Innovative concepts for product and process design
DIL seminar series on meat and meat products now well established
With the second seminar of this series, the German Institute of Food Technologies (DIL) was able to repeat the success from the first seminar held the year before. 60 participants from Germany and abroad met in Quakenbrueck to learn more about current developments in the production of meat and meat products. The subsequent tasting showed that the knowledge communicated can be immediately transferred into practice and results in delicious meat and meat products.
The event, that took place last October, was opened with a lecture on "New technologies for new markets" presented by the director of the DIL, Dr. Volker Heinz. He introduced product-preserving and energy-efficient processes whose well-known and proven mechanisms are now increasingly adapted to industrial use. One example of this is the high pressure technology. The treatment of food with hydrostatic pressure often aims at preserving the food while maintaining valuable ingredients. However, this technology can also be used for the formation of food structures, for biotechnological applications and for the functionalization of food. Shock wave technology, on the other hand, is a process where biological tissues and other solid matters are mechanically exposed to hydrodynamic shock waves. In this way, for example, the ripening and tenderization of beef can be accelerated which in turn increases the product quality and reduces distribution and storage efforts. Another technology, namely one that utilizes pulsed electrical field can, for example, inactivate microorganisms and is thus a suitable preservation method. Application examples include sauces, dressings, marinades and blood. The advantages of this process include reduced energy consumption and gentle handling of the product.
Dr. Claudia Durmus of the WIBERG GmbH addressed the issue of salt reduction. In her lecture on “Tradition meets innovation - salt-reduced Wieners” she referred to the opportunities arising from the ongoing trend for convenience, indulgence and wellness food. As healthy nutrition is gaining importance among a constantly growing number of consumers, innovative food concepts should point in this direction with one focus being low-salt products, for example. Salt, which is composed of 40% sodium and 60% chloride, is an essential ingredient but also assumes several technological functions. However, there is sufficient evidence available that links a high intake of sodium to hypertension. Because the average intake of salt is clearly higher than 6 g/day, the maximum level requested by the German Nutrition Society (DGE), the EU demands that within four years the salt content of important food groups including meat products shall be reduced by 16% compared to the level of 2008. Such reduction can be achieved, for example, with ingredient premixes which replace the common salt (also nitrite curing salt) in the ratio 1:1. In this way, a 25% salt reduction can be achieved. Remarkable for this approach is that it does not require any modifications of the production process. On the example of Wiener sausages, the lecture demonstrated that the claim “low sodium or low salt” is possible while maintaining a full and balanced flavor.
“Healthy dietary fibers in meat and processed meat products” was the subject of a lecture presented by Stefan Schmitt-Rechlin of J. Rettenmaier & Söhne GmbH + Co. KG. Meat and meat products are an essential source of vitamins and trace elements. However, a diet rich in meat and meat products may result in a high intake of fat and calories. Highly functional fat replacers and dietary fibers have been developed that counteract this effect and also meet the consumers’ nutritional and sensory requirements. Such ingredients can be used to combine technological benefits such as optimized texture and bite, reduced cooking losses, efficient binding/retention of fat and water, reduced syneresis effects in the packagings during storage and many more with nutritional benefits including reduction of fat and calories or fiber enrichment . In this way a comprehensive range of products can be produced that correspond to the consumer’s demands, including low-fat BBQ sausages, fiber-enriched salami and low-fat meat patties.
Dr. Christian Hertel of the DIL presented his lecture on “New aspects in biological preservation of meat products” to the professional audience. The biological preservation is an old concept for prolonging the shelf life and increasing the safety of food by using natural microflora and/or its antimicrobial products. In the past, the research focused on lactic acid bacteria and their antimicrobial potential. This resulted in the development of commercial applications for the meat sector (e.g. bacteriocin-forming starter or protective cultures or the bacteriocin nisin). The term “biopreservation” has recently been replaced by the term “biocontrol” that takes the entire food chain (“from farm to fork”) into account. The term “natural antimicrobials” accommodates the current trend for “clean label” products. These “natural antimicrobials” are substances of vegetable origin (e.g. phenolic compounds from essential oil fractions) or animal origin (e.g. lactoferrin, pleurocidin) that are currently intensely researched. With respect to protecting the principle of a preservation that is as natural as possible, the application of natural antimicrobials in combination with physical, non-thermal preservation methods such as pulsed electrical fields or high pressure are of interest because of synergistic effects observed.
The lecture held by Dr. Markus Grube of Krell Weyland GmbH dealt with “Current legal aspects in production and marketing of meat products”. A key aspect in the production and marketing of meat products is the issue of how to classify e.g. carrot, spinach and beetroot extract. Are they coloring foods or food colors? Legally seen, both are food ingredients, but there are different legal requirements in terms of use and labeling. In particular food colors are additives and with that subject to an obligatory approval (see § 6 German Food Law). Added to that, food colors have to be stated with their class name and their sales name or E number in the list of ingredients. On the other hand, coloring food can be used without approval and listed in the list of ingredients as “normal food ingredient" with its sales name. The decisive differentiation criterion for a classification as coloring food or as food color (which needs to be approved) is the “selective extraction”. If a substance was obtained by this process, then it has to be classified as additive in accordance with the relevant legislation. However, the problem lies in the differentiation between selective and non-selective extraction. The European Commission has compiled a guidance that describes such differentiation criteria based on the Commission’s interpretation of the EC Regulation (WGA/05/08 Rev 6).
In his lecture, Klaus Wewers of NORDENIA DEUTSCHLAND Halle GmbH introduced “New ways in packaging design” showing packaging concepts that are directly adjusted to the requirements of the final consumer. He presented films with integrated "valves" that can be used as cover film for large tray packagings and allow to cook the food in the microwave oven. Such concepts are the basis for ultra fresh meals, a trend that is becoming more and more popular. Furthermore, the audience was also highly interested in a cup stacking system that offers the consumer the individual components of a meal in an easy to handle format.
Detailed information on “Phosphates in meat processing” was presented by Dr. Rainer Schnee of the Chemische Fabrik Budenheim KG. Phosphates are natural components of almost any food. They are used in the processing of numerous food products, for example as functional food additives. With their multiple technological properties, phosphates assume important functions in the production of meat products. Right after slaughtering, biochemical processes take place that decrease the pH; the proteins in the muscle start to shrink and the meat loses its water-binding capacity, it turns dry, firm and fibrous. The addition of phosphates restores the natural water-binding capacity of the muscle proteins. Short-chained phosphates with their buffering properties stabilize the pH, while diphosphates act as chelating agents for multivalent cations such as calcium and magnesium as well as for heavy metal ions such as prooxidative iron and copper. The supplying industry has developed fast-dissolving specialty phosphates that can also be used at high salt levels. Specific spray drying technologies allow to produce chemical mixtures of phosphates with different chain lengths. An integrated combination of sodium and/or potassium di- and triphosphates can be produced where the different phosphates are present in their molecular state and not as individual crystals as usual found in mechanically produced mixes. In this way, the solubility and rate of dissolution can be clearly improved.
Bajo Bajovich of the DIL discussed the “Stability of cured meat color in raw sausage”. Due to modified product parameters and requirements from the retail trade, the parameter “color” in meat and meat products is often subject of discussions. The lecture depicted the different factors and possibilities available for the stabilization of cured meat color and also addressed the use and significance of starter cultures, colors, "natural" antioxidants and "natural" ingredients.
Dr. Achim Knoch of the DIL presented an overview on “Texturized products based on meat and vegetable proteins”. Extrusion technology allows to use powdery or pasty raw materials for the production of products with meat-like structure. Depending on the recipe and parameters such as temperature, pressure and shear, it is possible to produce precisely defined structures with the extruder. With regard to the recipe design, 100% vegetable-based meat analogues can be produced but there is also the possibility to process formulations with a high amount of meat and thus to restructure the meat or meat by-products. Dr. Knoch demonstrated in his lecture the potential of this so-called “high moisture extrusion” and gave tips for the design of recipes and processes.
This one-day event closed with vivid discussions and a presentation and tasting of sample products, among them Teewurst (spreadable sausage made from raw meat), liverwurst and Kasseler (cold cuts from cured pork), all made with the use of high pressure technology, as well as another innovative sausage snack product that pleased the participants. Following up on this success, the event will be repeated with different topics next autumn in Quakenbrück. Come and meet us again when we say: “Welcome to the 3rd DIL seminar on meat and meat products!”
