HPP Research Outcomes for Enhanced Meat Quality · Italy 2003 Proscuitto ham, salami & pancetta...

HPP for Enhanced Meat Quality

MINTRAC National Meat Retail Trainer’s Conference - Melbourne

FOOD AND NUTRITION

Anita Sikes

18 November 2015

Overview

• High pressure processing ….what is it?

• High pressure processing (HPP) technology • Benefits

• Current applications

• Shelf-life and safety

• Meat quality• Tenderisation

• Salt reduction in processed meats

• Industry opportunities

Meat Retail Trainer's Conference | Anita Sikes2 |

High pressure processing - HPPWhat is it?

3 | Meat Retail Trainer's Conference | Anita Sikes

http://www.google.com.au/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://foodgalaxy.org/high-hydrostatic-pressure-0&ei=cCkaVbjjLaHZmgWU94DYBw&bvm=bv.89381419,d.dGY&psig=AFQjCNGHUHiRyDAjtcweiYPGLgZUrAlDZw&ust=1427864185743237

http://www.google.com.au/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://foodgalaxy.org/high-hydrostatic-pressure-0&ei=cCkaVbjjLaHZmgWU94DYBw&bvm=bv.89381419,d.dGY&psig=AFQjCNGHUHiRyDAjtcweiYPGLgZUrAlDZw&ust=1427864185743237

What pressures are involved?• For preservation 300 – 700 MPa• For tenderisation, 50 – 600 MPa


Barrel eye

4100 m

40 - 60 MPa

What is HPP?

Source: Hiperbaric

200 elephants x 3000 kg each on a CD = 600 MPa (6000 bar or 90,000 psi)

PistonSize CD

-

-

-

-

-

-

--

-

-

High Pressure Chamber

How does it work?


Avure Technologies

350 L vessel

420 L vessel

Industrial HPP machines

160 L vessel


http://www.avure.com/index.html

http://www.avure.com/index.html

Funktionsweise_englisch.wmv



How does HPP work – process steps

Source: Hiperbaric

HPP systems at CSIRO


35 L690 MPa & temp

0.3 L900 MPa & temp

3 L800 MPa & temp

• 2 mL kinetic 700 MPa & temp• 2 L, 500 MPa

Benefits and Applications


Benefits of HPP

• Preservation / extension of shelf-life• Packaged, sliced, cooked meats

• Alternative method to heat treatment; no thermal degradation

• Preservative-free “clean” label

• Increased food safety

• Flavour, colour, nutritional value – minimal effects

• Maintain quality attributes

• Improving functional properties


Commercial application of HPP – pressure range


HPP Commercial Products


• Global HPP food production estimated in 2014 : + 500 million kg

GuacamoleWet saladsRTE vegetable meals

Listeria-free dry-cured productsRaw beef productsPreservative-free sausages

Oysters shuckingLobster meat extractionClams & mussels shuckingRTE seafood meals

Fruit juicesSmoothiesVegetable juices

Toll processingCheese / Eggs products

Pathogens-free sliced cooked meatsPreservative-free deli meats

Source: Hiperbaric

HPP industrial machines


Total machine number in production (Hiperbaric & competitors): 261

Source: Hiperbaric

Current HPP processors in Australia


HPP Meat Value-Adders




Packaging requirements

• Flexible packaging (>15% volume contraction)

• Extra tight seals• Rounded and reinforced edges• Minimal head space• MAP possible• Tear strength, puncture resistance,

surface smoothness generally not affected by HPP

• Often flexible pouches or bottles are inserted in secondary cardboard containers or sleeves after processing


Damage can occur when insufficient packaging and

processing is used

In particular, modified atmosphere packs (MAP)

Micro defects

(„white spots“)

Micro defects

(„white spots“)Bending and delamination

of packaging film

Delamination of packaging film

Conventional HPP processing of typical MAP products

Source: Tobias Richter, Multivac


Estimating Costs of HPPCOST FACTORS VALUE UNITS

Exchange rates

EUR:USD 1.331824 a $/€

AUD:USD 1.05045 a $/AUD

JPY:USD 0.011094 a $/¥

General factors

Electric power 0.11 AUD/kWh

Water 2.74 AUD/m³

Factory overheads 13 %

Depreciation period 10 years

Interest rate per period 10 %/a

Production parameters

Process pressure 600 MPa

Starting temperature 5 °C

Yearly days of production 216 d/a

Production hours per day 24 h/d

Cycle time 9.0 min

Pressure come up time 3.0 min

Vessel filling estimate 60 %

Product density b 1.0 kg/L

Labour

Engineer(s) per shift 0.1 -

Worker(s) per shift 2 -

Annual costs per Engineer(s) 113000 AUD/a

Annual costs per Worker(s) 90000 AUD/a

Hours per shift 8 h

Factors to consider

• Processing conditions (pressure, temperature, time)

• Cycle time• Capital Costs (size of plant,

manufacturer)• Depreciation period (note:

number of cycles is limited)• Vessel filling efficiency• Labour costs• Energy/water costs• Factory overheads• Exchange rates


Shelf-life and Safety


Shelf-life extension• Cold pasteurisation in the final package• Increased shelf life• Destruction of pathogens – Listeria, Salmonella, coliforms• Stabilisation of preservative-free or low salt content products


Country Year Products

Spain 1998 Sliced cooked ham and “tapas”

USA 2001 Sliced cooked products and proscuitto ham

USA 2001 Poultry products

USA 2002 Pre-cooked chicken and beef strips

Spain 2002 Sliced cooked meats products, Serrano cured ham

Italy 2003 Proscuitto ham, salami & pancetta

Germany 2004 Cured and smoked sliced and diced ham

Japan 2004 Nitrites-free bacon, sausages and sliced meat

USA 2005 Ready-to-eat meat based products

Spain 2005 Cured meat products & Serrano ham

Canada 2006 Cured & cooked meat products

USA 2006 Whole roasted chicken

USA 2006 Sliced cooked turkey and chicken

Canada 2006 Ready-to-eat meat meals

USA 2007 Chicken sausages

USA 2008 Cooked pork & beef sliced products

USA 2008 Pet food

Canada 2008 Sausages and bacon

Canada 2009 German style cooked meat products

USA 2009 Sliced RTE meats

Canada 2010 Proscuitto ham and cured meats

Australia 2010 Sliced and diced preservative free poultry products

Switzerland 2011 Cooked pork sliced products and sausages

USA 2011 Proscuitto ham and cured meats

USA 2011 RTE sliced meats

Rumania 2011 RTE pork products

Spain 2011 Serrano ham and cured meats

Source: Carole Tonello, Hiperbaric

250 MPa 600 MPaBefore After

High pressure can kill microorganisms by interrupting their cellular function without the use of heat that can damage the taste, texture, and nutrition of the food.

Effect of pressure on micro organisms


In-pack pasteurisation by HPP

Ready-to-eat meats processed at 600MPa for 180s

Approx. 4-log reduction of L. monocytogenes

Extension of refrigerated shelf-life from 45-50

days to > 98 days

Hayman et al. 2004

Time (s)

0 10 20 30 40 50 60 70

CF

U/m

l

100

101

102

103

104

105

106

107

2472

2655

2657

2345

2340

2343

2542

2341

2342


CSIRO Chill-stable meals concept products


Meat qualityHPP for tenderisation


Pressure-heat treatment – neck muscle

• 200 MPa / 60°C / 20 min

• improvement in texture

Control Heat HPP / Heat

Peak F

orc

e (

kgF

)

0

2

4

6

8

10

12

14

2x


Beef neck muscle (tongue root)M. SternomandibularisHigh connective tissue content muscle

Tenderisation at high temperature – retail muscles


• 200 MPa / 60oC / 20 min

• varying connective tissue content

Raw

Heat treatment60°C, 20 min

P-H treatment200 MPa, 60°C, 20 min

Muscle

SM ST LD

Pea

k F

orc

e (

kg

F)

0

2

4

6

8

10Heat

HPP-Heat

200 MPa / 60°C / 20 min 70°C / 30 min tender meat

Topside Silverside Striploin

25°C

Ref. 100 200 300 400 500 MPa

Effect of high pressure on meat colourTurkey breast (M. pectoralis superficialis) after 1 min at 0.1-500 MPa and 25°C.

Ref. 100 200 300 400 500 600 MPa

25°CChicken breast (M. pectoralis superficialis) after 1 min at 0.1-600 MPa and 25°C.

Pork meat (M. longissimus dorsi) after 1 min at 0.1-600 MPa and 25°C.

Ref. 100 200 300 400 500 600 MPa

25°C


Ref. 0.5 s 15 s 30 s

0.5 s 10 s 20 s 30 s

10 s 20 s 30 s0.5 s

Colour change in minced meat

Minced Meat


One-step pressure-heat process

• Topside ≈ 150 g, 20 mm thick steak

• One-step P-H process

• 200 MPa for 20 min at 60 – 76°C

• No further cooking

• Measure texture and yield


Texture and yield of P-H treated steaks

Temperature (o

C)

60 64 68 72 76

Pe

ak

sh

ea

r fo

rce

(k

gF

)

0.0

0.4

0.8

1.2

1.6

2.0

Heat only

200 MPa

60oC / 20 min then cooked

200 MPa then cooked

Temperature (oC)

60 64 68 72 76

Ove

rall

we

igh

t lo

ss

(%

)

0

10

20

30

40

50

Heat only

200 MPa

60oC / 20 min then cooked

200 MPa then cooked

200 MPa / 76°C / 20 min tender meat + increased yield

One-step process


Lamb Tagine Goat Curry Beef Short Rib Beef Chuck Soft Taco

Concept products


https://www.youtube.com/watch?v=xkwrcHt2AXU&feature=youtu.beSearch YouTube – high pressure processing / MLA / red meat

https://www.youtube.com/watch?v=xkwrcHt2AXU&feature=youtu.be

Salt reduction in processed meats


Effect of pressure and salt content on cook loss


NaCl (%)

0.0 0.5 1.0 1.5 2.0

Cook loss (

%)

0

5

10

15

20

25

30

35

40

0.1 MPa

200 MPa

Pressure (MPa)

0 100 200 300 400

Cook loss (

%)

0

10

20

30

40

1 % NaCl

0.8 % NaCl

0.6 % NaCl

• pressure range 0.1 – 400 MPa

• salt content 0 – 2%

• 10o C, 2 min

• optimal for cook loss - 200 MPa, 1% salt

Textural differences and acceptability


NaCl (%)

0.0 0.5 1.0 1.5 2.0

Hard

ne

ss (

N)

0

2

4

6

8

10

12

14

0.1 MPa

200 MPa

Control

HPP (200 MPa), 1% salt

• At 1% salt, all of the sensory parameters were improved by HPP (informal sensory panel)

• Texture was firmer with a more appealing bite

• Optimal at 200 MPa

Significance for industry


Opportunities

• Extension of shelf life• ready-to-eat (RTE) meat products : sliced/diced cooked meat products, ready-

to-eat meals, marinated meats, dry cured products

• Enhance quality of low-value cuts (value addition)• HPP combined with heat can tenderise low-value whole meat cuts

• one-step process can significantly improve yield

• Provide healthy, convenient, alternative processed meat products• HPP at low temperature improves the functional properties (binding, texture)

of meat batters using reduced salt content

• Commercialisation opportunities• business models (toll manufacturing)

• product types (meal solutions, smallgoods)


Anita Sikes

t +61 7 3214 2151e [email protected]

Project team:

Tomas BolumarJoanne HughesJanet StarkAarti TobinRon Tume

FOOD AND NUTRITION

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HPP Research Outcomes for Enhanced Meat Quality · Italy 2003 Proscuitto ham, salami & pancetta...

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