Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
HOME-STYLE MEAT PRODUCT AND METHOD OF PRODUCING SAME
FIELD
[0002] This disclosure relates generally to a method for producing a home-
style
meat product and, more specifically, to a method for mass producing a home-
style meat
product such as a sliced, pulled, or shredded meat product.
BACKGROUND
[0003] Processing systems for various food products like vegetables,
fruits, and
meat products are known. When focused on meat products, the systems in the art
are
typically directed to producing uniform slices and cuts. In fact, the art
exhibits a
systematic progression to achieve greater and greater uniformity. This is true
whether
the system is producing a diced product, where the squareness of the final
product is
the desired trait, or producing a sliced product, where uniformity of
thickness, size, and
shape is preferred. These systems produce a final meat product that is
packaged and
presented to the consumer with each piece looking generally the same as the
next.
[0004] An important factor in a consumer's selection is the visual
appearance of
the cut food product. If put off by the uniformity normally on display by mass
produced
meat products, consumers may instead desire "home-style" products with an
appearance similar to meat cut from a home cooked turkey or ham. Meat products
that
are irregular in shape and size can solve this need without requiring the
consumer to
spend hours preparing a home cooked meat product. However, the known
processing
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systems for producing slices of meat with irregular shapes and sizes do not
provide a
sufficient solution to this problem.
[0005] When applied on a mass scale, manual cutting and slicing is
simply not
cost effective, requiring tedious processing and excessive manual labor.
Accordingly,
there have been other attempts at producing irregular shaped and sized slices.
One
method known in the art involves using molds to shape the meat in casing to
give them
an irregular shape. These molded slices of meat are then put through a
traditional
cutting or slicing system, which produces a product where consecutive slices
appear
different from one another, but also with a pattern of repeating shapes,
uniform
thickness and size. Another method uses a technique of skimming the bottom of
a
cooked meat product to produce slices with a roughed up appearance. A final
method
to produce slices with an irregular shape and size involves simply taking
slices from
several different sticks of meat and packaging them together. However, all of
these
techniques still result in slices of meat that have an overall uniform
appearance and/or a
lack of a cost-effective technique.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIGURE 1 is a flow diagram of a method for producing meat
slices of
irregular shape and size;
[0007] FIGURE 2 is a side elevation view of an apparatus for
producing meat
slices of irregular shape and size;
[0008] FIGURE 3 is a front elevation view of an apparatus shown in
FIG. 2;
[0009] FIGURE 4 is a perspective view of the apparatus of FIG. 2
with the
optional front panel open;
[0010] FIGURE 5 is a side elevation view of the impeller and knife
assembly of
the apparatus of FIG. 2;
[0011] FIGURE 6 is a perspective view of an optional circular
knife assembly for
use in the apparatus of FIG. 2;
[0012] FIGURE 7 is a flow diagram illustrating a process as
described below;
[0013] FIGURE 8 is a flow diagram illustrating a process as
described below; and
[0014] FIGURE 9 is a flow diagram illustrating a process as
described below.
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DETAILED DESCRIPTION
[0015] In accordance with one aspect, a method is provided for producing a
sliced
meat product that closely resembles sliced meat produced using manual culinary
techniques. The method includes combining boneless whole muscle meat with a
mixture having a low phosphate concentration. The mixture has a phosphate
concentration, such as approximately 1-2%, which is a significant decrease
from
conventional solutions having a phosphate concentration of about 3-3.5%. A low
phosphate mixture produces a lower bind between the individual muscle pieces
during
thermal processing or cooking, which forms a meat product that is more easily
separated prior to slicing. In one approach, the mixture having a low
phosphate
concentration is injected using a conventional pickle injector and/or tumbled
with the
whole muscle meat to combine the mixture and the whole muscle meat with a
minimal
amount of mechanical work being done to the whole muscle meat. Due to the low-
phosphate level of the mixture and the limited amount of working done to the
meat prior
to cooking, the binding between the individual muscle pieces is much looser
than a
conventional product. In yet another aspect, the mixture may have a low
phosphate
and a low salt concentration.
[0016] In another aspect, the method further includes stuffing the combined
boneless
whole muscle meat and the mixture having the low phosphate concentration into
a
casing and cooking the casing such that individual pieces of the whole muscle
meat are
bound together inside the casing during cooking. Next, the cooked boneless
whole
muscle meat is worked to loosen the binding between the individual whole
muscle meat
pieces. The working may be performed prior to slicing and includes pressing,
puncturing, massaging, kneading, pounding, tearing, or pulling. By working the
meat to
loosen the binding, the individual muscle pieces separate from one another
such that
when they undergo the slicing operation, they have a high degree of
irregularity. In
another approach, the method includes working the cooked boneless whole muscle
meat after slicing. Working the cooked and sliced whole muscle meat, such as
by
tumbling or augering, produces movement of the meat slices to give the meat
slices an
irregular appearance.
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[0017] In accordance with another aspect, a method is provided for producing a
pulled, shredded, or sliced meat product having an appearance that closely
resembles
pulled, shredded, or sliced meat produced using manual culinary techniques.
The
method includes combining a whole muscle meat with a solution having a low
salt
content, such as by using a conventional pickle injection process to inject
the solution
into the whole muscle meat. The solution has a salt concentration in the range
of
approximately 5% to approximately 15%, which is a significant decrease in the
amount
of salt used in prior approaches. The low-salt solution is a relatively poor
water binder
that encourages water loss through evaporation and expulsion during cooking in
a
manner similar to home-style cooking. The combined whole muscle meat and
solution
are mixed in a manner to maintain muscle fiber integrity and preserve the
natural
appearance and irregularity of the whole muscle meat. The mixed whole muscle
meat
is cured and loosely stuffed into a casing so as to preserve an irregular
composition of
the whole muscle meat within the casing. The loose stuffing also creates void
space
within the casing to permit moisture expulsion and keep the whole muscle meat
pieces
from gluing together during thermal processing.
[0018] The stuffed casings may be cooked to break down the collagen and
connective
tissue holding the muscle fibers together and optionally smoked to deliver a
high quality
flavor. Cooking the stuffed casings at higher temperatures than prior
approaches
further encourages water loss, breaks down collagen and connective tissue, and
produces a desired texture. The cooked whole muscle meat may be cooled and
pulled,
shredded, or sliced at reduced temperatures. In this manner, the method
provides a
loosely bound cooked whole muscle meat that may be stored at refrigerated
temperatures until subsequent pulling, shredding, or slicing as desired for a
particular
meat product. Further, mixing the whole muscle meat and low salt solution to
achieve
minimal protein extraction and loosely stuffing the whole muscle meat into
casings
loosely binds the whole muscle meat. In another aspect, the mixture may
include a low
salt and a low phosphate concentration. The loosely bound muscle meat may then
be
readily pulled, shredded, or sliced despite being cooled and stored at
refrigerated
temperatures.
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,
[0018a]
In accordance with another aspect, there is provided a method of mass-
producing a home-style meat product having an irregular appearance, the method
comprising:
providing boneless whole muscle meat;
combining the boneless whole muscle meat with a mixture having a low salt
concentration having less than approximately 15% salt;
stuffing the boneless whole muscle meat and the mixture having the low salt
concentration into a casing;
cooking the casing stuffed with the boneless whole muscle meat and the mixture
having the low salt concentration wherein individual whole muscle meat pieces
are bound
together inside the casing during cooking; and
pulling or shredding the cooked boneless whole muscle meat to produce a
home-style meat product wherein individual pieces of the home-style meat
product have an
irregular appearance,
wherein the individual pieces of the meat product are non-uniform in shape
and have a surface that displays the natural structure of the cooked boneless
whole
muscle meat.
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[0019] With reference to the drawings, a method and processing machine is
provided
for use in producing irregularly shaped and sized food products and, in
particular, for
use in producing irregularly shaped and sized meat slices. The processing
machine is
generally referred to by reference numeral 10 in FIGS. 2-4.
[0020] With reference to Figs. 2-5, the rotary processing machine 10
comprises a
support frame 12 and a housing 14. Prepared meat products 46 are fed into a
rotary
impeller 34, which is rotatably attached in the housing 14. The impeller 34
comprises a
plurality of equally spaced paddles 40 and is encircled by a stationary
cylinder 48. A
motor 42 drives the rotation of the impeller 34. As the impeller 34 rotates,
the paddles
40 catch the meat product 46 and carry it along an inner surface 50 of the
stationary
cylinder 48. The stationary cylinder 48 includes an opening 54. On one side of
the
opening 54, a slicing knife 56 is attached. As the impeller 34 drives the meat
product 46
around the inner surface 50 of the stationary cylinder 48, the meat product 46
approaches the opening 54 and impacts the slicing knife 56. The meat products
46 are
able to tumble in the impeller so that different sides are engaged by the
slicing knife 56.
This process produces meat slices 46a of irregular shape and size.
[0021] The rotary processing machine 10 can further include a circular
knife
assembly 62. The circular knife assembly 62 is positioned proximal to the
opening 54,
but downstream of the slicing knife 56. The circular knife assembly 62 is
oriented
generally parallel with the slicing knife 56. The circular knife assembly 62
may then
further reduce the size of the meat product 46, while still producing meat
slices 46a of
irregular shape and size. The circular knife assembly 62 would have at least
one
circular, rotating cutting blade 68. The blade 68 preferably is dulled to
produce rough
cutting edges.
[0022] The rotary processing machine 10 can further include a cross cut
knife
assembly 76. The cross cut knife assembly 76 is positioned proximal to and
downstream of the circular knife assembly 62 and the slicing knife 56. The
cross cut
knife assembly 76 is oriented generally parallel with the slicing knife 56.
The cross cut
knife assembly 76 may then further reduce the size of the meat product 46,
while still
producing meat slices 46a of irregular shape and size. The cross cut knife
assembly 76
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would have at least one cross cut blade 78. The blade 78 preferably is dulled
to
produce rough cutting edges.
[0023] The rotary processing machine 10 can be made to be highly space
efficient. For example, in one embodiment, the rotary processing machine 10
may have
a height in the range of 50 inches to 72 inches, and preferably in the range
of 54 inches
to 69 inches. In addition, the rotary processing machine 10 may weigh in the
range of
1,400 pounds to 1,600 pounds, and preferably about 1,500 pounds.
[0024] The frame 12 provides the support for the rotary processing machine
10.
In one embodiment, the frame 12 may have a length in the range of 26 inches to
38
inches and a width in the range of 25 inches to 37 inches. In the preferred
embodiment,
the frame 12 has a length of about 32 inches and a width of about 31 inches.
These
embodiments are designed to utilize a relatively small area while still
allowing the rotary
processing machine 10 to operate in a high-speed commercial environment.
[0025] The small area allows the rotary processing machine 10 to seamlessly
integrate with existing operations. The frame 12 may further comprise numerous
legs
16. In the preferred embodiment, each of the legs 16 has casters 18 at their
terminal
end to allow for greater mobility of the rotary processing machine 10. At
least one
caster 18 preferably has a locking mechanism 20 that an operator can engage to
prevent the rotary processing machine 10 from moving when movement is not
desired.
[0026] The frame 12 is attached to and supports the housing 14. In one
embodiment, the housing 14 may have a length in the range of 37 inches to 67
inches,
and preferably in the range of 47 inches to 62 inches, and more preferably
about 57
inches. The housing 14 may enclose any or all of the motor 42, the impeller
34, the
stationary cylinder 48, the knife assembly 52, and an electrical component box
32. The
housing 14 may also include access to the devices enclosed within it. In one
embodiment, this access comprises a front panel 22. The front panel 22 may be
hinged
to provide the operator access to the impeller 34, the stationary cylinder 48
and the
knife assembly 52. This feature provides the user with easy access to these
devices as
needed, for example, for maintenance or cleaning. In another embodiment, this
access
may include a back panel 24. The back panel 24 may be hinged to provide the
operator
access to at least the electrical component box 32, as needed.
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[0027] The housing 14 includes a hopper 26. The hopper 26 is positioned to
receive the prepared meat product 46 and feed it into the stationary cylinder
48. The
hopper 26 is positioned adjacent to the stationary cylinder 48, and preferably
centered
with the stationary cylinder 48. In the preferred embodiment, the hopper 26
has an
opening directed upwards for loading of the prepared meat product 46 and
urging of the
prepared meat product 46 into the stationary cylinder 48 by gravitational
force. The
diameter of the hopper 26 where it provides access to the stationary cylinder
48 may be
in the range of 13.5 inches to 14.8 inches, and preferably about 13.5 inches.
The
hopper 26 may preferably be positioned on the front panel 22 to provide access
to the
stationary cylinder 48 and the impeller 34 as needed, for example, for
maintenance or
cleaning.
[0028] In the preferred embodiment, the housing 14 also comprises a feeder
chute 28. The feeder chute 28 is attached to the hopper 26 to provide an
extended and
more covered access route for the prepared meat product to reach the
stationary
cylinder 48. The access opening of the feeder chute 28 may be vertically
aligned or
preferably facing generally upwards. In one embodiment, the feeder chute 28 is
generally circular with an opening generally equal to that of the hopper 26 at
its distal
end where the chute 28 meets the hopper 26. Alternatively, in the preferred
embodiment, the feeder chute 28 starts with a generally square opening,
preferably
about 13.5 inches on each side, and ends with an opening generally equal to
that of the
hopper 26 at its distal end where the chute 28 meets the hopper 26.
[0029] The housing 14 also may include a discharge chute 30. The discharge
chute 30 is positioned below the knife assembly 52 to direct the discharge of
the meat
slices 46a from the rotary processing machine 10. The discharge chute 30 may
be
downward facing. The distal end of the discharge chute 30 may be in the range
of 10
inches to 20 inches above the floor, and preferably about 15 inches. This
preferable
height from the floor provides the discharge chute 30 with a sufficient height
to
accommodate larger slices produced by the processing machine 10. It may be of
a
generally rectangular shape with a width equal to or larger than the width of
the
stationary cylinder 48, and preferably in the range of 13 inches to 15 inches,
and more
preferably about 13.7 inches. The length of the distal end of the discharge
chute 30
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may be in the range of 5 inches to 15 inches, and preferably about 10 inches.
In one
embodiment, the discharge chute 30 is attached to the housing 14 directly
below the
knife assembly 52 and angles away from the rotary processing machine 10, so
that the
distal end of the discharge chute 30 is spaced from the frame 12 in the range
of about 4
inches to 12 inches, and preferably in the range of 8 inches to 9 inches. In
addition, the
discharge chute 30 preferably does not contain any obstructions in order to
provide an
easier discharge path for the meat slices 46a.
[0030] The impeller 34 includes a pair of rotating end discs 36, 38
interconnected
by the paddles 40. The paddles 40 are equally spaced around the interior
circumference of the end discs 36, 38. The impeller 34 is rotatably attached
in the
housing 14. The paddles 40 are preferably attached perpendicular to the end
discs 36,
38. The paddles may be orientated generally radially, or alternatively, they
may be
angled toward the direction of rotation of the impeller 34. This angle can be
between 0
and 55 degrees from radial in the direction of rotation of the impeller 34,
and preferably
about 30 degrees. The paddles 40 may preferably start at the outer edge of the
impeller 34 or, alternatively, start in a range up to 1 inch from the edge.
The paddles 40
have a length in the range of 3 inches to 6 inches, and preferably 4 to 5
inches. This
preferable length allows the meat product 46 to tumble and present different
oriented
slicing surfaces to the slicing knife 56. In one embodiment, the impeller 34
has between
two and six paddles 40, and preferably between three and five paddles 40. In
the most
preferred embodiment, the impeller 34 has four paddles 40.
[0031] The motor 42 drives the rotation of the impeller 34, such as in a
direction
indicated by the arrow 44. The motor 42 can operate at any feasible hertz
level, and
preferably in a range from 60 to 75 hertz, and more preferably 75 hertz. In
addition, the
motor 42 can operate at any feasible horsepower, and preferably at 10
horsepower.
The motor 42 may preferably be supplied voltage across the line or,
alternatively, by a
variable frequency drive.
[0032] As the motor 42 causes the impeller 34 to rotate, the paddles 40
contact
the prepared meat product 46 and cause it to rotate along with the impeller 34
in the
direction of the arrow 44. As a result of the rotation, centrifugal force
presses the
prepared meat product 46 against the inner surface 50 of the stationary
cylinder 48.
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The paddles 40, in turn, drive the prepared food product 46 around the inner
surface 50
of the stationary cylinder 48. Because the rotary cutting machine 10 does not
restrain
or control the position of the prepared meat product 46 beyond the application
of
centrifugal force, the prepared food product 46 can tumble and fall within the
impeller
34. As a result of this process, the prepared meat product 46 is pressed
against the
inner surface 50 of the stationary cylinder 48 in random and different
orientations as it is
driven by the paddles 40 of the impeller 34.
[0033] The degree of random and different orientations can be increased
depending upon the amount of meat product 46 present in the impeller 34. For
example, having more meat products 46 in the impeller 34 than the number of
paddles
40 can advantageously result in the excess meat products 46 accumulating in a
lower
region of the cylinder 48. After a meat product 46 has been sliced, the meat
product 46
can continue to rotated toward the lower region where the accumulated meat
products
46 can cause the just-sliced meat product 46 to become dislodged from adjacent
the
paddle 40. Another meat product 46 can then take the place of the just-sliced
meat
product 46. When the just-sliced meat product 46 is subsequently advanced by
the
same of a different paddle 40, it can be in a different orientation than if it
had continued
to rotate by the same paddle 40, and thereby the next time it is sliced, a
differently
shaped slice can be cut.
[0034] As the prepared meat product 46 is driven around the inner surface
50 of
the stationary cylinder 48, it encounters the knife assembly 52, as shown in
FIG. 5. The
knife assembly 52 includes the opening 54 and the slicing knife 56.
[0035] The opening 54 is formed in the stationary cylinder 48 by spacing
the side
of the opening 54 positioned earlier in the path of rotation of the impeller
34 from the
outer periphery of the impeller 34. The opening 54 can be formed anywhere on
the
stationary cylinder 48, and preferably is formed at a position of the
stationary cylinder 48
where the rotation of the impeller 34 is in a generally downward direction
and, more
preferably, where the velocity of the prepared meat product 46 is generally
perpendicular with the floor. The opening 54 preferably spans the width of the
stationary cylinder 48 and is preferably generally horizontal. Alternatively,
the opening
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54 may be formed in the stationary cylinder 48 at an angle in the range of 45
degrees
above or below horizontal.
[0036] In the preferred embodiment, the width of the opening 54 can be
adjusted
by a control knob 58. The control knob 58 is preferably adjacent to the
opening 54 and
attached to the side of the opening 54 spaced from the outer periphery of the
impeller
34. To adjust the width of the opening 54, the control knob 58 can adjust the
distance
the side of the opening 54 is spaced from the outer periphery of the impeller
34. The
control knob 58 can vary the width of the opening 54 in a range from 1/16 inch
to 1 inch,
and preferably the opening 54 is set between 1/8 inch and 3/16 inch. The width
of the
opening 54 set by the control knob 58 determines the maximum thickness of the
meat
slices 46a produced by the rotary processing machine 10.
[0037] The slicing knife 56 is positioned at the side of the opening 54
that
extends along the outer periphery of the impeller 34. In the preferred
embodiment, the
slicing knife 56 is removably positioned at the opening 54. The removably
attached
slicing knife 56 may then be removed and inserted as needed, for example, to
select a
different type of the slicing knife 56, with a scalloped blade being
preferred, to repair or
maintain the slicing knife 56, or to replace the slicing knife 56. The slicing
knife 56
preferably spans the length of the opening 54 and is positioned to provide the
first point
of contact for the meat product 46 as it is driven into the opening 54 by the
impeller 34.
As the paddles 40 drive the meat product 46 to the opening 54, the meat
product 46 is
driven beyond the outer periphery of the impeller 34 due to the spacing of the
opening
54. As the paddle 40 continues to rotate, the meat product 46 is driven into
the slicing
knife 56 which is positioned at the outer periphery of the impeller 34,
producing meat
slices 46a of thickness determined by the width of the opening 54.
[0038] The slicing knife 56 may further comprise a guide surface 60. As the
slicing knife 56 cuts into the prepared meat product 46, meat slices 46a are
produced,
and the guide surface 60 can direct the meat slices 46a away from the knife
assembly
52 and towards the discharge chute 30.
[0039] The knife assembly 52 may further comprise the circular knife
assembly
62, as shown in FIG. 6. The circular knife assembly 62 comprises at least one
circular
blade 68 mounted on a rotatable shaft 64 and is positioned in a direction that
is
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generally parallel to the process feed direction. The circular knife assembly
62 is
rotatably mounted to the housing 14 to preferably rotate in a direction as
indicated by
the arrow 66. The circular knife assembly 62 is preferably downstream and
proximal to
the slicing knife 56. As the meat slices 46a are produced, they may travel
down the
guide surface 60 of the slicing knife 56. While on the guide surface 60, the
at least one
circular blade 68 may then further reduce the size of the meat slices 46a.
[0040] In the preferred embodiment, the circular knife assembly 62 has
dulled
circular blades 68. The circular blades 68 may be artificially dulled by any
method, or
preferably, the circular blades 68 may be allowed to dull naturally and are
not
sharpened. The dulled circular blades 68 may then reduce the meat slice 46a
size
while still producing meat slices 46a with irregular edges consistent with the
appearance
of "home-style" carved meat. The dull circular blades 68 provide a natural cut
by pulling
the muscle fibers of the sliced meat product 46a.
[0041] The circular knife assembly 62 may alternatively contain feed discs
70 to
assist in advancing the meat slices 46a. The feed discs 70 may be mounted on
the
rotatable shaft 64 in place of any number of the circular blades 68.
[0042] The circular knife assembly 62 may consist of between one and
fifteen
circular blades 68, and preferably one circular blade 68, depending on the
size of the
prepared meat product 46 being used and the size of the meat slices 46a
desired. The
chosen number of blades 68 having different spacings therebetween to cut the
meat
slices 46a into further reduced sizes of varying widths. As illustrated in
FIG. 6, a first
spacer 72 creates a gap or space of length 'a,' and a second spacer 74 creates
a gap of
length 'b.' The spacers 72, 74 can be alternated every other one, such that
the spacing
between the blades 68 is also alternating between a space of length `a' and
'b,' or,
alternatively, may be placed in any other suitable combination. The blade 68
spacing
may be varied from 1/8 inch to 1 inch. For any number of the circular blades
68 not
used, the feed discs 70 may be positioned on the rotatable shaft 64 instead.
Preferably,
the circular knife assembly 62 is composed of two circular blades 68 spaced
apart by 3
inches and centered on the rotatable shaft 64 having 3/4 inch spacers 72, 74
running
the length of the rotatable shaft 64. The remaining spaces between the spacers
72, 74
on the rotatable shaft 64 preferably have feed discs 70.
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[0043] The knife assembly 52 may also comprise the cross cut knife assembly
76. The cross cut knife assembly 76 is positioned in a direction that is
generally parallel
to the process feed direction. The cross cut knife assembly 76 can be
comprised of a
number of cross cut blades 78 in the range of 1 to 14, and preferably 2. The
cross cut
blades 78 preferably run the length of the cross cut knife assembly 76 and are
positioned generally parallel to the process feed direction. The cross cut
knife assembly
76 is rotatably mounted to the housing 14 to preferably rotate in a direction
as indicated
by the arrow 80. The cross cut knife assembly 76 is preferably downstream and
proximal to the slicing knife 56. As the meat slices 46a are produced, they
may travel
down the guide surface 60 of the slicing knife 56. As the meat slices advance
beyond
the end of the guide surface 60, the cross cut blades 78 may then further
reduce the
size of the meat slices 46a.
[0044] In the preferred embodiment, the cross cut knife assembly 76 has
dulled
cross cut blades 78. The cross cut blades 78 may be artificially dulled by any
method,
or preferably, the cross cut blades 78 may be allowed to dull naturally and
are not
sharpened. The dulled cross cut blades 78 may then reduce the meat slice 46a
size
while still producing meat slices 46a with irregular edges consistent with the
appearance
of "home-style" carved meat. The dull cross cut blades 78 provide a natural
cut by
pulling the muscle fibers of the sliced meat product 46a.
[0045] With reference to the diagram of FIG. 1, a bulk meat product is
first
selected for processing by the processing machine. The bulk meat product can
be
selected from any variety of meat product, including, for example, ham,
turkey, chicken,
or beef. Once the bulk meat product is selected, it can then be prepared for
processing.
This preparation can first include chilling the bulk meat product to the
required
temperature. This may include storing the bulk meat product at the desired
temperature
or instead chilling the bulk meat product further to reach the desired
temperature. The
meat product should be kept at a temperature below 40 degrees Fahrenheit for
food
safety purposes, and preferably, the meat product should have a temperature in
the
range of 30 to 35 degrees Fahrenheit when processed by the processing machine.
Alternatively, the bulk meat product can be cooked or heated prior to
processing. This
may include cooking the meat product by any suitable means. This preparation
can
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also include removing the bulk meat product from any casing or wrapping used
to store
and ship the product. This preparation may ensure that the meat product is
free of any
foreign material to keep any foreign material out of the final sliced product.
Another
option for preparation includes breaking down the bulk meat product prior to
processing.
The bulk meat product may be broken down by hand or other suitable means.
However, it has been found that breaking down formulated turkey into smaller
portions
before processing can create a good, but small end product. In any case, the
prepared
meat product is preferably about 10 inches in any dimension or less. Finally,
the total
amount of meat product may be selected. The amount of meat product selected is
dependent on the amount of output slices desired and can be in a range of one
meat
product to more than 20 with each load into the processing machine.
[0046] A next step can include selecting a slicing knife. The slicing knife
can
have any type of edge, including, for example, a scalloped or a wavy edge.
Once the
slicing knife is selected, it may then be inserted into the processing
machine. As
disclosed above, inserting the slicing knife into the processing machine
positions the
knife at the opening formed in the stationary cylinder.
[0047] Next, a desired slice thickness can be determined. As disclosed
above,
the slice thickness may be in the range of 1/16 inch to 1 inch. The desired
slice
thickness may vary depending on the selected type of meat or the application
of the
desired output. Once selected, the slice thickness may then be represented on
the
processing machine. To alter the thickness of the slices produced by the
processing
machine, the width of the opening can be adjusted. The control knob is
operably
attached to the opening to adjust the width thereof. The slice thickness
corresponds to
the distance between the slicing knife and the side of the opening spaced from
the outer
periphery of the impeller.
[0048] The following step may include determining a desired slice width.
This
width may be as large as the selected bulk meat product or the broken down
selected
meat product, or as small as 1/8 inch as disclosed in the discussion of the
circular knife
assembly above. The desired slice width may vary depending on the type of the
selected meat product or the application of the product intended to be
produced by the
processing machine. Once the desired slice width is determined, it can then be
13
CA 2994010 2018-02-02
determined whether a circular knife assembly is needed. If the desired slice
width is
less than any dimension of the prepared meat product, the circular knife
assembly may
be used to further reduce the width. If the circular knife assembly is
required, its setup
must then be determined. This includes choosing the number of pre-dulled
circular
blades desired and the spacing between the pre-dulled circular blades. After
the
desired number of blades and spacing is determined, then the type of spacers
and
number of feed discs can be ascertained. Once all of the circular knife
assembly
materials are chosen, they may be mounted on a rotatable shaft. The assembled
circular knife assembly may then be rotatably attached to the housing of the
processing
machine proximal to and downstream of the slicing knife.
[0049] Another step may include determining a desired slice height. This
height
may be as large as the height of the selected bulk meat product or the broken
down
selected meat product, or instead, a smaller slice may be desired. If a
smaller slice
height is desired, a cross cut knife assembly may be used. If the cross cut
knife
assembly is required, its setup must then be determined. This includes
choosing the
number of pre-dulled cross cut blades desired and the spacing between the pre-
dulled
cross cut blades, and preferably two evenly spaced dulled cross cut blades.
The cross
cut knife assembly may then be rotatably attached to the housing of the
processing
machine proximal to and downstream of the slicing knife.
[0050] Next, the processing machine may be started. A desired speed of
rotation
of the impeller may then be determined. The speed of the rotation of impeller
influences
the magnitude of the centrifugal force applied on the prepared meat product
while in the
impeller and, similarly, it may also influence the tumbling and orientation of
the meat
products while in the impeller. This process determines the edge of the meat
product
from which the slices are produced. If a desired speed is determined, the
speed of
rotation of the impeller may then be set. The available speeds may vary with
the type of
motor operating the processing machine, and preferably the motor can operate
at 75
hertz.
[0051] The processing machine comprised of a housing, a motor, an impeller,
and a knife assembly may then use the impeller having at least one paddle to
rotatably
drive the prepared meat product around the housing, the prepared meat product
held to
14
CA 2994010 2018-02-02
=
the housing by centrifugal force, to impact the knife assembly to create
irregularly
shaped meat slices.
[0052] The selected and prepared meat product can then be loaded into the
processing machine. The machine operates as detailed above to output mass-
scale
"home-style" slices of meat of irregular shape and size. As the slices of meat
are output
by the processing machine, they can be collected. This may be done by placing
a bag
or collection bin under the discharge chute. Finally, the collected slices can
be
packaged.
EXAMPLES
[0053] The following examples illustrate presently preferred methods and
should
be understood to be illustrative of, but not limiting upon, the scope of the
apparatus and
method which are set forth in the appended claims.
[0054] For the following tests, the processing machine had an impeller with
four
equally spaced paddles, a ten horsepower motor operating at sixty hertz across
the line,
and a scalloped slicing knife with a 3/16 inch slice thickness. Two bags of
bulk meat
product, removed from the plastic casing, were used in the tests.
Test Meat Temp. Prep. Result
1 Ham Loaves 32 F Whole Very Good Slices of
Irregular Shape and Size
2 Ham Loaves 35 F Broken into pieces Very Good Slices of
by hand Irregular Shape and Size
3 Ham Loaves 35 F Whole Very Good Slices of
Irregular Shape and Size
4 Formulated Turkey 30 F Whole Very Good Slices of
Irregular Shape and Size
Formulated Turkey 30 F Broken into pieces Very Small Slices of
by hand Irregular Shape and Size
6 K Butt Tumbled 32 F Broken into pieces Very Good Slices of
Ham Loaves by hand Irregular Shape and Size
7 K Butt Not Tumbled 32 F Broken into pieces Very Good Slices of
Ham Loaves by hand Irregular Shape and Size
[0055] For the following tests, the processing machine had an impeller with
four
equally spaced paddles, a ten horsepower motor operating at sixty hertz across
the line,
CA 2994010 2018-02-02
a scalloped insert knife with a 3/16 inch slice thickness, and a circular
knife assembly.
The circular knife assembly had one circular blade at 5 1/4 inches and feed
discs
positioned at the remaining spaces between the 3/4 inch spacers. Two bags of
bulk
meat product, removed from the plastic casing, were used in the tests.
Test Meat Temp. Prep. Result
8 Formulated Turkey 38 F Whole Good Slices of Irregular
Shape and Size
9 Ham Loaves 34 F Broken into pieces Very Good Slices of
by hand Irregular Shape and Size
[0056] For the final test, the processing machine had an impeller with four
equally
spaced paddles, a ten horsepower motor operating at seventy five hertz across
the line,
a scalloped insert knife with a 1/8 inch slice thickness, and a circular knife
assembly.
The circular knife assembly had one circular blade at 5 1/4 inches and feed
discs
positioned at the remaining spaces between the 3/4 inch spacers. Two bags of
bulk
meat product, removed from the plastic casing, were used in the test.
Test Meat Temp. Prep. Result
Ham Loaves 34 F Whole Very Good Slices of
Irregular Shape and Size
[0057] For the following tests, the processing machine had an impeller with
four
equally spaced paddles, a ten horsepower motor operating at 75 hertz across
the line, a
scalloped slicing knife with a 3/16 inch slice thickness, and a circular knife
assembly.
The circular knife assembly had two dulled circular blades one 3 inches from
either end
of the rotatable shaft and feed discs positioned at the remaining spaces
between the 3/4
inch spacers. Four pieces of bulk meat product were used in the tests.
Test Meat Temp. Prep. Result
11 Chicken ¨ Slit 31 F Whole, drained Very Good Slices of
casing juices Irregular Shape and Size
12 Chicken 31 F Whole, drained Very Good Slices of
juices Irregular Shape and Size
13 Turkey ¨ Slit casing 31 F Whole, drained Very
Good Slices of
juices Irregular Shape and Size
16
CA 2994010 2018-02-02
14 Turkey 31 F Whole, drained Very Good Slices of
juices Irregular Shape and Size
15 Ham ¨ Split Top 31 F Whole, drained Very Good Slices of
juices Irregular Shape and Size
16 Ham 31 F Whole, drained Very Good Slices of
juices Irregular Shape and Size
17 Beef Split Top 31 F Whole, drained Very Good Slices of
juices Irregular Shape and Size
18 Turkey Breasts 31 F Halved, drained Very Good Slices of
Halved juices Irregular Shape and Size
19 Chicken Breasts 31 F In 12 pieces, Very Good Slices of
drained juices Irregular Shape and Size
[0058] For the following tests, the processing machine had an impeller with
four
equally spaced paddles, a ten horsepower motor operating at 75 hertz across
the line, a
scalloped slicing knife with a 1/2 inch slice thickness, a circular knife
assembly, and a
cross cut knife assembly. The circular knife assembly had dulled circular
blades at
every 1 1/2 inches and feed discs positioned at the remaining spaces between
the 3/4
inch spacers. Four pieces of bulk meat product were used in the tests.
Test Meat Temp. Prep. Result
20 Beef 97 F Whole, drained Chunk style shreds
juices
21 Ham 125 F Whole, drained Chunk style shreds
juices
22 Ham 120 F Whole, drained Chunk style shreds
juices
23 Beef 135 F Whole, drained Chunk style shreds
juices
[0059] For the following tests, the processing machine had an impeller with
four
equally spaced paddles, a ten horsepower motor operating at 75 hertz across
the line, a
scalloped slicing knife with a 3/16 inch slice thickness, a circular knife
assembly, and a
cross cut knife assembly. The circular knife assembly had dulled circular
blades spaced
3 3/4 inches from each end of the rotatable shaft and feed discs positioned at
the
remaining spaces between the 3/4 inch spacers. The cross cut knife assembly
had two
dulled cross cut blades positioned on opposite sides of the assembly. Two
pieces of
bulk meat product were used in the tests.
17
CA 2994010 2018-02-02
Test Meat _ Temp. Prep. Result
24 Ham 33 F Whole, drained Very Good Slices of
juices Irregular Shape and Size
25 Ham 33 F Whole, drained Very Good Slices of
juices Irregular Shape and Size
26 Ham 33 F Whole, drained Very Good Slices of
juices Irregular Shape and Size
27 Ham 33 F Whole, drained Very Good Slices of
juices Irregular Shape and Size
28 Turkey 33 F Whole, drained Very Good Slices of
juices Irregular Shape and Size
29 Turkey 33 F Whole, drained Very Good Slices of
juices Irregular Shape and Size
[0060] For the foregoing, it will be appreciated that apparatus and methods
are
described herein for manufacturing irregularly shaped and sized food products.
While
the figures and description herein are illustrative of certain aspects of
methods and
apparatus for manufacturing irregularly shaped and sized food products, the
apparatus
and methods are not limited to the aspects illustrated in the figures and
described
hereinabove. For example, while the description generally refers to meat as
the product
being produced in irregular shapes and sizes, it is understood that a process
according
to the present description may be used for other suitable products.
[0061] Turning now to the preparation of the sliced meat, FIG. 7
illustrates a
process 200 for producing a shaped home-style meat product having an irregular
appearance. Such home-style meat products may have a variety of irregular
shapes,
sizes, and textures, to note but a few of the varied characteristics. By one
approach, a
package of such home-style meat products may have individual meat slices or
pieces
with irregular shapes, sizes, textured surfaces, and density. Further, it is
anticipated
that although each of the individual slices is varied from one slice to the
next, the
various parameters of each of the slices may fall within a predetermined
range. For
example, though the shape of the meat slices may be irregular, the shape may
nonetheless, fall into a range such that a majority of the slices in a package
may have a
small, diced configuration or all of the slices in a package may be flat with
a relatively
thin depth compared to the width, to note but a few shape options.
18
CA 2994010 2018-02-02
L0062] To
produce such varied slices, the rotary processing machine 10, as
discussed above, may be employed to mass produce slices of meat having an
irregular
appearance. Process 200 also may be used to that end. Further, process 200 may
be
used to produce such a home-style meat product having an irregular appearance
with
conventional slicing equipment. Indeed,
process 200 may be used, either in
combination with the rotary processing machine 10 discussed above or in
combination
with other slicing equipment such as a reciprocating-carriage slicer, among
others.
Thus, if a high degree of irregularity between the meat slices is desired, the
rotary
processing machine 10 may be used to slice meat prepared according to process
200.
[0063] Prior to
slicing the whole muscle meat, process 200 formulates a whole
muscle meat mixture having a low-salt, no-phosphate solution mixed therein
such that
when the meat mixture is cooked and chilled, this formulation produces a whole
muscle
meat structure characterized by individual meat fibers that bind modest
amounts of
water and fat. Further, such a mixture may be loosely stuffed, as detailed
below. Thus,
when such formulated meat products are sliced, such as by the rotary
processing
machine 10 or other slicing equipment, the cut surface of the whole muscle
meat is
typically fractured along the lines between weakly bound fibers, thereby
resulting in a
sliced meat product having a rough irregular surface that displays the natural
structure
of the meat. Such an irregular surface is commonly found in whole muscle meats
that
have been prepared in the home.
[0064]
Alternatively, in conventional meat processing applications, product
formulations are designed to maximize protein functionality and when such a
formulation is combined with conventional slicing technology, a meat product
with
smooth, regular surface cuts is produced. To create such a standardized
product,
conventional processing indicates that once the deboned whole muscle meat is
supplied, it is then mixed with a pickle solution having a relatively high
salt concentration
and phosphates to increase functionality. Phosphates function like ATP in the
muscle
structure. They temporarily break the chemical bonds between protein bundles
and
allow the protein structure to open up and hold water. By one approach, the
deboned
whole muscle meat is treated in a pickle injector that injects pickle solution
into the
meat. The injector uses hypodermic-type needles to puncture the meat and to
inject a
19
CA 2994010 2018-02-02
pickle solution through needles into the meat, as the meat travels through the
pickle
injector on a conveyor. The injection step helps diffuse pickle solution
through the meat
and also serves to tenderize the meat. Various pickle solutions may be
employed for
meat processing. Conventional pickle solutions include a mixture of: water,
salt, nitrite,
phosphate, ascorbate, erythorbate, and sugar to note but a few ingredients. A
typical
curing solution contains 10% salt, 2.3 % sodium phosphate, 62% water, 0.3 %
sodium
ascorbate, 0.09% sodium nitrite, 3.5 % sugar, 20% sodium lactate. In a typical
product,
such as a deli-shaved meats, around 20 lbs of pickle may added to 100 lbs of
meat.
This will result in having 2 lbs of salt per 100 lbs of meat.
[0065] Additional pickle solution may be added to the whole muscle meat
after
the injector step if desired. Once the meat has been combined with the
solution, the
conventional batch is mixed for a specified period of time, typically about 60
minutes.
Once mixed, the meat mixture is allowed to cure for between approximately 24-
48
hours.
[0066] Once the meat has cured, the conventional meat is tightly stuffed
into
casings. Conventional wisdom encouraged stuffing the casings tightly to avoid
creating
void spaces inside the casings, which resulted in excess moisture being
expelled from
the meat. Once stuffed, the meat is cooked just above 155 F, anywhere from
between
3 and 6 hours. Then, the meat is cooled, and sliced. Such conventionally
prepared
meat may be sliced in a variety of slicing equipment including the rotary
processing
machine 10 discussed above. Slicing such conventionally prepared meat on
conventional slicing equipment produced a meat product having regular,
standardized
appearance. Such a meat product typically has little variations between shape,
surface,
and texture of the slices or pieces produced. Alternatively, if the
conventional meat
product is sliced using the rotary processing machine 10, the resulting
product exhibits
a moderate degree of irregularity between the meat pieces and avoids the meat
product
having the standardized regular appearance typically resulting from meat
processing.
[0067] In another embodiment, to mass produce a home-style product having
an
intentionally differentiated texture and appearance with a high degree of
irregularity
between the meat pieces, process 200 may be employed with the rotary
processing
machine 10. Further, as discussed below, process 200 may also be employed with
CA 2994010 2018-02-02
other slicing equipment to provide a moderate degree of irregularity between
the meat
pieces. In determining how to prepare and slice the whole muscle meat, the
desired
product including the desired level of irregularity and differentiation
between the various
meat slices should be considered.
[0068] As illustrated in FIG. 7, process 200 includes receiving or
providing 201
deboned whole muscle meat at a processing plant. Further, the whole muscle
meat is
combined 203 with a mixture or solution having a small amount of salt and
having no
phosphates. By one approach, the whole muscle meat provided 201 undergoes a
pickle injection step 202. Such a pickle injection step, as discussed above,
delivers the
pickle solution to the whole muscle meat via hypodermic-type needles. However,
unlike
the conventional process, the whole muscle meat is not combined with
phosphates in
process 200. Thus, the pickle solution of process 200 has no phosphates and,
further,
has a limited amount of salt therein. By one approach, the pickle solution
added to the
whole muscle meat will be less than 2 lbs. of salt per 100 lbs. of meat. In
one illustrative
embodiment, approximately half the amount of salt used in a conventional
product is
added to the whole muscle meat in process 200. For example, about 10 lbs. of
pickle
solution having a 10% salt concentration may be added to 100 lbs of meat to
end up
with 1 lbs of salt in 100 lbs. of meat. Once the pickle injection step is
complete, the
whole muscle meat may be further combined with additional pickle solution
having a
small amount of salt and lacking any phosphates.
[0069] Once the whole muscle meat has been combined 203 with the low-salt,
phosphate-free solution, the combination may be mixed 204 together such as in
a
tumbler or other mixing apparatus. The combined whole muscle meat may be mixed
204 for a specified of time period. By one approach, the mixing step is
approximately
30 minutes or less. Alternatively, the mixing step may be between 30 and 60
minutes,
depending on the desired end product. However, it is important that the meat
not be
over mixed and, thus, it is desirable to have the mixing extend no longer than
60
minutes and preferably closer to 30 minutes. Significant mixing promotes
binding of the
muscle structure such that the structure binds more tightly. In turn, the cut
surface of
the meat slices will not fracture along the irregular protein strand seams but
will slice
smoothly and have a more conventional sliced meat appearance. Once the whole
21
CA 2994010 2018-02-02
muscle meat has undergone sufficient mixing, the meat is collected in a vat
for a period
of time to permit the salt and other ingredients to diffuse uniformly
throughout the meat
pieces. The length of the cure time may depend on the desired final product.
In one
illustrative embodiment, the whole muscle meat is retained in a cooler for
between 24
and 48 hours.
[0070] The whole muscle meat may then be stuffed 206 into casings in which
the
meat is cooked. Unlike conventional processing where the meat is tightly
packed into
the casing, however, process 200 loosely stuffs 206 the meat product into the
casings.
As used herein, the term loosely stuffs indicates that the whole muscle meat
is stuffed
into the casings such that voids are permitted to occur between the individual
whole
muscle meat pieces and between the pieces and the casing. Further, such voids
create
irregularities in the meat product during the cooking phase via moisture
expulsion. The
low-salt, no-phosphate solution is a relatively poor water binder and thereby
encourages
water loss through evaporation and expulsion, similar to what occurs in home-
style
cooking. Comparatively, a conventional product having a higher salt solution
and
phosphates is relatively a good water binder, which results in a higher
product yield.
However, such a product produces a very regular appearance. By allowing the
water to
escape form the system, irregularities in the final product are further
introduced.
[0071] Since the low-salt, no phosphate solution does not promote
significant
water binding, the casing is relied upon to retain some of the moisture within
the meat
structure. However, certain casings may retain too much water or may not
permit
expansion of the product, thereby unduly increasing the pressure inside the
casing,
while others may permit too much water loss. The meat cooked in the average
home-
oven produces a significant amount of steam and meat juices collect in the
pan, which
is the result of moisture evaporation and expulsion from the meat. Thus, the
casing
used in process 200 typically permits significant amounts of moisture loss.
[0072] As mentioned, the water loss occurs through the casings, which may
be
comprised of a variety of natural or synthetic materials. For example, a thin
mesh fabric
or wire mesh may be used, to note but a few. Whatever the material, it is
desirable for
the casing to permit some expansion of the meat product and also permit loss
of water,
both of which relieve some of the pressure created in the product. By one
approach,
22
CA 2994010 2018-02-02
the casings are pre-stuck casings that have openings, such as slits or holes,
created
therein prior to stuffing and cooking. These openings allow the water to
escape from
the casing.
[0073] In sum, some void space is deliberately left within the casing once
it is
filled with the meat product. This void space permits moisture expulsion and
keeps the
pieces from "gluing" together to thereby help create a meat product with a
home-style
appearance by creating surfaces with an irregular texture. To that. end, the
casings
selected also encourage some amount of water loss. Thus, the manner of
stuffing the
casings and the casings themselves contribute to the irregularities in the
final cooked
product.
[0074] Further, once the casings have been loosely stuffed 206, the casings
may
be thermally processed 207 such as through cooking at a temperature of at
least 155 F.
In one illustrative embodiment, a series of temperature steps are employed,
where the
temperature gradually increases to reach the final temperature, just over 155
F. For
example, by one approach, the final product temperature at the end of the
cooking cycle
is approximately in between the 155 -170 F range, whereas and the air
temperature in
the final cook step is in the range of approximately 180 -210 F, depending on
the
product. Comparatively, such temperatures are a bit higher than those
conventionally
used and this drives off more moisture by evaporation. A loss of between 22-
28% of
the total ingoing product weight is targeted. For example, for 100 lbs. of
product that is
introduced into the smokehouse, approximately 72-78 lbs. of product will exit
the
smokehouse after cooking. Such loss, as described above, results from
evaporation
and expulsion. This is quite different from conventional products, where as
much water
as possible is retained.
[0075] The cook process takes about 6 hours, while conventional cook times
range from 3 to 6 hours. Thus, the cook time of process 200 is at the long end
'of the
spectrum. Further, as mentioned above, the cook temperature is at the higher
end, as
well. Thus, water loss is encouraged, which contributes to the final product's
varied
texture. Encouraging such water loss is possible because the solution does not
have a
high salt concentration or phosphates that bind the water.
23
CA 2994010 2018-02-02
[0076] After the meat produce has been cooked, the casings of meat products
are cooled 208. By one approach, such cooling occurs by showering the casings
with
chilled water. By yet another approach, the casings and meat product are
permitted to
chill by removing the casings from the heat source and exposing the outside of
the
casings to chilled air. The water shower, if used, will expose the casings to
water at
approximately 34-38 F for about 30 minutes. The air chill takes about 7 hours
and uses
18-25 F air to reduce the product temperature to the desired slicing
temperature of 29-
31 F.
[0077] Once the casings and meat product have cooled, the prepared meat may
undergo slicing 209 to produce the home-style meat with individual pieces have
an
irregular appearance. Such slicing 209 may occur in a variety of slicing
equipment.
Since process 200 prepares the whole muscle meat in a manner such as to
purposefully create irregularities in the final product, such a prepared meat
mixture may
be sliced in a conventional slicer and may still exhibit a degree of
irregularity between
the sliced pieces. In addition, if a high degree of irregularity is desired
the whole muscle
meat prepared according to process 200 may be sliced in the rotary processing
machine 10. As discussed above, the rotary processing machine has an impeller
34
with equally spaced paddles 40 that rotate and carry the meat product to be
sliced by
slicing knife 56 having a dulled cutting edge. Such a configuration wherein
the chunks
of whole muscle meat are exposed to the stationary slicing knife from
different angles
creates further irregularities in the low-salt, phosphate-free meat product.
Alternatively,
a slicer with a less random and varied manner of slicing would still produce
an
irregularly textured meat product if process 200 were employed to prepare the
meat.
[0078] For example, a slicer with a reciprocating carriage and a stationary
blade
typically orients the meat relative to the slicing knife based on the manner
of delivery of
the meat, such as through a feed tube or hopper. The orientation of the meat
product in
such a feed tube does not widely vary as the whole muscle meat does not have
room to
rotate or significantly shift around. Instead, the whole muscle meat slowly
advances
toward the slicing knife as leading portions of the whole muscle meat are
sliced from the
unsliced portion. Such a slicer typically produces a sliced meat product
having
standardized, highly regular characteristics, however, such equipment may be
used to
24
CA 2994010 2018-02-02
produce irregularly textured and shaped meat slices if the sliced meat is
prepared
according to process 200.
[0079] Thus, a home-style carved meat product having intentionally
irregular and
controlled variations, which are within certain parameters including size,
shape, texture,
and density, may be produced by slicing on a rotary processing machine 10 or
by
preparing the whole muscle meat according to process 200. Further, a home-
style
carved meat product having a high degree of irregularity may be produced by
preparing
whole muscle meat according to process 200 and then slicing the prepared meat
in the
rotatry processing machine 10.
[0080] While process 200 illustrated in FIG. 7 may occur in order of the
steps
listed, such as combining 203 the whole muscle meat with a small amount of
salt and
without phosphates after the boneless whole muscle meat has been provided 201
to the
meat processing plant. It is also contemplated that the steps of process 200
may occur
in a variety of other orders as well For example, combining 203 the whole
muscle meat
with the low-salt, phosphate-free solution may occur prior to providing 201
the whole
muscle meat at the processing plant. Further, in such a configuration, curing
205 of the
whole muscle meat may occur during several of the other steps. Thus, it is
contemplated that the steps of process 200 may occur in a variety of
sequences.
[0081] Sliced meat having a home-style appearance preferably will have
increased irregularities in the slice surface, such as an increase in surface
roughness,
as compared to conventionally prepared meat. In addition, the range of
irregularities is
higher, such as the range of surface roughness is also larger.
[0082] To demonstrate the increased surface irregularity, test samples of
ham
processed according to process 200 were compared with samples of
conventionally
processed ham. As discussed below, five samples of conventionally produced ham
and
seven test samples of ham produced according to the invention described herein
were
examined.
[0083] To examine the differences between the two samples, digital images
of
the samples were taken and then the images were evaluating by examining the
difference in the contrast between pixels to determine a surface irregularity
value. The
images were captured by scanning the samples with an EPSON Pro 750 instrument
at
CA 2994010 2018-02-02
300 dpi and then analyzed using Image-Pro Plus Version 5.1. The texture
(surface
roughness) was examined by comparing the intensity of the light reflected off
the
_ surface. Elevated portions of the sample were indicated by a darker pixel
and lower
portions of the sample were indicated by a lighter pixel. For example, a
sample, with a
high degree of variation included many high spots (dark) and low spots (light)
within a
certain area indicated. This variations in pixels indicated that the sample
had a rough
surface.
[0084] To evaluate the images, a portion of the image (7 pixel by 7 pixel
area)
was examined for the variation in brightness, which was interpreted as texture
(surface
roughness). These 7x7 pixel areas were compared with other 7x7 pixel areas. By
one
approach, the mean brightness of the various areas was compared with mean
brightness of other 7x7 pixel areas. The surface irregularities value listed
below refers
= to local variation in brightness from one area to the next. Both the
range (difference
between the maximum and minimum brightness values in a neighborhood) and the
variance (statistical variance of pixel values in any particular area) were
examined.
VARIANCE 7x7 IMAGE SURFACE
IRREGULARITIES VALUE
Conventional Ham Sample #1 55.65
Conventional Ham Sample #2 44.60
Conventional Ham Sample #3 60.81
Conventional Ham Sample #4 = 53.91
Conventional Ham Sample #5 57.67
Test Ham #1 75.82
Test Ham #2 76.56
Test Ham #3 94.16
Test Ham #4 73.55
Test Ham #5 68.13
Test Ham #6 76.35
Test Ham #7 58.64
26
CA 2994010 2018-02-02
[0085] The five
samples of conventionally produced ham had surface irregularity
values falling between approximately 44.60 and 60.61. In contrast, images of
the seven
samples of the test ham had surface irregularity values ranging from
approximately
58.64 to 94.16. The mean variance for the conventional ham was 54.53, whereas
mean
variance for the test ham was 74.74. Thus, the test ham showed significantly
more
variation in the surface (increased amount of difference between the light and
dark
pixels). In short, ham according to process 200 has noticeable surface
irregularities that
help create the home-style appearance desired by many consumers. Thus, in one
embodiment, the home-style meat product has a surface irregularity value of
above 61.
In one example, the home-style meat product has a mean variance surface
irregularity
value of greater than about 70. In another embodiment, the home-style meat
product
has a mean variance surface irregularity value of greater than about 75. By
yet another
approach, the meat produced according to the invention herein has a mean
variance of
at least 25% more than conventionally produced meat products.
[0086] Turning
now to yet another manner of preparing the meat prior to slicing,
FIG 8 illustrates a low-phosphate process 300 that produces a home-style meat
product
having an irregular appearance. The process 300 may be used to mass-produce a
home-style meat product at a rate of 4,000-10,000 lbs per hour. The low-
phosphate
process 300, like process 200, may be employed with conventional slicing
equipment,
such as a Grote slicer. This ability to process home-style meat products on a
conventional slicer provides a significant amount of flexibility to process
300. Slicing
may also be performed using the rotary processing machine 10 described above.
In
another approach, a continuous feed involute blade slicer with adjustable hold
down
rollers may be used. The hold down rollers may perform working of a meat
product
before slicing, as discussed in greater detail below.
[0087] Low-
phosphate process 300 is configured to produce home-style meat
products having individual meat slices or pieces with irregular shapes, sizes,
textures,
and surface densities, to note a few of the varied characteristics. Further,
it is
anticipated that although each of the individual slices is varied from one
slice to the
next, the various parameters of each of the slices in a given package may fall
within a
predetermined range. For example, though the shape of the meat slices may be
27
CA 2994010 2018-02-02
irregular, the shape may, nonetheless, fall into a range such that a majority
of the slices
in a package may have a small, generally diced configuration or all of the
slices may be
generally flat with a relatively thin depth compared to the width, to note a
few of the
shape options.
[0088] As illustrated in FIG. 8, process 300 includes receiving or
providing 301
boneless whole muscle meat, which may include poultry, pork, and beef, to note
but a
few options. The whole muscle meat is combined 302 with a mixture, such as a
pickle
solution, having a low phosphate concentration. By one approach, the
combination 302
includes combining and mixing the pickle solution and raw meat with a minimal
amount
of mechanical work being done to the raw whole muscle meat. In an illustrative
approach, the whole muscle meat is not aggressively macerated, ground,
aggressively
mixed or tumbled for extended periods of time, or otherwise significantly
worked prior to
cooking 304.
[0089] A pickle injector and/or a tumbler may be used to combine 302 the
mixture
with the whole muscle meat. The pickle injection process, as described above,
may be
used to introduce the pickle solution into the inside of the individual muscle
pieces. A
pickle injector, such as the injector manufactured by Wolf-Tec, may be used
for such
purposes. Along with or instead of the pickle injection, the whole muscle meat
may
undergo tumbling such that the whole muscle meat is mixed and massaged with
the
pickle solution. The whole muscle meat may undergo tumbling for different
lengths of
time depending on the particular solution used, size of the whole muscle
pieces, and the
previous and subsequent processing of the meat. The whole muscle meat may be
tumbled with the pickle solution for between 30 minutes and 2 hours. In one
illustrative
example, the meat is tumbled tor between 1 to 1.5 hours. Tumbler equipment
that
gently tumbles or massages the pre-cooked whole muscle meat under vacuum to
thereby mix the meat and solution is known in the art and includes those
produced by
the manufacturer Challenge-RMF, Inc. Despite the approach employed for
combining
302 the meat and the mixture, it is anticipated that the method will impart a
limited
amount of mechanical action to the whole muscle meat prior to thermal
processing or
cooking 304.
28
CA 2994010 2018-02-02
[0090] As mentioned, the pickle solution or mixture combined in step 302
has a
low phosphate concentration. Conventional solutions may include about 3 to
3.5%
phosphate by weight, and sometimes may be even higher, resulting in a meat
formulation of up to 0.5% phosphate in the final meat product. In addition, a
typical
injection, tumbling, and mixing operation may add approximately 20% solution
or more,
such that at least 20 lbs. of solution is added to 100 lbs. of meat. The
pickle solution or
mixture used in step 302 is in the range of 1-2% sodium phosphate. Further, it
is
anticipated that the solution includes a moderate salt concentration such that
the salt
concentration is between 7-12%.
[0091] By one approach, the mixture may include 40-60% water, 1-2%
phosphate, 7-12% salt, 30-40% lactate, less than 0.3% nitrite, and less than
0.3%
sodium ascorbate. The amount of pickle solution added to the meat is typically
dependent on the particular final product desired and the particular pickle
solution being
added to the meat. Nonetheless, by one approach, approximately 10-20 lbs. of
the
mixture may be added to 100 lbs. of whole muscle meat. In yet another
illustrative
example, the mixture may include 48-52% water, 1-2% phosphate, 8-11% salt, 35-
39%
lactate, less than 0.3% nitrite, and less than 0.3% sodium ascorbate. In one
example,
approximately 14-18 lbs. of the mixture may be added to 100 lbs. of whole
muscle meat.
A low phosphate mixture produces a lower bind between the individual muscle
pieces
during the thermal processing or cooking stage, which will be more easily
separable
prior to slicing, as discussed below.
[0092] Once the whole muscle meat has been combined 302 with the low-
phosphate mixture, the combination may be stuffed 303 into a casing. A variety
of
equipment may be used during the stuffing operation. To advance the meat and
mixture into the casing, a piston-pump may be employed to push the meat into a
clipper/sizer that has casings and a stuffing horn attached thereto. To retain
the whole
muscle character of the whole muscle meat, a stuffing horn of sufficient size
is
employed. For example, ft is anticipated that a stuffing horn of between 3 and
4 inches
will be employed. In addition, an automatic double clipper such as the Poly-
Clip System
clippers may be used as well.
29
CA 2994010 2018-02-02
[0093] A number of different casings may be used including fibrous casings
such
as those considered pre-stuck casings. In one illustrative example, a Viskase
double
pre-stuck casing may be employed to contain the whole muscle meat. Since the
casings used in such processing are typically not edible, such casing should
be
removed before slicing.
[0094] Once the casings have been stuffed, they can be thermally processed
or
cooked 304 to produce cooked whole muscle meat logs. Due to the low-phosphate
levels of the mixture and the limited amount of mechanical working done to the
meat
prior to cooking, the binding between the individual muscle pieces is
relatively loose.
The cooking typically occurs such that the meat reaches a temperature of
between 155
to 170 F, whereas the air temperature in the final cook step is in the range
of
approximately 1800 to 210 F, depending on the final product. The cook process
may
take between approximately 3 to 6 hours. In one illustrative embodiment, the
cook
process takes approximately 4 to 5.5 hours. After the cooking step, the cooked
whole
muscle meat logs are permitted to chill prior to slicing. A variety of
processes may be
employed for cooling the cooked meat logs. For example, a cold water shower, a
brine
chill, or a cold air chill may be used, among others.
[0095] Once the meat has sufficiently cooled, the cooked meat may undergo
working 305 to loosen the binding between individual whole muscle meat pieces.
During the cooking operation, individual muscle pieces bind to water,
flavorings, and
one anther. Though, due to the low phosphate content along with a limited
amount of
mechanical action applied to the meat prior to cooking, the binding between
the whole
muscle pieces in the product produced according to process 300 is much looser
than is
otherwise present in a conventional product. By working the meat to loosen the
binding,
the individual muscle pieces separate from one another such that when they
undergo
the slicing operation, the slices appear irregular. More particularly, when a
solid, tightly
bound meat log is sliced, the resulting slices exhibit a high degree of
regularity.
Alternatively, when the meat log has variations in shape, variations in
appearance
around the outer edge of the product, density variations and possible void
spaces
between the whole muscles, the resulting slices exhibit a relatively high
degree of
irregularity. Working 305 creates such variations in the meat log or meat
slices.
CA 2994010 2018-02-02
[0096] Working 305 of the cooked whole muscle meat logs can occur in a
variety
of manners. By one approach, the working 305 of the cooked whole muscle meat
logs
may occur prior to slicing 306. By yet another approach, the working 305 of
the cooked
whole muscle meat logs may occur subsequent to slicing 306. The particular
approach
employed may depend on the desired final product, among other factors. It is
anticipated that the casings can be removed either before or after working 305
of the
whole muscle meat log if the working 305 precedes slicing 306. If the working
305
occurs after slicing 306, the casing would be removed prior to slicing 306 and
thus, the
working 305 occurs with the casings removed.
[0097] Working 305 that occurs prior to the slicing 306, though after
cooking 304,
may include pressing, puncturing, massaging, kneading, pounding, tearing, and
pulling,
among other options. These operations may occur such that the meat log is
stationary
or is advanced in a downstream direction, such as by feeding the meat onto a
moving
belt. If the whole muscle meat log remains stationary, a stationary press,
flat plate, or
other equipment may be employed. Alternatively, if the whole muscle meat is
advanced
in a downstream direction during working 305, the meat logs may pass through
rollers
or other equipment configured to exhibit pressure on the meat logs as it
advances
downstream. In one illustrative embodiment, the whole muscle meat logs may be
advanced between a pair of belts.
[0098] If the working 305 is generated by gently tearing and/or pulling,
the tearing
and pulling primarily separate individual whole muscle pieces apart from one
another
and do not significantly separate the muscle fibers of the individual whole
muscles.
[0099] Working 305 that occurs after the slicing operation 306 and after
cooking
304 may include tumbling and augering of the sliced whole muscle meat. By
tumbling
the cooked 304 and sliced 306 whole muscle meat, the slices are moved,
massaged,
and tumbled around to give the meat slices an irregular appearance. Unlike the
tumbling that may be done prior to cooking, which helps mix the pickle
solution with the
raw whole muscle meat, the post-slicing tumbling is typically not done under
vacuum.
Further, such post-slice tumbling is considerably shorter than the pre-cook
tumbling. By
employing auger equipment to gently work the cooked 304 and sliced 306 whole
muscle
31
CA 2994010 2018-02-02
meat, the slices are advanced through a screw or conveyor auger that is
sufficiently
sized to provide gently mixing and rotating of the meat pieces for a brief
period of time.
[00100] It should be noted that the working 305 of the whole muscle meat
logs
does not destroy the overall structure of the meat log or slice. Destroying
the overall
structure would not produce the home-style meat desired and creates problems
with
slicing and packaging.
[00101] The sliced home-style meat product produced using process 300 has a
range of meat piece sizes similar to sliced meat products produced in the
home. In one
approach for a sliced meat product, the sliced meat product includes small,
medium,
and large piece sizes. The small-sized pieces are sized to fall through a
vibratory
screen having % inch openings, the medium-sized pieces are sized to fall
through a
vibratory screen having 1 inch openings but be retained by a screen having 1/2
inch
openings, and the large-sized pieces are sized to be retained by a vibratory
screen
having 1 inch openings. The sizes of the sliced meat pieces may vary between
different
types of meat and different formulations.
[00102] In one form, a sliced home-style turkey product was produced using
the
process 300 and the rotary processing machine 10 described above. The home-
style
turkey product had piece sizes with the following ranges by approximate
percentage of
the total weight of the product:
Piece Size Percent of Product
Large 73-81
Medium 15-23
Small 4-5
[00103] In another form, a sliced home-style ham product was produced using
the
process 300 and the rotary processing machine 10 described above. The home-
style
ham product had piece sizes with the following ranges by approximate
percentage of
the total weight of the product:
32
CA 2994010 2018-02-02
Piece Size Percent of Product
Large 81-88
Medium 9-15
Small 2-4
[00104] In another form, a sliced home-style chicken product was produced
using
the process 300 and either a Grote slicer or the rotary processing machine 10.
The
home-style chicken product had piece sizes with the following ranges by
approximate
percentage of the total weight of the product:
Percent of Product Percent of Product
Piece Size
(Grote Slicer) (Rotary Processing Machine)
Large 73-81 43-51
Medium 14-22 34-42
Small 1-9 11-19
[00105] In one form, a sliced home-style beef product was produced using
the
process 300 and either a Grote slicer or the rotary processing machine 10. The
home-
style beef product had piece sizes with the following ranges by approximate
percentage
of the total weight of the product:
Percent of Product Percent of Product
Piece Size
(Grote Slicer) (Rotary Processing Machine)
Large 85-93 67-75
Medium 6-14 19-27
Small 2-10 2-10
[00106] Turning to another aspect, a process is provided for producing a
pulled,
shredded, or sliced meat product having an appearance that closely resembles
pulled,
shredded, or sliced meat produced using manual culinary techniques. The
process
includes mixing a whole muscle meat with a solution having a low salt content
in a
33
CA 2994010 2018-02-02
manner to provide minimal protein extraction and maintain the natural
appearance and
irregularity of the whole muscle meat. The mixed whole muscle meat is cured
and
loosely stuffed into a casing so as to preserve an irregular composition of
the whole
muscle meat within the casing. The whole muscle meat is then cooked to a
predetermined temperature and optionally smoked to deliver a high quality
flavor and to
break down the collagen and connective tissue holding the muscle fibers
together. The
cooked whole muscle meat is then cooled and pulled, shredded, or sliced at
reduced
temperatures. In this manner, the process provides a loosely bound cooked
whole
muscle meat that can be stored at refrigerated temperatures until subsequent
pulling,
shredding, or slicing as desired for a particular meat product.
[00107] Turning now to the preparation of a pulled, shredded, or sliced
meat
product, FIG. 9 illustrates a process 400 for producing a home-style meat
product
having a shredded, pulled, or sliced irregular appearance. The process 400 may
be
used to mass produce a home-style meat product at a rate of 5,000-10,000 lbs
per
hour. Such home-style meat products may have a variety of irregular shapes,
sizes,
and textures, to note but a few of the varied characteristics. By one
approach, a
package of such home-style meat products may have individual meat pieces with
irregular shapes, sizes, textured surfaces, and density. Further, it is
anticipated that
although each of the individual pieces is varied from one piece to the next,
the various
parameters of each of the pieces may fall within a predetermined range. For
example,
though the shapes of the meat pieces may be irregular, the shapes may
nonetheless
fall into a range such that a majority of the pieces in a package may have a
small thin,
shredded configuration, to name one shape option.
[00108] To produce such varied pieces, a pulling machine, such as the
pulling
machine disclosed in U.S. Patent No. 5,775,986 to Law et al. which issued on
July 7,
1998, may be used in conjunction with process 400 to mass produce pieces of
meat
having an irregular appearance. Alternatively, other pulling, shredding, or
slicing
equipment may be used in conjunction with process 400 to produce such a home-
style
meat product having an irregular appearance.
[00109] Prior to pulling, shredding, or slicing the whole muscle meat,
process 400
includes providing a whole muscle meat mixture having a low-salt solution
mixed
34
CA 2994010 2018-02-02
therein. When the meat mixture is cooked and chilled, the formulation produces
a
whole muscle meat structure characterized by individual meat fibers that bind
modest
amounts of water and fat. Further, such a mixture may be loosely stuffed, as
detailed
below. Thus, when such formulated meat products are pulled, shredded, or
sliced, such
as by a pulling machine or other equipment, the cut surface of the whole
muscle meat is
typically fractured along the lines between weakly bound fibers, thereby
resulting in a
pulled meat product having a rough irregular surface that displays the natural
structure
of the meat. Such an irregular surface is commonly found in whole muscle meats
that
have been prepared in the home.
[00110] As illustrated in FIG. 9, the process 400 includes receiving or
providing
401 deboned whole muscle meat at a processing plant. The whole muscle meat is
combined 403 with a mixture or solution having a small amount of salt. By one
approach, the whole muscle meat provided at step 401 undergoes pickle
injection 402.
A conventional pickle injection procedure, as discussed above with respect to
process
200, delivers a pickle solution to the whole muscle meat via hypodermic-type
needles.
However, unlike conventional pulled or shredded meat, the whole muscle meat
utilized
in process 400 has a limited amount of salt therein. To limit the amount of
salt in the
whole muscle meat of process 400, the pickle solution added to the whole
muscle meat
will be less than 2 lbs. of salt per 100 lbs. of meat. In one illustrative
embodiment,
approximately half the amount of salt used in a conventional product is added
to the
whole muscle meat in process 400. For example, about 10 lbs. of pickle
solution having
a 10% salt concentration may be added to 100 lbs of meat to end up with 1 lbs
of salt in
100 lbs. of meat. Once the pickle injection step is complete, the whole muscle
meat
may be further combined with additional pickle solution having a small amount
of salt.
[00111] Once the whole muscle meat has been combined 403 with the low-salt
solution, the combination may be mixed 404 together such as in a tumbler or
other
mixing apparatus. The combined whole muscle meat may be mixed 404 for a
desired
time period. Mixing 404 delivers sufficient mixing for ingredient dispersion
and retention
while retaining the natural muscle fibers, rather than achieving significant
protein
extraction as in some conventional approaches. The mixing step is
approximately 30
minutes or less in one approach. Alternatively, the mixing step may be between
30 and
CA 2994010 2018-02-02
60 minutes, depending on the desired end product. However, it is important
that the
meat not be over mixed and, thus, it is desirable to have the mixing extend no
longer
than 60 minutes and preferably closer to 30 minutes. Significant mixing
promotes
binding of the muscle structure such that the structure binds more tightly. In
turn, the
cut surface of the meat pieces will not fracture along the irregular protein
strand seams
but will separate smoothly and have a more conventional pulled meat
appearance.
Once the whole muscle meat has undergone sufficient mixing, the meat is
collected in a
vat for a period of time to cure 405 which permits the salt and other
ingredients to
diffuse uniformly throughout the meat pieces. The length of the cure time may
depend
on the desired final product. In one illustrative embodiment, the whole muscle
meat is
retained in a cooler for between 24 and 48 hours.
[00112] The whole muscle meat may then be stuffed 406 into casings in which
the
meat is cooked. Unlike some conventional approaches where the meat is tightly
packed into the casing, process 400 loosely stuffs 406 the meat product into
the
casings. As used herein, the term loosely stuffs indicates that the whole
muscle meat is
stuffed into the casings such that voids are permitted to occur between the
individual
whole muscle meat pieces and between the pieces and the casing. Further, such
voids
create irregularities in the meat product during the cooking phase via
moisture
expulsion. The low-salt solution is a relatively poor water binder and thereby
encourages water loss through evaporation and expulsion, similar to what
occurs in
home-style cooking. Comparatively, a conventional product having a higher salt
solution is a relatively better water binder, which results in a higher
product yield.
However, such a product produces a very regular appearance. By allowing the
water to
escape from the system, irregularities in the final product are further
introduced.
[00113] Since the low-salt solution provides a lower amount of water
binding, the
casing is relied upon to retain some of the moisture within the meat
structure. However,
certain casings may retain too much water or may not permit expansion of the
product,
thereby unduly increasing the pressure inside the casing, while others may
permit too
much water loss. The meat cooked in the average home-oven produces a
significant
amount of steam and meat juices collect in the pan, which is the result of
moisture
36
CA 2994010 2018-02-02
evaporation and expulsion from the meat. Thus, the casing used in process 400
typically permits significant amounts of moisture loss.
[00114] As mentioned, the water loss occurs through the casings, which may
be
comprised of a variety of natural or synthetic materials. For example, a thin
mesh fabric
or wire mesh may be used, to note but a few. Whatever the material, it is
desirable for
the casing to permit some expansion of the meat product and also permit loss
of water,
both of which relieve some of the pressure created in the product. By one
approach,
the casings are pre-stuck casings that have openings, such as slits or holes,
created
therein prior to stuffing and cooking. These openings allow the water to
escape from
the casing.
[00115] In sum, some void space is deliberately left within the casing once
it is
filled with the meat product. This void space permits moisture expulsion and
keeps the
pieces from "gluing" together to thereby help create a meat product with a
home-style
appearance by creating surfaces with an irregular texture. To that end, the
casings
selected also encourage some amount of water loss. Thus, the manner of
stuffing the
casings and the casings themselves contribute to the irregularities in the
final cooked
product.
[00116] Further, once the casings have been loosely stuffed 406, the
casings may
be thermally processed 407 such as through cooking at a temperature of at
least 155 F.
In one approach, a series of temperature steps are employed, where the
temperature
gradually increases to reach the final temperature, just over 200 F. For
example, the
final product temperature at the end of the cooking cycle is approximately in
between
the 170 -200 F range, whereas the air temperature in the final cook step is in
the range
of approximately 180 -210 F, depending on the product. In one approach, the
final
product temperature is in the 160 -215 F range. As an example, the thermal
processing 407 of pork may utilize the following temperature steps:
Dry Wet
Step # Step Time (min) Smoke
Bulb Bulb
1 30 145 115 off
2 30 150 125 SMOKE
3 60 170 145 SMOKE
37
CA 2994010 2018-02-02
4 60 190 165 SMOKE
30 200 175 SMOKE
6 60 210 205 off
To 200 F internal
7 225 210 off
Temp
[00117] As another example, thermal processing 407 of chicken may utilize
the
following temperature steps:
Dry Wet
Step # Step Time (min) Smoke
Bulb Bulb
1 30 130 115 off
2 30 170 125 SMOKE
3 30 180 145 off
4 30 190 160 off
5 To 170 F internal Temp _ 210 180
off
[00118] Comparatively, such temperatures are a bit higher than those
conventionally used and this drives off more moisture by evaporation. A loss
of
between 10-28% of the total ingoing product weight is targeted depending on
the
product. For example, for 100 lbs. of product that is introduced into the
smokehouse,
approximately 75-88 lbs. of product will exit the smokehouse after cooking.
Such loss,
as described above, results from evaporation and expulsion. This is quite
different from
conventional products, where as much water as possible is retained.
[00119] The cook process may take about 6 hours, while conventional cook
times
range from 3 to 6 hours. Thus, the cook time of process 400 is at the long end
of the
spectrum. Further, as mentioned above, the cook temperature is at the higher
end, as
well. Thus, water loss is encouraged, which contributes to the final product's
varied
texture. Encouraging such water loss is possible because the solution does not
have a
high salt concentration that binds the water. Also, the high cook temperatures
and
longer cook time breaks down the collagen and connective tissues holding the
meat
together, allowing meat fiber bundles to separate from one another during
pulling.
[00120] After the meat product has been cooked, the meat product is cooled
408.
By one approach, such cooling occurs by showering the casings with chilled
water. By
38
CA 2994010 2018-02-02
yet another approach, the meat product is permitted to chill by removing the
casings
from the heat source and exposing the outside of the casings to chilled air.
The water
shower, if used, will expose the casings to water at approximately 34-38 F for
about 30
minutes. The air chill takes about 7 hours and uses 18-25 F air to reduce the
product
temperature to the desired pulling and/or slicing temperature of 28-38 F. In
one
approach, the product temperature is reduced to a desired pulling and/or
slicing
temperature of 29-31 F. In another approach, the meat product is cooled to a
product
temperature below 38 F before pulling.
[00121] Once the meat product has cooled, the prepared meat may undergo
pulling, shredding, or slicing 409 to produce the home-style meat with
individual pieces
have an irregular appearance. The pulling, shredding, or slicing 409 may occur
in a
variety of pulling, shredding, or slicing equipment. Since process 400
prepares the
whole muscle meat in a manner such as to purposefully create irregularities in
the final
product, such a prepared meat mixture may be pulled, shredded, or sliced in
conventional equipment and may still exhibit a degree of irregularity between
the pieces.
[00122] Pulling, shredding, or slicing 409 the meat products after cooling
stands in
contrast to a conventional process for producing pulled meat products, where
the meat
is pulled shortly after being cooked. Cooling the meat products after cooking
provides
flexibility in manufacturing because the cooled meat products may be stored
and/or
transported before pulling, shredding, or slicing. This flexibility is a
significant benefit for
larger batch sizes of cooked meat products, such as 5,000-10,000 lbs, where
smaller
portions of a batch may be pulled, shredded, or slices, and the remainder
cooled. The
conventional process, by contrast, requires the machinery for pulling or
shredding to be
in close proximity to the oven in order to pull or shred the cooked meat
product before
spoilage of the meat product due to elevated temperatures. Further, mixing 404
the
whole muscle meat and low salt solution to achieve minimal protein extraction
and
loosely stuffing 406 the whole muscle meat into casings loosely binds the
whole muscle
meat. The loosely bound whole muscle meat of process 400 may then be readily
pulled,
shredded, or sliced 409 despite being cooled 408.
[00123] Thus, a home-style pulled meat product having intentionally
irregular and
controlled variations, which are within certain parameters including size,
shape, texture,
39
CA 2994010 2019-08-08
and density, may be produced by preparing the whole muscle meat according to
process 400. Further, a home-style pulled or shredded meat product having a
high
degree of irregularity may be produced by preparing whole muscle meat
according to
the process 400 and then pulling or shredding the prepared meat in the pulling
or
shredding machine. While process 400 may be used to produce a pulled or
shredded
product, similar steps may be taken to produce a home-style sliced meat
product. For
example, as shown in FIG. 9, the pulling or shredding 409 may be replaced with
a
slicing operation that results in irregularly shaped meat slices. To that end,
a variety of
meat slicers may be employed including those previously described.
[00124] While process 400 illustrated in FIG. 9 may occur in order of the
steps
listed, such as combining 403 the whole muscle meat with a small amount of
salt after
the boneless whole muscle meat has been provided 401 to the meat processing
plant.
It is also contemplated that the steps of process 400 may occur in a variety
of other
orders as well. For example, combining 403 the whole muscle meat with the low-
salt
solution may occur prior to providing 401 the whole muscle meat at the
processing
plant. Further, in such a configuration, curing 405 of the whole muscle meat
may occur
during several of the other steps. Thus, it is contemplated that the steps of
process 400
may occur in a variety of sequences.
[00125] The process 400 may be used with different formulas to produce a
desired
pulled, shredded, or sliced meat product. One embodiment of a rotisserie
seasoned
pulled chicken product has the following composition by approximate percentage
of raw
formulation:
Ingredient Percent
Boneless/Skinless Chicken Breast 42.97
Boneless/Skinless Chicken Thigh 42.97
Salt S0.90
Verdad NV 30 2.22
Verdad NV 20 2.97
Water 6.51
Sugar 0.96
CA 2994010 2018-02-02
Sodium Phosphate 0.20
Rotisserie Seasoning 0.30
Total 100
[00126] Another embodiment of a rotisserie seasoned pulled chicken product
produced using the method 400 has the following composition by approximate
percentage of raw formulation:
Ingredient Percent
Boneless/Skinless Chicken Breast 42.66
Boneless/Skinless Chicken Thigh 42.66
Salt 0.89
Verdad NV 30 1.39
Verdad NV 20 3.76
Water 6.26
Sugar 0.96
Sodium Tripolyphosphate 0.40
Rotisserie Seasoning Blend 0.30
Sodium Masker 0.74
Total 100
[00127] In one approach, the rotisserie seasoning blend and the sodium
masker
are topically added to the whole muscle meat after the meat has been combined
403
with the low-salt solution and before the whole muscle meat and the low-salt
solution
are mixed 404 together using a tumbler or other mixing apparatus.
[00128] The process 400 may be used to produce a BBQ seasoned pork product.
One exemplary embodiment of a BBQ seasoned pork product has the following
composition by approximate percentage of raw formulation:
Ingredient Percent
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Pork Cushions 81.05
Salt 1.14
Verdad NV 30 1.06
Verdad NV 20 3.89
Water 7.07
Sodium Phosphate 0.38
Brown Sugar 0.64
BBQ Seasoning Blend 4.76
Total 100
[00129] Another embodiment of a BBQ seasoned pork product produced using
the
process 400 has the following composition by approximate percentage of raw
formulation:
Ingredient Percent
Pork Cushions 80.86
Salt 1.14
Verdad NV 30 1.06
Verdad NV 20 4.18
Water 6.98
Sodium Tripolyphosphate 0.38
Brown Sugar 0.64
BBQ Seasoning Blend 4.76
Total 100
[00130] In one approach, the BBQ seasoning blend is topically added to the
whole
muscle meat after the meat has been combined 403 with the low-salt solution
and
before the whole muscle meat and the low-salt solution are mixed 404 together
using a
tumbler or other mixing apparatus.
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[00131] The process 400 may also be used to produce a hickory smoked pulled
pork product. One embodiment of a hickory smoked pulled pork product has the
following composition by approximate percentage of raw formulation:
Ingredient Percent
Pork Cushions 84.26
Salt 1.19
Verdad NV 30 1.10
Verdad NV 20 4.05
Water 7.35
Sodium Phosphate 0.40
Brown Sugar 0.66
Hickory Seasoning Blend 0.99
Total 100
[00132] Another embodiment of a hickory smoked pulled pork product produced
using the process 400 has the following composition by approximate percentage
of raw
formulation:
Ingredient Percent
Pork Cushions 84.91 -
Salt 1.2
Verdad NV 30 1.11
Verdad NV 20 4.39
Water 7.32
Sodium Tripolyphosphate 0.40
Brown Sugar 0.67
Total 100
[00133] Rather than utilize a hickory seasoning blend as in the first
embodiment of
the hickory smoked pulled pork product, producing the second embodiment
involves
applying a smoke during cooking of the hickory smoked pulled pork product. In
one
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approach, smoke is applied during cooking by burning or smoldering wood chips
and
drawing the smoke from the burning or smoldering wood chips into the
smokehouse.
[00134] In general, meat products produced using the process 400 can have
the
following composition ranges by approximate percentage of raw formulation:
tisserie o
Ingredient Hickory Pork BBO Pork RC Meat
hicken
Meat 75 - 90 % 75 - 90 % 75 - 90 % 75 - 90 %
Salt 0.8- 1.5 0.8- 1.5 0.8- 1.5 0.8 - 1.5
Water 5.0 - 15.0 5.0 - 15.0 5.0 - 15.0 5.0 - 15.0
Verdad NV 30 0.5 - 3.0 0.5 - 3.0 1.0 - 2.5 0.5 - 3.0
Verdad NV 20 3.0 - 6.0 3.0 -6.0 2.0 - 5.0 2.0 - 6.0
Phosphate 1.5 - 4.5 1.5 - 4.5 1.5 - 4.5 1.5 - 4.5
Sugars 0.75 - 4.0 0.75 - 4.0 1.0 - 4.0 0.75 - 4.0
Seasoning / 0.0 - 2.0 2.5 - 7.5 0.2 - 2.0 0.0 - 7.5
Spices
[00135] The composition ranges are listed in the above table by meat type.
The
table also discloses general composition ranges in the rightmost column of the
table for
meat products in general.
[00136] As will be appreciated, there are many different types of salts and
phosphates that are commonly used within the meat industry and may be used as
ingredients of meat products produced from processes described herein. For
example,
phosphates that may be used include monophosphates, polyphosphates, and
tripoly
phosphates, and their derivative sources such as sodium phosphates, potassium,
and
calcium phosphates. Salts that may be used include sea salts, flake salts,
potassium
chloride, and curing salts, among others.
[00137] In another approach, pre-converted celery juice may be used to
replace
sodium nitrite in the meat products disclosed herein. Approximately 0.5% pre-
converted
celery juice may be used as calculated on a 100% raw formula basis.
Concentrated
celery juice (and most all other vegetables) contain naturally occurring
nitrates. These
nitrates are absorbed by the vegetable as the vegetable grows and matures. The
nitrates are converted to nitrites during a pre-conversion process,
facilitating a natural
curing agent. In conjunction with the celery juice, a 0.1% cherry powder may
be added
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CA 2994010 2018-02-02
=
as a "cure accelerator". The function of cherry powder is similar to that of
sodium
ascorbateterythorbate and is used for color development and color
preservation.
[00138] The pulled, shredded, or sliced meat product produced using
process 400
has individual muscle strands and a range of meat piece sizes similar to
pulled,
shredded, or sliced meat products produced in the home. In one approach for a
pulled
meat product, the pulled meat product includes small, medium, and large piece
sizes.
The small-sized pieces are sized to fit through a screen having 1/4 inch
openings, the
medium-sized pieces are sized to fit through a screen having % inch openings
but be
retained by a screen having 1/4 inch openings, and the large-sized pieces are
sized to be
retained by a screen having 1/2 inch openings. As an example, a pulled pork
product
may have the following sizes by approximate percentage of the total weight of
the final
pulled pork product: 36% large, 50% medium, and 14% small.
[00139] The sizes of the pulled meat pieces may vary between different
types of
meat and different formulations. In one form, acceptable pulled or shredded
meat piece
sizes for pork and chicken have the following ranges by approximate percentage
of the
total weight of the final pulled or shredded product:
Piece Size Percent of Product -
Large 24-36
Medium 50-69
Small 7-14
[00140] One type of pulling equipment that may be used in conjunction
with the
process 400 is a 2-D belt slicer modified to produce a pulled meat product.
More
specifically, the 2-0 belt slicer may have a belt that transports cooked and
cooled meat
from step 408 of process 400. The 2-D belt slicer may also have a first
spindle that
performs a compression and advancement of the cooked and cooled meat. The 2-D
belt slicer may have a second spindle that advances the meat and may cut the
meat.
Finally, the meat may be advanced toward a third .spindle of the machine that
has
elements configured to pull and tear the meat. The pulled meat may be
collected and
packaged after being advanced beyond the third spindle.
CA 2994010 2018-02-02
=
[00141] In one form, the process 400 was performed using the modified 2-D
belt
slicer described above to produce a pulled pork product. The pulled pork
product had
the following ranges of meat piece sizes by approximate percentage of the
total weight
of the product:
Piece Size Percent of Product
Large 58-68
Medium 21-31
Small 5-15
[00142] The small-sized pieces fit through a vibratory screen having 1/4
inch
openings, the medium-sized pieces fit through a vibratory screen having 1/2
inch
openings but were retained by a screen having % inch openings, and the large-
sized
pieces were retained by a screen having 1/2 inch openings. Further, the muscle
meat of
the pulled pork product retained a fibrous appearance similar to pulled pork
produced in
the home.
[00143] It will be appreciated by those skilled in the art that other
modifications to
the foregoing preferred embodiments may be made in various aspects. The
present
invention is set forth with particularity in any appended claims. It is deemed
that the
spirit and scope of that invention encompasses such modifications and
alterations to the
preferred embodiments as would be apparent to one of ordinary skill in the art
and
familiar with the teachings of the present application.
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