Meat processing system

(54) Title: METHOD AND APPARATUS TO PREPARE PROCESSED MEAT PRODUCTS (30) Unionist Priority: 20/08/2003 us 10/644624 (71) Depositor (s): Kraft Foods Holdings, INC (US) (72) Inventor ( es): Jennrfer L. Tomey, Donald Edward Lucke, Paul Gerard Morin, Michele L. Reeve, Daniel Brent Wilke (74) Attorney: Momsen, Leonardos & Cia (57) Abstract: METHOD AND APPARATUS FOR PREPARING PROCESSED MEAT PRODUCTS. A system to prepare processed cam products using an anticipated feed analysis in which the input flows are analyzed and their flow rates are reciprocally controlled. The system incorporates mixing devices in a housing through which input flows are forced. The mixing devices provide high shear mixing and homogenization, and in some cases maceration and salt infusion for rapid protein extraction.

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ize “METHOD AND APPARATUS FOR PREPARING PROCESSED MEAT PRODUCTS”

Field of the Invention

The invention relates to a meat processing system in which input flows are flow controlled and homogenized to produce a combined outflow.

Fundamentals of the Invention

In commercial systems for the preparation of certain processed meat products such as bologna and sausages, loaves or pieces of raw meat and other ingredients such as condiments are ground, chopped and / or otherwise combined with one or more salts or salts to offer a mixture that can subsequently be converted into a stable emulsion or cam matrix. Similar steps of grinding, chopping and / or other preparation are also used in the manufacture of sausages, processed ham, processed turkey, and other processed meat products. In both cases, the proteins retain or interconnect the combined pieces.

The creation of protein bonds in this context requires a commonly known method of protein extraction. In this method, thermo-coagulable, salt-soluble proteins such as myosin, actomyosin and actin bind with water, swell and become sticky as a result of making or mixing the cam in the presence of a salt or saline solution. The proteins are subsequently cured when heated to create a bond. Other myofibrillar proteins, as well as sarcoplasmic or water-soluble proteins, can also play a role in binding. Salts that can be used in protein extraction include, but are not limited to, sodium chloride, sodium pyrophosphate or diphosphate, potassium chloride, sodium lactate, and potassium lactate. In protein extraction as described here, the mechanism that is believed to be basically

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responsible for creating the bonds involves binding proteins and water and subsequent swelling of the proteins, more precisely than the dissolution of the proteins.

Intermittent methods for combining meat and other ingredients and extracting proteins are well known. A known method for extracting proteins for certain products such as processed turkey and processed ham involves puncturing the entire muscle cam with needles, injecting brine through the needles, and using a processor or intermittent mixer to work the cam for approximately 45 minutes. under vacuum to remove air. For other products such as sausages, the cam is ground and added to a batch processor with water, salt, condiments, and / or other ingredients and worked with or without a vacuum for 15 to 45 minutes. A large batch mixer can process approximately 2,721 to 5,443 kg / hour. Although mixers of this type have been in commercial use for many years, they have significant deficiencies in terms of space and cost requirements due not only to their large dimensions, but also the time required to process each batch, and the time and expense involved in cleaning the appliances.

summary

The invention relates to an improved method and apparatus for use in making processed cam products that offers significant advantages with respect to the dimensions of the apparatus, the time required for processing, the control of the method and / or other aspects of the manufacturing method .

In one embodiment, the method comprises feeding a plurality of streams of input food ingredients including one or more streams of cam ingredients, measuring at least one component of at least one stream of cam ingredients, and regulating reciprocal flows

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of input food ingredient streams based on measurements using an anticipated feed analysis to maintain a percentage of at least one component in the combined stream within a predetermined range. Where two streams of meat ingredients are employed, they can be differentiated by fat content, with one having a significantly higher fat content than the other. In addition to one or more meat ingredient streams, other input streams may comprise water, salts, condiments, preservatives, and other ingredients, separately or in combination.

The control system of preference includes at least one in-line analyzer to measure a composition characteristic of at least one meat input stream and regulate one or more input flows in response to analyzer / es output data. The system can directly measure a composition characteristic such as fat content, or it can measure a related characteristic such as moisture content from which the fat content can be estimated. The control system can include a plurality of in-line analyzers to analyze composition characteristics of a plurality of non-homogeneous input streams. The control system preferably operates one or more pumps or valves for each flow of food input. The flow can be regulated by varying the pump speed, by intermittent pump operation, by opening and closing one or more valves, by varying the flow with one or more metering valves, or by other means. The control system can thus regulate both the combined flow and the relative flow rates of the input flows. Relative or reciprocal flow rates can be adjusted by the control system based on the analysis of composition characteristics by the analyzer.

Analysis of the feed composition can enable the rapid adjustment of the flow rates of the input flows to enable the control of fat content, protein content, moisture content, and / or other variables of the combined flow without the need to rely on a feedback loop based on component measurements in the combined flow. By introducing the controlled components in the desired proportions at the inlet end, the feed control system can also improve processing time by eliminating delays associated with adding and mixing additional ingredients to correct deviations from desired content levels. The anticipated feed control system can thus enable a mixture or combination with a desired composition to be produced from ingredients introduced at the input end and flowing through the processor in a single pass, with no recycling of any part of the processor output.

The preferred apparatus comprises a housing within which the input streams are processed, and at least one rotating mixing device located within the housing. Each mixing device may comprise a plurality of elements such as shovels, blades or screws or it may consist of a single element such as a single screw, blade or shovel. The mixing devices can be removably supported on one or more axes, however, to facilitate complete cleaning without disassembly, they are integrated with them. In some embodiments, the mixing and shaft devices can be jointly welded or formed as a single, one-piece machined part.

Rapid protein extraction and / or maceration can be carried out using a continuous high cutting action mixer for a short period of time. A mixer according to an embodiment of the invention comprises a plurality of rotating blades that force part or all of the mixture through one or more intervals of about 2.03 mm between the blades and the interior of the housing, and between several pairs of paddles as the mixture progresses through the appliance. The system preferably performs sufficient protein extraction, mixing and in some cases maceration in less than a minute. In a specific mode, the processing time is about 45 seconds. That is, the average time required for a given element of the mixture to pass through the processor is about 45 seconds. Within that time, the mixer is able to form ingredients comprising chunks or pieces of raw meat, along with salts, water, spices, etc., in a mixture that, when cooked, will form a processed, cohesive, self-supporting meat product without additional protein extraction or maceration. It should be noted that for certain products, eg bologna and sausages, additional processing steps may take place that may incidentally involve extracting additional protein.

In some embodiments, mixing may occur at atmospheric pressure. In other embodiments, the mixing operation can take place in a vacuum environment, eg 635 to 736 mm Hg vacuum.

Short Description of the Drawings

Fig. 1 is a schematic representation of a continuous mixing processor according to an embodiment of the invention;

Fig. 2 is a perspective view of a mixing apparatus used in an embodiment of the invention, illustrated with a housing part removed;

Fig. 3 is a front elevation view of a component of the apparatus of fig. 2;

Fig. 4 is a front elevation view of another component of the apparatus of fig. 2;

Fig. 5 is a partial side view of a segment of a rotating element according to an embodiment of the invention; e * * · + 9 4 9 4

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Fig. 6 [and a flow chart representing a method according to an embodiment of the invention].

Detailed Description of Preferred Arrangements

The invention is preferably incorporated into a method and apparatus for the preparation of processed meat products. An apparatus according to an embodiment of the invention is shown schematically at 10 in fig. 1. The illustrated apparatus comprises a motor 12 and a belt transmission 14 transmitting force to one or more mixing devices 16 located in a housing 20. Ingredients such as chunks or pieces of meat, one or more salts, water, flavorings such as condiments and preservatives are introduced through a hopper 62. The mixing devices advance the mixture through the housing and apply a high shearing effort to the mixture to make it fast protein extraction from meat components. These mixing devices are preferably constructed of stainless steel or other material that is wear resistant and suitable for contact with food product components.

Although a single elongated screw as shown in fig. 1 can be used as a mixing device in some modalities, other modalities employ other types of mixing devices. The embodiment illustrated in fig. 2 employs a twin shaft assembly with a relatively short lead screw 17 used in λ

combination with a longer set of blades 18 on each axis 19. As the ingredients are forced through the housing 20, the rotating blades 18 macerate and / or mix the ingredients and subject the ingredients to a high shearing force by forcing them through of intervals between the blades 18, and between the blades 18 and the inner wall surfaces of the housing 20. The minimum intervals or clearances between the blades 18 of an axis 19 and the blades of a second mixing device 16, as well as between the blades 18 and the housing 20, are preferably between 1.524 mm and 3.048 mm. In

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some modes the intervals are 2.032 mm. Forcing the mixture through these intervals provides a high shearing effort and results in rapid protein extraction. This device is believed to be able to process meat ingredients and extract proteins from them much more quickly than the intermittent methods of the previously existing technique, and specifically it is believed to be able to reduce the processing time of about 45 minutes for approximately 45 seconds or without the need for a vacuum environment. An example of a commercially available mixer such as the one described is a Twin Shaft Continuous Processor manufactured by Readco Manufacturing, Inc., of York, PA, equipped with 12.7 cm 12 blades on counter-rotating shafts 19, and producing about of 2721 kg / h around 200 rpm. In operation, the axles can have adjustable speeds. The satisfactory operation of the system can be achieved with rotation speeds of, for example, 100-200 rpm. In other modalities, larger or smaller mixers can be used, eg mixers with a diameter of 20.32 cm having an operational productivity of up to about 11,339 kg / h.

As shown in figs. 3 and 4, each of the illustrated blades 18 has an internal diameter 200 through which an axis can pass. To couple each blade with the shaft for rotation with it, each blade has a non-circular through hole and the shaft has a cross section of the same shape. In the illustrated embodiment, each blade has a square internal diameter, and the shaft therefore has a square cross section. This allows the blades to be arranged in different rotation orientations and in different orders, that is, configurations to vary the shear rate, operational productivity rate, and / or other method parameters. The blades can also be interchanged with blades of different configurations. In other modalities, to facilitate cleaning and sterilization of the appliance, the blades can be formed integrally with the shaft as a single piece, rotor

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unitary, or may otherwise be supported for rotation with it.

In the illustrated embodiment, each paddle 18 has a generally oval profile similar to a football, with a very small tip or radius of curvature at each end (Fig. 3). The illustrated blades have flat parallel faces 206 and arched edge edges 204. As illustrated in fig. 3, for some of the blades, the edge surface 204 is perpendicular to the faces. In other of the blades, illustrated in fig. 4, the edge surface 204 is angled with respect to the faces, and the faces are angled slightly apart, so that the rotation of the paddle helps the screws 17 to pump the mixture forward through the housing.

On each axis 19, each of the blades 18 has a sliding action in relation to one or more blades on the opposite axis to prevent the accumulation of ingredients on the blades. This self-cleaning feature helps to maintain the flow of ingredients through the mixer, and helps to maintain a satisfactory distribution of the ingredients. The shaft 19 is preferably a single unit component which can be removed from the housing 20.

A modified screw element 30 that can be used in conjunction with or instead of one or both of the screw elements 17 and blades 18 described above as shown in fig. 2. The screw element 30 has a helical outer edge 34 disposed at a predetermined radius of the geometric axis of the screw and spaced from the interior of the housing by a narrow gap, e.g. about 2.032 mm. On the face 32 of the screw, a plurality of protuberances or sharp-edged blocks 40 are provided to puncture the entire muscular meat components of the mixture to facilitate the extraction of proteins. Each of the protrusions 40 has five exposed faces. Each of the protrusions illustrated comprises two pairs of generally parallel quadrilateral side faces 41 and an extreme face

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quadrilateral 43. The extreme faces are rectangular, and in particular, square, and are perpendicular to the lateral faces. The end faces and the side faces are substantially planar.

As shown in fig. 1, the ingredients are channeled into the mixer via an inlet hopper 62. A pre-mix device 64 can be provided in front of or inside the hopper to provide an initial or combinatorial mixing action, and / or assist in the pumping input flows, and / or assisting in pumping input flows down through the hopper.

The ingredients are provided as input streams by a plurality of input sets 66. Input streams can include a first stream comprising predominantly lean or muscular meat, a second stream comprising predominantly fat content, a third stream comprising one or more more salts such as sodium chloride dissolved in water, a fourth flow comprising an aqueous solution of nitrite, and a fifth flow consisting essentially of water. Additional ingredients including flavorings such as condiments, preservatives and / or other ingredients can be introduced in additional streams, or can be incorporated into one of the five streams described above.

In the embodiment of fig. 1, each of the inlet assemblies 66 includes a feed line 80 for driving an ingredient to the inlet hopper 62, a content analyzer 82 in the feed line, and a metering pump 84 or valve downstream of the analyzer in the feed line. In other modalities, eg in the modality of fig. 6, content analyzers are employed in some but not all input sets.

When a flow of ingredients passes through an associated content analyzer 82, the flow is analyzed to determine, for example, the levels of fat, moisture and / or protein. In order to obtain a balance between the various ingredients in the desired ratio, a control system receives input from a plurality of analyzers, and regulates the operational productivity rates of the metering pumps 84 so that the ingredients flow into the intake hopper 62 in the desired relationship.

Several methods can be used to analyze the fat content or protein content. Known methods include the use of microwave energy or infrared light. Commercially available in-line analyzers can be programmed to analyze characteristics of a wide variety of substances ranging from, for example, petrochemicals to processed cheese. Examples of said analyzers include GMS # 44 and GM # 446 in-line analyzers manufactured by ESE Inc. of Marshfield, WT. These analyzers typically have to be calibrated for each individual application, either by the manufacturer or the end user.

Fig. 6 illustrates a method incorporating the invention that includes a control system 100 balancing the flow rates of a plurality of input streams to maintain composition parameters within desired ranges using an anticipated feed analysis. In the method of fig. 6, there are two flows of meat input 102 and 104. In other modalities, the method may employ only one flow of meat input, or three or more flows of meat input.

The preferred method employs one or more additional input streams to provide moisture, flavorings, preservatives, and / or other ingredients. In the method of fig. 6, there are three semocame input streams comprising a condiment / water mixture input stream 106, a water input stream 107, and an aqueous nitrite solution input stream 109. Other embodiments may employ a greater number or less meat-free input flows.

To produce a mixture with the desired levels of moisture, protein and fat content, the control system 100 regulates the flow rates of the input flows by adjusting the speed of a pump or valve associated with each input flow. In the embodiment of fig. 6, metering pumps 110 and 112 regulate the flow rates of the meat mixture input streams, and additional pumps or valves 114, 115 and 117 are used to regulate the flow rates of the other input streams.

Adjustments are made using an advance feed method in which the pumps and valves provide the correct reciprocal proportions of the input flows based on an upstream analysis. To determine the need for adjustments for the various flow rates, the control system 100 uses content analyzers 82 to determine the levels of protein, fat and / or moisture content of ingredient input flow 102, 104 upstream of the metering pumps 110 and 112. In some embodiments, for each input flow element that is analyzed, the analysis is completed before the element reaches the metering pump associated with the input flow so that the flow of the associated input flow can be regulated as needed to maintain the parameters desired composition rates of the combined output flow continuously within the desired range. In other modalities, the analysis can be carried out after the element has passed through the metering pump, and the flow rates can be adjusted as necessary to compensate for the delay. Thus, the percentages of protein, moisture and fat entering the mixer are preferably regulated so that adjustments for variations in input flow characteristics are made when the input flows enter the hopper, preferably to be performed in response to the characteristics of the input. mix measures downstream of mixer 10.

The mixer 10 preferably includes an outlet orifice 122 for discharging the mixture, and may include an outlet hopper 124 for • β · · ♦ »· · · · • •····· · · 9 99 9

9 99 99 99 999 99 receive the mixture and channel it to a discharge pump 126. To maintain the method at subatmospheric pressure, one or more vacuum lines may be in communication with the apparatus at one or more points. Fig. 1 illustrates a vacuum line 120 in communication with the input hopper 62. In other embodiments, vacuum lines can be connected with locations other than or in place of the input hopper. For example, vacuum lines can be connected with the outgoing hopper, with points between the incoming and outgoing hoppers, and with points downstream of the outgoing hopper.

As protein extraction is a function of time and cutting force in the presence of a saline solution, the transmission of force 12 is by a variable speed motor so that the constituents are contained within the housing 2 for mixing for a time necessary to allow both the infusion of saline solution and the cutting action. After being processed by the mixer 10, the mixture can be subjected to other processing steps, e.g. a diffusive chemical method such as a cure. Curing can be carried out using eg sodium nitrite and / or sodium chloride. In a method for making products such as bologna and sausages, the mixture can be subjected to another step of reducing the particle size to produce an emulsion from the mixture.

In relation to the detection of the fat, moisture and protein content of meat components, it was found that the moisture content may be correlated with the fat and protein content. It is believed that the correlation may be sufficient to enable the moisture content of meat components from a known source to be used as a predictor of fat and / or protein content with sufficient accuracy for the fat content and / or protein can be effectively measured simply by measuring the moisture content. Consequently, in certain embodiments of the invention, the step of measuring the fat and / or protein content may consist of measuring the moisture content after having properly calibrated the moisture meter. The control system can then control the fat and / or protein input based on the moisture content readings of one or more input streams.

From the foregoing, it should be appreciated that the invention presents a new and improved method for extracting protein and mixing meat components for certain processed meat products. The term meat is used generically here to refer to meat such as beef, pork, chicken, fish and meat by-products, including cuts or pieces that are all or basically 100% fat, thus cuts or lean pieces that have relatively higher protein content. The terms cam products and cam ingredient are used widely here to refer to products or ingredients that contain cam alone or in combination with other components.

The preferred embodiments described above relate to continuous methods, that is, methods in which the ingredients are incorporated during the discharge of a combined outlet. In these methods, the input and / or output steps may be interrupted periodically or may be intermittent.

The preferred embodiments of the invention are believed to be effective for performing rapid protein extraction and mixing of food components in an apparatus much smaller than that used in certain mixing methods or stages of the previously known technique. In addition to reducing the requirements of floor space occupied, the preferred embodiments of the invention can also reduce the cost and time of cleaning when compared to these prior art methods and devices. The invention can also result in significant cost savings by enabling more accurate control of the composition of the combined outflow.

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