ITAV20130002A1 - PROCESSING METHOD FOR THE PRODUCTION OF SALAMI AND BAGS AND RELATIVE SALAMI AND PICKED UP - Google Patents

Description

DESCRIPTION

State of the art

The decree 21.09.2005 of the Ministry of Productive Activities (Discipline of the production and sale of certain delicatessen products) in Chapter III - Salami (arts. 16-21) defines by "salami" "the delicatessen product, consisting of meat obtained from striated muscles belonging to the pig carcass with the addition of salt and possibly meat of other animal species, minced and mixed with pork fat in variable proportions and stuffed into natural or artificial casings ". The state of the art salami production technique has been known and consolidated for decades if not centuries.

The macro phases of the traditional production process can be summarized as follows:

1. Preparation of the meats. It consists of two main moments: husking and cooling / drying. With the husking, the meat is subjected to an initial selection phase, eliminating tendons, aponeuroses and parts of soft fat. Subsequently, the hulled meat, placed in low containers and with the bottom made of a metal mesh, is left to dry for a few days (usually 2 to 4 days) in a cold room at 0 ° C / + 2 ° C.

2. Mincing of meat. The dried meat is minced in meat mincing machines on which specific molds and knives are mounted depending on the type of result desired (for example, coarser grind for the "Felino" salami, with 6-8 mm holes; finer grind for the "Milano" salami, with 3-4 mm holes). In the grinding phase, the grease is added which also acts as a lubricant and reduces friction and processing temperatures. You can proceed by adding regular-shaped pieces of fat prepared by a dicing machine (so-called "lardelli") or grind the fat together with the lean meat. The minced meat is sent to the tanning phase.

3. Preparation of the components for tanning. The different components of the tanning are selected and appropriately combined and weighed: salt, pepper, other spices, flavorings and additives. These components are added in grains (such as pepper) or ground in turn.

4. Mixing. The components for the tanning are mixed in the mixture until they are distributed homogeneously and uniformly in the mass obtained and left for a few hours (usually from 3 to 7 hours) in the fridge at 2 ° C to allow the salt to extract the soluble proteins and to the nitrite to start its function. The dough can be enriched with bacteria useful for catalyzing the acidification process.

5. Selection and preparation of the casing. It is possible to use natural casing (obtained from the intestine of pig or bovine or from the bladder) or artificial casing depending on the caliber to be obtained (dimensions and uniformity) and the desired degree of permeability (higher for natural casing).

6. Bagging. Bagging machines, operating under vacuum, proceed with the bagging by reducing the pressure of the dough.

7. Binding. The binding allows to preserve the desired shape for the product avoiding the natural downward drift due to gravity.

8. Drying. The product, tied and still fresh, is crammed for a few hours (usually from 12 to 24 hours) in special "stove" chambers at different temperatures (usually from 16 ° C to 22 ° C) and humidity (usually from 65% to 80%) in order to dry it, dehydrate it and start bacterial fermentation. The combination of time, temperature and humidity varies according to the type of product to be obtained.

9. Seasoning. The curing phase can also vary greatly in relation to the type of product to be obtained (size, type of casing). The main parameters are the duration (usually from 45 days up to 120 days), the seasoning temperature (from 12 ° C up to 20 ° C) and humidity. In this phase, due to a series of metabolic processes, also due to the sugars added to the dough (glucose-lactose), the salt concentration increases and the typical consistency and aroma of the finished product develop. Compared to the "traditional" technical matrix just described, there is the presence of "alternative" techniques which have the sole objective of reducing the cholesterol level of salamis and sausages. The common matrix of these techniques is the replacement of animal fat with other fats deriving from monounsaturated vegetable oils, with particular reference to olive oil.

Problems of existing processing methods

With reference to "traditional" techniques, the main problem is that they allow to obtain as the ultimate result a meat product, at different degrees of seasoning, with

a high fat content (from 30% to 35%), which can be easily found on a visual examination of the section of the product once it has been sliced. Furthermore, deepening the nutritional analysis, the animal fat used is characterized by a predominant content of saturated fatty acids. The international medical-scientific literature has broadly and unanimously correlated the high consumption of saturated fatty acids with the development of severe cardiovascular diseases and, more generally, with negative nutritional impact. A correct diet must systematically contain the consumption of saturated fatty acids and cholesterol.

The "alternative" techniques focused on procedures for replacing vegetable fats with animal fat are characterized by at least two problems.

The first is of a nutritional nature in that while reducing, even if not significantly, the cholesterol content does not reduce that of fats. For example, resorting to the use of olive oil (the most important monounsaturated vegetable oil), an intake of 56% to 86% of monounsaturated fatty acids is obtained but:

a) a high percentage (which can range from 4% to 21%) of polyunsaturated fatty acids is maintained;

b) a high percentage (which can range from 8% to 25%) of saturated fatty acids is maintained.

The second problem of these techniques is of a physical / technical nature and refers to one or more of the following cases:

a) the presence of oil percolation processes from the product;

b) the presence of processes of transudation of the oil from the casing;

c) the presence of mold inhibition processes on the casing with negative effects on the curing phase of the product;

d) the presence of detachment processes of the casing from the dough both in the curing phase and in the subsequent slicing phase of the finished product;

e) the presence of disintegration processes of the seasoned product.

Purpose of the invention and resolution of existing technical problems

Unlike the existing processing methods, the innovative processing method object of this description is aimed at the almost total reduction of fat, with the

containment of the presence of saturated fatty acids to values close to 0% (ZERO PER CENT), as reported in Table 1.

Table 1 - Nutritional profile of the product resulting from the new production method

The processing method is also aimed at obtaining a product with a low level of cholesterol, best in class compared to all the main salamis on the market, as shown in Table 2.

Table 2 - Average cholesterol contents of the main types of salami on the market and comparison with the salami deriving from the new production method

The processing method therefore allows to obtain a product that can be defined as 'dietetic' ex. Legislative Decree 11 of January 27, 1992 (which implements the EEC directive 89/398) as its nutritional content has been modified to make it suitable for particular dietary regimes:

a) food for celiacs as it is gluten-free;

b) food for slimming regimes as it has a reduced energy and low calorie value and therefore can be used for the specific nutritional goal of weight control;

c) food for hypolipidic diets as it is low in fats of any type and therefore suitable for diets against hypertriglyceridemia;

d) food for diets designed to combat hypercholesterolemia as it is low in cholesterol.

Finally, the qualitative characteristics highlight significant differences compared to traditional salami also from a sensorial point of view. From this point of view, the present invention has the purpose of making products characterized by greater softness and chewability. The product generated by the present invention also represents not only a valid substitute for traditional salami and sausages but also for another category of products (bresaola, turkey breast, nutritional bars) due to the best, exclusive and innovative nutritional profile (reported in the previous Table 1) with very low fat and high protein intake.

All the dependent claims describe preferred embodiments of the invention, forming an integral part of the present description.

Description of an embodiment of the invention

The innovative processing method for producing low-fat, low-cholesterol dietary salamis and sausages and related salamis and sausages is applicable to differentiated embodiments. In the description below, reference is made to the embodiment of a 300 gram product as final weight for consumption, after weight loss due to seasoning. The processing method according to the present invention comprises the following steps:

I. preparation;

II. slaughter;

III. cooling and pH control;

IV. husking, denervation and degreasing;

V. seasoning under refrigerated conditions;

YOU. grinding and kneading under refrigerated conditions;

VII. bagging under refrigerated conditions;

Vili. drying with double thermal shock;

IX. seasoning;

X. washing;

XI. quality check;

XII. enveloping.

Heavy pigs (with a minimum weight of 180 kg up to a maximum of 220 kg) of national origin are used for the production of salami and sausages with low fat and cholesterol content and related salami and sausages.

I. Preparation

Before slaughtering, the pigs are left to rest for about 24 hours without causing them any stress. Subsequently, they are subjected to a temperature-controlled washing with water at about 30 ° C which has the effect of relaxing the pigs and speeding up the complete bleeding which allows the meat to be completely whitened and subsequently to give it a very delicate flavor.

II. Slaughter

The slaughter takes place in compliance with the EC Regulation n.1099 of 2009 relating to the protection of animals during killing, which came into force on January 1, 2013. The regulation establishes minimum rules on the Community territory to spare the animals avoidable pain, anxiety or suffering. through:

- physical comfort;

protection from injuries;

consideration of normal behavior;

- absence of signs of avoidable pain or fears

protection from prolonged absence of food and water;

protection from avoidable interactions.

The slaughter takes place in slaughter rooms at a controlled temperature (10-12 ° C), according to the following procedure:

1. stunning of the pig by means of electric pliers;

2. suspension by means of a hook in the part of the rear tendon and lifting by means of a pulley in the upside down position of the live pig;

3. bleeding from live pig (about 5 kg of blood).

The process takes about 7/8 minutes.

Subsequently, the pig is moved for about 4 minutes in tanks with hot water at a temperature of 90 ° C and then on continuous rollers for peeling. The pig, which is still whole, is then lifted upside down again and eviscerated. At this point it is deprived of the head and divided into two equal parts (half carcasses) by means of an electric cleaver.

III. Cooling and pH control

After slaughtering, for about 48 hours, the pork sides are left to rest in a cooling room with a rapid blast chilling tunnel of 6-8 ° C. After 7/8 hours the pH is checked, which must not exceed the limit of 5, 5/6, 5. After 48 hours, the pig is deboned and the pH is checked again to ensure that it does not exceed the maximum limit established. of 5, 5/6, 5.

IV. Hulling, denervation and degreasing

During the deboning of the pig, the husking is carried out, which is the operation of preparing the meat that will subsequently be minced. By means of special knives all the noble parts are separated: ham, loin, coppa and shoulder. At this point the most delicate phase of the whole processing method of the product begins, which will affect its organoleptic aspect (visual, tactile and gustatory) or the denervation and degreasing. Denervation and degreasing are carried out through a very accurate and meticulous procedure which is divided into two phases:

1. separation in bands, with longitudinal cut, of the single parts (ham, loin, coppa and shoulder): each band is denervated and degreased manually through a careful sieving aimed at eliminating all the fatty parts;

2. the parts subjected to the first manual sieving are further separated into bands, this time making a transversal cut. In this way we proceed with the denervation and degreasing of the parts of the fabric not examined in the first phase.

At the end of this process, which lasts about 40 minutes, the pork parts to be ground are completely free of fat. In order to keep this phase under control, a calculation was made of the percentage of fat less that the pig has at the end of the manual denervation and degreasing process; this is equal to -11.1% corresponding to a weight loss compared to the moment of husking equal to about 5.19 kg per half-carcass, as reported in Table 3.

Table 3 - INPUT-OUTPUT weight control phase of husking, denervation and degreasing Percentage of nerves and nerves and

Noble parts of the weight at the moment Net weight of the fat extracted isso extracted from

hulled pig parts manually in each part

Ham 20 Kg 12% 2,4 Kg 17,6 Kg Cup 4 Kg 8% 0,32 Kg 3,68 Kg Shoulder 9 Kg 15% 1,35 Kg 7,65 Kg Loin 14 Kg 8% 1,12 Kg 12, 88 Kg Total 47 kg 5.19 Kg 41.81 Kg

V. Seasoning under refrigerated conditions

The seasoning process takes place in refrigerated tanks (temperature 2 ° C) of 4 quintals. The meat is seasoned with:

fine mine salt (rock salt) 1%;

- spices 40 gr. per quintal: bay leaf (10gr./q.), nutmeg (10gr./q.), thyme (10gr./q.), fennel (10gr./q.).

After the seasoning, the meat is left to macerate and flavor in the refrigerated tank for 48 hours. This phase has the function of allowing the tissues of the meat to soften, preserving the particular and characteristic level of softness and chewability until the moment of consumption of the finished product.

YOU. Grinding and kneading under refrigerated conditions

The grinding takes place through a refrigerating machine (temperature 3/4 ° C.) with a meat grinder and denervation function with a 10 mm hole. The mincing with a refrigerated machine has the function of avoiding the heating of the meat due to the internal friction generated by the movement of the meat and the absence of fat. This phase allows to eliminate the residual part of nerves still present in the flesh by a further percentage equal to 1%. At the end of this phase, the meat shows an absolute absence of nerves. After grinding, the product is mixed with a refrigerated mixer at a temperature of 2 ° C. During the dough the meat is further seasoned with:

- fine mine salt (rock salt) 1%;

sucrose 50 gr./q .;

- dextrose 50 gr./q .;

antioxidant: E300 30 gr./q .; E301 30gr./q .;

- preservative: E250 15 gr./q .; E251 15gr./q.

The kneading process takes 10 minutes.

VII. Bagging under refrigerated conditions

After the mixture, the meat is stuffed into 490 g pieces. approximately. Bagging also takes place in refrigerated conditions at a temperature of 2 ° C. A particular black NATURIN recomposed gut is used, called CONET, caliber 50/6 knots. After bagging, the product is hung in the refrigerator for 12 hours at a temperature of 0 ° C to rest.

Vili. Double thermal shock drying

The drying of the product is the longest phase of the whole process and is a critical phase as it affects both the taste and the softness and chewability of the finished product. It is divided into 7 sub-phases, to be carried out in the exact sequence shown below and with controlled temperatures and durations.

I <3> Sub-phase: COOLING at a temperature of 2 ° C for 6 hours;

2 <a> Sub-phase: HEATING at a temperature of 23/26 ° C for 8 hours;

3 <a> Sub-phase: HEATING at a temperature of 25/28 ° C for 8 hours;

4 <a> Sub-phase: COOLING at a temperature of 5/8 ° C for 9 hours (1st THERMAL SHOCK); 5 <a> Sub-phase: DRYING at a temperature of 19/22 ° C for 24 hours;

6 <a> Sub-phase: DRYING at a temperature of 18/21 ° C for 24 hours;

7 <a> Sub-phase: COOLING at a temperature of 5/8 ° C for 9 hours (2nd THERMAL SHOCK).

IX. Seasoning

At the end of the drying phase, the product is left to mature hanging for 30 days at a temperature of 11/15 ° C.

X. Washing

At the end of the seasoning, the product is washed with water at a temperature of 35 ° C. Washing has the function of cleaning the product of any traces of external mold. Each single piece is carefully washed and dried, leaving no trace of humidity on the product or on the twine that could deteriorate the product.

XI. Quality check

After the washing phase, the products are organized in batches and subjected to quality control by a team of experts with special equipment. Quality control operates on five primary factors:

- visual inspection: compliance with the standard shape and color is checked;

- tactile control: the maintenance of the desired degree of softness is verified;

- olfactory / gustatory control: the aroma, flavor and chewability are verified by sample tasting;

- acidity control: the pH level is measured and must be in the range between 4.8 and 5.2;

- weight control: the product must have registered a controlled weight loss of about 37%. From the original weight (about 490 grams / piece) the final weight must be about 300 grams / piece.

XII. Bagging

The products that comply with the quality control standards pass to bagging which takes place through a vacuum machine with an envelope subject to heat-shrinking.

The following shows the results of the tests and laboratory analyzes performed on the product resulting from the new processing method in order to scientifically find all its specificities. All tests were entrusted to a research and analysis center of excellence (BonassisaLab Srl, based in Foggia). The following wording appears on the product packaging: "Chemical analysis carried out at the Bonassisa Lab Research Center (Foggia)". The tests and analyzes carried out are as follows:

• Microbiological analysis

• Nutritional analysis

• Measurement of the pH value

• Analysis of structural properties (Texture Analysis)

• Analysis of sensory properties

Microbiological analysis

The microbiological analysis aimed to ascertain the absence of pathogens and to microbiologically characterize the product by evaluating the bacterial microflora. The following Table 4 reports the results of the microbiological analyzes.

Table 4 - Microbiological analysis results

Nutritional analysis

The composition of the food is calculated for 100 grams of food net of waste (non-edible parts). The edible part of food has taken into consideration the salami with the exception of the casing. The humidity of the sample was determined by weight method and expressed in g / 100g. Total protein was calculated as total nitrogen (N) multiplied by factor 6.25. Total fat substances were determined by weight method and indicate the sum of trigiicerides, phospholipids, sterols and related compounds. Expressed in grams per 100 grams of food. The acidic composition determined by gas chromatography and expressed both as a relative percentage of the individual fatty acids and as the sum of saturated, monounsaturated and then unsaturated fatty acids. Cholesterol determined by gas chromatography and expressed in milligrams per 100 grams of product. Carbohydrates are determined by calculation as the difference to 100 of ashes, proteins, fats, humidity and with the deduction of the fibrous fraction. Single or mixed carbohydrates indicate the composition of soluble carbohydrates such as monosaccharides (Glucose, fructose) and disaccharides such as (sucrose and lactose). Dietary fiber represents the sum of cellulose hemicellulose pectin gum and lignin and was determined by gravimetric enzymatic method. The methods of analysis used for the above determinations are all official analysis methods or internal procedures validated and / or accredited by ACCREDIA. The energy values are calculated in accordance with the Directive 2008/100 / ec of the European Commission of 28 October 2008.

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Table 5 - Nutritional analysis results

Claims (1)

CLAIMS I. Processing method for the production of low-fat and low-cholesterol dietary salami and sausages characterized by the following sequence of phases: to. Preparation; b. cooling and pH control; c. husking, denervation and degreasing; d. seasoning under refrigerated conditions; And. grinding and kneading under refrigerated conditions; f. bagging under refrigerated conditions; g. drying with double thermal shock. II. Processing method according to claim I, wherein the preparation of the pigs comprises the following sub-steps: to. the pig rests for no less than 24 hours b. washing at a controlled temperature of not less than 30 degrees centigrade III. Processing method according to claim I, wherein the cooling and pH control comprises the following sub-steps: to. maintaining the slaughtered meat at a constant temperature for no less than 48 hours b. check the pH level at intervals of up to eight hours IV. Processing method according to claim III, wherein said constant temperature must not be lower than 6 degrees centigrade and higher than 8 degrees centigrade V. Processing method according to claim III, wherein said pH level must not be lower than 5.5 and higher than 6.5 YOU. Processing method according to claim I, wherein husking, denervating and degreasing comprise the following sub-steps to. separation of the noble parts b. separation into bands through longitudinal cut c. further separation into bands through transversal cut VII. Processing method according to claim I, in which the meat is seasoned in refrigerated tanks for a period of not less than 48 hours 26 Vili. Processing method according to claim I, wherein the grinding takes place through a refrigerating machine at a controlled temperature comprised between 3 and 4 degrees centigrade IX. Processing method according to claim I, wherein the dough is made at a controlled temperature not exceeding 2 degrees centigrade X. Processing method according to claim I, wherein the stuffing takes place at a controlled temperature which must not exceed 2 degrees centigrade XI. Processing method according to claim I, in which the bagged product is hung in a controlled temperature environment which must not exceed ZERO degrees centigrade XII. Processing method according to claim I, wherein the drying process comprises the following sub-steps: - COOLING at a temperature of 2 ° C for 6 hours -HEATING at a temperature of 23/26 ° C for 8 hours -HEATING at a temperature of 25/28 ° C for 8 hours - COOLING at a temperature of 5/8 ° C for 9 hours (1st THERMAL SHOCK) - DRYING at a temperature of 19/22 ° C for 24 hours - DRYING at a temperature of 18/21 ° C for 24 hours - COOLING temperature of 5/8 ° C for 9 hours (2nd THERMAL SHOCK) XIII. Processing method according to claim XII, characterized in that it causes two thermal shocks to the final product XIV. Low-fat, low-cholesterol dietary salami or sausage, characterized by the fact that it includes: d. total fat less than 1.5% And. saturated fats less than 0.5% f. total cholesterol below 79mg / 100gr g. caloric intake lower than 191 Kcal / 100gr h. protein intake is less than 41%