Meat Capability presentation

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Stephany Hood
5 years ago
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1 Meat Capability presentation

2 Avebe has the right expertise We can deliver with speed Avebe is your supporter of New Product Development We know industry needs We have an extensive toolbox of recipes We have an excellent toolbox of ingredients

3 Avebe has the right expertise

Potato and meat match made in heaven Historically the leftover cooked potatoes where saved to be used in meat, such as meat balls and sausages a way to provide texture and juiciness.

4 Potato and meat match made in heaven Historically the leftover cooked potatoes where saved to be used in meat, such as meat balls and sausages a way to provide texture and juiciness. Today we use the tricks from grandma, but in a more workable way we use the potato in the form of pure starch, fibre and protein for a wide range of meat products. And what would the mash be without the banger, the shepherd s pie without the potato cover, the Sunday steak without the potato

5 Avebe has 100 years of experience in meat Native potato starch Traditional binder for meat Specialized starch and protein products for meat application Products specially developed for optimizing the meat systems

R&D capability of Avebe Efficient equipped lab for application and fundamental work Application specialists Starch specialist Meat lab with

6 R&D capability of Avebe Efficient equipped lab for application and fundamental work Application specialists Starch specialist Meat lab with key equipment for development work Connection with top meat science institutes - DILL, DMRI Application, R&D and recipe optimization support

7 Avebe s approach for customer projects and research Meat project RVA Model System Meat Model System (Lab Scale) Production Outsource Validation at Customers Market introduction

8 Meat research publications in leading scientific journals

9 We know industry needs

10 Industry needs connected with Avebe s capabilities Industry Needs Make our product more healthy Avebe platforms Fat reduction Have cleaner labelling Be suitable for all consumers Low cost price with high quality Cleaner label with modified starch and phosphate replacement Free from ingredients suitable for gluten-free, dairy-free (casinate replacement) and non-gmo Affordable quality through recipe optimization Make our product even better Optimal product features though improved whitening and texture. What is your need?

11 Platforms Fat reduction Cleaner Label Free From Affordable quality Optimal product features

12 Our offerings in the different meat products Fresh processed meat products Burgers Fresh sausages Kebab/Gyros Cured cooked meats Cooked Ham Reconstituted products Canned and sterilized products "Emulsified" meat products Frankfurter Mortadella Liver sausage Paté

13 Fat reduction Social Sustainability less fat: Caloric values Fat Avebe starch based alternatives 9 kcal/g 1-2 kcal/g Reduction in fat caloric value up to 80% Environmental Sustainability: Primarily Meat based diet Primarily Plant based diet Land required 0.5 ha < 0.4 ha Fossil energy (1 kcal protein) 4 57 kcal (average 25 kcal) 2.2 kcal Water required (kg protein) L L CO 2 release 30 % meat 70 % vegetables CO 2 release 20 % meat 80 % vegetables 8 kg /day 7,5 kg /day

14 Cleaner Label The consumer and food industry is looking more and more for cleaner labels, supported by the fact of double digit growth in clean label claims Avebe is offering a whole range of clean label ingredients, that can be alternatives to phosphate, modified starches and Carrageenan

15 Free From Potato has no allergenicity and can enable formulations with free from claims milk, egg, soy, wheat Avebe s products are all GMO-free

16 Affordable Quality Avebe can support formulating affordable, still good quality meat products by reducing/replacing higher cost ingredients or due to very good water binding, providing superior yield management. NPS Perfectabind C Beef Pork fat 14,6 14,6 High water binding Dosage advantage against native potato starch Yield advantage Pork meat Water 28 29,2 Phosphate 0,4 0,4 Nitrite salt 2 2 Soy protein (isolate) 1 1 Native potato starch 4 Perfectabind C 2,8 Process losses Cost in use Native potato starch 10% 1,64 /kg Perfectabind C 3% 1,54 /kg Cost in use savings of 6% TOTAL

17 Optimize product features Texture differentiation firmness, spreadability, elasticity Visual - whitening Eating quality - juiciness

18 We have an excellent toolbox of ingredients

19 Potato starch: Excellent water binding and texturizing properties Potato protein: Good emulsion capacity Potato: Sustainable Environment-friendly Non-GMO Kosher and Halal Processed meat products: Lower cost-in-use Clean(er) label High quality

20 Tool box overview STARCHES: Perfectabind C Etenia 505 PROTEIN: Solanic 100T Complete texture solutions: Perfectamyl EF emulsified fat mimetic Perfectamyl VF visible fat mimetic

21 Meat & Potato starch fits because Potato starch is often used in meat products, because of its excellent ability to bind water, compared to other starches. Potato starch is the 'standard, because of its fast swelling, high water binding capacity and its bland flavour and taste. Another advantage is the low gelatinization temperature of potato starch, enabling the binding of water released upon denaturation of meat proteins in the heating stage. It is thus the only starch that doesn't require big changes in processing conditions in cooked meat products.

22 Perfectabind C gives you the best of both worlds

Perfectabind C Waxy potatoes naturally provides tenderness and enable a neutral flavor release suitable for delicate meat applications Improved

23 Perfectabind C Waxy potatoes naturally provides tenderness and enable a neutral flavor release suitable for delicate meat applications Improved product quality Provide juicy tender texture An optimal strong water binding Clean labelling No E-number Cost saving opportunities Halal, Kosher and non-gmo

24 The impact of salt on the water binding capacity, comparison Perfectabind C against a native starch In a salt matrix Perfectabind outperforms the native starch by far

25 Reduction of carrageenan in combination with the Perfectabind C Perfectabind C in basic recipe Carrageenan (high levels) limit optimal functionality of Perfectabind C and has a negative impact on texture. Perfectabind C in a optimized recipe Perfectabind C performs optimal with a lower level of carrageenan (20% lower). Carrageenan reduction is the solution

26 Replacement advice scheme for Perfectabind C part of the ingredient can be replaced by x parts of Perfectabind C The advice is a rule of thumb for single changes Other ingredients can influence the dosages. In complex recipes advices could be different. Example ISP 1.5%, NPS 3% Replacement Perfectabind C 3% min dosage max dosage

27 FIRMNESS Perfectamyl EF Emulsified Fat Replacer Clean label starch (in EU) Used for replacement of fat in emulsified products There is NO change in processing added with other dry ingredients Possibility of replacing of TOTAL added fat Excellent fat-like texture Raw ingredients Meat Fat Bowl chopper Dry ingredients Water/ice STARCH (+ Water) Replace with FIRMNESS OF FRANKFURTERS 400 Filling Cooking/ smoking 0 20% added fat 0% added fat 0% added fat + 9,5% Perfectamyl EF Storage COLD - HOT

Perfectamyl VF Visible Fat Replacer Used for

or fresh products Ingredient % Perfectamyl TM VF

cold Artificial fat made of starch and water, cooked

28 Perfectamyl VF Visible Fat Replacer Used for replacement of visible fat-like particles in cooked or fresh products Ingredient % Perfectamyl TM VF Water Cooked products that are consumed cold Artificial fat made of starch and water, cooked to 85 C and cooled overnight Fresh products that are consumed warm

29 Etenia 505 Meat/meat batter whitener Improvement of spreadability pate products Shows thermo-reversability through heating / cooling cycles Low dosage levels

30 Solanic 100T Solanic 100 low ph Solanic 100N Neutral ph Solanic 100T Alkaline ph

31 Emulsifying properties of Solanic 100T Solanic 100T has a good emulsion capacity (up to 1:15:15) Need new more better look pic Contributes to a firmer meat dough, hence better processing Supports desired firmness of final product Enhances the protein content of final application

32 And combinations. When using MDM instead of higher quality meat, waterbinding and texture stability are challenged The Avebe solution offers significant cost savings without compromising on quality Quality MDM + Avebe Solution Meat A perfect match of waterbinding and emulsification In addition, a cleaner label is achieved MDM Costs

33 And combinations.. Control with MDM and fat By combining Perfectabind C and Solanic 100T significant texture improvements can be achieved

34 Summary of benefits A combination of Solanic 100T and Perfectabind C delivers : A clean(er) label: GMO-free, allergen-free, less additives High water binding + great emulsification Firmness and elasticity comparable to standard Frankfurter sausages Nice spreadable liver paté without any fat separation or drip loss

35 We have an extensive toolbox of recipes

36 Recipe tool box overview (each recipe to highlight value i.e. cost saving, cleaner labeling etc.) Cooked sausages Kebab/Gyros Ham Burgers & meatballs Paté Nuggets Luncheon meat

37 Cooked sausages

38 Improvement of waterbinding with the Perfectabind C in sausages Ingredients (%) NPS Perfectabind C Beef Pork fat 14,6 14,6 Pork meat Water 28 29,2 Phosphate 0,4 0,4 Nitrite salt 2 2 Soy protein (isolate) 1 1 Native potato starch 4 - Perfectabind C - 2,8 TOTAL Minced meat pieces at 13mm Add the ingredients and water Mix the mass during several minutes Minced the mass at the required endsize. Heat the sausages until core temperature of 72 C. Cool down and pack.

39 Improvement of waterbinding with the Perfectabind C in chicken sausages Ingredients (%) NPS Perfectabind C Chicken thigh Chicken skin 14,6 14,6 Chicken MDM Water 28 29,2 Phosphate 0,4 0,4 Salt (NO3) 2 2 ISP 1 1 Native potato starch 4 - Perfectabind C - 2,8 TOTAL Minced meat pieces at 13mm Add the ingredients and water Mix the mass during several minutes Minced the mass at the required endsize. Heat the sausages until core temperature of 72 C. Cool down and pack.

40 Frankfurter formulations cleaner label Ingredients (%) Control Clean(er) label MDM (mechanically deboned meat) 45 41,1 Porkfat without rind Water 31,65 31,65 Salt (Nitrite) 1,5 1,5 Seasoning 1 1 Ascorbate 0,05 0,05 Clean(er) label no phosphates no carrageenan no allergens non-gmo Labeling: starch, potato protein Carrageenan (Meatline 1265 Danisco) 0,5 - Sodium tri polyphosphate 0,3 - Perfectabind C - 3,5 Solanic 100T - 1,5 TOTAL 100,0 100,0

41 Fat replacement in frankfurters Ingredients (%) Control Starch Meat (turkey breast) 42,00 42,00 Fat (pig back fat) 25,00 - Water (ice) 27,45 42,95 Starch* - 9,50 Nitrite salt 2,00 2,00 TPP 0,30 0,30 Spices 1,70 1,70 Replacement of TOTAL added fat in frankfurters No change in production process Substantial reduction in caloric value Texture comparable to full fat group even after reheating Ascorbate 0,05 0,05 Lactate 1,50 1,50 TOTAL 100,0 100,0

42 Sausage ( hotdog, frankfurter) Ingredients (%) Control Optimized MDM chicken Salt (Nitrate) 2,2 2,2 Water (ice) % optimizing in cost Better flavour release Meaty texture can be obtained Protein soy 0,5 - Modified starch 0,5 - Carrageenan 0,15 0,15 Wheat flour Perfectabind C - 1,6 Other ingredients 1,7 1,7 TOTAL 100,0 100,0

43 Solanic 100T / Perfectabind C Ingredients Dosage (%) MDM (mechanically deboned meat) 28,4 Porkfat without rind 15,0 Water 42,0 Perfectabind C 3,9 Solanic 100T 3,0 Native potato starch 5,0 Sugar 1,0 Salt 1,2 Concept uniqueness: A cost-effective clean(er) label sausage Cost savings up to 30% possible Clean(er) label non-gmo no allergens no phosphates or carrageenan Seasoning 0,7 TOTAL 100,0

44 Ham

Brine composition in 90% injected shoulder ham Ingredients Control % in the brine Perfectabind % in the brine Lactate 3,17 3,17 Salt (Nitrite) 4,22 4,22 Water 81,32 84,69 Phosphate (STPP) 0,84 0,84

45 Brine composition in 90% injected shoulder ham Ingredients Control % in the brine Perfectabind % in the brine Lactate 3,17 3,17 Salt (Nitrite) 4,22 4,22 Water 81,32 84,69 Phosphate (STPP) 0,84 0,84 Potato starch 6,33 - Soy protein isolate 3,17 - Carrageenan (semi) 0,95 0,74 Perfectabind C - 6,33 TOTAL 100,0 100,0 Mix the ingredients with the water. Keep the brine in motion during processing Inject the meat (100 kg) with the brine (90kg)

Brine composition of a reconstructed ham with 90% added brine Ingredients Benchmark % in the brine Perfectabind % in the brine Lactate 3,17 3,17 Salt (Nitrite) 4,22 4,22 Water 81,32 84,67 Phosphate

46 Brine composition of a reconstructed ham with 90% added brine Ingredients Benchmark % in the brine Perfectabind % in the brine Lactate 3,17 3,17 Salt (Nitrite) 4,22 4,22 Water 81,32 84,67 Phosphate (STPP) 0,84 0,84 Native potato starch 6,33 - Soy protein isolate 3,17 - Carrageenan (semi) 0,95 0,74 Perfectabind C - 6,33 Fibers - 0,03 TOTAL 100,0 100,0 Mix the ingredients with the water. Add the meat (100 kg) with the brine (90kg) into the tumbler After tumbling and filling, cook the ham to a core minimal temperature of 72 C (162 F)

47 Brine for reconstructed ham with an 145 % extension Brine Benchmark % FP / % Water 395,78 413,97 408,80 Salt (Nitrite) 2,11 2,07 2,07 Salt 8,44 8,28 8,28 Flavours + Carrageenan 33,25 32,60 32,60 Jamon flavor 1,05 1,03 1,03 Soy protein (Arcon S) 26,38-0,00 Perfectabind C 0,00 42,05 42,05 Native potato starch 82,98 40,68 40,68 Fibers - - 5,17 TOTAL 500,00 500,00 500,00

48 Paté

49 Liver paté formulations Free from allergen labeling Ingredients (%) Reference Allergen-free Pork liver Fat Water 48,6 49,8 Spices 0,5 0,5 Salt 1 1 Potato fibre 0,8 0,8 Plasma protein 0,9 0,9 Soy protein concentrate 1,5 - Skimmed milk powder 3,7 - Free from No soy No milk No gluten Non-GMO Clean label: starch, potato protein Perfectabind C - 1,5 Solanic 100T - 1,5 Spraydried Glucose syrup (Avebe SPG30 Avebe) - 1 TOTAL 100,0 100,0

50 Luncheon meat

Basic formulation for canned luncheon meat Ingredients (%) Basic recipe Phosphate free Chicken breast 54,7 54,7 Chicken meat MDM 33 33 Salt 2 2 Sugar 1,6 1,6 Water 4,9 5,8 Modified starch 3 -

51 Basic formulation for canned luncheon meat Ingredients (%) Basic recipe Phosphate free Chicken breast 54,7 54,7 Chicken meat MDM Salt 2 2 Sugar 1,6 1,6 Water 4,9 5,8 Modified starch 3 - Perfectabind C - 2,4 Phosphates (STPP) 0,3 0 Spices 0,5 0,5 Minced meat and mixed together with the water Add the ingredients Fill the mass in the can Put the cans in the autoclave. Heat for 12 min at 125 C Cool down TOTAL 100,0 100,0

52 Nuggets

53 Chicken nuggets Recipe Raw materials Dosage (%) Chicken filet, grinded 94 Water 4 Perfectabind C 1 Salt 1 Total 100 Preparation Tumble meat and brine, form, freeze, milk wash, steam cooking (72 C in core), batter, pre-fry (30 sec), freeze, fry (3 min) and hold for 30 min at 60 C in holding cabin

54 Burgers and meatballs

55 Phosphate replacement with Perfectabind C in RTE chicken burger Ingredients (%) Standard phosphate Perfectabind C without STPP Chicken pieces 87,00 87,00 Water 10,22 10,52 Salt 1,00 1,00 Phosphate (STPP) 0,30 - Potato starch 1,52 - Perfectabind C - 1,52 Tumbling: 20 min under vacuum Cooking process: steam until core temperature ~ C Reheating process: reheat by using microwave, 850W for 1 minute 30 seconds TOTAL 100,00 100,00

56 Improvement of water-binding and juiciness with the Perfectabind C in chicken stripes Ingredients % Chicken filets 82 Coconut milk 13,5 Perfectabind C 2 Salt 1 Lemon grass paste 1 Honey 0,5 TOTAL 100,00 Cut the breast fillet into stripes Tumble the meat together with the rest of the ingredients during 20 minutes Grill the pieces Freeze the pieces Reheat before serving

57 Kebab/Gyros

58 Pork gyros whiter meat Ingredients Meat (pork shoulder) 100,000 Water 17,000 TUMBLING: 40 min in full vacuum, 4rpm Native potato starch 1,080 Soy protein 70% 0,400 Sodium citrate 0,150 Citric acid 0,020 Fibers 0,500 Wheat fibre 0,150 Etenia 505 0,500 Salt 1,500

59 We can deliver with speed

60 Why can we deliver with speed? We have the right expertise We know industry needs We have an excellent toolbox of ingredients We have an extensive toolbox of recipes We already have a lot of knowledge available, just customer specific adaptations and assembling is needed to create a great product for you.

61 Innovation by nature

CLEAN LABEL SOLUTIONS FOR MEAT APPLICATIONS

CLEAN LABEL SOLUTIONS FOR MEAT APPLICATIONS Simplify your label by using potato starch and potato protein 1 Coöperatie AVEBE U.A. P.O. Box 15 964 AA Veendam The Netherlands Introduction While cost effectiveness