Global trends in ingredients for processed meat Jesper Kampp Danisco
World tour of ingredients 2
Ingredient trends in Europe E number concern No definition of Natural Strong GMO concern Focus on removal of allergens 3
Europe is not a homogeneous market 4
Low/No/Reduced allergens New products launched in 2009 Allergens that require specific labelling: Gluten Crustaceans Egg Fish Peanuts Soybeans Milk Nuts Celery Mustard Sesame seeds Sulphite Lupin Molluscs 5
Naturalness of texturants Ingredient Wheat Flour Rice Flour Gelatin Very Natural or Natural [%] 90.2 86.0 56.3 Proteins 54.0 Locust Bean Gum = St. John s bread flour [German] Locust Bean Gum, E 410 Guar Gum, E 412 Carrageenan, E 407 Carboxymethylcellulose Xanthan Gum Modified Starch, e.g. E 1442 44.1 20.8 1.2 Diacetyl Tartaric and Fatty Acid Esters of Glycerol Polyoxyethylene (20) Sorbitan Monostearate 1.9 Source: GfK, Germany 2009 (Food Marketing & Technology, Aug. 2009) 6
Alginate How can it be used in fat and oil emulsions? Linear, unbranched polysaccharide Extracted from various seaweeds Cold gelation with calcium ions Strong, cohesive and heat-stable gels 7
Alginate gelation 8
Fat emulsions A gelled, stabilised emulsion of water, fat/oil/skin A typical fat emulsion is a 1:10:10 emulsion (Stabiliser system : Water : Fat) Can replace fat 1:1 Ingredients Ratio % Pork fat Water Stabiliser system Total 10 10 1 47.62 47.62 4.76 100.00 Potential benefits of fat emulsions Improved texture Improved water binding Potential fat reduction Potential replacement of animal fat 9
Production of fat emulsions based on alginate Add water (0 C) to bowl chopper Spray stabiliser into water, start to chop, slow speed for a few rounds Increase speed, chop until a smooth and homogeneous paste is obtained Add ground fat or oil (slowly) Stop chopping when a homogeneous and creamy texture is obtained 10
Fat emulsion for fat reduction and improved yield The fat emulsion will build a gelled structure The gel can be chopped or ground Gel pieces and fragments to be added to the meat batter as fat substitute 11
Confocal laser scanning microscope photo of a fat emulsion Fat Alginate matrix 150 µm 12
Confocal laser scanning microscope photo of an oil emulsion Vegetable oil Alginate matrix 150 µm 13
Reduced cooking and storage loss - even with 1:10:10 emulsions (stabiliser:water:fat) Soy isolate 1:5:5 Stabiliser system 1:5:5 Stabiliser system 1:10:10 14
Oil emulsions as alternatives to standard fat Fat addition can easily be reduced by 50% without altering product characteristics Fully stable oil emulsions firm texture Opportunity to add vegetable fat instead of animal fat Addition of unsaturated fat Reduction in cholesterol Example: 1:10:5 oil emulsion (stabiliser:water:oil) 15
Oil emulsions in pepperonis Ordinary pepperonis Pepperonis with oil emulsion 48% less fat 35% less cholesterol No fat separation during baking 16
Fibres for extension of ground meat Very popular in the Middle East Includes e.g. beef, mutton and poultry Up to 35% added water Blends of fibres and hydrocolloids bind water 17
Cost reduction in minced meat with fibre/hydrocolloid blends Recipe for minced meat Ingredients Ground beef meat TVP Water Fibre/hydrocolloid blends Total Control 60.00% 10.00% 30.00% 100.00% Test 1 50.00% 10.00% 39.00% 1.00% 100.00% Drip loss after 1 hour at 12 º C: 5 % 4 3 2 1 Control Stabiliser System 18
Syneresis control with fibre/hydrocolloid blend After 1 hour at 12 º C: Syneresis after 1 hour at 12 º C: % Syneresis 5,00% 4,50% 4,00% 3,50% 3,00% 2,50% 2,00% 1,50% 1,00% 0,50% 0,00% Control Stabiliser system, 5% less meat Stabiliser System - 10% less meat Stabiliser System - 15% less meat 19
Functionality of fibre/hydrocolloid blend in burgers Control recipe for medium/high-quality burger 80% beef meat 20% water, salt, spices, etc. Recipe with fibre/hydrocolloid blend: 79% beef meat 1% fibre/hydrocolloid blend 20% water, salt, spices, etc. 20
Naturally cured cooked meat - how does it work? Current curing process Nitrite salt (E 250...) NO 2 Na Ascorbate (E 301...) Myoglobin NO Nitrosometmyoglobin Nitrosomyoglobin Upon cooking Cured colour (Nitrosoheme + Globine) 21
Naturally cured cooked meat - how does it work? Natural curing process Vegetables Vegetables containing containing NO NO 3 3 Nitrite salt (E 250...) Na Ascorbate (E 301...) Myoglobin NO 2 NO Nitrate reductase Activity Catalase and O 2 consumption Starter Starter culture with with nitrate nitrate reductase activity Nitrosometmyoglobin Nitrosomyoglobin Upon cooking Cured colour (Nitrosoheme + Globine) 22
Naturally cured ham with and without culture with high nitrate reductase activity Control with NO 2 With vegetable juice and culture No colour development With vegetable juice but without culture 23
Emulsifiers in meat products Traditionally used in liver sausages Reduced liver content Improved stability Improved spreadability 24
Spreadable textures Spreadable, cooked sausages Denaturation of meat proteins due to heat treatment or blocking by other additives. No texture building during cooking Emulsion created by the addition of emulsifiers 25
RUSSIA: Semi-smoked sausages Made with large, coarse fat particles The use of emulsifiers provides: Reduced greasiness Improved flavour release Added at the beginning of the process 26
CHINA: Traditional Chinese sausages 27
Chinese sausages Typical recipes: Basic ingredients for 100 kg 60 74 kg lean pork or lean pork trimmings 25 40 kg pork backfat 10 kg water 1.5 kg Chinese wine ( Mei Kwei Lo etc.) 20 g nitrite salt 10-50 g sugar MSG, soy sauce, cinnamon Emulsifier blend 28
Manufacture of Chinese sausages Grinding Mixing Mixing Stuffing Drying Dryingand smoking: 48 48 50ºC 50ºC (118-122ºF) for for 72 72 hours hours 60 60 65ºC 65ºC (140-149ºF) for for 24 24 hours hours Weight Weightloss loss40 40 45% 45% Emulsifiers: Prevent fat from melting during drying Increase yield Extend shelf life 29
Time for questions 30