Food Product Development: Buffalo Meat

1. (Buffalo Meat)
Presented by : Prakash Kumar
(Ph.D. Research Scholar, AGFE,
IIT-Kharagpur, India)
prakashfoodtech@gmail.com

2. Food Product Development:
Creating or modifying new food product ultimately increases the sale, give
beneficial nutrition to the consumer, maintain competitiveness, filling market
gaps , helps in decreasing carbon and water foot prints. This is good for the
final food system.
Idea Idea screening Development and Testing Marketing Strategies
Commercialization Test marketing Pdt Development Business Analysis
Success and failure of product depends on the uniqueness of the product, unique
benefits to the consumer, superior quality and environment friendly etc.
Presentation on new product development
CATEGORY: from the buffalo meat (Source from which new product being developed)
It is important to know about the source from which new products being developed.
PRODUCTS : 1) Meat Biscuits (History and new development)
2) Sausages (innovations and new researches in it)

3. Bhusa
(Wheat straws)
Daliya
(Ground wheat)
Gur
(jaggery)
Khali
(Mustard oilcake)
Feed
Water

4. Feed
Skin
Blood
Meat
Bone
Meat processing
industry
Leather industry,
skin oil used by
cosmetic industry
Manufacturing of
shaving cream,
gelatin ,
toothpaste, talcum
powder etc.
Pharmaceutical
industry
dung
Milk
Manure
BUFFALO BY-PRODUCTS

5. Sausage’s
Meat patties
Meat loaf
Meat ham’s
Steak’s
Ground
Carabeef
Steak sizzler
Carabeef ribs
Meat Product’s

6. MOITURE :
76.63%
ASH :
1.08%
FAT :
0.84%
WHC :
2.39%
pH :
5.42
PROTEIN :
19.39 %
WHY??
ENERGY :
515 KJ /100g
For Lean
Meat

7. Meat and Meat Products Overview in INDIA
According to Food and Agriculture Organization Statistics
(FAOSTAT), the world livestock population is about 195 million
buffaloes, 1428 million cattle's, 924 million goat and 1093 million
sheep.
India has 113 million buffaloes, 211 million cattle's, 157 millions
goat and 74.5 million sheep populations, which is 58%, 15%, 17%
and 7% of their world population, respectively (According to 2011
livestock census )
From 2001 to 2011, cattle population increased by 11.2%; buffalo
by 18.6%; sheep and goat by 23.9% and 26.8%, respectively .
The Indian export value of buffalo meat for 1.2 MT is 23000 cr
which makes India 3rd biggest beef (carabeef) exporter after
Brazil and Australia. (acc. to APEDA)
World average per capita meat consumption 39.8 kg. In India it
is about 5.2 kg/year, Developed countries it is 80.3 kg/year.

8. Developing countries average 28.9 kg.
70% of Indian population is non vegetarians.
Livestock trading in India is done in Livestock
markets regulated by state governments supervised
by local authorities like : municipal corporations.
Animal farmers are not realizing the full potential of
value of their produce due to lack of awareness.
The involvement of middle men in several stages is
hampering the farmers actual economic returns.

9. In the total Export of meat from India 90 % of Meat is
obtained from Buffalo Beef and 3% is obtained from
Sheep & Goat.
Deboned frozen meat of Buffalo is high in demand in
global market
APEDA (Agricultural and Processed Food
Export Development Agency) Under
the Ministry of Commerce is the
governing body which regulates the exports.
33 Export oriented modern combined slaughter
houses and meat processing plants is registered with
the APEDA.
35 Meat processing and Packaging units are present in
India out of that 12 is registered wit APEDA

10. 200 processing meat units licensed under MFPO order
1973
The meat of the spent animal is generally tough and
thus more suitable for processing to value added
products both on economic and quality consideration.
Organized development of processed meat sector is
important to realize the full benefit from meat
animals.
Value addition is important for the effective utilization
of livestock resources.

11. State wise average carcass yield and breeds
of Buffalo

12. Animal product exported from India during
April-February 2017-2018 (source: APEDA provisional data)
Product quality Quantity (Tonnes) values (Cr)
Buffalo Meat 1234288 23774
Sheep / Goat meat 21995 802
Poultry products - 489
Processed meat 237 9
Other meat 997 16
Animal casing 10682 277
Dairy products 86893 1672
LIVESTOCK
PRODUCT
1355092
(excluding poultry)
27039

13. State wise overview

14. Buffalo meat value chain

15. Role of different actors in Domestic value
chain of buffalo meat production

16. Stages in buffalo meat production for domestic
market and cost involved in each stage
SP : Sale Price
PBM : Sale Price of Buffalo Meat
Leg 1 :
Farmer rear buffalo and sell them either to traders or at a livestock
market
Leg 2:
Trader transport the purchased animal to a municipal slaughterhouse.
Leg 3:
Retailer/wholesale meat dealers purchase buffalo meat (carabeef) from
municipal slaughterhouse and sell it to consumers.
Estimating weight of
buffalo is 200kg approx.

17. SLAUGHTER HOUSE
PROCESSING

18. Packaging Material used for Carabeef
•Vacuum packaging : Oxygen impermeable, moisture impermeable,
extends shelf life.
•Traditional Overwrap Packaging : Use styrofoam tray, Uses PVC
wrap, Moisture impermeable, Oxygen permeable (Allows for bright red color)
Disadvantages: Short shelf-life, Exposure to O2 (lipid and pigment oxidation)
•MAP(Modified Atmospheric Packaging) : MAP is the removal/replacement of
the atmosphere surround the product before sealing in vapor-barrier materials”
(McMillin, Huang, Ho, & Smith, 1999).
Types of MAP: Vacuum, Oxygen/Nitrogen/CO2, Peel able film etc.
•Polymeric films

19. Cost incurred by farmers

20. Cost incurred by traders

21. Cost incurred by exporter
Major costs involved in undertaking primary operations in
export units after receiving of animals and shipment of
final marketable products include :
(a) Transportation,
(b) Packaging,
(c) Service costs,
(d) Energy source, and
(e) Labor
In the entire value chain, transport costs, which consume
nearly two fifths of the total expenditure, end up being the
most expensive operation category.

22. Environmental concern
POLLUTION CONTROL NORMS:
According to the zero-discharge policy by CPCB :
BOD level should < 30mg/l,
COD level should < 250 mg/l,
TSS should < 100 mg/l
Oil and grease should < 10 mg/l and
meat packers are not allowed to discharge any effluent
outside
Standards to be achieved under water & air (prevention and
control of pollution) act 1974
The adequacy and efficacy of the effluent treatment plant/air
pollution control devices will be the entire responsibility of
the industry.
(On average 600-1000 liter water/day is used for buffalo in a
slaughter house)

23. Meat biscuits brief history
Gail Borden was the man behind the manufacturing of meat
biscuit. (He also having patent of condensed milk)
Roughly on 1849, he was experimenting with creation of the
dehydrated beef product known as “Meat Biscuits”.
He was operating a factory in Galveston, Texas to produce
meat biscuits by 1851 and won Great council medal at the
1851 London world’s fair.
Within short time his product get huge demand in the market
including U.S. Army.
high protein, low-fat,
nutrient-dense

24. 1. Meat Biscuits for Dog’s
Dog Biscuits were invented accidentally in London butcher shop during
the late 1800 by Carleton Ellis.
Shop owner wants to expand his business by creating a new biscuit
recipe for his customer.
After baking one batch, he tasted them and thought they were terrible.
He gave one to his dog, his dog gobbled it right up. This gave him idea of
making biscuit especially for dogs.
In 1908, F.H. Bennett company was established
and they began selling their Dog Biscuits under
the name of malatoid.
1911, the recipe granted a patent
1915, the name was changed to Milkbone.

25. 6 % CAGR for the pet food market between 2011 and 2016, according to a
Euromonitor International global trends report presented at Global Pet
Expo, 2017
The Milkbone Dog Biscuit brand was then acquired by Nabisco Biscuit
company and it dominated the dog biscuit market until the late 1960s.
Initially, it was marketed as the treat for dog.
In their new strategies, they changes their mind set toward the health of
the dog to increase the market value of their product, thus created like
cleaner teeth and better breath etc.
In early 1970s lots of new competitor came out.
Nestlé sells pet food as “Supercoat brand” in India.

26. Now, researcher focusing on development of innovative pet functional food
products.
Challenge of developing such products, and have been produced by combining
three different knowledge areas - ‘establishing of an innovative niche market’,
‘functional foods’, and ‘the pet food industry’ - through the building blocks of the
Business Model Canvas.
Research’s product development is based on 6 factors :
•Value propositions : It should be centered around the functionality of the
product.
•Customer segment : The targeted customer is the future of the product.
•Customer relationship : To make the customers to adapt and accept an
innovative functional pet food
•Channels : Channels concern the means of getting in touch with the specific
customer segment.
•Cost structure :The cost structure concerns the costs involved in the business
model.
•Revenue stream :The analysis finds that when developing an innovative
functional pet food, value-based pricing is the recommended
pricing strategy to use.

27. The primary ingredients in a dog biscuit recipe are carbohydrates, proteins,
fats and oils, and fiber. Now, researchers focusing on functional ingredients
that have a significant effect on the dog biscuit's final characteristics.
The ingredients used for dog biscuits are specially for dogs, and are chosen
to be nutritious, easily digested, palatable, and economically feasible.
Carbohydrates:
It is obtained by grinding corn, wheat, or rice into a powder. This powder
contains the three main parts of the seeds including the bran, germ, and
endosperm.
the endosperm is responsible for most of the important baking and shaping
characteristics.
Chemically, flour is composed of starch and protein.
When mixed with water, it creates a mass called gluten that can be cut and
formed into the dog biscuit form.
Product specifications

28. Protein :
The proteins added to dog biscuits supply the animal with
essential amino acids, taurine, improve taste, and in some cases supply
energy.
Total meat and meat derivatives content is up to 65% for wet food and 39%
for dry food
They are derived from a variety of sources including animal and plant.
Typical plant protein ingredients found in a dog biscuit are such things as
corn gluten meal and soybean meal.
They are generally less expensive than animal proteins and are therefore
used in greater quantities.
Ingredients such as poultry byproduct meal, meat and bone meal, and dried
liver meal. Milk and egg are also used as a supply of protein.
A drawback to plant proteins is that they contain certain indigestible
oligosaccharides that can cause undesirable flatulence.

29. Fats and oils :
It provide flavor and nutritional energy and texture to the finished product.
They are derived from plants, fish and animal sources. Much of the fats and
oils used in pet food is obtained from the fast food industry.
Fibers : It is important in calorie-controlled recipe.
Extra fiber, such as wheat bran or corn bran, is added to improve droppings
and water absorption.
Other additives and Functional ingredients :
Antioxidants are added to prevent the breakdown of vitamins and other
nutrients present in the biscuit, and to maintain freshness. Examples of
these materials include zinc oxide and manganous oxide.
Functional ingredients (on research) to enhance the overall nutritive value.
Although dogs are essentially color blind, artificial color additives are added
for the benefit of the pet's owner.
Finally, preservatives such as BHA are added to prevent microbial growth.

30. Manufacturing Process
Ingredient handling :
•In the first step, the dry ingredients are mixed together.
•Water is then added to this blend to bring the moisture content up to
about 30%.
• This creates a paste-like dough that is next pumped into a conditioner
chamber and heated.
•Within this chamber, other ingredients such as animal byproducts or
other moist ingredients are added.
•From this chamber, the batch is moved into an extrusion machine.
Shaping :
•After extrusion it is sent to the forming dies , which have a variety of
shapes such as bones, stars, circles, etc.
•Then, laid on drying sheets. The sudden release of pressure causes the
entrapped moisture to create an expansion of the biscuit much like
exploding popcorn.
•From here, the biscuits are transferred to a metal conveyor belt and
moved through an oven.
Ingredient handling Shaping Baking Finishing step Packaging

31. Baking :
•The baking of the dog biscuits is done in a tunnel oven.
•The oven is anywhere from 100-300 ft (30.48-91.44 m) long.
•As the biscuits travel through the oven, the biscuit goes through a setting
phase where it takes on the shape of the final product.
•Next, it is dried out to about 10% moisture content.
•The amount of time baking time is controlled by the speed of the moving
conveyor belt
Finishing steps :
•The dog biscuits exit the ovens and travel through a series of conveyors to
cool.
•Depending on the recipe, additional coating ingredients may be added.
These can include fats, vitamins, and other flavor enhancers. They are
applied using depositor machines that spray coat the biscuits. If
necessary, excess topping removed by forced air or shaker devices.
Packaging
Dog Biscuits are fragile, the packaging is typically rigid with polymeric
packaging inside it. These boxes are put into larger case boxes, stacked on
pallets, and shipped to stores

32. 2. Carabeef sausages
Sausages are the oldest form of processed meat products known through
historical evidence. It is considered one of the most appetizing, nutritious,
enjoyable, and convenient meat products.
Global hot dogs and sausages market to grow at a CAGR of 3.22% during
the period 2017-2021. The report has been prepared based on an in-depth
market analysis with inputs from industry experts.
The latest trend gaining momentum in the market is Rising demand for
organic sausages. With growing health-consciousness, consumers are
shifting toward healthier varieties of hot dogs and sausages.
Organic production is a sustainable and environmentally safe way of
producing. Meats are extracted from animals who are raised without the
use of any antibiotics, are fed natural feed, and are not genetically
modified.
Sausages can be made by grinding meat from beef, pork, poultry, or game
meat, mixing with salt and other seasonings followed by stuffing into a
container or a casing

34. Salt It is necessary for enhancing flavor, preserving the
sausage from microbial spoilage, and extracting the soluble
meat proteins.
Sugar Sucrose (table sugar), brown sugar, dextrose, and corn
syrup. The lactic acid produced due to fermentation reduces the
pH of the meat and gives sausage a characteristic tangy flavor.
Spices Characteristic flavor.
Nitrate and nitrite are converted to nitric oxide by
microorganisms and combine with the meat pigment
(myoglobin) to give the characteristic pink cured-meat color.
Less than 2.75 ounces of sodium or potassium nitrate per 100
pounds of chopped meat .
Reducing Agents Ascorbic acid or Sodium erythrobate are
active reducing agents that react with nitrite to accelerate the
curing process. USDA regulations allow the use of up to 7/8
ounce per 100 pounds of meat.
Ingredients

35. Antioxidants are approved for use in fresh sausages to retard
oxidative rancidity and protect flavor, including butylated
hydroxytoluene (BHT), butylated hydroxyanisole (BHA),
propyl gallate, tertiary butylhydroquinone (TBHQ), and
tocopherols.
Mold Inhibitors The common technique for preventing the
growth of mold is to dip the sausage in a mold inhibitor
solution, typically 2.5 percent solution of potassium sorbate or
a 3.5 percent solution of propylparaben.
Binders and Extenders To retain natural juices and reduce
the cost of the formulation. These ingredients help may
improve the binding characteristics, flavor, cook yield. The
most commonly used ingredients of this type are nonfat dry
milk, cereal flours, and soy protein products
Water To rehydrate the nonfat dry milk and to replace the
expected moisture loss during smoking and cooking.
Approximagtely 10 % added water typically is used in moist
types of cooked sausage.

36. Casings
Two types of sausage casings are :
1)Natural casings are obtained from the digestive tract of
animals.
Now there is innovations in casing of the sausages.
2) synthetic casings made from collagen, cellulose etc.
• Collagen casing derived from animal protein, often extracted
from beef hides etc.
• Collagen is also the main protein present in natural casings.
• Synthetic casings come in a variety of forms.
• “Skinless” hot dogs are manufactured in cellulose casings
(made from inedible plant and tree fibers), which allow smoke
to penetrate and moisture to escape during cooking.
•These cellulose or fibrous casings have the advantage of being
uniform in size (diameter) and generally free of defects

37. References :
•http://watermr.com/hide-on-washer/
• http://indianexpress.com/article/india/the-journey-of-a-400-kg-buffalo-cow-
slaughter-uttar-pradesh-4644146/
•http://efsonline.uga.edu/wp-content/uploads/2016/08/Basics-of-Sausage-
Making.pdf
•https://www.peta.org/issues/animals-used-for-food/meat-environment/
•NABARD Consultancy Services (NABCONS) FAO online database, 2011
•http://www.madehow.com/Volume-5/Dog-Biscuit.html
•Evaluation of sensory characteristics and texture of an economic
Buffalo meat (Bubalus bubalis) sausage and an economic beef
sausage with addition of bovine hemoglobin powder.
•CPCB (Effluent treatment of slaughter house as per 23rd Oct 2017)
•Development of innovative functional pet food products by Authors: Lovisa
Bengtsson, Gunnel Bildt & Julia Skäremo Supervisors: Stein Kleppesto & Malin
Sjoo(http://lup.lub.lu.se/luur/download?func=downloadFile&recordOId=5463978&fileOId=54
63982 )

38. THANK YOU