolutely the equal<br />
of traditional meat products. These new products contain protein of<br />
high biological value and take into account the composition of the proteins,<br />
i.e. the amino acids they contain. Animal proteins consist of<br />
20 amino acids, some of which the human body can synthesise. Those it<br />
cannot must be supplied by food. These are the essential amino acids.<br />
The biological value of proteins is based on their content of essential<br />
amino acids and ranks proteins in how well they meet human nutritional<br />
needs. High quality plant protein can have the biological value of<br />
pig protein (PEIN, 2016).<br />
An important argument in favour of meat extensions It is also the fact<br />
that fewer animals need to be slaughtered to supply the raw materials.<br />
This is another reason that this product category can be expected to become<br />
more widespread here in future. In other countries, recipes are<br />
already calling for less meat and making use of the possibilities afforded<br />
by additives. In England, the firm of Debbie and Andrew’s presented a line<br />
last year for flexitarians that contains both animal and plant components.<br />
This is a welcome development, and constitutes an image shift.<br />
Sustainable solutions for meat products<br />
In the growing segment of meat alternatives, the Hydrosol company in<br />
Ahrensburg, Germany, has developed various formulations for making<br />
meat extensions. These stabilising systems make it possible to use considerably<br />
less meat, opening up the possibility of products made of meat and
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
21<br />
Combined Proteins<br />
vegetables, for example. This enables conservation of valuable meat resources,<br />
which is a step in the right direction for the environment. With<br />
these ingredient combinations it is possible to use formulations that give<br />
high-quality products with lower meat content. The spectrum of these<br />
stabilising systems ranges from low-cost to premium qualities. These<br />
individual all-in solutions from a single source make it possible to produce<br />
foods that combine enjoyment, convenience and healthy nutrition.<br />
References:<br />
1. Impossible Foods (2017): www.impossiblefoods.com . Accessed 12 September<br />
2017. – 2. REMKE, M. (2017): Meat alternatives. A vegetarian burger that is bloody on<br />
the inside (in German). Welt, 31 March 2017. – 3. PEIN, D. (2016): Substitutes for meat<br />
and dairy products (in German). Dei 1/2016, 42–43. – 4. PRECHT, R.D. (2017): Presentation<br />
at Meat Vision Day 2017 (in German), Frankfurt Fair, Deutscher Fachverlag<br />
GmbH, 26 April 2017. – 5. RÜTZLER, H. (2017): Zukunftsinstitut GmbH. www.zukunftsinsitut.de.<br />
Accessed 10 September 2017. – 6. WEBER, H. (2010): Current developments<br />
in packaging meat, sausage and convenience products. Trend to robot integration<br />
(in German). Fleischwirtschaft 90 (11), 52–60.<br />
Herbert Weber<br />
is a retired professor. Until April 2015 he taught food and packaging technology at<br />
the Beuth University of Applied Sciences in Berlin. He was an instructor at the<br />
University of Hohenheim, and is co-founder of the ifp Institute for Product Quality<br />
in Berlin. A butcher and food technologist by profession, prior to entering<br />
academia he worked in the seasonings and additives industry. Today he is active as a senior<br />
consultant.<br />
Author’s address<br />
Dr. Herbert Weber, Stahlackerweg 3, 73733 Esslingen, Germany, dr.web@t-online.de<br />
Givaudan<br />
Consumers look for protein<br />
The development of meat<br />
analogues often comes with<br />
sensory challenges.<br />
Proteins perform many functions in<br />
the body. As well as helping the<br />
human body to grow and repair,<br />
they are essential for maintaining<br />
good health. Consumers everywhere<br />
have become more aware<br />
that plant-based protein sources<br />
offer many positive nutritional and<br />
emotional properties. So proteins<br />
have become an important consideration<br />
for many consumers. A<br />
study by the Institute of Food<br />
Technologists (IFT) showed that<br />
59% of consumers globally are<br />
actively seeking foods that are<br />
high in protein, and plant-based<br />
protein sources in particular. This<br />
has led to a surge in growth of<br />
non-animal meat products, known<br />
as meat analogues. Along with<br />
their benefits, however, these<br />
protein products also often come<br />
with taste, mouthfeel and texture<br />
challenges. Solutions for success<br />
require deep knowledge of different<br />
proteins, their functionality,<br />
nutritional and taste characteristics.<br />
When a prdoduct developer is<br />
searching for authentic, real<br />
meatiness for an alternative meat<br />
product, Givaudan from Vernier,<br />
Switzerland, can help with the<br />
company’s expertise to make it<br />
taste great.<br />
//www.givaudan.com<br />
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Atago<br />
Salinity checks done easily<br />
Adding salt is one of the most<br />
critical processes in food manufacturing<br />
as it has a significant<br />
effect on the color, taste, and<br />
texture of food. Salt meters designed<br />
by Atago from Tokyo, Japan,<br />
are ideal for quick and easy salinity<br />
checks on the production floor.<br />
Recently, in addition to use in<br />
the production are, many companies<br />
are validating these salt<br />
meters as the preferred method in<br />
lab setting as well. Food scientists<br />
are choosing to limit the use of<br />
precipitation titration with harmful<br />
The salt meter is easy to use.<br />
sliver nitrate which is needed for<br />
the classical Mohr's method.<br />
The salt meters are sage, fast,<br />
and simple. Due to the difference<br />
in measurement principles, reading<br />
from the conductivity salt meters<br />
may not match up exactly with the<br />
reading by titration for certain<br />
samples. However, by creating a<br />
conversion table between the two<br />
testing methods, correlation between<br />
the set of results can be<br />
seen. Unlike titration, no expensive<br />
and harmful chemical is involved in<br />
the measurement process. The<br />
results are displayed within 3<br />
seconds. To start the measurment,<br />
the user has just to press the start<br />
key. Also calibration is easy: Only<br />
the sensor has to be cleaned and<br />
than the zero key must be pressed.<br />
The digital display guarantees for<br />
no more varied readings caused by<br />
user interpretation. The salt meter<br />
is equipped with an automatic<br />
temperature compensation; that<br />
makes the measuring device reliable<br />
for any samples, hot or cold.<br />
//www.atago.net
22<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
Hygiene<br />
Fig. 1: Rapid<br />
agglutination assays<br />
show a negative<br />
result, when the<br />
original color<br />
retains; a positive<br />
result is indicated<br />
by distinct color<br />
agglutination.<br />
Detection assures food safety<br />
State-of-the-art microbiological tests help to reduce the risk of human illness cases – Part 2<br />
Consumption of minimally processed<br />
RTE-meats increases the risk<br />
of human illness cases since these<br />
products generally do not receive any<br />
further treatment before consumption.<br />
All raw meat can have some<br />
level of microbial contamination<br />
present. Modern microbiological<br />
methods are able to deliver detailed<br />
insight of a microbial contamination<br />
of meat or a meat product.<br />
By Akhilesh K. Verma,<br />
A. Prajapati and<br />
Pramila Umaraw<br />
Conventional or traditional methods<br />
for detecting microorganisms<br />
in meats are based on the<br />
incorporation of samples into a<br />
nutrient medium in which microorganisms<br />
can multiply, thus providing<br />
visual confirmation of their<br />
growth. These conventional test<br />
methods are simple, easily adaptable,<br />
very practical, and generally<br />
inexpensive. More and more new<br />
technolgies find their way into labs<br />
specialized in meat testing.<br />
Immunological detection<br />
methods<br />
These techniques are based on<br />
specific body-antibody reactions.<br />
Rapid agglutination assays<br />
The test is based on visible clumps<br />
shown by organisms in presence of<br />
specific antibodies. These are rapid<br />
and easy to perform. Sensitivity and<br />
specificity may vary from organism<br />
to organism and the antibodies<br />
used which may lack specificity due<br />
to non-specific agglutination of<br />
some other organisms (CHEES-<br />
BROUGH and DONNELLY, 1996).<br />
These tests are primarily used for<br />
screening of suspected bacterial<br />
colonies after culture isolation from<br />
selective agar plates. Latex agglutination<br />
assay tests are widely used<br />
for the rapid detection of Salmonella<br />
in which a drop of colony suspension<br />
or enrichment broth is mixed<br />
with the latex reagent. The latex<br />
remains in the homogenous suspension<br />
and retains its original<br />
color in a negative test. A positive<br />
result is indicated by distinct color<br />
agglutination against an altered<br />
background (Fig. 1).<br />
Lateral flow devices<br />
Lateral flow devices (LFD) are<br />
typically comprised of a simple<br />
dipstick made of a porous membrane<br />
that contains colored latex<br />
beads or colloidal gold particles<br />
coated with detection antibodies<br />
targeted toward a specific microorganism.<br />
The particles are found<br />
on the base of the dipstick, which is<br />
put in contact with the enrichment<br />
medium (POSTHUMA-TRUMPIE et<br />
al., 2009). If the target organism is<br />
present it will bind with the colored<br />
particles. This conjugated cell/<br />
particle moves by capillary action<br />
until it finds the immobilized<br />
capture antibodies. Upon binding<br />
with these, it forms a colored line<br />
that is clearly visible in the device<br />
window, indicating a positive result<br />
(BETTS and BLACKBURN, 2009). LFD<br />
also requires previous enrichment.<br />
Results are often available within<br />
24 h. False positive results may be<br />
observed during the reaction because<br />
of denaturation or degradation<br />
of the capture antibody and it is<br />
likely that the detection antibody or<br />
the enzyme-conjugated antibody<br />
may also bind the non-specifically<br />
to denatured capture antibody. The<br />
technique is extremely simple to<br />
use and easy to interpret, requires<br />
no washing or manipulation, and<br />
can be completed within 10 min<br />
after culture enrichment (ALDUS et<br />
al., 2003).<br />
ELISA and ELFA<br />
The Enzyme-Linked Immunosorbent<br />
Assay (ELISA) is a biochemical<br />
technique that combines an immunoassay<br />
with an enzymatic assay.<br />
An antibody bound to a solid matrix<br />
is used to capture the antigen from<br />
enrichment cultures and a second<br />
antibody conjugated to an enzyme is<br />
used for detection. The enzyme is<br />
capable of generating a product<br />
detectable by a change in color, or in<br />
the case of Enzyme-Linked Fluorescence<br />
Assay (ELFA) in fluorescence,<br />
which allows for indirect measurement<br />
using spectrophotometry (or<br />
fluorometry for ELFA) of the antigen<br />
present in the sample (microorganism<br />
or toxin) (COHEN and KERDAHI,<br />
1996; JASSON et al., 2010). The success<br />
of an immunoassay depends on<br />
the specificity of the antibody. The<br />
limit of detection for immunoassays<br />
is approximately 10 4 –10 5 CFU/g<br />
depending on the type of antibody<br />
and its affinity for the corresponding<br />
epitope, which means that one or<br />
two previous enrichment stages are<br />
always required (JASSON et al., 2010).<br />
High limits of sensitivity of<br />
>10 5 CFU/mL (COX, 1988), cross<br />
reactivity and changes to antigens<br />
due to acetylation and changing<br />
recognition by assay antibodies<br />
(KIM and SLAUCH, 1999) are the<br />
some disadvantages of ELISA<br />
methods.<br />
Molecular detection methods<br />
These techniques base on specific<br />
molecular reactions.<br />
DNA based methods<br />
The ability of two single stranded<br />
DNA-molecules in vitro, under the<br />
right conditions, to form double<br />
stranded DNA by specific base<br />
pairing, i.e. to hybridize, is the basis<br />
of all DNA-based detection methods<br />
(Fig. 2). While many different<br />
methods based on specific base
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
23<br />
Hygiene<br />
pairing have been developed (WOL-<br />
COTT, 1992), three methods, i.e.<br />
colony hybridization (GRUNSTEIN<br />
and HOGNESS, 1975), single phase,<br />
liquid hybridization assays (CURI-<br />
ALE, KLATT and MOZOLA, 1990), and<br />
PCR (SAIKI et al., 1988) are in particular<br />
relevant for the detection of<br />
bacteria in meats.<br />
Nucleic acid-based technologies<br />
A DNA probe is a short<br />
(14–40 bases) single-stranded<br />
sequence of nucleotide bases that<br />
will bind to specific regions of<br />
single-stranded target DNA sequences;<br />
the homology between the<br />
target and the DNA probe results in<br />
stable hybridization. Hybridization<br />
is monitored by labeling probes, by<br />
attachment to or incorporation into<br />
the probe, with compounds that can<br />
be detected visually or chemically.<br />
Isotopes such as P 32 , enzymes such<br />
as alkaline phosphatase or horseradish<br />
peroxidase (HRP) and fluorescently<br />
labeled compounds such<br />
as fluorescein isothiocyanate are<br />
often linked to the probe via a<br />
chemical linkage.<br />
Colony hybridization<br />
In the colony hybridization assay, a<br />
meat sample or an enrichment<br />
culture is spread on a nylon or<br />
paper filter and incubated until<br />
visible colonies are present. These<br />
are processed to destroy the cells,<br />
remove cell substances and leave<br />
fixed single-stranded DNA for<br />
hybridization, usually by treatment<br />
with detergents and alkali or by<br />
microwave treatment as in the<br />
method of DATTA et al. (1987). A<br />
radio, enzyme or hapten labeled<br />
DNA-probe, which constitutes parts<br />
of the target DNA-sequence, is<br />
applied to hybridize to the sample<br />
DNA. Each signal on the filter<br />
corresponds to a positive identification,<br />
and upon direct spreading of<br />
samples, colony hybridization is a<br />
quantitative method. Since oligonucleotides<br />
can be synthesized in vivo,<br />
short, defined and synthetic<br />
oligonucleotides were quickly<br />
introduces into food microbiology<br />
(HILL et al., 1985) and are now by<br />
far preferred as probe molecules.<br />
An essential step in colony hybridization<br />
is the separation between<br />
labeled probe molecules<br />
bound to the target DNA and those<br />
that bind non-specifically to the<br />
filter. This is obtained by stringency<br />
washing, which is only possible<br />
when the target DNA is fixed to a<br />
solid support, i.e. the filter.<br />
Isolates of Bacillus cereus from<br />
traditional Indian foods were<br />
detected by colony hybridization<br />
using the PCR-generated phospholipase<br />
(PL-1) method. In all, 29 isolates<br />
picked up by the probe were<br />
confirmed as B. cereus by conventional<br />
cultural and biochemical<br />
characteristics (RADHIKA et al.,<br />
2002). A genetic probe was used to<br />
identify and enumerate virulent<br />
Yersinia enterocolitica colonies in<br />
eleven artificially contaminated<br />
foods. Efficiency of enumeration,<br />
determined by autoradiography<br />
after DNA colony hybridization,<br />
ranged from 66% to 100% (average<br />
86%) and was influenced by the<br />
number of indigenous bacteria<br />
(JAGOW and WE, 1986.) A plasmid<br />
containing the cloned listeriolysin<br />
gene of Listeria monocytogenes was<br />
used as a probe to identify Listeria<br />
strains by DNA colony hybridization.<br />
Of the 150 Listeria strains and<br />
16 non-Listeria strains examined,<br />
the probe hybridized only with L.<br />
monocytogenes. The technique was<br />
also used to enumerate L. monocytogenes<br />
in artificially contaminated<br />
foods (DATTA et al., 1993). JONES et<br />
al. (2009) examined for detection of<br />
Vibrios from postharvest-processed<br />
(PHP) oysters and each sample<br />
was analyzed for Vibrio parahaemolyticus<br />
and V. vulnificus; here<br />
was 96% agreement between<br />
real-time and DNA colony hybridization.<br />
Fluorescent in-situ hybridization<br />
Fluorescent in-situ hybridization<br />
(FISH) with oligonucleotide probes<br />
directed at rRNA is the most common<br />
method among molecular<br />
techniques not based on PCR. The<br />
probes used by FISH tend to be<br />
15–25 nucleotides in length, and are<br />
covalently labeled at their 5’ end<br />
with fluorescent labels. After hybridization,<br />
the specifically stained<br />
cells are detected using epifluorescence<br />
microscopy (WAGNER et al.,<br />
2003). The detection limit of this<br />
technique is around 10 4 CFU/g.<br />
Following pre-enrichment results<br />
can be achieved in 3h.<br />
Whole fixed cells can be identified<br />
and counted directly by fluorescent<br />
in-situ hybridization<br />
(FISH), allowing different microbial<br />
species in mixed cultures to be<br />
distinguished. Detection of specific<br />
food contaminants can be<br />
achieved by FISH coupled with<br />
FCM (FLOW–FISH). For example,<br />
rapid and sensitive FLOW–FISH<br />
methods have been used for detecting<br />
and enumerating Cornybacteria<br />
and Lactobacillus brevis in<br />
seafood products and lactic acid<br />
bacteria used as starter cultures.<br />
This technique can provide a rapid<br />
Fig. 2: Three DNA-based methods are in particular relevant for the detection of bacteria in meats.
24<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
Hygiene<br />
Detection assures food safety<br />
Fig. 3: The analysis of the patterns obtained by PCR can take a number of hours.<br />
and sensitive method for the rapid<br />
enumeration of microorganisms.<br />
The success of the system depends<br />
on the development and use of<br />
suitable staining systems, and<br />
protocols for the separation of<br />
microorganisms from food debris<br />
that would otherwise interfere<br />
with the detection system.<br />
Polymerase chain reaction<br />
Polymerase chain reaction (PCR)<br />
is a method used for the in vitro<br />
enzymatic synthesis of specific<br />
DNA sequences by Taq and other<br />
thermoresistant DNA polymerases.<br />
PCR uses oligonucleotide<br />
primers that are usually<br />
20–30 nucleotides in length and<br />
whose sequence is homologous to<br />
the ends of the genomic DNA<br />
region to be amplified. The<br />
method is performed in repeated<br />
cycles, so that the products of one<br />
cycle serve as the DNA template<br />
for the next cycle, doubling the<br />
number of target DNA copies in<br />
each cycle (HILL, 1996).<br />
Conventional PCR relies on<br />
amplification of the target gene(s)<br />
in a thermo-cycler, separation of<br />
PCR products by gel electrophoresis,<br />
followed by visualization and<br />
analysis of the resulting electrophoretic<br />
patterns (Fig. 3), a<br />
process that can take a number of<br />
hours. The specificity can be subsequently<br />
confirmed by sequencing<br />
the amplified fragment. PCR can<br />
be superior to culture for detecting<br />
the main pathogens in food samples<br />
(ABUBAKAR et al., 2007).<br />
Multiplex PCR (mPCR) combines<br />
several specific primersets<br />
into a single PCR assay for the<br />
simultaneous amplification of<br />
more than one target DNA sequence<br />
(CHAMBERLAIN et al., 1988).<br />
As with conventional or endpoint<br />
PCR, the amplified DNA targets are<br />
separated by agarose gel electrophoresis<br />
and visualized by ethidium<br />
bromide staining. O’REGAN et<br />
al. (2008) developed a real-time<br />
multiplex PCR assay for the detection<br />
of multiple Salmonella<br />
serotypes in chicken samples.<br />
Poultry-associated serotypes detected<br />
in the assay included S.<br />
Enteritidis, S. Gallinarum, S. Typhimurium,<br />
S. Kentucky and S.<br />
Dublin.<br />
RPeal-time PCR allows both the<br />
detection and quantification of a<br />
signal emitted by the amplified<br />
product by using the continuous<br />
measurement of a fluorescent label<br />
during the PCR reaction. The<br />
increase in fluorescence can be<br />
monitored in real time, which<br />
allows accurate quantification over<br />
several orders of magnitude of the<br />
DNA target sequence. Results can<br />
be obtained in an hour or less,<br />
which is considerably faster than<br />
conventional PCR without the he<br />
need for post-amplification steps<br />
such as gel electrophoresis. Realtime<br />
PCR based system is used in<br />
food microbiology, which is a fast<br />
and accurate test for screening food<br />
and environmental samples for<br />
pathogens, e.g. E. coli O157:H7,<br />
Listeria monocytogenes, Enterobacter<br />
sakazakii, Salmonella, Campylobacter<br />
coli etc.<br />
The simplest approach involves<br />
the use of the intercalating fluorescent<br />
dye SYBR Green. This fluorogenic<br />
dye exhibits little fluorescence<br />
when in solution, but emits a<br />
strong fluorescent signal upon<br />
binding to double-stranded DNA.<br />
Thus, as a PCR product accumulates,<br />
fluorescence increases. The<br />
advantages of SYBR Green are that<br />
it is inexpensive, simple, and sensitive.<br />
The disadvantage is that SYBR<br />
Green will bind to any doublestranded<br />
DNA in the reaction,<br />
which may result in an overestimation<br />
of the target concentration. A<br />
second, more accurate and reliable<br />
method is to use fluorescent reporter<br />
probes (TaqMan, Molecular<br />
Beacons, and Scorpions). These<br />
probes depend on Forster Resonance<br />
Energy Transfer (FRET) to<br />
generate the fluorescence signal via<br />
the coupling of a fluorogenic dye<br />
molecule and a quencher moiety to<br />
the same or different oligonucleotide<br />
substrates. The main<br />
advantage of TaqMan probes,<br />
Molecular Beacons and Scorpions<br />
is that they allow for multiplex PCR<br />
assays by using spectrally separated<br />
fluor/quench moieties for each<br />
probe. Multiplex PCR allows internal<br />
controls to be co-amplified and<br />
permits allele discrimination in<br />
single-tube, homogeneous assays.<br />
These hybridization probes afford a<br />
level of discrimination impossible<br />
to obtain with SYBR Green, since<br />
they will only hybridize to true<br />
targets in a PCR and not toprimerdimers<br />
or other spurious products.<br />
However these probes can be expensive<br />
to synthesize, with a separate<br />
probe needed for each target<br />
being analyzed.<br />
Detection of pathogens by PCR<br />
in meats samples often requires<br />
additional evidence of viability<br />
before risks can be assigned. PCR<br />
assay cannot differentiate viable<br />
and non viable organism in the<br />
sample. So amplification of genomic<br />
DNA by PCR has been<br />
shown to be inappropriate for<br />
distinguishing viable from nonviable<br />
bacteria (MASTERS et al.,<br />
1994). Furthermore, in an effort to<br />
address the issue of viability, many<br />
researchers turned to RNA amplification<br />
methods using mRNA as a<br />
target since it is a molecule with a<br />
very short half-life of 0.5 to 2min<br />
due to the rapid degradation by<br />
endogenous RNAases (KING et al.,<br />
1986). For this purpose RT-PCR has<br />
been developed to detect the specific<br />
mRNA. In RT-PCR, an RNA<br />
Fig. 4: Bacteriophages are viruses infecting bacteria and kill them during their multiplication.
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
25<br />
Hygiene<br />
strand is first reverse transcribed<br />
into its DNA complement (complementary<br />
DNA, or cDNA) using the<br />
enzyme reverse transcriptase, and<br />
the resulting cDNA is then amplified<br />
using conventional, multiplex,<br />
or real-time PCR. RIJPENS et al.<br />
(2002) targeted the housekeeping<br />
rpoD gene of Salmonella which can<br />
detect only viable Salmonella and<br />
not killed germs.<br />
Gene sequencing methods<br />
Many laboratories have been shifting<br />
to genotypic characterization<br />
methods. The most prevalent<br />
methods use comparative DNA<br />
sequencing of the 16 SrRNA gene<br />
in bacteria and a region associated<br />
with the 26 SrRNA gene in fungi.<br />
After extraction and purification of<br />
the genomic DNA, PCR amplifies<br />
the gene or region of interest. A<br />
DNA sequencer automatically<br />
determines the nucleotide sequence<br />
using a process similar to<br />
PCR, but incorporating fluorescently<br />
labeled terminators to create<br />
DNA fragments spanning the<br />
length of the sequence. The comparison<br />
of the resulting DNA sequence<br />
to a database library files<br />
provides identification data including<br />
taxonomy, data quality, and level<br />
of confidence.<br />
Other genotypic methods include<br />
the analysis of restriction endonuclease<br />
patterns. Use of restriction<br />
mapping also allows strain differentiation<br />
and isolates comparisons.<br />
These genetic methods replace<br />
classical methods or they may<br />
supplement testing when the classical<br />
methods fail to yield an acceptable<br />
level of identity. Genetic methods<br />
can reduce identity testing to an<br />
overnight procedure.<br />
domains of phage are specific to the<br />
bacteria wall and help in binding to<br />
specific bacteria. This has been<br />
utilized for immune magnetic<br />
separation of bacteria by replacing<br />
the antibody in a magnetic complex.<br />
And it was found to outperform<br />
commercially available antibodybased<br />
magnetic beads with respect to<br />
sensitivity and percent recovery<br />
(KRETZER et al., 2007).<br />
Conclusion<br />
Currently, traditional culture-based<br />
methods are still used to identify<br />
the majority of meats-associated<br />
bacteria in the daily routine of meat<br />
industry microbiology laboratories.<br />
Complete identification requires at<br />
least two days or more for fastidious<br />
organisms.<br />
In addition, differentiation of<br />
isolates with a different taxonomic<br />
background but similar physiological<br />
characteristics is limited using<br />
these phenotypic methods. Therefore,<br />
traditional phenotypic methods<br />
are – to some extent – supplemented<br />
with serological and genotyping<br />
methods. Generally, serological<br />
methods do not require pure<br />
cultures, but have a low-level of<br />
discriminatory power and are restricted<br />
to species for which antisera<br />
are available. In contrast, genotyping<br />
methods enable rapid identification<br />
and are highly sensitive and<br />
specific, but require high levels of<br />
technical expertise and remain<br />
expensive. Therefore, they are not<br />
suitable for routine identification.<br />
References<br />
Literature references can be requested<br />
from the corresponding author or the<br />
editorial office, respectively.<br />
Phage based diagnosis<br />
Lytic bacteriophages (Fig. 4) are<br />
viruses infecting bacteria and kill the<br />
bacteria during its multiplication.<br />
They are extremely host-specific, and<br />
able only to infect specific species or<br />
even strains. Various workers used<br />
different technique to utilize the<br />
phages for bacterial detection. A<br />
vector phage is cloned with luciferase<br />
lux genes of Vibrio fisherii.<br />
The gene acts as a reporter gene<br />
which expressed only after infection<br />
and gives bio luminescence. Another<br />
approach is the adsorption of phages<br />
on target bacteria followed by killing<br />
the free phages by veridical. Adsorbed<br />
phages can be detected by<br />
plague assay. Cell wall binding<br />
Authors’ addresses<br />
Akhilesh K. Verma (corresponding author:<br />
vetakhilesh@rediffmail.com, s/o Uday Raj<br />
Verma, Village & Post-Rukunpur-Kasimpur,<br />
Tehsil-Jalalpur District, Ambedkar Nagar,<br />
Uttar Pradesh 224149), Department of<br />
Livestock Products Technology, College of<br />
Veterinary and Animal Sciences, Sardar<br />
Vallabhbhai Patel University of Agriculture &<br />
Technology, Meerut, U.P.-250110, India, A.<br />
Prajapati, National Institute of Veterinary<br />
Epidemiology and Disease Informatics,<br />
Hebbal, Bengaluru-560024, Karnataka, India,<br />
and Pramila Umaraw, Division of Livestock<br />
Products Technology, Indian Veterinary<br />
Research Institute, Bareilly-243122, Uttar<br />
Pradesh, India.
26<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
Marking<br />
Technology makes it easier to<br />
code and mark in the meat and<br />
poultry sector.<br />
Food packaging and labeling<br />
Driving efficiency in meat and poultry coding<br />
To keep pace with the growing<br />
demand on the <strong>international</strong> markets,<br />
especially because of China,<br />
meat and poultry producers have to<br />
ensure that production lines are<br />
optimized. The trend towards<br />
automation to reduce human contact<br />
with the product has gathered<br />
serious momentum in recent years.<br />
By James Wolff<br />
Global production in the meat<br />
and poultry industry has only<br />
seen modest growth in recent<br />
years. Beef and veal production is<br />
forecast by USDA to grow by 2%<br />
in <strong>2018</strong> to 62.6 mill. t. Pork production<br />
is experiencing similar<br />
growth at 2%, growing to<br />
113.1mill. t., while broiler meat<br />
(poultry) is forecast to increase by<br />
1% to 91.3 mill. t. China is a key<br />
driver for the export market, as its<br />
domestic production cannot keep<br />
pace with growing national demand.<br />
In developed markets, such as<br />
the US and Europe, red meat<br />
consumption has seen declines in<br />
recent years, in part due to consumers<br />
cutting back amidst fears<br />
of negative health effects. However,<br />
even though consumption<br />
has decreased, dollar sales have<br />
increased due to heavily marketed<br />
value-added products according to<br />
Packaged Facts.<br />
Time-strapped consumers are<br />
increasingly being targeted with<br />
convenience and on-the-go products,<br />
often in portion-controlled<br />
pack sizes. Further, consumer<br />
demand for a broader variety of<br />
product selections is driving<br />
product proliferation.<br />
In addition, higher end meat<br />
purchases have helped to stabilise<br />
sales, as those consumers with<br />
higher levels of disposable income<br />
continue to select more<br />
premium cuts.<br />
Meat and poultry processors, to<br />
keep pace with demand, have to<br />
ensure that production lines are<br />
optimized – particularly given that<br />
profit margins in this sector are<br />
notoriously slim – and the trend<br />
towards automation to reduce<br />
human contact with the product<br />
has gathered serious momentum<br />
in recent years.<br />
Additionally, sanitation is a key<br />
factor in meat and poultry production<br />
- particularly given that consumers<br />
are more aware of how<br />
their food is produced and under<br />
what conditions. Consumers’<br />
instant ability, via social media<br />
channels, for example, to make<br />
their dissatisfaction public cannot<br />
be overlooked.<br />
Regulatory compliance helps<br />
mitigate the risk of recalls<br />
Damage to your brand and product<br />
recalls can have a significant<br />
financial impact on a business,<br />
and are often experienced because<br />
of a substandard or mislabelled<br />
product reaching a consumer.<br />
Strict regulatory guidelines<br />
are in place in a number of<br />
areas in order to ensure everything<br />
in a processor’s power is<br />
done to protect public health,<br />
and compliance ensures the best<br />
possible working practices are<br />
maintained. In addition to bacterial<br />
contamination, mislabelling<br />
and undeclared allergen information<br />
are common causes for
28<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
Marking<br />
Food packaging and labeling<br />
In addition to using a bar<br />
code to load product codes in<br />
amulti-product operation,<br />
coders can help to ensure<br />
code accuracy.<br />
Awell-structured display simplifies the adjustment of the labels.<br />
Staying in touch with the<br />
latest trends is important for<br />
manufacturers.<br />
product recalls and can be avoided<br />
through the use of the correct<br />
software at the coding and marking<br />
stage of production. With<br />
increasing SKU complexity, it is<br />
ever more likely that human error<br />
could lead to incorrect information<br />
being printed onto a product,<br />
and in order to combat this, advanced<br />
code assurance technology<br />
has been developed to make this<br />
occurrence a near impossibility.<br />
Bar code scanners are a relatively<br />
inexpensive way to reduce<br />
the risk of selecting the wrong<br />
code when changing over to a<br />
different production run. A handheld<br />
bar code scanner plugs into<br />
the bottom of a coder that either<br />
has internal memory or is connected<br />
to a network. At installation,<br />
all codes used for the specific<br />
line are pre-programmed into the<br />
coder or on the network along<br />
with a UPC code for each package<br />
type. Then, during a changeover,<br />
the line manager simply scans the<br />
new package UPC or associated<br />
bar code from a job card to automatically<br />
retrieve the correct code<br />
format and content. No required<br />
typing means no room for code<br />
errors.<br />
In addition to using a bar code<br />
scanner to load product codes in a<br />
multi-product operation, coders<br />
can be networked to help ensure<br />
product code accuracy. Multiple<br />
coders can be connected using<br />
common software through a<br />
company network and an internet<br />
or Ethernet connection. Networking<br />
enables centralized message<br />
creation and message loading to<br />
multiple coders on a line or in a<br />
facility. Once all the coders are<br />
connected to a single network, a<br />
production manager can use a<br />
computer to create or load specific<br />
codes from the saved database.<br />
Immaculate sanitation is key<br />
Wherever food products are concerned,<br />
sanitation must be a<br />
priority for a number of reasons.<br />
Firstly, regulatory requirements<br />
will often dictate that a line must<br />
be washed down at regular intervals.<br />
Secondly, the risks of contamination,<br />
particularly where<br />
meat and poultry are concerned,<br />
are very real. Sending contaminated<br />
product into the retail supply<br />
chain not only puts a business<br />
at severe risk – but more importantly,<br />
also puts the end consumer<br />
at risk.<br />
One of the challenges of such<br />
vigorous sanitation requirements<br />
is downtime. A line will have to be<br />
stopped to be sanitized, therefore<br />
speed is of the essence if lost<br />
production time is to be kept to a<br />
minimum. Where coding and<br />
marking systems are concerned,<br />
an expert provider will work<br />
closely with its customers to<br />
identify the pain points such as<br />
removing the printer or placing<br />
plastic bags over printers during a<br />
washdown. For example, Continuous<br />
Inkjet (CIJ) Printers are available<br />
on the market today that<br />
enable efficient cleaning operations<br />
without the need to use<br />
bags. The Videojet 1860 CIJ<br />
printer, for example, enables an<br />
efficient cleaning operation and<br />
faster restart of your line. Hygienic<br />
design following industry<br />
guidelines incorporates slanted<br />
surfaces that help to prevent<br />
fluids or debris build-up, and help<br />
eliminate potential dirt traps. In<br />
addition, an optional IP66 ingress<br />
protection rating enables operators<br />
to clean printers without<br />
removing them from the production<br />
line. This further enhances<br />
the speed at which washdowns<br />
can be carried out, as the printer<br />
effectively lives on the line –<br />
having been designed specifically<br />
to deal with its intended environment.<br />
Driving down<br />
operational costs<br />
Profit margins in the meat and<br />
poultry industry can be slim,<br />
therefore any measures that reduce<br />
operational costs will add<br />
significantly to a processor’s<br />
bottom line. Advanced coding and<br />
marking systems can have an<br />
important role to play. In order to<br />
meet regulatory requirements,<br />
food products must be coded and<br />
marked. A line will not run if the<br />
coder is down for any reason, and<br />
if errors occur due to incorrect<br />
codes, for example, this can also<br />
lead to downtime and product<br />
waste.<br />
Coding and marking systems<br />
have evolved alongside industry<br />
challenges to reduce costs and<br />
withstand challenging environments.<br />
Smart CIJ printers, commonly<br />
used in the meat and<br />
poultry industry, now have several<br />
built-in features that help to<br />
streamline costs. Ink consumption,<br />
for example, where through<br />
an innovative condenser and<br />
solvent recirculation design,<br />
consumption levels have been<br />
reduced by up to 20% compared<br />
to older printer models. Intelligent<br />
printer air flow systems also<br />
allow for smart temperature<br />
regulation without the need for<br />
expensive factory air systems.<br />
Intelligent printer air flow system<br />
directs clean, cool air to critical<br />
components in the printer, extending<br />
the stable operating<br />
temperature range to 0-50 °C,<br />
even in the most challenging<br />
environments.<br />
Printhead design for CIJ units<br />
has also evolved to deliver better<br />
line integration through more<br />
mounting options and closer<br />
proximity to the product. Printheads<br />
can now get as close as<br />
2mm to the package, delivering<br />
crisper, better quality codes and<br />
therefore reducing product waste<br />
and improving quality. Ink build
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
29<br />
Marking<br />
up sensors are now available,<br />
which significantly reduce the<br />
main cause of unplanned printer<br />
downtime. Printheads incorporate<br />
unique sensors, which enable<br />
the printer to detect ink build up<br />
in the printhead, alerting the user<br />
with advanced notification before<br />
significant faults occur. In addition,<br />
continuous monitoring of<br />
the health of the printer – carried<br />
out by inbuilt sensors – means<br />
potential issues can be identified,<br />
diagnosed and avoided before<br />
they even happen.<br />
gather momentum, so too does<br />
the drive of machine manufacturers<br />
to offer ever more advanced<br />
and efficient capital equipment.<br />
By working with an expert<br />
provider to ensure the correct<br />
configuration is selected for a<br />
particular line, manufacturers can<br />
start to reap the rewards from the<br />
very first day of installation, ensuring<br />
profit margins remain the<br />
right side of the line.<br />
References<br />
1. USDA (10.<strong>04</strong>.<strong>2018</strong>): Livestock and<br />
Poultry: World Markets and Trade.<br />
https://apps.fas.usda.gov/psdonline/<br />
circulars/livestock_poultry.pdf . –<br />
2. Packaged Facts (4.<strong>04</strong>.2013): Meat<br />
and Poultry Trends in the U.S. https://<br />
www.packagedfacts.com/Meat-<br />
Poultry-Trends-7494416/ .<br />
James Wolff<br />
looks at coding and marking in the meat<br />
and poultry sector and how technology has<br />
advanced to adapt to this often challenging<br />
environment. The author is Global<br />
Marketing Manager at Videojet Technologies.<br />
Author’s adress<br />
James Wolff, Videojet Technologies, 1500<br />
Mittel Boulevard, Wood Dale, IL 60191, USA.<br />
Advertisement<br />
Keeping abreast of<br />
packaging trends<br />
Manufacturers of meat and poultry<br />
products rightly must stay in<br />
touch with the latest trends in<br />
packaging. One trend is an increased<br />
use of flexible films.<br />
Flexible packaging often offers<br />
greater sustainability over its rigid<br />
counterparts and, due to the<br />
ability to vacuum seal certain<br />
varieties, also allows for extended<br />
shelf lives. In addition, single<br />
serve portions are easily packaged<br />
in flexible films, catering for both<br />
on-the-go convenience and for<br />
ever more popular smaller portion<br />
sizes – whether for a single<br />
person or a smaller family.<br />
Coding and marking flexible<br />
packaging can be undertaken with<br />
CIJ printers, but often Thermal<br />
Transfer Overprinters (TTO) are<br />
deployed, particularly where<br />
coding applications require a<br />
significant amount of content,<br />
such as ingredient lists and traceability<br />
information, for example.<br />
They are suitable for high speed<br />
applications and offer significant<br />
uptime advantages. Clutchless<br />
ribbon drives maintain consistent<br />
tension making ribbon breaks<br />
virtually a thing of the past, while<br />
simple cassette design means<br />
changing ribbons is fast and has<br />
minimal impact on production.<br />
TTO printers are available in<br />
IP65 washdown standards and are<br />
ideal where multi lane and thermoforming<br />
applications are<br />
concerned in washdown environments.<br />
This eliminates the need<br />
for special enclosures for protection<br />
and further enables washdowns<br />
to be carried out quickly<br />
and efficiently on the line.<br />
Working smart in meat and<br />
poultry is the only way to remain<br />
profitable, and as the move towards<br />
automation continues to
...........................................<br />
30<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
Storage<br />
Packaging assures quality<br />
Modified atmosphere packaging is the most commonly packaging method used in poultry marketing<br />
Modified atmosphere packaging<br />
(MAP) is the displacement/ replacement<br />
of gaseous environment<br />
around the product by using suitable<br />
combination of gases (carbon<br />
dioxide, oxygen and nitrogen)<br />
before sealing in selective packaging<br />
materials. It extends the shelf<br />
life of meat and meat products by<br />
inhibiting microbial growth, lipid<br />
oxidation and maintaining desirable<br />
color.<br />
By Pramila Umaraw,<br />
Akhilesh K. Verma,<br />
Pavan Kumar and<br />
Devendra Kumar<br />
However, the shelf-life extension<br />
depends upon the various<br />
factors such as type of meat<br />
(species), combination of gases<br />
used, processing (cured, cocked,<br />
smoked etc.). Today consumers are<br />
more aware about nutritive quality<br />
and sensory attributes and safety of<br />
the meat and meat products which<br />
is better maintained in modified<br />
atmosphere packaging as compared<br />
to the vacuum and aerobic packaging<br />
condition.<br />
At the time of purchasing of meat<br />
and meat products consumer use<br />
appearance and color attributes as<br />
an indicator for judging the freshness<br />
quality (Fig. 1). So the gaseous<br />
mixture used in modified atmosphere<br />
packing plays an important<br />
role for both consumer as well as<br />
retailer because it maintains the<br />
Fig. 1: Consumers use appearance and color attributes as an indicator for judging the quality of poultry.<br />
fresh meat color and stability and<br />
extends the storage life of products,<br />
reduces microorganism’s growth<br />
and lipid oxidation and assures<br />
product safety.<br />
Packaging is a method of containing<br />
food products to extend<br />
their shelf life without much<br />
change in the nutritional, physicochemical<br />
and sensory quality. Type<br />
of the packaging and packaging<br />
material used is depending on the<br />
nature of the products such as<br />
vacuum packaging, aerobic packaging<br />
and modified atmosphere<br />
packaging (SAHOO and AN-<br />
JANEYULU , 1995).<br />
The term ‘modified atmosphere<br />
packaging’ usually indicates that air<br />
surrounding meat and meat prod-<br />
ucts is replaced with various gas<br />
combinations that differ in their<br />
composition from air. Modified<br />
atmosphere packaging (MAP) has<br />
become more popular and is used<br />
for various meat products including<br />
poultry, because it has some advantages<br />
as compared to vacuum<br />
packaging techniques. Due to<br />
absence of the oxygen in packaging<br />
Advertisement<br />
Gas mixtures<br />
Tab. 1: Some suitable gas combination used in meats<br />
Meat/<br />
products<br />
Temperature<br />
(C o )<br />
Oxygen<br />
(%)<br />
Carbon<br />
dioxide (%)<br />
Nitrogen<br />
(%)<br />
Cooked 0–2 0 20–35 65–80<br />
Fresh meat 0–2 70 20 10<br />
Cured meat 1–2 0 30 70<br />
Pork 0–2 80 20 0<br />
Poultry 0–2 0 20–40 80–60<br />
Fish 1–2 30 40 30<br />
Fish (oily) 0–2 0 60 40<br />
Source: UMARAW et al. <strong>FLEISCHWIRTSCHAFT</strong> <strong>international</strong> 4_<strong>2018</strong>
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
31<br />
Storage<br />
vacuum packaging may inhibit the<br />
obligate aerobic microorganisms<br />
which causes spoilage of meat and<br />
meat products, but a disadvantage<br />
of this technology is, that it does not<br />
maintain the color appearance and<br />
stability during storage.<br />
Meat and meat products are<br />
highly perishable food items. Using<br />
a suitable packaging method leads<br />
to a number of benefits like the<br />
delay of microbial spoilage, avoidance<br />
of contamination during<br />
handling and transport, maintenance<br />
of a desirable color particularly<br />
in red meat (fresh) preservation,<br />
minimization of moisture loss<br />
and simplification in transport and<br />
distribution. Appearance especially<br />
the color of meat and meat products<br />
has a great influence on the consumer<br />
acceptance and buying<br />
decision. Fresh meat color, as an<br />
indicator of wholesomeness, is<br />
preferred and can be maintained by<br />
using 60–80% oxygen (O2) which<br />
retards the metmyoglobin formation<br />
(a brown color pigment). The<br />
bright-red color of fresh meat can<br />
be stabilized by employing modified<br />
atmosphere packaging (MAP)<br />
and using a combination of gas<br />
such as oxygen (O2), nitrogen (N2)<br />
and carbon dioxide (CO2). Oxygen<br />
(O2), nitrogen (N2) and carbon<br />
dioxide (CO2) are the most frequently<br />
used gases.<br />
However, other gases used in<br />
packaging system such as carbon<br />
monoxide (CO), nitrous oxide (NO2)<br />
and sulfur dioxide (SO2) have also<br />
been used. CO2 and N2 gas combinations<br />
are suitable for the preservation<br />
of cured meat products, for a<br />
numbers of reasons including<br />
strong inhibition of the growth of<br />
microorganisms (RONCALE , 1994).<br />
Storage of meat is done in highoxygen<br />
packaging conditions for<br />
maintaining of the color, but packaging<br />
conditions with less than<br />
80% O2 had been found to decrease<br />
meat quality (LUND et al., 2007)<br />
(Tab. 1). Meat lipids form secondary<br />
oxidative products upon oxidation<br />
are leading to rancid off-flavor<br />
development in meat and meat<br />
products including poultry.<br />
The rancid aromas produce a<br />
detrimental effect on the product<br />
quality and marketing possibilities.<br />
An alternative antioxidant effect<br />
may be found by packaging of meat<br />
in combination with different<br />
gasses like carbon dioxide, carbon<br />
monoxide, sulfur dioxide etc.<br />
(Fig. 2).<br />
Various gasses and<br />
their role in MAP<br />
Following are some common<br />
widely used gases in modified<br />
atmospheric packaging:<br />
r Carbon dioxide<br />
r Oxygen<br />
r Nitrogen<br />
r Carbon monoxide.<br />
At the moment for MAP packaging<br />
three principal gas are used like<br />
carbon dioxide (to inhibit aerobic<br />
microbial growth), and oxygen (to<br />
prevent anaerobic microbial<br />
growth) and nitrogen used as inert<br />
filler (prevents oxidation of fats and<br />
pack collapse).<br />
Carbon dioxide (CO2)<br />
Carbon dioxide is an important gas<br />
for the use in MAP because it has<br />
unique properties of solubility in<br />
the muscle as well as in lipid. One<br />
liter CO2 can dissolve in one kilogram<br />
of meat, i.e. in 1:1 ratio. The<br />
solubility of CO2 in meat is inversely<br />
related with temperature.<br />
When using a CO2 rich gas combination<br />
in packs, the ratio of the total<br />
package volume (liter) to the meat<br />
weight (kilogram) is dependent on<br />
the gas mix composition and could<br />
be up to 3:1 for mixtures in which<br />
CO2 predominates.<br />
Carbon dioxide enhances the<br />
shelf-life of perishable meats by<br />
retarding the microbial growth by<br />
enhancing both lag phase and<br />
generation time of microbes. The<br />
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32<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
Storage<br />
Packaging assures quality<br />
Fig. 2: The composition of the gas mixture has to be adapted to the meat to be<br />
packaged. O. Fischer / pixelio.de<br />
gas has a very high penetration<br />
capacity and penetrates the bacterial<br />
membrane causing changes in<br />
the intra-cellular pH which cannot<br />
be buffered by the microorganisms<br />
(NARASIMHA and SACHINDRA,<br />
2002).<br />
Absorption of CO2 by the meats<br />
leads to a decrease in the volume of<br />
the package which provides a similar<br />
look like vacuum packages. It is<br />
known as pack collapse. Dissolved<br />
CO2 in meats leads to the formation<br />
of carbonic acid due to the reaction<br />
between CO2 and H2O. This drop in<br />
the pH of meats leads to lowering<br />
the water retention ability, resulting<br />
in an accumulation of liquid in the<br />
package (LUND et al., 2007). However,<br />
the absorption of CO2 depends<br />
on various factors, such as pH,<br />
moisture, fat content, packaging<br />
and storage condition, partial pressure<br />
of CO2 etc. High levels of CO2<br />
are desirable for the preservation of<br />
meats because it inhibits superficial<br />
microbial growth and enhances the<br />
shelf-life. Among various gas uses<br />
in the MAP, only CO2 has antimicrobial<br />
effects. Microbial properties<br />
of CO2 is hampered in presence of<br />
some other gas, especially oxygen.<br />
The growth of microorganisms in<br />
MAP is inhibited by CO2 due to its<br />
bacteriostatic effect. The bacteriostatic<br />
effect of carbon dioxide is<br />
influenced by the various factors<br />
like concentration of CO2, level of<br />
initial contamination, age of microbes,<br />
storage condition i.e. temperature,<br />
humidity, type of products<br />
etc.<br />
However, some disadvantages<br />
are also documented at high concentrations<br />
of CO2 in MAP, such as<br />
a dark color of meat especially due<br />
Advertisement<br />
to formation of metmyoglobin at<br />
low O2 concentrations (VIANA et al.,<br />
2005). The gas mixture for the<br />
packaging of beef in MAP varies<br />
from 75–80% O2 and 20–25% CO2.<br />
The increase of the O2 concentration<br />
above 55% may not provide<br />
additional benefits to maintain the<br />
color attributes as higher levels of<br />
the O2 content may promote lipid<br />
oxidation, leading to the production<br />
of off-flavor compounds.<br />
The selection of the combinations<br />
of gas mixtures depends on<br />
the product sensitivity to O2 and<br />
CO2, consumer’s product color<br />
demands in the market and the type<br />
of microbial growing on the meats.<br />
For the storage of the fresh meat O2<br />
is very important because it helps in<br />
the formation of oxymyoglobin<br />
which is responsible for the formation<br />
of a bright red color; but it is<br />
not required in the gas combination<br />
for the preservation of pork.<br />
Oxygen (O2)<br />
Oxygen is an important gas for the<br />
survivability of aerobic microorganisms.<br />
It plays a major role in the<br />
determination of storage life of<br />
meats. However, oxygen plays an<br />
important role in the maintenance<br />
of the meat color, which is an important<br />
parameter for the marketing<br />
of fresh products. So various<br />
researchers focused on finding the<br />
correct gas combination for the use<br />
in MAP for maintaining the color,<br />
storage stability, reduced microbial<br />
growth and reduced fat oxidation.<br />
However, oxygen plays a major<br />
role in MAP to maintain the color<br />
stability of meat by formation of<br />
oxmyoglobin, which is responsible<br />
for the bright red color of meat.<br />
Oxygen is essential for the<br />
growth of the spoilage microbes<br />
and it also enhances the oxidative<br />
rancidity in meats leading to reduced<br />
shelf-life. Thus the proper<br />
gas combinations for the maintenance<br />
of the red meat color, oxidative<br />
detrition and control of the<br />
oxidative process in meats are still<br />
desirable. The ultra-low level of<br />
oxygen used for pork is less than<br />
1% and for beef 0.05%, respectively.<br />
The benefits of the ultra-low oxygen<br />
over the high oxygen gas combination<br />
are reduced lipid oxidation as<br />
well a reduced aerobic microbe’s<br />
growth.<br />
Nitrogen (N2)<br />
It is very well documented that the<br />
composition of the gas mixture in<br />
MAP systems (O2, CO2 and N2) can<br />
effectively control/ stop the growth<br />
of aerobic micro-organisms of<br />
perishable food items such as meat,<br />
fish and their products, as well as<br />
maintain the visual quality of red<br />
meat. The objective of MAP is the<br />
exclusion of oxygen from the<br />
sounding of packaged meat and<br />
meats with the help of a combination<br />
of gases which have unique<br />
properties of inhibiting oxidative<br />
changes and microbial growth.<br />
Nitrogen is an inert gas and it has<br />
unique properties like low solubility<br />
in polar as well in nonpolar solvents.<br />
Its main function in MAP is to<br />
replace O2, indirectly reducing the<br />
oxidation of fat enriched products<br />
and the growth of aerobic microorganism.<br />
It helps in the extension<br />
of the shelf-life of the meats in MAP.<br />
Nitrogen plays another important<br />
role in MAP in combination with<br />
CO2, by preventing pack collapsing.<br />
Carbon monoxide<br />
Carbon monoxide gas combines<br />
with myoglobin and forms a complex<br />
compound known as carboxymyoglobin,<br />
which is responsible for<br />
the maintaining cherry red color in<br />
fresh meat. However, due to its<br />
toxic nature most of the regulatory<br />
bodies do not approve its use except<br />
Norway. The level of CO use in the<br />
MAP is 0.4%; at this level it improves<br />
the color.<br />
Effect on the<br />
quality attributes<br />
Color and appearance, sensorial<br />
attributes, microbial and oxidative<br />
changes are the important parameters<br />
that limit the shelf-life and<br />
marketability of meats (Tab. 2).<br />
Therefor researchers want to minimize<br />
these changes in meats by<br />
using various techniques and<br />
preservatives. Out of all techniques<br />
available at present, MAP offers a<br />
novel approach for maintaining the<br />
quality attributes and extending<br />
storage life. The overall effect of<br />
MAP can be grouped into following<br />
three categories as:<br />
r Effect on sensory attributes<br />
r Effect on microbial quality<br />
r Effect on lipid oxidation.<br />
Effect on sensory attributes<br />
Color is the prime attribute that<br />
affects the marketing and purchasing<br />
of meats. Consumers judge the<br />
quality of meat products with the<br />
help of color. However, color of
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
33<br />
Storage<br />
meats varies with the species, types,<br />
age, processing etc. The color of<br />
meats acts as an indicator for consumer<br />
at the time of purchase.<br />
Myoglobin is the main pigment<br />
responsible for the meat color;<br />
some other pigments are playing<br />
minor roles as heme protein. The<br />
meat industry has adopted various<br />
techniques for retaining freshness<br />
to ensure products with greater<br />
color stability, consistency, juiciness<br />
and tenderness. SEYFERT et al.<br />
(20<strong>04</strong>) reported for beef during<br />
MAP packaging at higher partial<br />
pressures of oxygen that the highoxygen<br />
system resulted in a<br />
stronger formation of oxymyoglobin<br />
in deep layers of the meat in<br />
comparison to low-oxygen packaging<br />
systems. This was due to formation<br />
of oxymyoglobin, imparting<br />
bright red color to the meat, and its<br />
appearance like cherry-red color<br />
that remained stable even with<br />
extended storage life.<br />
However, low-oxygen partial<br />
pressure packaging systems need<br />
much greater control in comparison<br />
to high-oxygen packaging<br />
systems during storage ( PAULSEN<br />
et al., 2006). In low-oxygen MAP<br />
systems the storage life of fresh<br />
meats is higher in comparison to<br />
high-oxygen systems due to the<br />
presence of carbon dioxide and<br />
omission of oxygen from product’s<br />
vicinity. LUND et al. (2009) reported<br />
that storage in high-oxygen packaging<br />
system resulted in lowering the<br />
meat tenderness and protein content<br />
as compared to packaging<br />
systems without oxygen due to the<br />
oxidation of protein. Meat protein<br />
like myosin was observed to form<br />
crosslinks in meat stored only in<br />
the presence of high-oxygen, thus<br />
decreasing the tenderness of meat.<br />
Various researchers also studied the<br />
effect of MAP on the aroma of<br />
meats at different levels of oxygen<br />
(O2) concentration in the package.<br />
RESCONI et al. (2009) documented<br />
a non-significant effect of<br />
oxygen levels on the sensory attributes.<br />
The chief concern was<br />
increased rancidity of the products<br />
due to the lipid oxidation and production<br />
of off-flavor compounds<br />
during storage.<br />
MORALES DE LA NUEZ et al. (2009)<br />
studied the effect of three different<br />
packaging conditions viz. atmospheric<br />
air/ aerobic, vacuum and<br />
MAP consisting in a 10:70:20 mixture<br />
of N2:O2:CO2 , respectively, on<br />
the meat quality attributes of kid rib<br />
cages chops at refrigerated storage<br />
conditions (4 °C) for 7days. The<br />
lightness values (L*) were affected<br />
by the packaging method and a<br />
lighter color was reported in MAP<br />
chops than under aerobic packaging<br />
conditions. The redness values<br />
(a*) significantly increased during<br />
the entire storage study. For MAP<br />
and atmospheric air/ aerobic<br />
packed chops, the yellowness values<br />
(b*) increased during storage time,<br />
whereas they remained non-significant<br />
throughout storage during<br />
vacuum pack. The pH values were<br />
not affected by the entire storage<br />
study or under various packaging<br />
conditions. Sensory panelist rated<br />
the color acceptability lower at 3, 5<br />
and 7days as compared to day 1 of<br />
storage for vacuum and atmospheric<br />
air packaging, whereas for<br />
the MAP the average values on<br />
days 5 and 7 were lower than those<br />
rated on days 1 or 3. The sensory<br />
panelist observed lower odor for<br />
atmospheric air and vacuum packaging<br />
at 3, 5 and 7days of storage as<br />
compared to day 1, whereas no<br />
changes were observed in MAP<br />
packages. Thus researchers concluded<br />
that MAP as method of<br />
choice for storing goat meat, rather<br />
than vacuum or atmospheric air<br />
packaging.<br />
MILIJASEVIC et al. (2008) reported<br />
that an increase in concentration of<br />
oxygen from 20–70% in packaging<br />
had a positive effect on the color<br />
stability of beef leg due to the formation<br />
of a larger amount of<br />
oxymyoglobin which was in proportion<br />
to the oxygen concentration in<br />
the mixture of gases used. The use<br />
of a larger amount of CO2 resulted<br />
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................................................................................................................................................................<br />
34<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
Storage<br />
Packaging assures quality<br />
Products in MAP<br />
Tab. 2: Various meats treated with modified atmosphere packaging for the extension of<br />
their shelf-life<br />
Type of meat/ Gas combination<br />
Extended Storage References<br />
products<br />
shelf-life condition<br />
Fresh camel meat 60% CO2/40% N2 21 days – JOUKI and KHAZAEI,<br />
2012<br />
Low grade beef CO2:N2 = 3:7 Cold storage HUR et al., 2013<br />
Cod fillets 100% CO2 2–3 days 0°C DALGAARD et al., 1993<br />
Lamb meat MAP1 (60% CO2/40% N2) and<br />
MAP2 (80% CO2/20% N2)<br />
14 days 4°C KARABAGIAS et al.,<br />
2011<br />
Seabass slices 80–100% CO2 20 days 4°C MASNIYOM et al., 20<strong>04</strong><br />
Chicken breast (30% CO2/70% N2 and 12 days Refrigerated CHOULIARA et al., 2007<br />
meat<br />
70% CO2/30% N2) and gamma<br />
irradiation<br />
temperature<br />
Beef patties 100% N2; 80% O2/20% N2 6days Chill storage LUND et al., 2007<br />
Pork patties 80% O2/20% CO2 7days 4°C LUND et al., 2008<br />
Beef steaks and 0.4% CO/30% CO2/69.6% N2 35 days – HUNT et al., 20<strong>04</strong><br />
ground beef<br />
Pastirma 50% N2/50% CO2 150 days 4°C AKSU et al., 2005<br />
Source: UMARAW et al. <strong>FLEISCHWIRTSCHAFT</strong> <strong>international</strong> 4_<strong>2018</strong><br />
in the development of an objectionable<br />
dark green color due to the<br />
formation of a higher amount of<br />
metmyoglobin.<br />
Packaging conditions, where a<br />
higher percentage of carbon dioxide<br />
was used, showed lower pH values<br />
and due to the dissolution of carbon<br />
dioxide in meat and its reaction<br />
with water present in the meat<br />
leading to formation of carbonic<br />
acid. The pH plays an important<br />
role in maintaining the quality and<br />
stability of fresh meats packed in<br />
MAP. Extreme increase or falling of<br />
the pH value during the conversion<br />
of muscle to meat affects the color<br />
attributes of meat and provides the<br />
basis for two of the most wellknown<br />
poor meat quality conditions<br />
viz. dark firm dry (DFD) and<br />
pale soft exudative (PSE) meat (<br />
LINDAHL et al., 2006). A higher pH<br />
plays an important role in the<br />
protection of myoglobin from heat<br />
denaturation and also maintains<br />
the red or pink color of meat during<br />
and after cooking (MANCINI and<br />
HUNT , 2005).<br />
Effect on the microbial quality<br />
Microbial growth during preservation<br />
of meats depends on several<br />
factors such as type of the packaging<br />
condition (aerobic, vacuum and<br />
modified atmospheric packaging),<br />
incorporation of antimicrobial<br />
substances in products or packaging<br />
materials, storage conditions<br />
(temperature, relative humidity)<br />
etc. The presence of a high level of<br />
oxygen in food packages enhances<br />
the growth of microbes and overcomes<br />
it in oxygen sensitive meats,<br />
which can be packaged under<br />
vacuum or modified atmospheric<br />
packaging conditions.<br />
SCHOLTZ et al. (1992) reported<br />
that display ready pork cuts had a<br />
higher storage life under MAP at<br />
refrigerated temperature such as<br />
7days in vacuum skin packaging,<br />
14 days in modified atmosphere<br />
(75% oxygen and 25% carbon<br />
dioxide) and 21 days in 100% carbon<br />
dioxide.<br />
JEREMIAH and GIBSON (1997)<br />
studied the storage life of chilled<br />
pork stored in modified atmospheric<br />
packaging (70% oxygen and<br />
30% carbon dioxide) at refrigerated<br />
temperature and concluded that<br />
pork could be stored for 3weeks at<br />
high oxygen concentration. GOK et<br />
al. (2008) compared the various<br />
packaging conditions (modified<br />
atmosphere packaging, aerobic<br />
packaging and vacuum packaging)<br />
for chemical, microbiological and<br />
sensory properties of Turkish<br />
pastrima and found all these parameters<br />
maintained better in<br />
modified atmosphere packaging<br />
than in aerobic packaging and<br />
vacuum packaging.<br />
LAURY and SEBRANEK (2007)<br />
reported that by using modified<br />
atmosphere packaging a 0.4%<br />
carbon monoxide (CO) and 99.6%<br />
carbon dioxide (CO2) gas combination<br />
for pork sausages is a useful<br />
tool to enhance the product shelflife.<br />
VIUDA-MARTOS et al . (2010)<br />
studied the effect of incorporating<br />
of a natural source antioxidant such<br />
as orange dietary fiber and oregano<br />
essential oil along with the various<br />
packaging conditions like vacuum,<br />
aerobic and modified atmosphere<br />
(80% N2 and 20% CO2) packaging<br />
conditions on the shelf-life of<br />
bologna sausages. They observed<br />
that the MAP packaged product on<br />
day 24 of storage as fresh as on day<br />
1, with a slight increase in the<br />
TBARS value of the MAP product.<br />
KARABAGIAS et al. (2011) observed<br />
the effect of thyme and oregano<br />
essential oils as well as modified<br />
atmosphere packaging (MAP) for<br />
extending the shelf life of fresh<br />
Advertisement
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
35<br />
Storage<br />
lamb meat stored at refrigerated<br />
temperature. They reported the<br />
increase in storage life of lamb<br />
meat from 7 days in aerobic packaged<br />
products to 9–10 days for<br />
samples containing 0.1% of thyme<br />
oil and 21–22 days for MAP packaged<br />
samples containing 0.1%<br />
thyme. HASAPIDOU and SAVVAIDIS<br />
(2011) studied the effects of<br />
modified atmosphere packaging<br />
(30% CO2/70% N2), EDTA and<br />
oregano oil on the quality of<br />
chicken liver and reported that the<br />
shelf-life of chicken liver was enhanced<br />
almost 3times as compared<br />
to regular product’s shelf-life with a<br />
natural antimicrobial amalgamation<br />
(EDTA, oregano oil and MAP).<br />
and the evolution of the spoilage<br />
microorganisms like lactic acid<br />
bacteria, Enterobacteriacae and<br />
Pseudomonas were studied. At the<br />
end of all assessed storage states,<br />
the microbial concentrations obtained<br />
under MAP packaging<br />
(11days) and were significantly<br />
lower than those obtained under<br />
aerobic conditions (7 days) and<br />
remained within the limit. Thus a<br />
4days extention in pork shelf life<br />
was possible when packed under<br />
the specific modified atmosphere<br />
packaging conditions.<br />
Effect on the lipid oxidation<br />
Lipid oxidation still remains a<br />
major problem during storage and<br />
limits the shelf-life as well as the<br />
marketability of meats. Oxidation<br />
can be reduced/ retarded by incorporation<br />
of antioxidant compounds<br />
in the meat, meat products or<br />
packaging materials or by using<br />
combination of gases.<br />
JOUKI and KHAZAEI (2012) studied<br />
the inhibition of lipid oxidation<br />
of camel meat stored at refrigerated<br />
temperature packaged under various<br />
packaging conditions viz. AP<br />
(air packaging), VP (vacuum packaging)<br />
and MAP (60% CO2/<br />
40% N2). The MAP fresh camel<br />
meat had almost similar TBARS<br />
values as compared to the control<br />
Advertisement<br />
SKANDAMIS and GEORGE-JOHN<br />
(2002) studied the change in sensory,<br />
microbiological and physicochemical<br />
parameters on fresh meat<br />
stored at 5 and 15 o C under combined<br />
effects of volatile compounds<br />
of oregano oil and modified atmosphere<br />
packaging conditions<br />
(40% CO2/30% N2/30% O2;<br />
100% CO2; 80% CO2/20% air;<br />
vacuum pack and air) and noticed<br />
increased shelf-life of meat samples<br />
depending on the packaging conditions.<br />
The extended storage life was<br />
in the order: aerobic
.........................................................<br />
36<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
Storage<br />
Packaging assures quality<br />
Fig. 3: Recently MAP is the most commonly packaging method used in meat marketing systems in the industry.<br />
Pros and Cons<br />
and the levels of TBARS were not<br />
significantly increased with the<br />
advancement of the storage period.<br />
Sensory panelists were in general<br />
agreement with the physico-chemical<br />
changes and MAP had a significant<br />
effect on the quality of refrigerated<br />
camel meat. The camel meat<br />
under MAP accompanied by refrigeration<br />
storage had an increased<br />
product shelf life of 21 days without<br />
compromising sensory attributes.<br />
CLAUSEN et al. (2009) studied the<br />
effects of different MAP systems<br />
during ageing and retail displaying<br />
on the quality characteristics of beef<br />
longissimus dorsi muscles . The<br />
quality characteristics of steaks was<br />
Tab. 3: Advantages and disadvantages of modified<br />
atmosphere packaging<br />
Advantages<br />
Enhanced shelf-life<br />
Reduction in retail waste<br />
Improved presentation and<br />
visibility of products<br />
Easy in slicing of products<br />
Reduction in the amount of<br />
chemical preservatives<br />
Improved appearance and<br />
color of products<br />
Disadvantages<br />
High costs of equipment and<br />
trained staff<br />
Cost of gases and packaging<br />
pouches<br />
Chances of leaking of gases<br />
Increase the pack size (bulkiness);<br />
more space required for<br />
storage and transport<br />
MAP condition is lost once the<br />
package was opened or leaks<br />
Increased amount of exudate<br />
inside the pack<br />
Source: UMARAW et al. <strong>FLEISCHWIRTSCHAFT</strong> <strong>international</strong> 4_<strong>2018</strong><br />
determined by using various parameter<br />
such as sensory evaluation,<br />
thiobarbituric acid-reactive substances<br />
(TBARS), myofibrillar<br />
fragmentation index (MFI), protein<br />
oxidation, weight loss, cooking loss<br />
and vitamin E content. High oxygen<br />
MAP systems resulted in an<br />
increase in the warmed-over flavor<br />
(WOF) and in TBARS values as well<br />
as a reduction in juiciness, tenderness<br />
and vitamin E content, compared<br />
to vacuum systems.<br />
TANGKHAM et al. (2014) studied<br />
the effect of modified atmosphere<br />
packaging on meat quality attributes<br />
of goat meat.<br />
Goat meat was randomly packaged<br />
into four modified atmosphere<br />
packaging (MAP) conditions<br />
like 80% O2/ 20% CO2; 80% N2/<br />
20% CO2; 69.65% N2/29.85% CO2/<br />
0.5% CO) and stored at refrigerated<br />
temperature for 21 days. The results<br />
of this study showed that<br />
69.65% N2/29.85% CO2/0.5% CO<br />
significantly reduced the lipid<br />
oxidation (TBARS) in comparison<br />
to other MAP combinations.<br />
GATELLIER et al. (2001) reported<br />
the effects of a dietary supplementation<br />
with vitamin E on the susceptibility<br />
of fresh and modified atmosphere<br />
packaged beef on the myoglobin<br />
and lipid oxidation. On the<br />
basis of visual assessment, essentially<br />
with MAP, the results concluded<br />
a significant and positive<br />
effect of vitamin E supplementation<br />
which resulted in a lower<br />
discoloration. The TBARS values<br />
were significantly decreased in<br />
MAP as compared to other packaging<br />
condition after supplementation<br />
of α-tocopherol acetate in<br />
diets. TANG et al. (2006) studied the<br />
effect of addition of tea catechins<br />
on the color stabilizing and antioxidant<br />
activity in fresh minced beef<br />
patties on lipid oxidation and color<br />
stability during refrigerated temperature<br />
under aerobic and modified<br />
atmosphere packaging (MAP,<br />
80% O2/ 20% CO2) conditions.<br />
Fresh minced beef muscle ( M.<br />
longissimus dorsi ) was incorporated<br />
with tea catechins at various levels<br />
such as 0 (T0), 200 (T200), 400<br />
(T400), 600 (T600), 800 (T800) and<br />
1000 (T1000) mg/kg minced meat.<br />
Treated groups were stored in<br />
refrigerated temperature in a display<br />
cabinet under aerobic and<br />
MAP conditions for 7days.<br />
The lipid oxidation (TBARS) and<br />
proportion of oxymyoglobin<br />
(MbO2) and metmyoglobin<br />
(MetMb) were examined during<br />
storage. Tea catechins incorporated<br />
samples had significantly lower<br />
lipid oxidation than control in both<br />
packaging conditions. The color<br />
deterioration and lipid oxidation<br />
rate was lower in the MAP group as<br />
compared to the other conditions.<br />
ZAKRYS et al. (2008) studied beef<br />
steaks under high oxygen MAP in<br />
order to enhance color stability.<br />
However, such conditions may also<br />
enhance the lipid oxidation leading<br />
to deterioration in the product<br />
quality and lowering tenderness.<br />
The steaks were stored at refrigerated<br />
temperature for 15 days and<br />
studied for lipid and protein oxidation<br />
(for 12 days). Sensory panelists<br />
rated best for steaks stored in MAP<br />
containing 50% oxygen, despite<br />
noticing oxidized flavors under<br />
these conditions.<br />
JOHN et al. (2005) compared the<br />
effect of different packaging conditions<br />
on the quality attributes of<br />
fresh beef. The fresh beef was<br />
packaged in modified atmosphere<br />
packaging (80% O2/20% CO2),<br />
vacuum packaging, 80% oxygen<br />
and 0.4% carbon monoxide. Steaks<br />
stored in high oxygen MAP showed<br />
the highest TBRAS values and<br />
myoglobin denaturation during the<br />
entire storage study. The results
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
37<br />
Storage<br />
concluded that using 0.4% CO in<br />
MAP successfully retards the lipid<br />
oxidation during storage of the beef<br />
steaks.<br />
Safety of modified<br />
atmospheric packaging<br />
For the consumer and producer<br />
the safety of meats became major<br />
concern from the stable to the table<br />
philosophy and it is also a challenge<br />
for the meat researchers. In<br />
MAP packaging the visible color of<br />
the meats is maintained for longer<br />
time as compared to the other<br />
packaging systems. Color and the<br />
visible impression of a product are<br />
the only guidiance for consumers<br />
in their decision to buy a product<br />
or not.<br />
However, during storage of such<br />
highly nutritious food items, some<br />
spoilage bacteria as well as pathogenic<br />
microorganisms can grow on<br />
them and the consumption of these<br />
products results in various health<br />
problems. Clostridium botulinum is<br />
the most important microorganism<br />
as it can grow in anaerobic condition<br />
and produces serious illness<br />
after consumption of contaminated<br />
meats. Certain strains of C. botulinum<br />
are very well known to<br />
produce toxins even at refrigerator<br />
temperatures. Certain other pathogenic<br />
microorganisms such as<br />
Listeria monocytogenes and Yersinia<br />
enterocolitica are also having the<br />
ability to grow at refrigerated temperatures<br />
during storage. These<br />
microorganisms can multiply at<br />
temperatures as low as 0°C, but are<br />
inhibited markedly at higher levels<br />
of CO2 concentration.<br />
However, temperature abuse<br />
during the storage of meats is the<br />
most critical extrinsic factor influencing<br />
the shelf-life. MAP of raw<br />
meat is generally considered more<br />
hazardous than MAP of cooked<br />
products because cooking generally<br />
kills most of the pathogenic as well<br />
as spoilage pathogens.<br />
Therefore, microbiological contamination<br />
is an important concern<br />
and MAP is not a substitute for<br />
poor hygiene practice during<br />
slaughtering, processing as well as<br />
during handling and transport.<br />
MAP like other packaging method<br />
helps in maintaining good quality<br />
of the products if high standards of<br />
hygiene and temperature control<br />
are maintained (Tab. 3).<br />
Conclusions<br />
At present the marketing scenario<br />
conditions of the meat industry has<br />
transformed from being production-driven<br />
to becoming consumerled.<br />
At present MAP is the most<br />
commonly packaging method used<br />
in meat marketing systems for<br />
extending shelf-life and preserving<br />
desirable quality attributes such as<br />
bright red color, which is an important<br />
quality attribute for meat<br />
marketing (Fig. 3).<br />
The use of MAP resulted in an<br />
increased consumer demand due to<br />
an increase in shelf-life. It helps in<br />
maintaining a better quality and<br />
green-consumerisms by lowering<br />
the use of chemical preservatives.<br />
MAP helps in controlling the production<br />
of off-odor compounds and<br />
it is increasing tenderness. The<br />
incorporation of natural preservatives<br />
in meats along with MAP<br />
packaging tends to extensively<br />
prolong the shelf-life.<br />
References<br />
Literature references can be requested<br />
from the corresponding author or the<br />
editorial office, respectively.<br />
Author’s addresses<br />
Pramila Umaraw, Division of Livestock<br />
Products Technology, Indian Veterinary<br />
Research Institute, Bareilly, Uttar Pradesh,<br />
India-243122 and Akhilesh K. Verma (corresponding<br />
author: vetakhilesh@rediffmail.com),<br />
Department of Livestock Products<br />
Technology, College of Veterinary and Animal<br />
Sciences, Sardar Vallabhbhai Patel University<br />
of Agriculture & Technology, Meerut,<br />
U.P.-250110, India, Pavan Kumar and<br />
Devendra Kumar, Department of Livestock<br />
Products Technology, College of Veterinary<br />
Science, Guru Angad Dev Veterinary and<br />
Animal Sciences University, Ludhiana,<br />
Punjab, India-1410<strong>04</strong>.<br />
Advertisement
38<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
Legislation<br />
Smoking Technologies<br />
Assessment under the European food law<br />
Smoking foodstuffs by exposing<br />
them to smoke that is<br />
generated from primary smoke<br />
products offers many advantages.<br />
With this technology it is<br />
possible to convert primary<br />
smoke products as defined by<br />
Regulation (EC) No 2065/2003 (EU<br />
Regulation on Smoke Flavourings)<br />
into smoke which is then fed into<br />
the smoking chamber. The smoking<br />
process is akin to conventional<br />
smoking, including, for<br />
example, the time of exposure of<br />
the products in the smoking<br />
chamber. There are undoubtedly<br />
many health benefits to the<br />
consumers, because primary<br />
smoke products are pre-purified<br />
and thus largely free from harmful<br />
substances. Beyond that, the<br />
technology is resource-efficient<br />
and ensures increased occupational<br />
safety.<br />
There is no specific legal framework<br />
for the smoking of foodstuffs<br />
by locally burning organic<br />
materials (conventional smoking).<br />
Merely the principles of good<br />
manufacturing practice and the<br />
general guidelines of food safety<br />
law are applicable here. Furthermore,<br />
the requirements for the<br />
maximum permissible levels of<br />
contaminants in foodstuffs apply.<br />
However, it is necessary to stipulate<br />
exceptions for smoked foodstuffs<br />
on a regular basis. Such<br />
exceptions must allow higher<br />
maximum levels because otherwise,<br />
conventionally smoked<br />
products would not be marketable.<br />
The food law does not provide any<br />
specific regulations for the smoking<br />
of foodstuffs using smoke<br />
that is generated from primary<br />
smoke products. There are only<br />
legal provisions stipulating the<br />
requirements for the basic product,<br />
thus the primary smoke<br />
products, which have to be approved<br />
on the basis of a safety<br />
assessment. The approval procedure<br />
for primary smoke products<br />
is laid down in the context of the<br />
EU Regulation on Smoke Flavourings<br />
(namely in Regulation EU<br />
No 1321/2013). This entails issues<br />
of interpretation: The basic product<br />
used for smoking (primary<br />
smoke products) falls under the<br />
law on smoke flavourings in<br />
accordance with the letter of the<br />
law. However, there is no use of<br />
smoke flavourings as such; the<br />
product in use is smoke.<br />
The so-called REFIT process of<br />
the European Union represents a<br />
kind of fitness check for food<br />
legislation. Within the context of<br />
this process the European Commission<br />
was asked whether it<br />
considered the existing legal<br />
framework for modern smoking<br />
technologies necessary to be<br />
adapted. Special emphasis was<br />
put on the idea to introduce<br />
general uniform rules for smoking<br />
techniques, that is irrespective of<br />
the basic materials used, and of<br />
the type and location of combustion<br />
of organic materials. Regulation<br />
(EU) No 1321/2013 solely<br />
requires approval of a basic material<br />
for smoking techniques<br />
using primary smoke products.<br />
There is no legal framework for<br />
other smoking techniques. Thus,<br />
any type of organic material can<br />
Advertisement<br />
There is no specific legal framework for the smoking of foodstuffs by locally<br />
burning organic materials (conventional smoking). Photo: siepmannH / pixelio.de<br />
be used (burnt) without prior<br />
inspection or authorisation. This<br />
may entail problems, especially<br />
with respect to contaminants.<br />
In a communication dated 8 May,<br />
<strong>2018</strong>, the Commission declared<br />
that basically, it did not consider<br />
the existing legal framework<br />
necessary to be adapted (apart<br />
from some editorial adaptations<br />
in connection with food labelling).<br />
The Commission argued that the<br />
process of smoking, which also<br />
included the “use of generated<br />
smoke” produced from primary<br />
smoke products, fell under various<br />
regulatory measures (e.g.<br />
under the Food Information Regulation<br />
(Regulation EU No 1169/<br />
2011) with regard to food information,<br />
or under European legislation<br />
on contaminants with regard<br />
to contaminants).<br />
Even if the Commission’s answer<br />
sounds a little "meatless", we<br />
think it must mean the following:<br />
The Commission confirms that the<br />
process of smoking foodstuffs<br />
using smoke that is generated<br />
from primary smoke products is<br />
indeed a smoking technology; it<br />
does not imply the application of<br />
the (liquid) ingredient “smoke<br />
flavouring”. However, if it is a<br />
smoking technology, the principle<br />
that all smoking techniques have<br />
to be labelled the same way must<br />
be applied.<br />
As a consequence, the reference<br />
to information requirements<br />
under the Food Information Regulation<br />
must point to Annex VI<br />
Section A No 1 to the Food Information<br />
Regulation.<br />
Therefore, foodstuffs that are<br />
treated with this technology must<br />
be labelled as being “smoked”.<br />
Accordingly, the structure of the<br />
list of ingredients will be similar<br />
to that of conventionally smoked<br />
products. In our opinion, this<br />
understanding does not contradict<br />
a resolution of the food<br />
hygiene and food of animal origin<br />
working group, ALTS (73rd conference<br />
in Berlin from 23-25 June,<br />
2014, agenda item 19) concerning<br />
the labelling of smoke flavourings<br />
as such when used in food production.<br />
Call Smoke by its name!<br />
r Dr. Markus Grube,<br />
Gummersbach, Germany
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
39<br />
Calendar<br />
CALENDAR<br />
12 – 14 September<br />
St. Petersburg, Russia<br />
3rd IIR Conference on Cold Applications in<br />
Life Sciences<br />
ITMO University ( +7 911 095-75-48)<br />
8 – 12 October<br />
Moscow, Russia<br />
Meat Industry / AgroProdMash<br />
IFWexpo Heidelberg GmbH<br />
( +49 6221 1357-0)<br />
17 – 20 September<br />
Moscow, Russia<br />
WorldFood Moscow, 27th International<br />
Food Exhibition<br />
ITE Group ( +44 207 596 5086)<br />
15 – 17 October<br />
Muscat, Oman<br />
Food and Hospitality Oman Exhibition &<br />
Conference <strong>2018</strong>, Oman Convention & Exhibition<br />
Centre Muscat ( +968 24660124)<br />
20 – 22 September<br />
Beijing, China<br />
21 – 23 September<br />
Nairobi, Kenya<br />
25 – 27 September<br />
Nuremberg, Germany<br />
CIMIE – The 16th China International Meat<br />
Industrie Exhibition <strong>2018</strong><br />
CMA ( +86 10 84119370)<br />
Food & Hotel Kenya Expo <strong>2018</strong><br />
Grow Exhibitions ( +971 4 3964906)<br />
FachPack<br />
NürnbergMesse ( +49 911 8606-8676)<br />
17 – 19 October<br />
Ho Chi Minh City, VNM<br />
21 – 25 October<br />
Paris, France<br />
23 – 24 October<br />
Hattersheim, Germany<br />
Vietstock, <strong>2018</strong> Expo & Forum Vietnam<br />
UBM ( +84 28 36 222 588)<br />
SIAL Paris<br />
Sial Paris ( +33 1 76 77 13 33)<br />
Training course on the machine type<br />
FCA 100/140, Poly-clip System GmbH & Co. KG<br />
( +49 6190 8886-341)<br />
26 – 27 September<br />
Latam, Mexico<br />
27 - 29 September<br />
Mumbai, India<br />
30 September –<br />
4 October<br />
Pozan, Poland<br />
1 – 2 October<br />
Cologne, Germany<br />
FoodTech Summit & Expo <strong>2018</strong><br />
Énfasis Alimentación ( +52 55 5605 1777)<br />
Annapoorna – World of Food India<br />
Koelnmesse YA Tradefair PvT. Ltd.<br />
( +91 22 28715200)<br />
Polagra Tech/Food<br />
Poznań International Fair Ltd.<br />
( +48 61 869 2000)<br />
Revolution in Food and Biomass Production<br />
(REFAB), Future Protein Award,<br />
nova-Institut GmbH ( +49 2233 481440)<br />
25 October<br />
Hattersheim, Germany<br />
1 – 2 November<br />
Hattersheim, Germany<br />
6 November<br />
Hattersheim, Germany<br />
6 – 8 November<br />
Dubai, UAE<br />
Training course on the machine type<br />
FCA 80, Poly-clip System GmbH & Co. KG<br />
( +49 6190 8886-341)<br />
Training course on the machine type<br />
FCA 120/160, Poly-clip System GmbH & Co. KG<br />
( +49 6190 8886-341)<br />
Training course on the machine type<br />
FCA 80, Poly-clip System GmbH & Co. KG<br />
( +49 6190 8886-341)<br />
Gulfood Manufacturing, Dubai World Trade<br />
Centre ( +971 4 332 1000)<br />
Marel<br />
Reliability for chicken processing with an all-time high speed<br />
Marel Poultry is the world’s first<br />
supplier of integrated 15,000 bph<br />
lines. Dealing with such high<br />
speed, there is no other way than<br />
to have reliability; if not, every<br />
minute of malfunctioning means<br />
250 lost chickens. Therefore the<br />
company has profoundly tried and<br />
tested its new 15,000 bph configuration<br />
before launching it at the<br />
market. After this long period of<br />
extensive research and development,<br />
it is labeled as a proven<br />
solution.<br />
All systems are set for a processing<br />
speed of 15,000 bph. From<br />
live bird handling with Atlas and<br />
stunning with CAS SmoothFlow, via<br />
15,000 bph<br />
processing – a<br />
proven solution with<br />
uncompromised high<br />
efficiency and<br />
quality.<br />
evisceration and chilling, up to the<br />
distribution line, every process<br />
step solidly handles this all-time<br />
high speed. Innova software runs<br />
in the background to supervise all<br />
fast processes plant-wide. The ATC<br />
tension control system keeps the<br />
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while they move at an incredible<br />
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seamlessly hand over products<br />
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An all-time high processing<br />
speed is not a goal in itself. Already<br />
proven in practice, the fast operational<br />
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significant increase in performance<br />
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modification of machinery can be<br />
used for a considerable production<br />
growth. Achieving lowest production<br />
costs, it is of importance that<br />
highest quality and efficiency<br />
remain uncompromised.<br />
//www.marel.com<br />
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40<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
imprint<br />
Supplement references<br />
Please note that this issue<br />
contains inserts published by:<br />
REX-Technologie GmbH & Co. KG,<br />
5303 Thalgau, Austria<br />
Schröter Technologie<br />
GmbH & Co.KG<br />
33829 Borgholzhausen, Germany<br />
Index of advertisers<br />
Almi GmbH 19<br />
AVO-Werke August Beisse 18<br />
GmbH<br />
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Volume 33 _ D 428<strong>04</strong> F<br />
Research and<br />
Development<br />
4_<strong>2018</strong><br />
Quality characteristics and shelf life<br />
evaluation of functional mutton patties<br />
Investigations on incorporated combinations of plant materials<br />
By Om Prakash Malav, Brahm Deo Sharma, Rajiv Ranjan Kumar, Suman Talukder,<br />
Sakeh Rafeh Ahmed and Irshad A. Dahsri<br />
A study was conducted to assess the potential of three plant materials<br />
viz. cabbage powder, red kidney bean powder and orange pulp as the<br />
source of natural antioxidants and dietary fiber for the preparation of<br />
functional mutton patties. These plant materials were incorporated at a<br />
9% level by replacing the lean meat in a pre-standardized mutton patties<br />
formulation in three different combinations. The protein percentages<br />
were significantly lower (P
42<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
Research & Development<br />
Quality characteristics and shelf life evaluation of functional mutton patties<br />
ion chelators and singlet oxygen quenchers (MATHEW and ABRAHAM, 2006).<br />
Cabbage (Brassica oleracea var. capitata) is one of the most important<br />
vegetables grown worldwide. It has been reported to contain high amount<br />
of DF and various bioactive compounds with high antioxidant activity. The<br />
protective action of cruciferous vegetables has been attributed to the<br />
presence of antioxidant phytochemicals especially antioxidant vitamins<br />
including ascorbic acid, alpha-tocopherol and beta-carotene (PRIOR and<br />
CAO, 2000) and phenolic compounds such as flavonoids, isoflavone,<br />
flavones, anthocyanin, catechin and isocatechin (WANG et al., 1996).<br />
Cabbage leaves powder contained approximately 41–43% total dietary<br />
fiber on dry weight basis (JONGAROONTAPRANGSEE et al., 2007).<br />
Red kidney beans are widely known for their fiber, minerals (Mo, Mn, P,<br />
Fe, Cu, Mg, K), vitamins (folate, thiamine and vitamin K) and protein contents<br />
(OSORIO-DIAZ et al., 2003).<br />
Polyphenols from dry beans may possibly act as antioxidants, hindering<br />
the formation of free radicals that eventually lead to the deterioration of<br />
biological molecules. Orange pulp, a citrus fruit by-product has high fiber<br />
and vitamin contents as well as other associated bioactive compounds<br />
such as flavonoids and terpenes which exhibit antioxidant properties<br />
(LARIO et al., 20<strong>04</strong>).<br />
Potential use of powders and extracts of different plant materials as<br />
biopreservatives and functional ingredients have been studied in recent<br />
years. Many natural antioxidants have been reported to be more active<br />
than synthetic antioxidants and the food application of these compounds<br />
need to be explored.<br />
The utilization of a blend of cabbage powder, red kidney bean powder<br />
and orange pulp as the source of antioxidants and dietary fiber, may offer<br />
meat processors the opportunity to develop novel meat products with<br />
enhanced nutritional and health benefits with improved shelf life and<br />
quality. In the light of the above discussion, the present study has been<br />
envisaged to assess the potential of orange pulp as the source of natural<br />
antioxidants and dietary fiber for the production of functional mutton<br />
patties.<br />
Materials and methods<br />
Source of materials<br />
Mutton was procured from the experimental abattoir of the Division of<br />
Livestock Products Technology, Indian Veterinary Research Institute,<br />
Izatnagar. Onion and garlic were procured from the local market of Bareilly.<br />
To prepare a condiment mix, onion and garlic were peeled off, cut into<br />
small pieces and homogenized separately in a kitchen mixer to obtain a<br />
fine paste and used in the ratio of 3:1. Refined salt (Tata Chemicals Ltd.,<br />
Mumbai), refined wheat flour (maida), orange pulp and LDPE pouches were<br />
purchased from the local market.<br />
The spice mix was prepared for mutton patties as per the standardized<br />
formulation. All the chemicals were obtained from standard firms (Qualigen,<br />
Hi-Media, SD Fine etc.). Nylon barrier pouches (150gauge) in natural<br />
colour were procured from M/s Hitkari Industries Ltd., New Delhi-14.<br />
Preparation of mutton patties<br />
Formulation: Lean mutton (70%), vegetable oil (10%), chilled water (9%),<br />
condiments (3.8%), refined wheat flour (3.5%), dry spices (1.5%), salt<br />
(1.6%), STPP (0.3%), sugar (0.3%) and nitrite (100mg.kg -1 ).<br />
Mutton was partially thawed overnight, cut into small chunks and double<br />
minced with an Electrolux meat mincer. The meat batter was prepared in a<br />
bowl chopper (Seydelmann K20, Ras, Germany). Pre-weighed quantities of<br />
minced mutton, salt, sodium triphosphate (STPP) and sodium nitrite was<br />
added and chopping was done for about 2 to 3min.<br />
It was chopped again for 2min after the addition of ice flakes. Refined<br />
vegetable oil was slowly incorporated while chopping till it was completely<br />
dispersed in the batter.<br />
Condiments, dry spice mix, refined wheat flour and the other ingredients<br />
were added. Chopping was continued till uniform dispersion of all the ingredients<br />
and desired consistency of the batter was achieved. Meat patties of<br />
about 70 g each were formed manually utilizing a Petri plate of 80 mm diameter.<br />
The mutton patties were cooked in hot air oven at 180 o C for 30 min with in<br />
between turning of patties once. The core temperature of cooked patties<br />
was recorded by using a probe thermometer to reach to 72 o C.<br />
Analytical procedure<br />
pH and emulsion stability<br />
The pH of emulsion as well as mutton patties was determined following<br />
TROUT et al. (1992) by a combination electrode digital pH meter (model CP<br />
901, century Instrument Ltd. India). The emulsion stability was determined<br />
as per the method of TOWNSEND et al. (1968) with some modifications.<br />
About 25 g each of batter was placed in polyethylene bags and heated at<br />
80 °C in a thermostatically controlled water bath for 20 min. After cooling<br />
and draining the exudate, the cooked batter mass was weighed and the<br />
yield was expressed as emulsion stability in percentage.<br />
Cooking yield<br />
Weights of raw and cooked mutton patties were recorded. The percent<br />
cooking yield for each mutton patties was calculated as follows:<br />
Proximate composition<br />
The moisture, protein, fat and ash content of the mutton patties were<br />
determined by standard methods using a hot air oven, Kjeldahl assembly,<br />
Soxhlet extraction apparatus and a Muffle furnace, respectively, as per<br />
AOAC (1995).<br />
Shear force value<br />
The shear force value was determined as per the method described by<br />
BERRY and STIFFLER (1981). It was measured as force required for shearing a<br />
1cm square block on a Warner-Bratzler Shear Press (81031307 GR Elec.<br />
MFG. Co. USA) and expressed in kg/cm 2 .<br />
Moisture and fat retention<br />
The moisture and fat retention values represent the amount of moisture<br />
and fat retained in the cooked product per 100gof raw sample. These<br />
values were calculated according to the following equations given by<br />
EL-MAGOLI et al. (1996).<br />
Reduction in diameter and thickness expansion<br />
The raw and cooked mutton patties diameter and thickness were measured<br />
by a vernier calliper at three different points. The change in mutton<br />
patties diameter and thickness was determined using the following equations:<br />
Total dietary fiber<br />
Total Dietary Fiber (TDF), Soluble Dietary Fiber (SDF) and Insoluble Dietary<br />
Fiber (IDF) were determined by slight modification of an enzymatic method<br />
given by FURDA (1981).
.......................................................<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
43<br />
Research & Development<br />
Calorific value<br />
Two grams of sample was electrically burnt in excess of oxygen in a bomb<br />
calorimeter. The maximum temperature rise of the bomb calorimeter was<br />
measured with a thermocouple and a galvanometer system. By comparing this<br />
rise with that obtained when a sample of known calorific value is burnt, the<br />
calorific value of the sample material could be determined. Gross energy of<br />
samples was determined by a Gallenkamp and Ballistic Bomb Calorimeter (HAQUE<br />
andMURALI LAL, 1999).<br />
Water activity (aw)<br />
The water activity of functional mutton patties was measured by an Aqua LAB<br />
dew point water activity meter 4TE.<br />
Total phenolics<br />
The total phenolic content in the phyto-ingredients powder and mutton patties<br />
were quantified using the Folin-Ciocalteu colorimetric method as described by<br />
MAKKAR (2000). Suitable aliquots of the extracts were taken in test tubes, and<br />
the volume was made upto 0.5 ml with distilled water and 0.25 ml Folin-Ciocalteu<br />
(1N) reagent was added and then the reaction was neutralized by addition<br />
with 1.25 ml sodium carbonate solution (20%). The tubes were vortexed and the<br />
absorbance of the resulting blue color was measured using a Beckman DU-640<br />
UV/Vis spectrophotometer at 760 nm against blank after incubation for 40min<br />
at room temperature. From the standard calibration curve equation y= f(x) the<br />
quantification of phenolics was done and expressed as mg tannic acid equivalents<br />
per gram of sample.<br />
Texture profile analysis<br />
The texture profile of mutton patties was measured with the help of instrumental<br />
texture profile analyzer (TAHD Plus Texture analyser). The procedure used for<br />
instrumental texture profile analysis was similar to those described by BOURNE<br />
(1978). Chilled samples were tempered to bring to room temperature and were<br />
cut into 1cm squares. The samples were placed on a platform in a fixture and<br />
compressed twice to 85% of their original height by a compression probe (P75)<br />
at a cross head speed of 10 mm/s through a two cycle sequence, using a 50 kg<br />
load cell.<br />
Antioxidant capacity<br />
Total Phenolics by F-C Method<br />
Dried (finely ground) phyto-ingredients powder (0.2g) was taken in a centrifuge<br />
tube of 25 ml capacity. 10 ml of aqueous acetone (70%) was added and subjected<br />
to centrifugation for 10 min at 3000 g in a REMI research centrifuge and<br />
then the contents were cooled by keeping the centrifuge tube in the refrigerator<br />
at 4±1°C (MAKKAR, 2000). Five gram of mutton patties was taken in a beaker<br />
of 100ml capacity. 25 ml of aqueous ice cold 70% acetone was added and<br />
subjected to homogenization for 60 s in an Ultra Turrax T25 tissue homogenizer<br />
(Janke and Kenkel IKA Labortechnik, Germany) and then the beaker was<br />
wrapped with aluminium foil and kept overnight for extraction at a refrigeration<br />
temperature of 4±1°C (NAVEENA et al., 2008).<br />
Preparation of a calibration curve using Standard Tannic Acid (TA)<br />
Table 1 shows the tannic acid stock standard concentration. The calibration<br />
curve was drawn and the equation was calculated in a Microsoft Excel 2007<br />
spread sheet. The linear correlation between standard concentration and<br />
absorbance was expressed with the equation y= f(x) and r 2 value. Where y=<br />
absorbance, x= standard concentration (µg/ml) and r 2 = correlation coefficient.<br />
Reducing power assay<br />
Suitable aliquots of the extracts containing 50 to 100 µg phenolics from<br />
phyto-ingredients and mutton patties were taken in test tubes, and the<br />
volume was made equal with acetone (70%) and mixed with 2.5 ml phosphate<br />
buffer (200 mM, pH 6.6) and 2.5 ml potassium ferricynide (1% w/v).<br />
This mixture was kept at 50 o C in a water bath for 20 min. After cooling,<br />
2.5 ml of 10% trichloro acetic acid was added and centrifuged at 5000 rpm<br />
for 10 min in a REMI research centrifuge. The upper layer of the solution<br />
(2.5 ml) was mixed with (2.5 ml) distilled water and 0.5 ml of freshly prepared<br />
ferric chloride (0.1% w/v) solution. The absorbance was measured<br />
using Beckman DU-640 UV/Vis spectrophotometer at 700 nm against<br />
blank without any extracts and 0.1% ferric chloride. An increase in absorbance<br />
of the reaction mixture indicated the reducing power of the<br />
sample.<br />
DPPH radical scavenging activity<br />
The ability to scavenge the 1,1-diphenyl-2-picrylhydrazyl (DPPH) radical by<br />
phyto-ingredients and mutton patties was estimated by the method of<br />
SINGH et al. (2002). Different concentrations (50 and 100 µL equivalent to<br />
50 and 100ppm of total phenolics) of phyto-ingredients and mutton<br />
patties were taken in different test tubes. The volume was adjusted to<br />
100 µL by adding MeOH. 5ml of 0.1mM methanolic solution of DPPH was<br />
added to these tubes and shaken vigorously. The tubes were allowed to<br />
stand at 27 °C for 20 min. The control was prepared as above without any<br />
extract, and MeOH was used for the baseline correction. Changes in the<br />
absorbance of the samples were measured at 517 nm using a Beckman<br />
DU-640 UV-VIS spectrophotometer. The radical scavenging activity was<br />
expressed as the inhibition percentage and was calculated using the<br />
following formula:<br />
Calibration<br />
Tab. 1: Preparation of the calibration curve using<br />
standard Tannic Acid (TA)<br />
Test<br />
tube<br />
Final<br />
conc. of<br />
TA<br />
(µg/ml)<br />
Stock TA<br />
0.1 mg/<br />
ml<br />
(µl)<br />
Distilled<br />
water<br />
(ml)<br />
F-C<br />
reagent<br />
(ml)<br />
Sodium<br />
carbonate<br />
solution<br />
(ml)<br />
Final<br />
volume<br />
(ml)<br />
Blank 0 0 0.50 0.25 1.25 2.0<br />
T1 2 20 0.48 0.25 1.25 2.0<br />
T2 4 40 0.46 0.25 1.25 2.0<br />
T3 6 60 0.44 0.25 1.25 2.0<br />
T4 8 80 0.42 0.25 1.25 2.0<br />
T5 10 100 0.40 0.25 1.25 2.0<br />
Stock standard (tannic acid) concentration – 0.1mg/ml;<br />
Vortexed and kept at room temp for 40 min then recorded at 760 nm<br />
Source: MALAV et al. <strong>FLEISCHWIRTSCHAFT</strong> <strong>international</strong> 4_<strong>2018</strong><br />
TBARS value<br />
The TBARS value of mutton patties was determined by using the distillation<br />
method described by TARLADGIS et al. (1960).<br />
Instrumental color analysis<br />
The color of mutton patties was measured using a Lovibond Tintometer<br />
(Model F, Greenwich, UK). Samples were cut with the help of scissors to<br />
the inner diameter of the sample holder and secured against the viewing<br />
aperture. The sample color was matched by adjusting the red (a*) and<br />
yellow (b*) units, while keeping the blue unit fixed at 0.1. The corresponding<br />
color units were recorded. The hue and chroma values were determined<br />
by using the formulae tan -1 (b/a) (LITTLE, 1975) and (a 2 +b 2 ) 1/2<br />
(FROEHLICH et al., 1983), respectively, where a= red unit and b= yellow unit.<br />
Free fatty acids<br />
The free fatty acids content were determined by the procedure as described<br />
by KONIECKO (1979):
................................................<br />
................................................................................................................................................................<br />
.....................................................................................................................<br />
44<br />
Fleischwirtschaft <strong>international</strong> 4_<strong>2018</strong><br />
Research & Development<br />
Quality characteristics and shelf life evaluation of functional mutton patties<br />
Bioactive materials<br />
Tab. 2: Levels of various bioactive rich plant materials for the preparation of blends<br />
(A, B and C)<br />
Bioactive rich plant materials Control Blend A Blend B Blend C<br />
Cabbage powder (1:1 hydration,<br />
w/w)<br />
Red kidney bean powder (1:1<br />
hydration, w/w)<br />
Tab. 3: Physico-chemical properties of functional mutton patties incorporated with<br />
blends of bioactive rich plant materials (Mean±S.E.)*.<br />
Parameters Control BRPM blend level (9%)<br />
Blend A Blend B Blend C<br />
Emulsion pH 6.35±0.01 a 6.33±0.01 a 6.32±0.01 a 6.20±0.02 b<br />
Emulsion stability (%) 94.50±0.88 95.18±0.53 94.88±0.72 95.12±0.39<br />
Cooking yield (%) 89.96±2.67 91.42±1.54 91.46±2.38 91.82±0.25<br />
Product pH 6.36±0.<strong>04</strong> 6.36±0.03 6.33±0.03 6.29±0.02<br />
Moisture (%) 60.48±0.31 b 61.56±0.34 a 61.21±0.27 ab 61.68±0.31 a<br />
Protein (%) 17.23±0.35 a 15.49±0.62 b 15.47±0.33 b 15.30±0.47 b<br />
Moisture:protein ratio 3.52±0.06 b 4.01±0.15 a 3.96±0.07 a 4.05±0.13 a<br />
Fat (%) 14.88±0.52 13.82±0.40 14.17±0.33 14.02±0.44<br />
Ash (%) 2.59±0.12 2.76±0.10 2.75±0.07 2.65±0.09<br />
Shear force value (N) 0.31±0.03 a 0.26±0.02 ab 0.27±0.02 ab 0.23±0.02 b<br />
*Mean±S.E. with different superscripts in a row differ significantly (P
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might be due to a comparatively<br />
higher proportion of orange pulp<br />
in blend C. Emulsion stability for<br />
all treatments was insignificantly<br />
higher (P>0.05) than control. The<br />
pH values for the treatment<br />
products were marginally lower<br />
than control and there was decline<br />
in product pH from blend A<br />
to C. The decreasing trend in<br />
product and emulsion pH from<br />
blend A to C might be due to<br />
progressively increasing levels of<br />
orange pulp in blends which have<br />
acidic nature.<br />
The cooking yields of all treatment<br />
products were marginally<br />
higher than control. It could be<br />
attributed to the characteristic<br />
properties of non-meat additives<br />
to bind the water (REITMER and<br />
PRUSA, 1991).<br />
The moisture percentage for<br />
treatment products with blend A<br />
and C were significantly higher<br />
(P0.05) than<br />
control, which could be due to a<br />
higher mineral content of plant<br />
materials as compared to lean<br />
meat. The shear force values of<br />
treatment products with blends A<br />
and B were comparable to control.<br />
Lower shear force values for<br />
treatments in comparison to<br />
control might be due to higher<br />
moisture retention.<br />
Mean sensory scores of functional<br />
mutton patties incorporated<br />
with three different combinations<br />
of plant materials i.e.<br />
Product profile<br />
Tab. 5: Detailed product profile and textural parameters of functional mutton patties<br />
incorporated with the most suitable blend of plant materials (Mean±S.E.)*.<br />
Parameters Control Blend A<br />
Moisture retention (%) 54.45±0.28 b 56.27±0.43 a<br />
Fat retention (%) 86.76±0.35 b 87.60±0.76 a<br />
Diameter reduction (%) 15.96±0.38 14.85±0.72<br />
Thickness expansion (%) 4.50±0.81 3.89±1.19<br />
Shear force value (N) 0.33±0.<strong>04</strong> a 0.26±0.02 b<br />
Total phenolic content<br />
1.29±0.03 b 17.67±0.20 a<br />
(mg TA eq./100 g)<br />
Reducing power 0.05±0.02 b 0.47±0.<strong>04</strong> a<br />
DPPH radical-scavenging activity (%) 5.76±0.28 b 45.23±0.77 a<br />
Total dietary fiber (%) 0.73±0.07 b 2.24±0.07 a<br />
Calorific value (Kcal/100 g) 194.65±3.34 a 180.21±5.87 b<br />
Water activity (aw) 0.964±0.001 b 0.972±0.002 a<br />
Textural Properties<br />
Hardness (N/cm 2 ) 27.21±1.20 27.09±1.46<br />
Adhesiveness (Ns/g) –18.43±1.41 –19.84±3.96<br />
Springiness (cm/mm) 0.37±0.02 0.34±0.01<br />
Cohesiveness 0.34±0.01 a 0.35±0.01<br />
Gumminess (N/cm 2 ) 9.29±0.36 9.44±0.71<br />
Chewiness (N/cm ) 3.48±0.32 3.21±0.28<br />
*Mean±S.E. with different superscripts in a row differ significantly (P
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Quality characteristics and shelf life evaluation of functional mutton patties<br />
blends A, B and C are presented in Table 4. The tabulated values of the<br />
sensory attributes revealed significant differences (P
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tage over dietary fibers from other sources due to the presence of associated<br />
bioactive compounds (i.e. flavonoids and vitamin C) with antioxidant<br />
properties.<br />
The total dietary fiber (TDF) percentage in the treatment mutton patties<br />
was significantly higher (P
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Quality characteristics and shelf life evaluation of functional mutton patties<br />
Aerobically packaged<br />
Tab. 9: Effect of refrigerated storage on sensory attributes of aerobically packaged<br />
functional mutton patties incorporated with the most suitable blend of plant materials<br />
(Mean±S.E.)*.<br />
Treatments<br />
Refrigerated storage period (Days)<br />
0 7 14 21<br />
General appearance<br />
Control 7.15±0.05 a 7.05±0.06 ab 6.84±0.08 bc 6.67±0.10 c<br />
Blend A (9%) 7.14±0.<strong>04</strong> a 7.<strong>04</strong>±0.<strong>04</strong> a 6.90±0.03 b 6.82±0.<strong>04</strong> b<br />
Flavor<br />
Control 7.17±0.<strong>04</strong> a 7.03±0.06 a 6.78±0.10 b 6.55±0.12 b<br />
Blend A (9%) 7.15±0.03 a 7.05±0.03 b 6.87±0.10 c 6.76±0.05 c<br />
Texture<br />
Control 7.18±0.06 a 7.05±0.07 ab 6.88±0.05 bc 6.74±0.07 c<br />
Blend A (9%) 7.13±0.<strong>04</strong> a 7.01±0.<strong>04</strong> b 6.84±0.<strong>04</strong> c 6.72±0.03 d<br />
Binding<br />
Control 7.23±0.<strong>04</strong> aA 7.00±0.06 b 6.82±0.07 bc 6.71±0.07 c<br />
Blend A (9%) 7.11±0.<strong>04</strong> aB 7.03±0.03 a 6.85±0.<strong>04</strong> b 6.74±0.03 b<br />
Juiciness<br />
Control 7.15±0.<strong>04</strong> a 7.07±0.05 ab 6.97±0.<strong>04</strong> b 6.71±0.07 c<br />
Blend A (9%) 7.17±0.03 a 7.07±0.03 b 6.94±0.03 c 6.69±0.05 d<br />
Overall acceptability<br />
Control 7.21±0.<strong>04</strong> a 7.09±0.<strong>04</strong> a 6.81±0.07 b 6.63±0.07 c<br />
Blend A (9%) 7.20±0.02 a 7.10±0.<strong>04</strong> a 6.91±0.03 b 6.71±0.06 c<br />
*Mean±S.E. with different superscripts row wise (small alphabet) and column wise (capital alphabet) differ significantly (P
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parison to control, which could<br />
be due to the antimicrobial properties<br />
of bioactive rich plant<br />
materials in functional mutton<br />
patties.<br />
Sensory quality<br />
(aerobic packaging)<br />
The mean sensory scores of<br />
aerobically packaged control and<br />
blend A incorporated functional<br />
mutton patties are presented in<br />
Table 9.<br />
The mean scores for all sensory<br />
attributes showed a decreasing<br />
trend with the increase in the<br />
storage period. There was a marginal<br />
decrease (P>0.05) in the<br />
flavor, texture, binding, juiciness<br />
and overall acceptability scores<br />
for control and the treatment<br />
product up to day 7 of storage but<br />
the scores declined significantly<br />
(P0.05) in<br />
scores of most sensory attributes for control as well as for treatment<br />
products up to day 30 of storage, thereafter the scores declined significantly<br />
(P
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Quality characteristics and shelf life evaluation of functional mutton patties<br />
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Authors’ addresses<br />
O.P. Malav (corresponding author: drmalav_vet2007@rediffmail.com), Department of Livestock<br />
Products Technology, College of Veterinary Science, Guru Angad Dev Veterinary and Animal<br />
Sciences University, Ludhiana-1410<strong>04</strong>, Punjab, India; B.D. Sharma, R.R. Kumar, S. Talukder, S.R.<br />
Ahmed and A. Irshad, Division of Livestock Products Technology, Indian Veterinary Research<br />
Institute, Izatnagar-243 122, U.P., India.
Volume 33 _ D 428<strong>04</strong> F<br />
Journal for meat production,<br />
processing and research<br />
<strong>international</strong>