Processed Natural Meats

Processed Natural MeatsProcessed Natural Meats

Jeff SindelarJeff Sindelar

University of WisconsinMadison, WI

Cured Meat ProductsCured Meat Products

Purpose of Sodium Nitrite/NitratePurpose of Sodium Nitrite/Nitrate

Cured meat colorCured meat color

Cured meat flavorCured meat flavor

Preservative propertiesPreservative propertiesGrowth of Growth of Clostridium Clostridium botulinumbotulinum

Powerful antioxidantPowerful antioxidantEffective in controlling fat oxidationEffective in controlling fat oxidation

Cured Meat Color DevelopmentCured Meat Color Development

Myoglobin Nitrosomyoglobin Nitrosohemochrome(Pink cured meat color)

Nitric oxide (gas)Heat

Addition of sodium nitrite

UnUncured cured Meat ProductsMeat Products

Natural, Organic and Conventional Natural, Organic and Conventional Labeling ClaimsLabeling Claims

OrganicOrganic100% organic100% organicOrganicOrganicMade with organicMade with organicLess than 70% organicLess than 70% organic

NaturalNatural

UncuredUncured Less Restrictive

More Restrictive

USDA Definition of Uncured Meat USDA Definition of Uncured Meat ProductsProducts

Definition found in 9 CFR 317.17 and 9 CFR 319.2 Definition found in 9 CFR 317.17 and 9 CFR 319.2 Normal cured products that can be made without nitrites or Normal cured products that can be made without nitrites or nitrates addednitrates added

Regulations effective for products found to be similar in size, Regulations effective for products found to be similar in size, flavor, consistency and general appearance to products flavor, consistency and general appearance to products prepared with nitrate and/or nitriteprepared with nitrate and/or nitrite

Other normal ingredients are allowedOther normal ingredients are allowedDextrose, phosphates, etcDextrose, phosphates, etc……

Required Label Modifications for Required Label Modifications for Uncured Meat ProductsUncured Meat Products

Statements/words that must be addedStatements/words that must be added““UncuredUncured”” before common name before common name

i.e. i.e. UncuredUncured FrankfurtersFrankfurters

““No Nitrate or Nitrite AddedNo Nitrate or Nitrite Added”” statement must be addedstatement must be added

““Not Preserved Not Preserved –– Keep Refrigerated Below 40Keep Refrigerated Below 40°°F At All F At All TimesTimes”” statement must be addedstatement must be added

USDA Revised LabelingUSDA Revised Labeling

““UncuredUncured”” Meat Products (April, Meat Products (April, 2006)2006)

USDA Labeling Division verbally USDA Labeling Division verbally announced changes for new label announced changes for new label approvals of uncured meat productsapprovals of uncured meat products

Changes take effect with all new label Changes take effect with all new label submissionssubmissions

Reasons for Labeling RevisionsReasons for Labeling Revisions

In response to: In response to: Realization that uncured meat products may be found to Realization that uncured meat products may be found to contain nitrates/nitrites contain nitrates/nitrites

Concern that products and product labels may not be truthful Concern that products and product labels may not be truthful to consumersto consumers

Emergence of rapid growth of product categoryEmergence of rapid growth of product category

New Labeling Changes for Uncured New Labeling Changes for Uncured Meat ProductsMeat Products

When submitting a label for uncured meat products:When submitting a label for uncured meat products:If USDA Labeling Division notices an ingredient that MAY If USDA Labeling Division notices an ingredient that MAY contain nitrates or nitrites, a disclaimer will have to be addedcontain nitrates or nitrites, a disclaimer will have to be added

New labeling changes will be reflected in new Food New labeling changes will be reflected in new Food Standards and Labeling Policy BookStandards and Labeling Policy Book

““No PreservativesNo Preservatives”” statement claim can no longer be usedstatement claim can no longer be used

Labeling Disclaimer for Uncured Labeling Disclaimer for Uncured Meat ProductsMeat Products

““No nitrates or nitrites No nitrates or nitrites added except for naturally added except for naturally occurring nitrates or nitrites found in occurring nitrates or nitrites found in ……....””

Celery juice powder, beet juice powder, carrot juice Celery juice powder, beet juice powder, carrot juice concentrate, sea salt, or any ingredient determined to contain concentrate, sea salt, or any ingredient determined to contain nitrates or nitrites by USDA.nitrates or nitrites by USDA.

Types of Uncured Meat ProductsTypes of Uncured Meat Products

No intention of replacing nitrite/nitrateNo intention of replacing nitrite/nitrateUncured appearance and flavorUncured appearance and flavor

Intention to replace nitrite/nitrateIntention to replace nitrite/nitrateCured appearance and flavorCured appearance and flavor


No intention of replacing No intention of replacing nitrite/nitratenitrite/nitrate


Intention is to replace Intention is to replace nitrite/nitratenitrite/nitrate

Uncured Meat Product Uncured Meat Product ManufactureManufacture

Two Approaches to Curing ReviewTwo Approaches to Curing Review

1.1. Addition of nitrite during Addition of nitrite during product manufactureproduct manufacture

2.2. CookCook

3.3. = Cured meat product= Cured meat product

1.1. Addition of nitrate Addition of nitrate containing sourcecontaining source

2.2. Incubation Incubation ––(conversion of (conversion of nitrate to nitrite)nitrate to nitrite)

3.3. CookCook

4.4. = Cured meat product= Cured meat product

Cured Meat Color DevelopmentCured Meat Color Development

Myoglobin

Nitrosomyoglobin Nitrosohemochrome(Pink cured meat color)

Nitric oxide (gas)Heat

Addition of nitrate source and starter culture.

Incubation reduces nitrate to nitrite

Step # 1:Step # 1:

Addition of nitrate containing source Addition of nitrate containing source &&

Nitrate reducing ingredientNitrate reducing ingredient

Ingredients NecessaryIngredients Necessary

Nitrate sourcesNitrate sourcesVegetablesVegetables

JuicesJuicesPowdersPowders

Sea saltSea saltRaw sugarRaw sugarOthersOthers……

Nitrate reducing sourceNitrate reducing sourceLactic acid starter cultureLactic acid starter culture

Natural Sources of NitrateNatural Sources of Nitrate

Radishes Radishes 26002600Celery Celery 31513151Lettuce Lettuce 23302330Spinach Spinach 24702470CarrotsCarrots 274274BeetsBeets 32883288Cabbage Cabbage 712712BeansBeans 466466

TomatoesTomatoes 8080PotatoesPotatoes 150 150 Turnip GreensTurnip Greens 90409040OnionsOnions 235235MelonMelon 49324932RhubarbRhubarb 29002900BroccoliBroccoli 10141014

Vegetable sources of Vegetable sources of ““naturalnatural”” nitrate (avg. nitrate (avg. ppmppm):):

R. Walker (1990), Food Add. R. Walker (1990), Food Add. ContamContam. 5:717. 5:717--768.768.

Limitations of IngredientsLimitations of Ingredients

Vegetable Juice PowderVegetable Juice PowderMinimum of 0.2%Minimum of 0.2%Maximum of 0.4% Maximum of 0.4% ……??

Depends on amount of spices in productDepends on amount of spices in product

Starter CultureStarter Culture25 g per 225 kg 25 g per 225 kg

Uncured Sausage SensoryUncured Sausage Sensory

TRTa Cured Aroma Cured Flavor

1 8.41 8.10e

2 8.77 8.66e

3 8.12 8.57e

4 8.45 9.01de

C 9.33 9.93d

SEM 0.40 0.38

a TRT: 1 = 0.20% VJP + 30 min incubation2 = 0.20% VJP + 120 min incubation 3 = 0.40% VJP + 30 min incubation 4 = 0.40% VJP + 120 min incubation C = 156 ppm (mg/kg) sodium nitrite

d-e Means within same column with different superscripts are different (P<0.05).

Sindelar et al. (2007), J. Food Sci. 72(5): 324-332.

Uncured Ham SensoryUncured Ham Sensory

TRTa Ham Aroma Veg Aroma Ham Flavor Veg Flavor

1 7.33df 3.54f 7.80de 2.17f

2 6.01def 4.26df 7.04de 3.78df

3 4.82e 6.63d 6.28d 5.05d

4 4.64e 6.15d 6.28d 4.65d

C 7.27f 2.68f 8.19e 1.96f

SEM 0.62 0.64 0.50 0.64


d-f Means within same column with different superscripts are different (P<0.05).


Step #2:Step #2:

Incubation Incubation -- conversion of nitrate conversion of nitrate to nitriteto nitrite

Requirements for Nitrate ConversionRequirements for Nitrate Conversion

Proper incubation of productProper incubation of productInternal temperature heldInternal temperature held

5050--113 113 °°F (86 F (86 °°F optimum)F optimum)~ 1~ 1--2 hours2 hoursDepends on product diameterDepends on product diameter

Frankfurters = 2 hoursFrankfurters = 2 hoursHam = 1 hourHam = 1 hour

Optimum time for starter culture functionOptimum time for starter culture functionNitrate Nitrate reductasereductase enzymes reduce nitrate to nitriteenzymes reduce nitrate to nitrite

Longer time = more nitrate to nitrite conversionLonger time = more nitrate to nitrite conversion

Uncured Sausage Nitrate and NitriteUncured Sausage Nitrate and Nitrite

PPM Residual Nitrite PPM Residual NitrateTRTa Pre-Incubate Post-Incubate Pre-Incubate Post-Incubate

1 0h 5.6ij 51.2i 38.5h

2 0h 24.5h 52.0i 14.0j

3 0h 7.7j 99.2g 89.7g

4 0h 46.0g 99.6g 26.3i

C 59.1g NA 34.8h NA

SEM 0.62 1.22 1.35 2.02


g-j Means within same column with different superscripts are different (P<0.05).


Uncured Ham Nitrate and NitriteUncured Ham Nitrate and Nitrite

PPM Residual Nitrite PPM Residual Nitrate

TRTa Pre-Incubate Post-Incubate Pre-Incubate Post-Incubate

1 0.00h NA 40.8jk NA

2 0.00h 19.5h 46.6ij 10.4

3 0.00h NA 78.2g NA

4 0.00h 36.1g 81.0g 14.6

C 61.1g NA 22.5hk NA

SEM 1.16 0.97 4.59 1.30


g-k Means within same column with different superscripts are different (P<0.05).


Step #3:Step #3:

CookingCooking

Cooking RequirementsCooking Requirements

Besides the addition of an Besides the addition of an incubation step, no other incubation step, no other changes are necessarychanges are necessary

Uncured Frankfurter Uncured Frankfurter Smokehouse ScheduleSmokehouse Schedule

*** Step 2 is where conversion of nitrate to nitrite will occur.

9393103103105105IT: 100 FIT: 100 FCookCook11

383811811815015000:3000:30Smoke CookSmoke Cook44

CookCook

CookCook

CookCook

CookCook

Step TypeStep Type

8585178178185185IT: 160 FIT: 160 F66

676714514516016000:2000:2055

000014014000:2000:2033

93931031031051052:002:0022

RHRH

(%)(%)

Wet BulbWet Bulb

((ooFF))

Dry BulbDry Bulb

((ooFF))

TimeTimeStepStep

Uncured Smoked Sausage Smokehouse Uncured Smoked Sausage Smokehouse ScheduleSchedule


9393103103105105IT: 100 FIT: 100 FCookCook11


CookCook

Smoke CookSmoke Cook

CookCookCookCook

Step TypeStep Type

7878160160170170IT: 160 FIT: 160 F77

474712012014514500:3000:3055

000012012000:4500:4533

93931031031051051:301:3022

RHRH

(%)(%)

Wet BulbWet Bulb

((ooFF))

Dry BulbDry Bulb

((ooFF))

TimeTimeStepStep


Uncured Ham Smokehouse Uncured Ham Smokehouse ScheduleSchedule


000017017000:4500:45CookCook66

606015015017017000:3000:30CookCook77

9393103103105105IT: 100 FIT: 100 FCookCook11

222211511516516500:3000:30CookCook44

CookCook

CookCook

CookCook

CookCook

Step TypeStep Type

100100180180180180IT: 160 FIT: 160 F88

242412012017017001:0001:0055

212111011016016000:3000:3033

93931031031051051:001:0022

RHRH

(%)(%)

Wet BulbWet Bulb

((ooFF))

Dry BulbDry Bulb

((ooFF))

TimeTimeStepStep

Processing ConsiderationsProcessing Considerations

Emulsion/Meat Batter Visual Emulsion/Meat Batter Visual DifferencesDifferences

Expect a different appearance between cured and uncured, no Expect a different appearance between cured and uncured, no nitrate or nitrite added emulsions/battersnitrate or nitrite added emulsions/batters

Whole Muscle Processing Whole Muscle Processing RequirementsRequirements

Starter culture must be injected into whole Starter culture must be injected into whole muscle cutsmuscle cuts

Not water solubleNot water soluble

Will not penetrate meat during tumbling or immersion curingWill not penetrate meat during tumbling or immersion curing

Injection CalculationsInjection Calculations

Amount of nitrate containing ingredient and starter Amount of nitrate containing ingredient and starter culture needed to add to brine is calculated from culture needed to add to brine is calculated from total injected weight basistotal injected weight basis

Calculation factors needed to know:Calculation factors needed to know:lbs of nonlbs of non--injected meat weightinjected meat weightInjection percentageInjection percentage% nitrate containing ingredient desired% nitrate containing ingredient desired% starter culture desired% starter culture desired

Example CalculationExample Calculation25 lb of meat to inject25 lb of meat to inject25% injection level25% injection level0.25% nitrate containing ingredient0.25% nitrate containing ingredient

Step 1Step 125 lb meat x 1.25% injection = 31.25 lb total injected weight25 lb meat x 1.25% injection = 31.25 lb total injected weightStep 2Step 231.25 lb x 0.25% (nitrate containing desired) = 0.078131.25 lb x 0.25% (nitrate containing desired) = 0.0781Step 3Step 30.0781 / 6.25 lb of brine added to 25 lb of meat0.0781 / 6.25 lb of brine added to 25 lb of meat

= 0.0125 = 1.25% of brine should be nitrate contai= 0.0125 = 1.25% of brine should be nitrate containing ning ingredientingredient

Processing ConcernsProcessing Concerns

““Natural CuringNatural Curing”” QualityQuality

Water and protein bindingWater and protein bindingControl of raw materialsControl of raw materialsModifications to processingModifications to processingControl of pHControl of pHIngredient choicesIngredient choices

““Natural CuringNatural Curing”” QualityQuality

Antioxidant protectionAntioxidant protection~ 50 ~ 50 ppmppm nitritenitriteDependent on amount of unsaturated lipidsDependent on amount of unsaturated lipidsNatural alternatives?Natural alternatives?

Maintaining cured colorMaintaining cured color22--14 14 ppmppm nitrite induces cured colornitrite induces cured color4040--50 50 ppmppm nitrite generally considered adequate nitrite generally considered adequate pH considerationspH considerations

Antimicrobial protectionAntimicrobial protectionIngredients?Ingredients?Processes?Processes?

““Natural CuringNatural Curing”” SafetySafety

Clostridium Clostridium BotulinumBotulinum inhibitioninhibition5050--60 60 ppmppm ingoing nitrite?ingoing nitrite?Difficult to assess without challenge studiesDifficult to assess without challenge studies

Difficult to quantify true amount of nitrite generatedDifficult to quantify true amount of nitrite generated

Currently being investigatedCurrently being investigated

Uncured Sausage Uncured Sausage -- Residual NitriteResidual NitriteDAY

TRTa 0 14 28 56 90

1 r16.1e r10.6f r 8.8fh r4.9gh r4.9gh

2 pq24.7e pq21.7e pq17.2f pq12.0gh pqr9.1h

3 qr21.3e q16.6f qr 12.9fh qr 9.9gh qr 8.5g

4 n 58.5e n44.3f n33.1g n22.3h n16.3i

C o 46.9e o31.4f op22.0g opq12.4hi opqr8.7i

SEM = 1.02a TRT: 1 = 0.20% VJP + 30 min incubation

2 = 0.20% VJP + 120 min incubation 3 = 0.40% VJP + 30 min incubation 4 = 0.40% VJP + 120 min incubation C = 156 ppm (mg/kg) sodium nitrite

e-i Means within same row with different superscripts are different (P<0.05).n-r Means within same column with different superscripts are different (P<0.05).


Uncured Ham Uncured Ham -- Residual NitriteResidual NitriteDAY

TRTa 0 14 28 56 90

1 n21.0e n14.6ef n18.4e n13.4ef n7.2f

2 n19.3e n15.6ef n18.3e n11.7ef n8.8f

3 nq 27.7e nq 23.6eh nq25.4eg nq 19.4fgh n11.7f

4 oq 36.0e oq 32.6eh oq32.8eg oq 25.4fgh o21.3f

C p63.4e p61.1e p56.0e p45.0f p34.1g

SEM= 1.72a TRT: 1 = 0.20% VJP + 0 min incubation

2 = 0.20% VJP + 120 min incubation 3 = 0.35% VJP + 0 min incubation 4 = 0.35% VJP + 120 min incubation C = 200 ppm (mg/kg) sodium nitrite

e-h Means within same row with different superscripts are different (P<0.05).n-q Means within same column with different superscripts are different (P<0.05).


Finished Product ConsiderationsFinished Product Considerations

Shorter shelf life?Shorter shelf life?Vacuum packagingVacuum packagingGas flushing and high oxygenGas flushing and high oxygen--barrier filmsbarrier films

Store product in cold refrigeration temperaturesStore product in cold refrigeration temperatures< 40< 40°°FF

Organic and Natural Claim Organic and Natural Claim ResourcesResources

USDA Food Standards and Labeling Policy BookUSDA Food Standards and Labeling Policy Bookwww.usda.fsis.govwww.usda.fsis.gov (then use (then use ““Search FSISSearch FSIS””))

USDA 21 CFR 101.22USDA 21 CFR 101.22www.access.gpo.gov/cgiwww.access.gpo.gov/cgi--bin/cfrassemble.cgi?title=200721bin/cfrassemble.cgi?title=200721

Foods; labeling of spices, flavorings, colorings and chemical prFoods; labeling of spices, flavorings, colorings and chemical preservativeseservatives

National Organic Program (NOP)National Organic Program (NOP)www.ams.usda.gov/nop/NOP/standards/ListReg.htmlwww.ams.usda.gov/nop/NOP/standards/ListReg.html

Questions?Questions?

Processed Natural Meats

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