CA3042059A1 - Methods and systems for producing a meat product - Google Patents

Abstract

A method for producing a meat jerky includes cooking a sauced, shredded cooked meat product, determining a moisture level associated with the sauced, shredded cooked meat product, and determining the sauced, shredded cooked meat product is a meat jerky product based on the water level.

Description

METHODS AND SYSTEMS FOR PRODUCING A MEAT PRODUCT
FIELD OF THE DISCLOSURE
[0001] The present disclosure relates to a meat product, such as a jerky product (e.g., a meat jerky product), a method of preparing the meat product, and a packaged meat product.
BACKGROUND

[0002] Jerky products (e.g., meat jerky) are usually made from whole stripes (e.g., slices) of meat or meat which is ground and then formed into a shape, such as a stick. A
slice or a formed shape is used in order to produce a jerky product that can be hand held. To produce the jerky product, slices of raw meat are often cured in a marinade. Raw meat absorbs flavor (of the marinade) better than cooked meat. After the slices are cured, the cured slices are dried in a smokehouse, such as a smoker.

[0003] Jerky products are typically safe to be stored at room temperature, or "on the shelf', which is often referred to as "shelf stable". To be shelf stable, a perishable food needs to be treated by heat and/or dried to destroy foodbome microorganisms that can cause illness or spoil food. If a perishable food is not properly stored (e.g., refrigerated), the perished food may grow organisms and spoil. An example of a perishable food is a pulled-meat. Pulled-meat is the result of a method of cooking a meat at a low temperature such that, instead of being sliced, the meat can be "pulled" or otherwise broken apart ¨ e.g., pulled into tender bites.
The resulting meat requires storage, such as refrigeration, and cannot be safely stored at room temperature (i.e. it is not shelf-stable).
SUMMARY

[0004] The present disclosure describes a method and system to produce a meat product, such as a jerky product, and a packaged meat product. The meat product may be produced from raw meat or cooked meat. In some implementations, the jerky product is made by drying shredded, precooked meat. To illustrate, as an illustrative, non-limiting example, the jerky product may be made by precooking meat (e.g., by steaming), shredding the precooked meat, mixing the shredded meat with marinade (e.g., a sauce), and then drying the mixture (of the shredded meat and the marinade) on one or more screens in a smokehouse to make shelf-stable jerky. In some such implementations, the mixture (of the shredded meat and the marinate) is spread on a screen to form a layer (e.g., a sheet), dried in a smokehouse, and then the dried sheet is cut to pieces.
The result is a meat product (e.g., the jerky) that tastes like pulled-pork, but does not require refrigeration.

[0005] Thus, the system(s), the method(s), and packaged meat product(s) described herein produce and/or include a produced meat product, such as a jerky that is shelf-stable. The meat product (e.g., a pulled-meat jerky product) advantageously has an appearance of irregular shredded pieces of meat. Additionally, or alternatively, the meat product (e.g., the jerky) may be free from extraneous material, may have visible spice distributed on the surface, or both. In some implementations, the meat product may also have a tender texture with occasional moist texture. The meat product (e.g., the jerky) may have a savory, smoky flavor, other flavor based on one or more spices and/or sauces used to prepare the produced meat product.
In a particular implementation, the meat product (e.g., the jerky) advantageously tastes like pulled-pork, but does not require refrigeration.

[0006] Some embodiments of the present methods include a method for producing a meat product, the method comprising: cooking a sauced, shredded cooked meat product; determining a moisture level associated with the sauced, shredded cooked meat product; and determining the sauced, shredded cooked meat product is a meat jerky product based on the water activity.

[0007] Some embodiments of the present methods include a method for producing a meat jerky product, the method comprising: cooking a first meat product to produce a second meat product; shredding the second meat product to produce a third meat product;
adding sauce to the third meat product to produce a fourth meat product; cooking the fourth meat product; measuring water activity of the fourth meat product; and determining the fourth meat product is a meat jerky product based on the water activity being within a target range. In some implementations, the first meat product comprises raw meat, the second meat product comprises a cooked meat product, the third meat product comprises a shredded cooked meat product, and/or the fourth meat product comprises a sauced, shredded cooked meat product. In a particular embodiment, the fourth meat product is cooked on the surface in a smokehouse.
Additionally, the method may include placing the fourth meat product on a surface. In some such embodiments, the surface comprises a surface of a screen.

[0008] Some embodiments of the present methods include a method for producing a meat jerky includes cooking a sauced, shredded cooked meat product, determining a moisture level associated with the sauced, shredded cooked meat product, and determining the sauced, shredded cooked meat product is a meat jerky product based on the moisture level.

[0009] Some embodiments of the present methods include a method for preparing a jerky product include precooking meat (e.g., by any suitable method such as steaming, in an oven, in a smokehouse, boiling, sous vide cooking, etc.), shredding the meat, mixing the shredded meat with a sauce or marinade, and then further cooking and drying the mixture on screens in a smokehouse to make shelf-stable pulled-meat product. In some such embodiments, the meat is precooked and shredded before drying. In a particular embodiment, the result is a meat product that tastes like pulled-pork, but does not require refrigeration.

[0010] Some embodiments of the present methods include a method for producing sauced pulled-meat jerky include cooking a meat product to produce a cooked meat product, shredding the cooked meat product to produce a shredded meat product, adding sauce to the shredded meat product to produce a sauced pulled-meat product, placing the sauced pulled-meat product on a screen, cooking the sauced pulled-meat product on the screen in a smokehouse, measuring water activity of the sauced pulled-meat product and removing the sauced pulled-meat product from the smokehouse once the water activity is within a target range.

[0011] One aspect of the present disclosure provides a method for producing sauced pulled-meat jerky comprising cooking a meat product to produce a cooked meat product, shredding the cooked meat product to produce a shredded meat product, adding sauce to the shredded meat product to produce a sauced pulled-meat product, placing the sauced pulled-meat product on a screen, cooking the sauced pulled-meat product on the screen in a smokehouse, measuring water activity of the sauced pulled-meat product and removing the sauced pulled-meat product from the smokehouse once the water activity is within a target range.

[0012] In some embodiments, the method comprises adding sauce to achieve a meat to sauce ratio of the sauced pulled-meat product in a range of 55:45 to 75:25 (11:9 to 3:1).

[0013] In some embodiments, the method comprises cooking the sauced pulled-meat product at a temperature of approximately 200 F.

[0014] In some embodiments, the target range is 0.76-0.82.

[0015] In some embodiments, the method comprises cooking the sauced pulled-meat product at a relative humidity of at least 30%.

[0016] Further aspects and details of example embodiments are set forth below.

[0017] As used herein, the term "meat" generally refers to animal flesh, such as beef, pork, lamb, chicken, turkey ostrich, fish, shellfish, another animal, or a combination of flesh from different animals. Additionally, as used herein, the term "meat product", such as a meat jerky product, may also be referred to as a jerky product, a shelf stable pulled-meat product, a sauced pulled-meat jerky, a pulled-meat jerky product, a pulled-meat product, or a pulled-meat. Meat and/or meat product may also refer to meat at different stage of process.
Accordingly, meat product may also refer to raw and/or uncooked meat, pre-processed meat, cooked meat, shredded (uncooked or cooked) meat, sauced (uncooked or cooked) meat, dried meat, smoked meat, etc.

[0018] As used herein, a "shelf-stable" food (sometimes referred to as ambient food) is a food of a type that can be safely stored at room temperature, such as stored at room temperature in a sealed container. This includes foods that would normally be stored refrigerated but which have been processed so that they can be safely stored at room or ambient temperature for a usefully long shelf life.

[0019] As used herein, water activity (aw) of a food is the ratio between the vapor pressure of the food itself, when in an undisturbed balance with the surrounding air mea, and the vapor pressure of distilled water under identical condition. To illustrate, a water activity of 0.80 means the vapor pressure is 80 percent of that of pure water, the water activity increases with temperature. The moisture condition of a product can be measured as the equilibrium relative humidity (ERH) expressed in percentage or as the water activity expressed as a decimal. The amount of available moisture can be reduced to a point which will inhibit the growth of organisms, such as bacteria, yeast, and mold. The water activity, ERH, and/or moisture content of a meat product may be subject to one or more international and/or national legal requirements, such as a standard defined by a regulatory body, such as the British Retail Consortium (BRC), International Featured Standards (IFS), the Global Food Safety Initiative (GFSI), the Food and Drug Administration (FDA), and the United States Department of Agriculture (USDA), as illustrative, non-limiting examples. As an illustrative, non-limiting example, if the water activity of food is controlled to 0.85 or less in a product, the product may not be subject to one or more international or national regulations, As an illustrative, non-limiting example, if the water activity of food is controlled to 0.85 or less in a product, the product may not be subject to 21 CRF Parts 108, 113, and 114.

[0020] Moisture content of a food material (e.g., a sample) is a ratio of a mass of water in the sample to a mass of the sample. Moisture content can be determined using one or more technologies/techniques, such as thermogravimetric analysis (e.g., oven drying, halogen/infrared (IR) drying, etc.), chemical analysis (Karl Fischer titration, calcium carbide testing), calorimetric analysis (e.g., differential scanning calorimetry (DSC), differential thermal analysis (DTA)), spectroscopic analysis (IR spectroscopy, microwave spectroscopy, proton nuclear magnetic resonance spectroscopy), or another technology/technique (e.g., gas chromatography, density determination, refractometry, etc.).

[0021] As used herein, various terminology is for the purpose of describing particular implementations only and is not intended to be limiting of implementations.
For example, as used herein, an ordinal term (e.g., "first," "second," "third," etc.) used to modify an element, such as a structure, a component, an operation, etc., does not by itself indicate any priority or order of the element with respect to another element, but rather merely distinguishes the element from another element having a same name (but for use of the ordinal term). The term "coupled"
is defined as connected, although not necessarily directly, and not necessarily mechanically; two items that are "coupled" may be unitary with each other. The terms "a" and "an" are defined as one or more unless this disclosure explicitly requires otherwise. The term "substantially" is defined as largely but not necessarily wholly what is specified (and includes what is specified;
e.g., substantially 90 degrees includes 90 degrees and substantially parallel includes parallel), as understood by a person of ordinary skill in the art. In any disclosed implementation, the term "substantially" may be substituted with "within [a percentage] of' what is specified, where the percentage includes .1, 1, or 5 percent; and the term "approximately" may be substituted with "within 10 percent of' what is specified. The phrase "and/or" means and or. To illustrate, A, B, and/or C includes: A alone, B alone, C alone, a combination of A and B, a combination of A and C, a combination of B and C, or a combination of A, B, and C. In other words, "and/or" operates as an inclusive or.

[0022] The terms "comprise" (and any form of comprise, such as "comprises"
and "comprising"), "have" (and any form of have, such as "has" and "having"), and "include"
(and any form of include, such as "includes" and "including"). As a result, an apparatus that "comprises," "has," or "includes" one or more elements possesses those one or more elements, but is not limited to possessing only those one or more elements. Likewise, a method that , "comprises," "has," or "includes" one or more steps possesses those one or more steps, but is not limited to possessing only those one or more steps.

[0023] Any implementation of any of the systems, methods, and article of manufacture can consist of or consist essentially of ¨ rather than comprise/have/include ¨ any of the described steps, elements, and/or features. Thus, in any of the claims, the term "consisting of' or "consisting essentially of' can be substituted for any of the open-ended linking verbs recited above, in order to change the scope of a given claim from what it would otherwise be using the open-ended linking verb. Additionally, the term "wherein" may be used interchangeably with "where."

[0024] Further, a device or system that is configured in a certain way is configured in at least that way, but it can also be configured in other ways than those specifically described. The feature or features of one implementation may be applied to other implementations, even though not described or illustrated, unless expressly prohibited by this disclosure or the nature of the implementations.

[0025] Some details associated with the implementations are described above, and others are described below. Other implementations, advantages, and features of the present disclosure will become apparent after review of the entire application, including the following sections: Brief Description of the Drawings, Detailed Description, and the Claims.
BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The following drawings illustrate by way of example and not limitation. For the sake of brevity and clarity, every feature of a given structure is not always labeled in every figure in which that structure appears. Identical reference numbers do not necessarily indicate an identical structure. Rather, the same reference number may be used to indicate a similar feature or a feature with similar functionality, as may non-identical reference numbers.
The figures are drawn to scale (unless otherwise noted), meaning the sizes of the depicted elements are accurate relative to each other for at least the implementation depicted in the figures. Views identified as schematics are not drawn to scale.

[0027] FIG. 1 is a flowchart illustrating an example of a method for producing sauced pulled-meat.

[0028] FIG. 2 is a flowchart illustrating another example of a method for producing sauced pulled-meat.

[0029] FIG. 3 is a photograph of an example product made by a method according to the present disclosure.

[0030] FIG. 4 is a flowchart illustrating an example of a method for producing a meat product.
DETAILED DESCRIPTION

[0031] Referring to FIG. 4, an example of a method of producing a meat product is shown.
Method 400 may be performed by a manufacturing device or a system. The meat product may include or correspond to a jerky product, such as a shelf-stable jerky product or a shelf-stable pulled-meat jerky product.

[0032] Method 400 includes cooking a first meat product to produce a second meat product, at 410. The first meat product may include or correspond to a raw meet product, such as an uncooked meat product. For example, the first meat product may include a cushion, such as a pork cushion. The second meat produce may include or correspond to a cooked meat product.
The first meat product may be cooked in an oven (e.g., a convection and forced draft oven, a vacuum oven, a microwave oven, an infrared lamp drying oven), a smoker (e.g., a smokehouse, a wood smoker, an electric smoker), sous-vide, in a crockpot, in a Dutch oven, a low temperature cook device, cooked via steaming, cooked via boiling, cooked via curing, or any combination thereof. In some implementations, the first meat product may be cooked according to a schedule of one or more time periods (e.g., one or more stages). Each of the one or more time periods (e.g., stages) may be associated with one or more cook parameter settings, such as duration, dry bulb temperature, wet bulb temperature, relative humidity, smoke (on or off), exhaust (on or off), steam (on or off), one or more additional parameter settings, or any combination thereof. In some implementation, at least two time periods have the same one or more cook parameter settings. In other implementations, no two time periods have the same one or more cook parameter settings.

[0033] In some implementations, the first meat product may be cooked at a temperature, or an average temperature, of 200 F, substantially 200 F, or approximately 200 F.
Additionally, or alternatively, the first meat product may be cooked at a humidity, or an average humidity, greater than or equal to 75 %, greater than or equal to substantially 75 %, or greater than or equal to approximately 75 %.

[0034] In some implementations, the fourth meat product (e.g., the sauced, shredded cooked meat product) may include 55-75 wt. % third meat product (e.g., the shredded meat product) and 25-45% sauce, where each weight-percent range is inclusive or exclusive.
Additionally, or alternatively, the fourth meat product (e.g., the sauced, shredded cooked meat product) may include a third meat product to sauce ratio within a range of 11:9 to 3:1, inclusive or exclusive.
In other implementations, an amount of sauce included in the fourth meat product may be determined based on the first meat product (e.g., the raw meet product) or the second meat product (e.g., the cooked meat product). For example, an amount of sauce mixed with the third meat product (e.g., the shredded meat product) to produce the fourth meat product (e.g., the rd sauced, shredded cooked meat product) may be 1/3 ¨ 9/11th, inclusive or exclusive, the weight of the first meat product or the second meat product that is processed to produce the third meat product.

[0035] In some implementations, the method 400 includes, prior to mixing the third meat product with a sauce, cooking the sauce until a temperature of the sauce is at least a threshold temperature for at least a particular amount of time ¨ e.g., 165 F for 5 minutes. Additionally, or alternatively, method 400 may include determining an amount of sauce to mix with the third meat product based on the first meat product, the second meat product, or the third meat product.
It is noted that each of the second meat product (e.g., the cooked meat product), the third meat product (e.g., the shredded meat product), and/or the sauce may be ready for consumption, but may be not shelf-stable and/or may need refrigeration.
Accordingly, in some such implementations, the fourth meat product (e.g., the sauced, shredded cooked meat product) is also ready for consumption, but may be not shelf-stable and/or may need refrigeration.

[0036]
Method 400 further includes cooking the fourth meat product, at 416. To illustrate, the fourth meat product may be cooked in an oven (e.g., a convection and forced draft oven, a vacuum oven, a microwave oven, an infrared lamp drying oven), a smoker (e.g., a smokehouse, a wood smoker, an electric smoker), a heating station, a dryer, a dehydrator, a temperature and/or humidity controlled chamber, a microwave, or any combination thereof, as illustrative, non-limiting examples.

[0037] In some implementations, the fourth meat product may be cooked according to a schedule (e.g., a first schedule) of one or more time periods (e.g., one or more stages). Each of the one or more time periods (e.g., stages) may be associated with one or more cook parameter settings, such as duration, dry bulb temperature, wet bulb temperature, relative humidity, smoke (on or off), exhaust (on or off), steam (on or off), one or more additional parameter settings, or any combination thereof. For example, the fourth meat product may be cooked at a temperature (or an average temperature) that is greater than or equal to 175 F, less than or equal to 200 F, within a range of 175 F ¨ 200 F (inclusive or exclusive). As another example, the fourth meat product may be cooked at a temperature (or an average temperature) that is greater than or equal to substantially or approximately 175 F, less than or equal to substantially or approximately 200 F, within a range of substantially or approximately 175 F ¨ 200 F
(inclusive or exclusive).
Additionally, or alternatively, the fourth meat product may be cooked for a time period of at least three hours, less than or equal to three hours, or greater than or equal to three hours. In some implementations, the relative humidity during cooking (t 416) is at least 30 %. Additionally, or alternatively, the relative humidity during cooking (at 416) may range between 0 ¨ 50 %; 1 % ¨
50%, 20 % - 50 %, or 30 % - 50 %.

[0038] Method 400 includes determining to stop cooking the fourth meat product, at 418. A
determination to stop cooking the fourth meat product is an indication that the fourth meat product is shelf-stable and does not need refrigeration. A determination to stop cooking the fourth meat product may be made based on a moisture level the fourth meat product. For example, the method 400 may include determining a moisture level, such as water activity and/or moisture content, of the fourth meat product. The moisture level, such as the water activity and/or the moisture content, may be compared to one or more thresholds to make the determination to stop cooking the fourth meat product. For example, the determination to stop cooking the fourth meat product may be made based on the water activity of the fourth meat product being less than or equal to 0.82, greater than or equal to 0.76, or within a range of 0.76 ¨
0.82 (inclusive or exclusive). As another example, the determination to stop cooking the fourth meat product may be made based on the water activity of the fourth meat product being less than or equal to 0.82, greater than or equal to 0.78, or within a range of 0.78 ¨
0.82 (inclusive or exclusive).

[0039] Additionally, or alternatively, the determination to stop cooking the fourth meat product may be made based on the moisture content of the fourth meat product being less than or equal to 26 %, greater than or equal to 20 %, or within a range of 20 % ¨ 26 %
(inclusive or exclusive). In some implementations, the determination to stop cooking the fourth meat product may be made based on the moisture content of the fourth meat product being less than or equal to substantially or approximately 26 %, greater than or equal to substantially or approximately 20 %, or within a range of substantially or approximately 20 % ¨ 26 %
(inclusive or exclusive).

[0040] In some implementations, a moisture level (e.g., water activity and/or moisture content) may be check (e.g., determine) one or more times. For example, the moisture level may be determined at one or more times based on a schedule (e.g., a second schedule) and/or periodically ¨ e.g., periodically after completion of the first schedule. For example, the fourth meat product may be cooked for a particular time period, such as thirty minutes, three hours, etc., and then the moisture level is determined. If a determination is not made to stop cooking the fourth meat product, cooking for the particular time period (or another time period) and checking the moisture level is repeated until a determination made (based on the moisture level of the fourth meat product) to stop cooking the fourth meat product. For example, the other time period may be thirty minutes.

[0041] Method 400 includes stopping cooking of the fourth meat product to result in a fifth meat product, at 420. For example, in response to the determination to stop cooking the fourth meat product, at 418, the method 400 may include removing the fourth meat product from a cooking device/environment and/or not returning the fourth meat product (i.e., the fifth meat product) to a cooking device/environment. The fifth meat product may include or correspond to a jerky meat product.

[0042] Method 400 may include, optionally, processing the fifth meat product, at 422.
Processing the fifth meat product may include removing the fifth meat product from the surface (e.g., the screen), cutting the fifth meat product, shredding the fifth meat product, examining (e.g., x-raying or subjecting to inspection using a metal detector) the fifth meat product ¨ e.g., to detect potential metal contaminants, such as from equipment used prior to or during 410-422, performing quality control measures on at least a sample of the fifth meat product, or any combination thereof, as illustrative, non-limiting examples.

[0043] The method 400 may also include packaging the fifth meat product to produce a packaged meat product, at 424. For example, for example, a packaging device or packaging system may receive the fifth meat product and package the fifth meat product into one or more packages.

[0044] In some implementations, the method 400 may include, optionally, preparing the first meat product (e.g., the raw meat). Preparing the first meat product may be performed prior to cooking the first meat product, at 410. Preparing the first meat product may include injecting the first meat product with a base solution, such as a brine. The base solution may be configured to assist in meat break-down during cooking of the first meat product (at 410).
Additionally, or alternatively, preparing the first meat product may include tumbling the first meat product, applying a rub (e.g., a dry rub) to the first meat product, or both. Tumbling may enable and/or allow the base solution to move freely throughout and/or migrate within the first meat product.
In a particular implementation, the rub and the first meat product are tumbled together to apply the rub to the first meat product.

[0045] In some implementations, after mixing the third meat product with the sauce, at 414, the fourth meat product may be placed on a surface and/or left to rest for a time period. In some implementations, the surface may be configured to support (e.g., hold) the fourth meat product and to enable air flow and/or drying on at least a portion of a top surface of the fourth meat product placed on the surface, at least a portion of a bottom surface of the fourth meat product placed on the surface, or both. Additionally, or alternatively, the fourth meat may be placed on the surface and/or left to rest for the time period, prior to cooking the fourth meat product at 416.
In some implementations, the surface may be the surface of a tray, a screen, a rack, a grill, netting, or any combination thereof, as illustrative, non-limiting examples.
As an illustrative, non-limiting example, the surface includes a screen having dimensions 33-34 inch by 29-30 inch.
In some implementations, the fourth meat product may be placed (on the surface) in a layer or as a sheet that is about 0.5 inches thick. In a particular implementation, surface (e.g., the screen) is configured such that multiple portions of the fourth meat product are positioned on the surface.
The fourth meat product may be cooked while positioned on the surface.

[0046]
Although method 400 has been described as including one or more operations and/or steps (e.g., 410-420), it is noted that one or more operations and/or steps described with reference to FIG. 4 may be optional. For example, in some implementations, prior to cooking the fourth meat product (at 416), the method 400 may not include 410-414 and, alternatively, may include receiving the fourth meat product.

[0047] Thus, method 400 describes producing a meat product (e.g., the fifth meat product).
The produced meat product (e.g., the fifth meat product) may include a jerky and may be shelf-stable. Method 400 advantageously enables production of the meat product (e.g., a pulled-meat jerky product) having an appearance of irregular shredded pieces of meat.
Additionally, or alternatively, the produced meat product may be free from extraneous material, may have visible spice distributed on the surface, or both. The produced meat product may also have a tender texture with occasional moist texture. The produced meat product may have a savory, smoky flavor, other flavor based on one or more spices and/or one or more sauces used to prepare the meat product (e.g., the fifth meat product). In a particular implementation, the produced meat product advantageously tastes like pulled-pork, but does not require refrigeration.

[0048] Referring to FIG. 1, FIG. 1 shows an example method 100 of preparing a pulled-meat jerky product from uncooked meat according to an embodiment. At step 102, uncooked meat is cooked, for example in an oven, other low temperature method such as smoking or sous-vide. At step 104, the cooked meat is shredded to create pulled-meat. At step 106, a sauce is added to the pulled-meat. The sauce comprises a mixture of water, sugar, salt and other flavoring ingredients, with the relative proportions selected as desired for a particular recipe. For example, in some embodiments, the sauce may be comprised of about 55% water, 15% brown sugar, 7% salt, 5%
tomato paste and 18% spices and other ingredients. In some embodiments, sauce is added to produce a sauced pulled-meat product at step 106 comprising between approximately 55-75%
meat and 25-45% sauce, by weight (or a meat to sauce ratio in a range about 11:9 to 3:1).

[0049] At step 108, the sauced pulled-meat is put on a screen. At step 110, the screen with the pulled-meat is put in an oven or smokehouse. At step 112, the pulled-meat is cooked in the oven and the water activity (moisture level) is measured periodically. At step 114, the pulled-meat is removed from the oven once the moisture level or water activity is within a desired target range.

[0050] In some embodiments, the water activity of the pulled-meat product at step 114 is 0.76 ¨ 0.82. In some embodiments, the moisture content of the pulled-meat product at step 114 may be approximately 20-26%.

[0051] FIG. 2 shows an example method 200 of preparing a pulled-meat product according to an embodiment. At step 210, uncooked meat (the cushion) is injected with a base solution (for example, a brine) which assists in meat break-down when cooking. At step 212, the meat is tumbled and a rub is added. Tumbling, allows the base solution to move more freely throughout the meat. At step 214, the meat is cooked by placing it in a smokehouse (or other low temperature cooking method). In some embodiments, the temperature of the smokehouse may be approximately 200 F and have a humidity greater than 75%. At step 216 the meat is shredded (for example, by hand or machine) and cooled. At step 220, the sauce is added to the cooled meat and mixed (for example, by tumbling the sauce and meat together) to make a mixture, such as a uniform mixture or a non-uniform mixture. After step 220, the meat and sauce mixture is ready to eat, but is not shelf-stable and requires refrigeration.

[0052] At step 222, pulled-meat is placed on a screen, for example a 33-34 inch by 29-30 inch screen, and the pulled-meat is placed in a layer that is about 0.5 inches thick. The screen holds the pulled-meat but allows for air flow and drying on both sides. At step 224, the pulled-meat on the screen is placed in a smokehouse and cooked at approximately 175 ¨ 200 F
for a pre-defined period of time, for example, three hours. In some embodiments, the relative humidity during cooking at step 224 is at least 30%. At step 226 the water activity of the pulled-meat is measured. At step 228 if the water activity is within a target range, for example, 0.78 ¨ 0.82, then one continues with step 230. Once the water activity is within the target range then the pulled-meat is shelf-stable (does not require refrigeration). If the water activity is not within the target range then one returns to step 224, and cooks the meat in the smokehouse for a predetermined time, which may be a shorter time than three hours (e.g. about thirty minutes in some embodiments), and continue on to step 226, and so on, until the water activity is within the target range.

[0053] At step 230, the pulled-meat is removed from the smokehouse. At step 232, the pulled-meat is removed from the screen. At step 234, the pulled-meat is examined for contaminants - for example, with a metal detector to detect any metal contaminants from the equipment used. At step 236, the pulled-meat is packaged.

[0054] It is noted that one or more operations described with reference to one of the methods of FIGS. 1, 2, and 4 may be combined with one or more operations of another of FIGS. 1, 2, and 4. For example, one or more operations of method 100 may be combined with one or more operations of method 400 and/or one or more operations of the method 200.
Additionally, one or more of the operations described with reference to the systems of FIGS. 1 and/or 2 may be combined with one or more operations described with reference to the methods of FIG. 4.

[0055] The pulled-meat jerky product resulting from methods described with reference to one or more of FIGS. 1, 2, and 4 may have the appearance of irregular shredded pieces of meat, free from extraneous material, and may have visible spice distributed on the surface. FIG. 3 is a photograph of an example product made by a method, such as the method 100, the method 200, and/or the method 400, according to the present disclosure.

[0056] The pulled-meat jerky product resulting from methods described with reference to one or more of FIGS. 1, 2, and 4 may have a tender texture with occasional moist texture.

[0057] The pulled-meat jerky product resulting from methods described with reference to one or more of FIGS. 1, 2, and 4 may have a savory, smoky flavor, other flavors will depend on the spice and sauce that is used.

[0058] It will be appreciated that numerous specific details are set forth in order to provide a thorough understanding of the exemplary embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein may be practiced without these specific details. In other instances, well-known methods, procedures and components have not been described in detail so as not to obscure the embodiments described herein. Furthermore, this description is not to be considered as limiting the scope of the embodiments described herein in any way, but rather as merely describing implementation of the various example embodiments described herein.

[0059] The above specification and examples provide a complete description of the structure and use of illustrative implementations. Although certain implementations have been described above with a certain degree of particularity, or with reference to one or more individual implementations, those skilled in the art could make numerous alterations to the disclosed implementations without departing from the scope of this disclosure. As such, the various illustrative implementations of the methods and systems are not intended to be limited to the particular forms disclosed. Rather, they include all modifications and alternatives falling within the scope of the claims, and implementations other than the one shown may include some or all of the features of the depicted implementations. For example, elements may be omitted or combined as a unitary structure, connections may be substituted, or both.
Further, where appropriate, aspects of any of the examples described above may be combined with aspects of any of the other examples described to form further examples having comparable or different properties and/or functions, and addressing the same or different problems.
Similarly, it will be understood that the benefits and advantages described above may relate to one implementation or may relate to several implementations. Accordingly, no single implementation described herein should be construed as limiting and implementations of the disclosure may be suitably combined without departing from the teachings of the disclosure.

[0060] The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) "means for" or "step for," respectively.

Claims (15)

1. A method for producing sauced pulled-meat jerky, the method comprising:
cooking a meat product to produce a cooked meat product;
shredding the cooked meat product to produce a shredded meat product;
adding sauce to the shredded meat product to produce a sauced pulled-meat product;
placing the sauced pulled-meat product on a screen;
cooking the sauced pulled-meat product on the screen in a smokehouse;
measuring water activity of the sauced pulled-meat product;
removing the sauced pulled-meat product from the smokehouse once the water activity is within a target range.

2. The method of claim 1, further comprising adding sauce to achieve a meat to sauce ratio of the sauced pulled-meat product in a range of 55:45 to 75:25 (11:9 to 3:1).

3. The method of claim 1 or claim 2, further comprising cooking the sauced pulled-meat product at a temperature of approximately 200 F.

4. The method of any one of claims 1 to 3, wherein the target range is 0.76-0.82.

5. The method of any one of claims 1 to 4, further comprising cooking the sauced pulled-meat product at a relative humidity of at least 30%.

6. A method for producing a meat jerky product, the method comprising:
cooking a first meat product to produce a second meat product;
shredding the second meat product to produce a third meat product;
adding sauce to the third meat product to produce a fourth meat product;
cooking the fourth meat product;
measuring water activity of the fourth meat product; and determining the fourth meat product is a meat jerky product based on the water activity being within a target range.

7. The method of claim 6, wherein the first meat product comprises raw meat.

8. The method of claim 6 or claim 7, wherein the first meat product comprises a pork cushion.

9. The method of any one of claims 6 to 8, wherein the second meat product comprises a cooked meat product.

10. The method of any one of claims 6 to 9, wherein the third meat product comprises a shredded cooked meat product.

11. The method of any one of claims 6 to 10, wherein the fourth meat product comprises a sauced, shredded cooked meat product.

12. The method of any one of claims 6 to 11, wherein the fourth meat product is cooked on the surface in a smokehouse.

13. The method of any one of claims 6 to 12, further comprising placing the fourth meat product on a surface.

14. The method of claim 13, wherein the surface comprises a surface of a screen.

15. A method for producing a meat product, the method comprising:
cooking a sauced, shredded cooked meat product;
determining a moisture level associated with the sauced, shredded cooked meat product;
and determining the sauced, shredded cooked meat product is a meat jerky product based on the water level.