Innovation in meat processing by high pressure application
Facts and Figures Institute FOUNDED IN.  1983 LEGAL FORM. Registered association (e.V.) EXECUTIVE DIRECTOR. Dr.-Ing. Volke...
Market development Food industry GERMAN FOOD INDUSTRY.  Share of sales - Germany food sectors in 2008: Meat: 22,5 % Dairy:...
DIL e.V. Member companies
<ul><li>Increased competitiveness through efficiency improvements of the production processes used, e.g. by improved energ...
Brownian /Diffusion mechanical electrical magnetical Mechanisms for food processing  stochastical stoch. targeted  targete...
High Pressure Processing
Inactivation Swelling Disintegration microbes starch tissue lipids Transition proteins Unfolding HP Effect
High Pressure Processing Why pressure for preservation? unwanted action
Source: Carole Tonello, NC Hyperbaric <ul><li>128 equipments used by 61 companies </li></ul><ul><li>Total production in 20...
<ul><li>First HPP meat product in the world </li></ul><ul><li>Sliced cooked ham launched in Spain in 1998 </li></ul><ul><l...
HORMEL (USA) <ul><li>HPP dry cured ham in the US market since 2001 </li></ul><ul><li>Large range of  natural  HPP sliced R...
High Pressure Processing Product examples <ul><li>HPP dry cured ham in the US market since 2004 </li></ul><ul><li>Vacuum-p...
TYSON (Ameriqual) (USA)   2 Wave 6000/300   Chicken preservative-free products High Pressure Processing Product examples
CAMPOFRIO (Spain) 1998/99  Campofrío is concerned about a  Listeria  contamination in USA (Sara Lee products). First trial...
April 2003  : Launching of “Vuelta y Vuelta” range: gross slices of ham, turkey, and chicken (meat taste, less additives, ...
25°C Ref.  100  200  300  400  500 MPa Ref.  100  200  300  400  500  600 MPa Change of turkey meat after 1 min at 0.1-500...
High pressure treated chicken fillet 6000 bar, 5min Shelf life > 30 days High Pressure Processing Marinated meat
Adaptation of marinade recipe Impact of marinade pH on lightness Potential to avoid discoloration High Pressure Processing...
Liver sausage High Pressure Processing HPP „cooking“
Liver sausage High Pressure Processing HPP „cooking“
<ul><li>Cold processed liver sausage </li></ul><ul><li>Time and energy saving </li></ul><ul><li>No cooking loss </li></ul>...
High pressure MDM turkey sausages   Cutting  Filling  Smoking  HPP High Pressure Processing HPP „cooking“ Ingredients  Wei...
Firmness and benefits of HP-treated sausages   <ul><li>Low-cost, safe product </li></ul><ul><li>Saving time and energy  </...
HPP Product Cold production of pork chop (Kassler) Pickling/Curing Tumbling Smoking High pressure treatment High Pressure ...
HPP Product Cold production of pork chop (Kassler) <ul><li>Cold processing – no heat </li></ul><ul><li>Saving energy </li>...
55l technical scale system 600 MPa ambient Available for product development and co-processing
<ul><li>Calculations: </li></ul><ul><li>including depreciation (5 years, 280 days/year, 16 h/day), wear parts and energy c...
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Innovative Meat Products by High Pressure

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Innovative Meat Products by High Pressure

  1. 1. Innovation in meat processing by high pressure application
  2. 2. Facts and Figures Institute FOUNDED IN. 1983 LEGAL FORM. Registered association (e.V.) EXECUTIVE DIRECTOR. Dr.-Ing. Volker Heinz MEMBERS. Approx. 113 member companies (53 of them from Lower Saxony) EMPLOYEES. Approx. 117 BUDGET 2009. Approx. 6.5 million Euro OBJECTIVE. Improvement of efficiency and increase of competitiveness of companies from the food industry MISSION MISSION INNOVATION – Knowledge for superior foods
  3. 3. Market development Food industry GERMAN FOOD INDUSTRY. Share of sales - Germany food sectors in 2008: Meat: 22,5 % Dairy: 16,8 % Confectionery, dry baked goods: 9,1 % Alcoholic beverages: 8,0 % Baked goods: 7,4 % Potato, fruit and vegetable processing: 6,5 % etc. Number of companies in 2008: approx. 5,800 Number of employees in 2008: approx. 530,000 75% of the companies have less than 100 employees!
  4. 4. DIL e.V. Member companies
  5. 5. <ul><li>Increased competitiveness through efficiency improvements of the production processes used, e.g. by improved energy management, automation or application of novel technologies on material conversion. </li></ul><ul><li>Support of the industry with new production processes Focus of development: </li></ul><ul><ul><li>Pulsed electrical fields </li></ul></ul><ul><ul><li>Extrusion </li></ul></ul><ul><ul><li>High pressure </li></ul></ul><ul><ul><li>Ultrasonic/shock waves technology </li></ul></ul><ul><ul><li>Application of supercritical fluids </li></ul></ul>Quelle Fotos: DIL, Business Field Process Design
  6. 6. Brownian /Diffusion mechanical electrical magnetical Mechanisms for food processing stochastical stoch. targeted targeted stoch. targeted stoch. electromagnetical thermal processes direct indirect High Pressure flow pattern Ultrasound turb. lam. PEF MW/RF PMF chemical, physico-chemical, physical, bio-chemical, biological Adapted from Windhab (2006) Business Field Process Design
  7. 7. High Pressure Processing
  8. 8. Inactivation Swelling Disintegration microbes starch tissue lipids Transition proteins Unfolding HP Effect
  9. 9. High Pressure Processing Why pressure for preservation? unwanted action
  10. 10. Source: Carole Tonello, NC Hyperbaric <ul><li>128 equipments used by 61 companies </li></ul><ul><li>Total production in 2008 : ~180 000 tons </li></ul>High Pressure Processing Industrial installations
  11. 11. <ul><li>First HPP meat product in the world </li></ul><ul><li>Sliced cooked ham launched in Spain in 1998 </li></ul><ul><li>“ Remains fresh until eaten” </li></ul><ul><li>Products with a label H.P.P. </li></ul>ESPUÑA (Spain) High Pressure Processing Product examples
  12. 12. HORMEL (USA) <ul><li>HPP dry cured ham in the US market since 2001 </li></ul><ul><li>Large range of natural HPP sliced RTE ham, turkey and beef </li></ul><ul><li>Vacuum-packed and MAP </li></ul><ul><li>Label “True Taste Technology” </li></ul><ul><li>Info on HPP in the web site and flyer </li></ul>High Pressure Processing Product examples
  13. 13. High Pressure Processing Product examples <ul><li>HPP dry cured ham in the US market since 2004 </li></ul><ul><li>Vacuum-packed and MAP </li></ul>
  14. 14. TYSON (Ameriqual) (USA) 2 Wave 6000/300 Chicken preservative-free products High Pressure Processing Product examples
  15. 15. CAMPOFRIO (Spain) 1998/99 Campofrío is concerned about a Listeria contamination in USA (Sara Lee products). First trials with HP. April 2002 Installation of first NCH equipment (300L – 500 MPa) for sliced cooked ham and boneless cured ham (Export to USA of cured ham “ Listeria -free”) High Pressure Processing Product examples
  16. 16. April 2003 : Launching of “Vuelta y Vuelta” range: gross slices of ham, turkey, and chicken (meat taste, less additives, longer shelf life : 8 weeks) October 2003 : Installation of 2nd equipment (300 L – 600 MPa) January 2005 : Installation of 3rd equipment (300 L – 600 MPa) to extend the “Vuelta y Vuelta” range April 2006 : “Sanissimo” (Super Healthy !) : cooked ham with Omega 3 & no added salt
  17. 17. 25°C Ref. 100 200 300 400 500 MPa Ref. 100 200 300 400 500 600 MPa Change of turkey meat after 1 min at 0.1-500 MPa and 25°C. Change of pork meat after 1 min at 0.1-600 MPa and 25°C. Ref. 100 200 300 400 500 600 MPa Change of chicken meat after 1 min at 0.1-600 MPa and 25°C. High Pressure Processing Limitations for red and white meat
  18. 18. High pressure treated chicken fillet 6000 bar, 5min Shelf life > 30 days High Pressure Processing Marinated meat
  19. 19. Adaptation of marinade recipe Impact of marinade pH on lightness Potential to avoid discoloration High Pressure Processing Marinated meat marination after HPP native/HPP pH 4.2 pH 5.7 pH 7.5
  20. 20. Liver sausage High Pressure Processing HPP „cooking“
  21. 21. Liver sausage High Pressure Processing HPP „cooking“
  22. 22. <ul><li>Cold processed liver sausage </li></ul><ul><li>Time and energy saving </li></ul><ul><li>No cooking loss </li></ul><ul><li>Fresher product </li></ul><ul><li>No nitrite added </li></ul>High Pressure Processing HPP „cooking“
  23. 23. High pressure MDM turkey sausages Cutting Filling Smoking HPP High Pressure Processing HPP „cooking“ Ingredients Weight Raw materials:   Turkey MDM meat 6.000 kg Ice 2.000 kg Extenders:   Wheat fibre 160 g Additives:   Nitrite curing salt 120 g Phosphate 18 g Ascorbic acid 30 g Seasonings 50 g Monosodium glutamate (E-621) 30 g
  24. 24. Firmness and benefits of HP-treated sausages <ul><li>Low-cost, safe product </li></ul><ul><li>Saving time and energy </li></ul><ul><li>No cooking – no drip loss </li></ul><ul><li>Reduced salt content </li></ul>High Pressure Processing HPP „cooking“
  25. 25. HPP Product Cold production of pork chop (Kassler) Pickling/Curing Tumbling Smoking High pressure treatment High Pressure Processing HPP „cooking“
  26. 26. HPP Product Cold production of pork chop (Kassler) <ul><li>Cold processing – no heat </li></ul><ul><li>Saving energy </li></ul><ul><li>Saving time </li></ul><ul><li>No cook loss, no cooking damage </li></ul>High Pressure Processing HPP „cooking“
  27. 27. 55l technical scale system 600 MPa ambient Available for product development and co-processing
  28. 28. <ul><li>Calculations: </li></ul><ul><li>including depreciation (5 years, 280 days/year, 16 h/day), wear parts and energy costs </li></ul><ul><li>based on a processing time of 3 min at 600 MPa (6000 bar) </li></ul>ECONOMIC MODEL FOR READY-TO-EAT PRODUCTS MODEL Vessel Diameter Vessel Volume Vessel filling ratio Total cycle time Production capacity Energy Consumption per hour Processing cost € per kg 6000/55 200 mm 55 l 43 % 9,1 min 150 Kg /h 14 KWh 0,221 €/ kg 6000/135 300 mm 135 l 50 % 10,3 min 400 Kg /h 30 KWh 0,167 €/ kg 6000/300 300 mm 300 l 50 % 11,3 min 800 Kg /h 60 KWh 0,119 €/ kg 6000/300T 2 x 300 mm 600 l 50 % 9,0 min 2000 Kg /h 150 KWh 0,103 €/ kg 6000/420 380 mm 420 l 63 % 9,1 min 1750 Kg /h 105 KWh 0,076 €/ kg

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