Red meat manufacture

An interactive PowerPoint presentation

for A-level students

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 Menu
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Information

1. Primary processing - Mince Questions

2. Secondary processing - Sausages Questions

3. Secondary processing - Beef burgers Questions

Extension Questions End

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 Background information - primary processing

Red meat is edible raw, yet it is normally

processed and cooked prior to consumption.
Primary processing is the first step which
involves preparing raw ingredients.

The first stage is to drain the blood from the

carcase.

Red meat can be stored at above its

freezing point (–1.5 °C) between two -
three weeks without spoilage.

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 Background information - primary processing

When an animal is killed, the circulation of blood ceases, but within the
muscles glucose continues to be broken down (in the production of ATP
(Adenosine triphosphate) under anaerobic glycolysis. This is due to a lack
of oxygen and results in the production of lactic acid. Lactic acid reduces
the pH of the muscle and inhibits the growth of microorganisms, thereby
slowing food spoilage and increasing the shelf-life of the meat.

The chemical reactions within the muscles gradually slow down. As a

result actin and myosin combine and the muscle contracts, but is no longer
able to relax leading to rigor mortis, the point at which the muscles become
firm and inextensible.

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 Background information - primary processing

Red meat must also be hung or ‘aged’ to allow the muscle fibres to relax,
otherwise it will not be tender. Proteolytic enzymes (these breakdown the
protein chains into smaller peptides and amino acids) help to tenderise the
meat while it is aged.

As the carcases are hygienically prepared, the following storage life can be
expected:
•Beef and veal up to 21 days
•Lamb up to 15 days
•Pigs up to 14 days
•Offal up to 7 days

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 What does primary processing include?
Once hung, the carcase is divided into fore and hindquarters. A butcher will
begin to trim the carcase into joints and cuts in line with modern demand from
consumers.

Every carcase consists of consumable and non-consumable parts, e.g. bone,

lean meat, fat and waste. Approximately 35% of any carcase can be butchered
and sold. Some primary processes undertaken by the butchers include:
• boning
• slicing
• mincing.

A variety of by-products can be produced from the remaining carcase,

e.g. pet food manufacture, edible fats, gelatine and collagen production
and sheep and cow hide processing.

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 Beef – examples of cuts produced by a butcher

Stir-fry strips
Rib-eye Steaks
Topside Steaks
Chuck Steak
Forerib
Fillet Steaks
Shank
Topside Joint

Shank

Diced Chuck
Rump Steaks
Shin Rings Rolled Brisket Sirloin Steaks Silverside Joint

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 Lamb – examples of cuts produced by a butcher
Valentine Steaks

Racks
Loin Chops Boneless Leg Steaks

Diced

Boneless Rump
Cutlets Noisettes

Neck Fillets Shank

Rump Steak
Kebabs
Half Leg
Shoulder steak
Rolled Shoulder Stir-fry Strips
Mince

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 Pork – examples of cuts produced by a butcher
Rack Roast Valentine steaks

Rolled Shoulder Joint Rolled Shoulder Joint

Rump steaks
T-Bone Chops
Rib chops Tender Loin
Osso Busso

Belly strips

Leg steaks
Spare ribs
Hock Boneless Leg

Diced Stir-fry Strips

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 Mince
Mince is 100% meat (typically containing 10-25%
fat) with no added water, additives, fillers or any
other ingredients.

Different grades of mince can be produced by the

butcher. Standard mince contains on average 20%
fat. Any mince identified as lean will contain no
more than 10%.

Organic minced meat is available for a premium

price. The animals used for this type of mince will
have been reared according to organic standards.
Mince provides consumers with a versatile
ingredient base for many dishes, e.g. koftas,
meatballs or curries.

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 Mincing
The process of mincing involves:
•trimming the meat to be minced
•placing the raw pieces of meat into the hopper of a
mincing machine
•the feeding ‘worm’ rotates, drawing the meat along
a cylindrical barrel
•star shaped blades rotate within the worm forcing
the meat through holes in perforated plates or
grinding disks
•heat may be applied or removed, depending on the
product
•the mince is extruded through the perforated plate
into a meat tray. Click to view the Digi Bite

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 Mincing
When mincing frozen meat or meat with a lot of connective tissue, plates with larger
perforations are used to produce a coarse mince. The mixture is then drawn through
plates with smaller perforations for a finer texture.

A variety of plates can be used on one machine – the size of the final perforations will
determine the final size of the piece of minced meat.
Hopper Heating elements (optional)
Blade

Drive
unit
and
gear
box
Feeding worm Plate

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 The colour of red meat
When meat is cut it loses water from the cut
surface and becomes darker in colour. The
protein myoglobin is purple in colour because
it contains iron and haem. When meat is cut
and exposed to air, the myoglobin is converted
to oxymyoglobin, which is bright red.

Consumers associate the red colour in meat

with freshness. It is important for food
manufacturers to maintain a red colour within
the meat which means keeping myoglobin in
the oxymyoglobin form to meet consumer
expectations. If the supply of oxygen is
inadequate, the pigment is oxidised to
metmyoglobin, which is brown.

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 The colour of red meat
Globin
H20 Fe3+
protein
Haem
Metmyglobin Red
u ctio
(Brownish red) n
Oxi Myoglobin
dati
Oxymyglobin - oxygen
on
(purple red)
(bright red)
+ oxygen Globin
02 Fe 2+ Globin H20 Fe2+
protein protein
Haem Haem
When meat is packaged it gradually uses up the
+ heat
oxygen present and at low levels of oxygen the
pigment turns brown through oxidation. Using high
Denatured globin
Haemochrome
oxygen packs enables the high levels of oxygen to
(brown to grey) be maintained longer in meat, keeping the red
appearance for longer.
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 Question 1
Why is red meat hung or aged?

1. To allow proteolysis to tenderise the meat.

2. To allow the micro-organisms to grow.

3. To allow the meat fibres to contract.

4. To prevent a build up of lactic acid.

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 Question 2
True or false? The enzymes within the meat continue to metabolise glucose
anaerobically producing lactic acid, which in turn slows down the growth of
microorganisms.

1. True

2. False

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 Question 3
Which protein provides the preferred meat colour
associated with freshness by consumers?

1. Metmyoglobin

2. Myoglobin

3. Oxymyoglobin

4. Haemochrome

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 Question 3
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 Question 4
Which of the following is not an example of primary
processing?

1. Sterilisation

2. Mincing

3. Slicing

4. Boning

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 Background information – secondary processing

Secondary processing is the conversion of meat cuts from primary processing

to food products. This could include a large number of products, such as:
• sausages
• cold meats
• cured meats
• pies and pasties
• burgers
• pâtés
• ready or frozen meals.

Throughout the manufacture of each food product, safety and hygiene remain
vitally important.

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 Hazard and Critical Control Points
HACCP (Hazard Analysis and Critical Control Point) is
a pro-active system, where all potential hazards to food
product safety at each stage of the production chain are
identified.

A Critical Control Point (CCP) is a point, step or

procedure where control must be applied to prevent,
eliminate or reduce a food hazard to an acceptable level.
To assure food safety, each CCP is monitored to check
that it is within critical limits.

If limits are in danger of being broken, corrective action

must be taken. This systematic approach,
if properly implemented, should ensure the safe
production of food.

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 7 principles of a HACCP system
These principles include:
1. Conduct a hazard analysis and develop production flow charts.

2. Identify the CCP’s.

3. Establish critical limits i.e. set target levels which must be met
to ensure the CCP is under control.

4. Establish a system to monitor control of the CCP.

5. Establish corrective actions to be taken when monitoring

indicates that a CCP is not under control.

6. Establish procedures for verification to confirm that the

HACCP system is working correctly.

7. Establish documentation/records for all procedures.

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 Sausage manufacture

Sausage manufacture involves combining a

variety of ingredients, in the right proportions,
to produce the desired quality of sausage. Cost
is also a key consideration.

In the United Kingdom (UK) fresh sausages are

made from fresh meat which are neither cured,
smoked, fermented or cooked. Fresh sausages
must be kept under refrigeration prior to
cooking and consumption.

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 Raw material procurement and intake

Sausage manufacturers carefully identify ingredient providers (who are

audited ) and careful records are kept for each delivery. Ingredients are
thoroughly inspected before they are received and stored at the factory. This
ensures full traceability.

The basic ingredients to produce sausages include:

•pork
•rusk
•seasoning
•casings.

Some sausages will also include additional ingredients such as fruit or

vegetables and cheese.

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 Raw material storage and preparation
Temperature control is vital in order to limit the growth of micro-organisms. Correct storage, in terms
of temperature and location of the ingredients and separation of potential allergens, is a key Critical
Control Point (CCP).

Refrigeration Ambient temperature Allergens

Perishable ingredients Other non-perishable Certain ingredients
are stored in a ingredients and which can cause an
refrigerated room. packaging materials allergic reaction, such
The refrigerator are stored at ambient as gluten, are stored in
temperature is held temperature (20-25°C) a separate location
between 1-4°C. in a separate area. (refrigerated or in
ambient temperature) in
order to reduce the risk
Production environment
of contamination.
The factory working environment is set at 10°C in
order to reduce the growth of microorganisms in
the product during production.
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 Mincing the pork meat Before

The pork meat will be inspected and weighed.

An accurate amount of pork is placed inside a hopper of the
large mincer. A certain amount of pork fat is also added and is
essential to help improve the flavour and succulence of the
sausages.
After
Rotating blades will cut the meat into fine pieces. The size
reduction of the meat and fat takes place as the sharpened
blades rotate at about 100 revolutions per minute (rpm).

Blade Hopper

Rotating blades
Feeding worm
Drive box and gear unit
Plate
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 Additional ingredients
Once the pork has been minced, other ingredients are
added, such as rusk, seasoning and water.

Different varieties of rusk, such as fine or coarse, may be used

to change the texture of the sausage filling.

Rusk absorbs moisture from the meat and water. It is known to

have a high water absorbency capacity of about 3-4 times
its weight and helps to bind the mixture together.

The required amount of rusk, seasoning and water are

measured and added to the hopper.

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 Additional ingredients
The accurate addition of ingredients is a Critical
Control Point (CCP) in the sausage making process. It
is vital the correct amount of ingredients are added to
ensure a consistent product each cycle.

The sausage filling is mixed with the rotating blades

and then drawn along a feeding worm.
The feeding worm rotates and draws the filling along a
cylindrical barrel towards star shaped blades which
rotate. The worm presses the meat through holes in
perforated plates or grinding disks.

The sausage filling is returned to the cold store to

reduce the temperature of the mixture, which has risen
Click to view the Digi Bite
due to the mechanical action of the mincer.
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 Filling the sausages
It is important that sausages are identical in length, diameter and weight, to create a uniform product each
cycle. This ensures that the weight and nutrition content of the sausages matches the information
displayed on the packaging.

When the temperature of the sausage filling has reduced, it is either manually or automatically transferred
into the hopper of the vacuum filler or sausage filling machine.

This machine will determine how many grams of

mixture will be extruded into each sausage casing.
The set amount of filling for the recipe is
programmed into the machine.

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 Filling the sausages
The feeding worm attached to the hopper draws a specific
amount of the filling under vacuum conditions into the nozzle to
be extruded into casings.

The casings will automatically or manually be placed onto the

linking nozzle. A specific amount of sausage filling will be
extruded into a section of the casing.

The machine ensures Feeding

optimum portioning Hopper worm
accuracy, precise Linking nozzle
distribution of the filling
and produces compact, Chilled
firm sausages. sausage
filling
Filling table Computer controls
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 Filling the sausages

Linking nozzle
A length portioning device, attached at the end of the
nozzle, accurately portions a consistent weight of
sausage filling and therefore creates a consistent
length of sausage. 

The sausage mixture passes through the calibrating

horn of the length portioning device into the casing
and onto the filling table.

Length portioning device

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 Casings

Casings, known as sausage skins, play a significant role in the portioning of

sausage meat.

Casings also improve the shelf life by providing moisture and oxygen resistant
properties. They also contribute to minimising weight loss of the sausage
during cooking.

Casings can be reformed or natural. Natural casings are produced from the
small intestines of pigs or sheep, the intestines are flushed, scraped and
cleaned. Alternatively, reformed casings are manufactured with collagen.

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 Trimmed sausages

The connected sausages automatically or manually

fed into an automatic link cutting machine. This
machine snips and separates the sausages with
great accuracy and precision reducing damage to
the sausages.

The machine also mechanically stretches the casing

in order to eliminate any residual air and separates
the sausage from the chain.

If any air were to remain inside the sausage, it would

result in the sausage bursting during cooking.

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Inspection and Modified Atmosphere Packing (MAP)

The sausages are individually inspected by food

technicians before they are packed into plastic
trays. Irregular shaped or burst sausages will be
removed from the production line.

The filled trays are placed on a conveyor belt

to the packing machine for Modified
Atmosphere Packaging (MAP).

The main advantage MAP is the increase in the

shelf life of food products, such as sausages,
without the addition of chemical preservatives
which may alter the taste, colour, flavour or
consistency of the product.

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 Modified Atmosphere Packing
The 3 main gases used for MAP are nitrogen (N2), Oxygen (O2) and carbon
dioxide (CO2). The composition of the gas mixture is specific to the type of
products being packaged. It works by surrounding the food with gases that
prevent or reduce the growth of bacteria, yeasts and moulds that spoil food. The
shelf-life of food products is increased by days, or weeks.

The packaging of the sausages is done by a vacuum chamber machines which

evacuates the normal atmosphere out of the package and replaces it with a
corresponding gas mixture (modifying the atmosphere) before the packet is
covered with film and heat sealed.

Sealing time, pressure and temperature are all monitored and

controlled, ensuring high-quality sealed packages every time.

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 Materials used for packaging
A range of synthetic materials suitable for meat packaging can be chosen.
Packaging films have many requirements, some of these include:
•flexibility
•mechanical strength
•light weight
•odourless
•hygienic (clean and toxicologically harmless)
•easy to recycling
•resistance to hot and cold temperatures
•resistance to oil and fats
•good barrier properties against gases
•low-cost or economical.

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 Check weighed and cardboard sleeve label
Sausage packages are check weighed to ensure each
packet is within the estimated weight range. Sausage
packages which are either too light or heavy will be
removed from the production line and inspected by a
member of the Quality Assurance team.

The packages proceed via conveyor belt for the

addition of an overwrapping cardboard sleeve. An
automatic arm opens the cardboard sleeves and
the sausage packet in transit moves through the
sleeve and on towards the metal detector.

Ensuring the correct label is applied is a CCP in

the sausage making process, for example,
gluten-free sausages must not contain gluten.

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 Metal detection
The metal detection unit is sensitive to metallic objects and another CCP within
the sausage making process.

All sausage packages must be passed through the metal detectors at the end of
production, where no further possible contamination could take place.

Any packages failing the test must be removed from the production line and
undergo an approved re-checking procedure. All packs failing metal detection
must be broken down by the Quality Assurance department to determine the
reason for failure.

Search head
From To boxing &
packaging palletisation
Control Conveyor belt
unit
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 Packaging, palletisation and distribution

A final visual check is conducted before the

sausage are packed into boxes, these boxes
are closed and scanned to ensure traceability
before being palletised.

The finished products are stored in a cool room

prior to distribution.

A infra-red thermometer is used to monitor the

temperature of the final goods. This allows the
temperature to be checked without damaging
the food products.

Click to view the Digi Bite

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 Cold chain
A quality assurance system, referred to as the cold chain, is in place to
measure, control and document the temperature of the sausages
between their journey from manufacture, to storage and to the retailer.
This ensures the quality and integrity of the food product.

The cold chain ensures that the temperature of the sausages remains
within a safe range during the storage and distribution system to help
extend and ensure the shelf-life of food products.

Refrigerated and insulated transport vehicles are involved when moving

the food product from the cold store of the manufacturer to storage
and/or the retailer.
Sausage Retail
Supplier factory Warehouse outlet

Refrigerator transport Temperature check

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 Question 1
Why is temperature important during the
manufacture of sausages?

1. To maintain the consistency of the sausage

filling and size of the sausage.

2. To retard the growth of micro-organisms and

increase the shelf-life of the product.

3. To increase the growth of micro-organisms

and increase the shelf-life of the product.

4. To increase the consistency of the sausage

filling and size of the sausage.

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 Question 1
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 Question 1
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 Question 2
Identify which ingredient is plays an important role in binding water and
improving the texture of the sausage.

1. Meat

2. Fat

3. Rusk

4. Seasoning

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 Question 2
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 Question 3
Which of the following would not be considered a
Critical Control Point (CCP) in the manufacture of
sausages?
1. Addition of accurate amount of the
correct ingredients.

2. Detection of metal within the food

product.

3. The use of natural casings instead

of reformed casings.

4. The correct labels are applied to the

sausage packets.

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 Question 3
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 Question 4
The Cold chain is used to measure, control and record the temperature of
the chilled or frozen products during transportation from the manufacture,
to storage and to the retailer.

1. True.

2. False.

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 Burger production – ingredient intake

A transit document is checked when fresh or

frozen beef is delivered. Each delivery is
inspected to ensure it complies with certain
specifications.

Checks, including temperature checks, are carried out before the goods are
accepted. These checks are recorded and maintained to ensure quality and
traceability of the products. A database is used to record details of each delivery.

The First In First Out (FIFO) inventory method is used for stock rotation to
ensure ingredients are not wasted. This means the meat which is delivered first to
the factory, will be used first in burger production.

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 Burger production – ingredient intake

To ensure traceability, EU legislation

states that beef sourced from different
countries cannot be mixed. The factory
stores UK and Irish beef separately to
ensure the meats are not mixed.

Random checks are carried out by

trained meat inspectors. Particles such
as bone or gristle are removed and
reported. This aims to help improve the
quality of the ingredients used.

Click to view the Digi Bite

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 Burger blending
At the beginning of the burger making process, the chilled and frozen
meat are transferred from the stores to the manufacture floor and placed
into large hoppers. The process of batch formulation is computer
controlled to ensure a consistent amount of meat is added.

A combination of 70% chilled and 30% frozen meat

is used. The meat will increase in temperature due
to the mechanical action of the grinder.

The addition of frozen meat helps to maintain a low

temperature. The frozen meat also helps to ensure
the mixture is stiff enough to form burgers in the
forming machine without sticking to the machinery
and causing problems and delays.

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 Pre-blenders
Burger blending
The initial mincing takes place and the meat is Forequarter Flank
mincing mincing
mixed in the pre-blenders.

Two separate mincers are used for the forequarter

and flank meat.
Final
The final mincing mixes a combination of both the mincing
flank and forequarter meat to ensure a consistent
burger is produced. Samples are taken to be
analysed to ensure consistency.

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 Burger forming and checking

Once the mince mixture has been

tested and approved, minced beef
is transferred to the burger forming
machines. These machines use
pressures of 45-70kg (100-150
pounds) per square inch to press
the mixture into the mould plate.

Once filled, the meat inside the

mould plate is punched out onto a
conveyor belt to produce ‘patties’.

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 Burger forming and checking

Thicker burgers will pass through an additional knife scoring stage to assist
heat penetration during cooking.

All patties are spayed with a fine water mist to replace water content and to
minimise the effect of dehydration.

The main aim of the forming stage is to ensure that the products are of a
uniform shape, size and weight each production cycle.

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 Removal of water
The water activity of a food describes the amount of available water in a food. It is
calculated by:

Water activity = water vapour pressure above the food at a certain temperature
water vapour pressure above pure water at the same temperature

The water activity of a food must be reduced to 0.6 to prevent the growth of
microorganisms. A number of techniques are used during the manufacture of
food to reduce the water content of food to this level.

During burger production a freezer tunnel is used to:

1) dramatically reduce the temperature to inhibit growth of micro-organisms and
limit enzyme and chemical activity

2) form ice crystals within the patties, reducing water activity to prevent the growth
of micro-organisms.
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 Burger freezing

The patties then enter the freezing tunnel on a conveyor belt while liquid
nitrogen (boils at -196°C) is blown against the flow of burgers.

The flow of gas and speed of the conveyor belt is controlled to ensure the
patties emerging at the end of the freezing tunnel are fully frozen
(approximately -20°C). The burgers will remain frozen until cooked by
consumers.
Liquid nitrogen

Unfrozen Frozen

Conveyor belt Click to view the Digi Bite

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 Burger packing and storage

Each pattie then passes through a metal

detector which is sensitive to metal
fragments. If metal is detected the pattie will
automatically be removed and sent to a
separate area to prevent it continuing in the
supply chain.

Throughout production quality assurance

checks of the burger pattie dimensions and
temperature are made to confirm the patties
are within specification.

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 Burger quality
The frozen burgers are packed into cardboard cartons lined with polythene
liners. Although the cartons are automatically formed and lined, the frozen
burgers are manually packed by food technicians into each carton. Once filled,
every carton has a production code and ‘Best before’ date printed on it. The
production code ensures the pack can be traced back to the time and date of
production at the particular plant.

All cartons are check weighed, the flaps are automatically closed and the
cartons sealed.

Bar code scanners identify and record the boxes before stacking these onto a
pallet. The pallet is then stretch wrapped to secure the load to the pallet during
transportation. The pallets are then transferred to the cold store and held at or
below -18°C before dispatch. The burgers are dispatched on the FIFO system
and in strict rotation.
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 Quality assurance

The Quality Assurance team will pan-fry and

test burgers from the production line before
the batches are dispatched to retail outlets.
Ideally, consumers should cook the burgers
until internal temperatures of 80°C are
reached in order to destroy food poisoning
agents potentially present in the raw meat
mixes (such as Listeria, Salmonella or E.
coli).
Food safety and quality checks are carried
out throughout the burger making process to
meet EU standards and protect consumers.

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 Question 1
Why is the First In First Out (FIFO) process important?

1. To ensure efficient stock rotation and reduce food waste.

2. To improve the colour of the burgers being produced.

3. To improve the traceability of the ingredients used in production.

4. To process the frozen meat before it defrosts while in storage.

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 Question 1
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 Question 2
Which of the following is not a reason for frozen meat to be added to the
mincer?
1. The frozen meat is added to stiffen the mixture to
enable the minced meat to easily pass through the
machinery without sticking.

2. The frozen meat helps to reduce the heat which is

created by the action of the mincer.

3. The meat patties will be frozen, adding frozen meat aids this
process.

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 Question 2
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 Question 3
True or false? Freezing will inhibit the growth of microorganisms (and
limit enzyme and chemical activity) and the formation of ice crystals
which reduces water activity in the food and in turn the growth of micro-
organisms.

1. True.

2. False.

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 Question 3
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 Question 4
True or false? Tunnel freezing is where food items are placed onto a
conveyor belt and are drawn through a tunnel while liquid nitrogen (boils
at -196°C) is blown against the food.

1. True.

2. False.

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 Extension questions

Q1. Explain, using examples, the controls a food producer would use to
ensure consistency between batches.

Q2. Describe ways in which manufacturers can control the temperature of

materials they use when producing meat products.

Q3. Explain, with examples, the Hazard Analysis and Critical Control point
(HACCP) system.

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