WO1994022325A1

WO1994022325A1 - Process for making fabricated meat products

Info

Publication number: WO1994022325A1
Application number: PCT/US1994/003682
Authority: WO
Inventors: Jayadev R. Bisineeru; Edwin J. Nyhof; Keith F. Rex; Glenn M. Suter
Original assignee: Societe Des Produits Nestle S.A.
Priority date: 1993-04-06
Filing date: 1994-03-24
Publication date: 1994-10-13

Abstract

The present invention includes an improved process for making an improved dense fabricated meat product that includes providing a mixture having meat and meat byproducts (14) having a concentration of at least about 80 % by weight and at least one binder having an effective concentration of not more than about 4.5 % by weight, where pockets of air are entrapped within the mixture. The mixture is subjected to a vacuum (31) and while under the vacuum, the mixture is agitated to open the air pockets and to remove the entrapped air. The agitated mixture is then compacted (30) to make the dense fabricated meat product having the effective concentration of binder of not more than about 4.5 % by weight of the mixture and meat and meat byproduct concentration of at least about 80 % by weight. The present invention also includes the fabricated meat product.

Description

PROCESS FORMAKING FABRICATED MEATPRODUCTS

BACKGROUND OF THE INVENTION The present invention relates to an improved process for preparing a fabricated meat product and to an improved fabricated meat product.

The preparation of fabricated meat products includes preparing canned products having a meat component. By the term "canned product" is meant a sealed, packaged food that has been subjected to retorting with steam at a high temperature for preservation. The canned fabricated meat product may include a gravy component. Canned fabricated meat products include food products for pets such as dogs and cats. Preparation of fabricated meat products has required a consideration of factors such as the nutritional value of the meat and any meat byproducts, sterility of the meat and gravy components, and aesthetic considerations. The aesthetic considerations include whether the meat and meat byproducts look appetizing. The aesthetic considerations also include whether a gravy component can be made to look like gravy at a minimum cost. Additionally, aesthetic consideration has been given to preventing a formation of unsightly materials such as a layer of fat.

Making a uniform and aesthetically appealing meat and meat byproduct mixture has required achieving uniformity of bulk density of the meat and meat byproducts. Achieving uniformity of bulk density has been daunting, however, because the meat mixture includes a broad spectrum of meat and meat byproduct consistency. Some meats are fibrous strands. Some meat byproducts are gel-like chunks. The meat and meat byproduct mixture also includes a wide range of meat particle sizes.

Making a uniform and aesthetically appealing meat and meat byproduct mixture has also required achieving a uniformity of visual consistency. However, the broad spectrum of meat and meat byproduct particle size and consistency makes achieving visual consistency difficult, particularly in a large scale manufacturing process. This is because the broad spectrum of size and consistency contributes to the meat and meat byproduct mixture being very difficult to convey during processing. Conveying the meat and meat byproduct mixture results in a segregation of the meat particles in the mixture. The segregation occurs because larger, heavier meat particles will tend to fall out of the mixture or be conveyed more slowly than small, lightweight particles. As a consequence, achieving a uniformity of visual consistency of the final product is difficult to obtain without wasting mixture fractions that are unacceptably biased with either large or small meat particles.

One method for achieving uniformity in bulk density and in visual consistency of meat and meat byproducts in a canned meat product includes adding a binder to the meat mixture. The binder aids in holding the meat and meat byproducts together thereby improving the uniformity of mixture bulk density. Unfortunately, addition of the binder is very expensive.

One attempt to make an aesthetically appealing canned meat product is described in the Reesman patent, U.S. No. 3,843,815. The Reesman patent describes a method that includes manipulating a gravy component to make the gravy more aesthetically acceptable. The manipulation of the gravy has included dissolving a collagen component of muscle in meat to make gelatin. The gelatin is usable as a gravy binder. Unfortunately, the formation of gelatin from collagen in meat is not easy to control. Consequently, gravy consistency is unpredictable. In one undesirable outcome, the gravy may set up to a gel consistency that must be spooned out of a container rather than be poured out of the container. Another attempt to make a gravy of aesthetic consistency is described in Glicksman et al., U.S. No. 3,881,031. The Glicksman et al. patent describes an addition of a material such as a vegetable base binder. The vegetable base binder includes gums such as xanthan gum and alginate as well as binders that include wheat gluten, egg albumen, starches and cellulose ethers. While these additives do aid in the formation of a gravy that pours, the additives tend to be very expensive.

The Baker et al. patent, U.S. No. 4,791,002, describes a process for preparing a canned pet food. The process includes preparing a slurry by grinding a mixture having liver and other meat and meat byproducts. A binder of soybean flour and dry blood plasma is added to impart to the mixture a total fat content of at least 2% and a total meat content of at least 75% by weight.

The slurry is subjected to agitation and to cutting to produce an emulsion. The emulsion is formed into a sheet, is heated and is cut into pieces. The pieces are combined with a gravy and are placed in a container. The container is closed and retorted.

SUMMARY OF THE INVENTION The present invention includes an improved process for making an improved dense fabricated meat product that includes providing a mixture having meat and meat byproducts in a concentration of at least about 80% by weight of the mixture and having pockets of air entrapped within the mixture. The mixture also includes an effective concentration of a binder of a concentration not more than about 4.5% by weight of the mixture. The mixture is subjected to a vacuum and is agitated while under vacuum in order to open the air pockets and remove the entrapped air. The agitated mixture is compacted to make the improved dense fabricated meat product. The present invention also includes an improved dense fabricated meat product that includes meat and meat byproducts in a concentration of at least about 80% by weight of the product and an effective concentration of a binder of not more than about 4.5% by weight of the product.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a schematic view of one embodiment of the improved process of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention includes an improved process for making an improved dense fabricated meat product, illustrated in schematic at 10 in Figure 1. The process includes providing a mixture 14 having meat and meat byproducts in a concentration of at least about 80% by weight and at least one binder having an effective concentration of not more than about 4.5% of the mixture 14, where pockets of air are entrapped within the mixture. The mixture 14 is emulsified and is transferred to a holding tank 16 and to a vacuumizer tank 31. In the vacuumizer tank 31, the mixture 14 is subjected to a vacuum and while under the vacuum, the mixture is agitated to open the air pockets and to remove the entrapped air. The agitated, deaerated mixture 14 is then compacted to make the dense fabricated meat product having a meat concentration of at least about 80% by weight of the product and having the effective concentration of binder that is not more than about 4.5% by weight of the product. The present invention also includes an improved dense fabricated meat product having a meat concentration of at least about 80% by weight of the product and having an effective concentration of binder that is not more than about 4.5% by weight of the product.

The effective binder concentration of the fabricated meat product is reduced and the meat concentration is increased as compared to existing fabricated meat products because the meat and meat byproduct mixture 14 is subjected to a vacuum and is agitated, thereby removing air pockets entrapped within the mixture. Removing the air pockets and agitating the mixture decreases the distance between meat particles, improves the homogeneity of the mixture and increases the density and concentration of the meat and meat byproduct mixture. By decreasing the distance between meat particles and increasing the homogeneity, the need for a binder to hold meat particles together is substantially reduced.

The term "fabricated meat mixture" as used herein refers to a mixture having a meat content that is greater than 70% by weight and more preferably within a range of 80% to 85%. The term "meat" includes not only the flesh of cattle, swine, sheep and goats, but also other mammals, poultry and fish. The term "meat byproducts" is defined to include non-rendered parts of the carcasses of slaughtered animals, poultry and the like. Preferred meaty materials include beef and pork liver, beef, whole chicken, chicken parts, beef and pork lungs, beef and pork spleen, turkey and other meat and meat-byproducts. The overall composition of meat and meat byproducts affects the texture, integrity and flavor of a fabricated meat mixture. In one prior art meat and meat byproduct mixture, beef accounts for about 27% by weight of the meat mixture. Pork or beef liver makes up about 8% by weight of the prior art product. Mechanically deboned turkey and mechanically deboned chicken make up about 27% and 16%, respectively, of the prior art meat mixture.

The meat and meat byproduct mixture 14 of the present invention preferably includes about 80% to 95% meat and meat byproducts. In one embodiment of the meat mixture 14 of the present invention, the beef concentration ranges from about 13% to 30%. The concentration of either pork or beef liver ranges from about zero to less than 8%. The concentration of mechanically deboned turkey ranges from about 13% to 30%. The concentration of mechanically deboned chicken ranges from about 10% to 82%.

The meat and meat byproduct mixture 14 of the present invention includes chunks or cubes of meat of a symmetry that contributes to a formation of air pockets in the mixture when the mixture is mixed and emulsified. The chunks or cubes are formed when meat and suitable soft tissue are removed from an animal and are subsequently reduced in size. Size reduction preferably occurs by mechanically cutting the meat. Size reduction may also occur by grinding the meat. The binder included in the fabricated meat mixture 14 of the present invention aids in holding the meat and meat byproduct chunks or cubes together. The concentration of the binder ranges from about 1% to about 4.5% by dry weight.

In one preferred embodiment of the mixture 14, the binder is a wheat gluten binder present in a concentration of about 3.74 to 4.5% as total dry matter of the mixture. In other embodiments, the binder includes beef plasma, egg albumin, starch, cellulose ether, gelatin or soybean flour. The binder also includes mixtures of the materials of wheat gluten, soy protein concentrate, soy protein isolates, beef plasma, egg albumin, starch, cellulose ether, gelatin or soybean flour. The binder mixture concentration also ranges from about 1% to 4.5% by dry weight of the mixture.

In the prior art meat mixture, the wheat gluten binder is present in a concentration of about 11% to 14% by weight of the mixture. The reduction in concentration of binder in the present invention is an improvement over the prior art mixture because the wheat gluten binder is the most expensive component of the fabricated meat mixture. The reduction in binder usage results in a substantial savings in the manufacturing process. A similar savings is achievable for other types of binders as well.

In one other mixture embodiment, the meat and meat byproduct mixture includes a protein supplement. The protein supplement includes a soy protein concentrate. The soy protein concentrate includes a moisture concentration of not more than about 9% by weight of the protein supplement, a minimum protein concentration of about 69% by weight of the protein supplement, and a total dietary fiber of about 21% by weight of the protein supplement.

In another embodiment, the meat and meat byproduct mixture includes vitamins and minerals in a concentration of about 1.4% by weight of the mixture. The mixture may also include coloring agents in a concentration of about 0.5 to 2% by weight of the mixture and water in a concentration of about 4 to 7% by weight of the mixture. The improved process, illustrated in schematic at 10 in Figure 1, for making the improved fabricated meat product of the present invention, is adaptable to a meat and meat byproduct mixture 14 having a wide variety of consistencies ranging from fine emulsions, to small particulates to whole-muscle pieces. In one embodiment, the mixture 14 is processed at a rate of about 10,000 to 12,000 lbs./hr.

The mixture 14 is preferably processed at a temperature within a range of about 40 to 55 degrees F. A mixture that is too cold will have a consistency too stiff to effectively process. A mixture that is too warm will have a consistency that is too mushy to effectively process.

The process 10 includes a supply hopper 12 for holding the mixture 14 of meat, meat byproducts, the binder and other additives described. In one embodiment, the supply hopper 12 includes a mixer 13 for mixing the meat mixture 14. When held in the supply hopper 12, the mixture 14 has a moisture concentration of about 62% by weight.

The mixture 14 is transferred from the supply hopper 12 to an emulsifier 28. The emulsifier 28 further reduces the size of meat particles. The emulsifier 28 also substantially hydrates the binder. In one embodiment, the emulsifier 28 includes a plurality of movable carbon-tipped blades 11 that reduce the size of meat particles. Once emulsified, the mixture 14 is transferred to a holding tank 16 by a conventional method such as by a pressure feed. The holding tank 16 prevents undesirable surges of mixture 14 from being transferred to a vacuumizer tank 31. The rate of transfer of the mixture 14 from the emulsifier 28 to the holding tank 16 is regulated by a level controller 27, positioned in the holding tank 16.

The mixture 14 is transferred to the vacuumizer tank 31 from the holding tank 16 by a vacuum created by a vacuum pump 15 positioned in the vacuumizer tank 31. The amount of the mixture 14 transferred from the holding tank 16 to the vacuumizer tank 31 is regulated by a level controller 29, positioned in the vacuumizer tank 31. The vacuum pump 15 is positioned in communication with the vacuumizer tank 31. In one embodiment, the vacuum generated is within a range of about 20 to *25 inches of mercury. In one embodiment, the vacuumizer tank 31 is manufactured by PRC of Englewood, Colorado.

As the mixture 14 is drawn into the vacuumizer tank 31, the mixture 14 is subjected to actions of a diffuser plate 33 and to an auger 34 to agitate the mixture 14. By "agitate" is meant that the mixture is treated to be substantially deaerated and rendered substantially homogeneous with respect to meat particle size and type. In one preferred embodiment, the auger 34 is a vertical ribbon style auger. The diffuser plate 33 and auger 34 agitate the mixture 14 and open air pockets to remove trapped air. The diffuser plate 33 and auger 34 also work to maximize deaeration of the binder and to fully hydrate a gluten binder. Once the trapped air is removed from the mixture 14 and the binder is fully hydrated, the effectiveness of the binder increases because the meat particles to be bound are in closer spacial proximity. Also, hydrating the binder maximizes the capacity of the binder to bind the meat particles.

By removing the trapped air and increasing the effectiveness of the binder, the mixture 14 increases in bulk density by about 3 to 4 lbs per cubic foot. With an increased bulk density and an effective binder, the meat particles in the mixture 14 have a decreased tendency to segregate by size and density during transfer to a compactor 30.

Thus, by subjecting the mixture 14 under vacuum to the diffuser plate 33 and the auger 34, a denser and more uniform visual consistency for the mixture 14 is obtained. Achieving this dense consistency with the diffuser plate 33 and auger 34 results in a substantial reduction in a binder concentration requirement and an increase in meat concentration over the prior art fabricated meat product.

The compactor 30 includes a synchronous twin piston pump assembly 41 having a pair of compacting components 18 and 20 and a sliding plate 42 that seals the compacting components 18 and 20 when positioned on the compacting components. The mixture 14 is compacted by a synchronous motion of the compacting components 18 and 20. In one preferred embodiment, the twin piston pump assembly 41 is manufactured by PRC of Englewood, Colorado. The synchronous twin piston assembly 41 is powered by electricity.

The compacting component 18 includes a piston 22. The compacting component 20 includes a piston 25. The pistons 22 and 25 are synchronized by a conventional electronic control scheme. The control scheme is preferably a feedback control based upon a measurement of product discharge pressure. The piston 22 tightly fits within the compacting component 18. The piston 25 tightly fits within the compacting component 20. Each of the pistons 22 and 25 is positioned vertically within one of the chambers 18 and 20, respectively. The mixture 14 is compressed by the synchronous action of the two pistons 22 and 25.

The mixture 14 is compacted by the compacting components 18 and 20. The mixture 14 is then discharged through a discharge valve 36. In one embodiment, the sliding cover plate 42 is retracted. The mixture 14 is pushed into the compacting components 18 and 20 by the downward directed radial motion of the auger 34. When the compacting components 18 and 20 are filled with the mixture 14, the sliding plate cover 42 is moved into position over the compacting components 18 and 20, sealing the components. The pistons 22 and 25 are moved upward, compressing the mixture 14 and displacing the compressed mixture 14 out of the compacting components 18 and 20, through the discharge valve 36.

Achieving a dense mixture consistency prior to compaction in the compactor 30 minimizes product cutoffs as the mixture 14 is compacted within the twin piston pump assembly 30. Additionally, a need for flow restrictions such as feed screws and vanes to compact the mixture is eliminated.

In one preferred embodiment, the compacted meat and meat byproduct mixture 14 is formed into a sheet by a process such as rolling the compacted mixture once the mixture passes through the compactor 30. Next the mixture is heated in an oven and is sliced into cubes. In one embodiment, the cubes are combined with a gravy.

Preferably, each of the cube product and the cube and gravy product is transferred to a container. The container is then sealed and retorted.

The present invention also includes the improved fabricated meat and meat byproduct product. The product is improved because the product includes significantly more meat and a significantly reduced quantity of binder as compared to fabricated meat products presently available. Additionally, in one embodiment, the fabricated meat and meat byproduct product is substantially all meat because the product includes a meat binder of plasma.

In one embodiment having use as a pet food, the fabricated meat product includes the ingredients described in Table 1:

TABLE 1

Inσredient Name Percent

Beef 13-30

Pork/Beef Liver 8.00

Mechanically Deboned Turkey 13-30

Mechanically Deboned Chicken 10-82

Total, Preferred 82

Wheat Gluten 3.74-4.5

Soy Protein Concentrate 3.0-4.5

Vitamins & Minerals 1.36

Color 2.00

Water 7.16

One other embodiment having use as a pet food includes a dry beef plasma. The dry beef plasma has use as a protein supplement and as a binder. A formulation of the fabricated meat product having the dry beef plasma is described as follows in Table 2:

TABLE 2

Inσredient Name Percent

Beef 0-80

Beef Liver 0-8

Dry Beef Plasma 1.00

Vitamins & Minerals 1.36

Color 0.51

Water 4.00 In one preferred embodiment, the fabricated meat product having the dry beef plasma is described as follows in Table 3. The formulations described in Tables 2 and 3 are substantially all meat formulations.

TABLE 3

Inσredient Name Percent

Beef 57.00

Beef Liver 4.13

Beef Hearts 32.00

Total 93.13

Dry Beef Plasma 1.00

Vitamins & Minerals 1.36

Color 0.51

Water 4.00

Total 100.0

Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.

Claims

WHAT IS CLAIMED IS:

1. A process for making an improved dense fabricated meat product, comprising: providing a mixture of meat and meat byproducts having a concentration of at least about 80% by weight and an effective concentration of binder not more than about 4.5% by weight of the mixture wherein the mixture includes pockets of air trapped within the mixture; subjecting the mixture to a vacuum; agitating the mixture while subjecting to the vacuum in order to open the air pockets and to remove the trapped air; and compacting the agitated mixture to make the dense fabricated meat product having an effective concentration of binder of not more than about 4.5% by weight and a concentration of meat of not less than about 80% by weight.

2. The process of claim 1 wherein the agitation of the mixture occurs by contacting the mixture to a diffuser plate and an auger.

3. The process of claim 1 wherein the compacting of the dispersed mixture occurs with a piston assembly.

4. The process of claim 3 wherein the piston assembly is arranged vertically.

5. The process of claim 3 wherein the piston assembly includes a synchronous twin piston.

6. The process of claim 1 and further including forming the compacted mixture into a sheet.

7. The process of claim 6 and further including slicing the sheet into cubes.

8. The process of claim 7 and further including combining the cubes with a gravy.

9. The process of claim 7 and further including adding the cubes into a container.

10. The process of claim 9 and further including sealing the container.

11. The process of claim 10 and further including retorting the container.

12. The process of claim 1 wherein the reduced effective amount of binder ranges from about 1% to about 4.5% by weight.

13. The process of claim 1 wherein the binder is selected from the group comprising wheat gluten, beef plasma, egg albumin, starch, cellulose ether, gelatin and soybean flour.

14. The process of claim 1 wherein the mixture further comprises an added protein, vitamins, minerals, coloring agents and water.

15. A fabricated meat product made by the process of claim 1.

16. A fabricated meat product comprising meat and meat byproducts having a concentration of at least about 80% by weight of the mixture and a binder having a concentration of not more than about 4.5% by weight of the mixture.

17. A fabricated meat product comprising meat and meat byproducts having a concentration of at least about 94% by weight.