Handbook on Meat Products Manufacturing (Processing, Preservation and Packaging)

Contents

Contents

1.    HOW TO START A MEAT PROCESSING
AND PRESERVATION BUSINESS
1.1.    Introduction
1.2.    Business Planning
1.2.1.    Market Research
1.2.2.    Business Structure
1.2.3.    Location Selection
1.2.4.    Legal Compliance
1.2.5.    Hygiene Standards
1.2.6.    Equipment Setup
1.2.7.    Meat Processing Methods
1.2.8.    Marketing Strategies
1.2.9.    Start-up Costs
2.    MEAT PROCESSING
2.1.    Introduction
2.2.    Conversion of Muscle to Meat
2.3.    History of Meat Processing
2.3.1.    Prehistoric Era – The Origins
2.3.2.    Ancient Civilizations (3000 BCE – 500 CE)
2.3.3.    Medieval Period (500 – 1500 CE)
2.3.4.    Renaissance to Early Industrial Period (1500 – 1800 CE)
2.3.5.    Industrial Revolution (1800 – 1900 CE)
2.3.6.    20th Century – Automation and Regulation
2.3.7.    21st Century – Modern Practices
2.4.    Evolving Purposes and Advantages of Meat Processing
2.5.    Machinery Used In Meat Processing
3.    BUSINESS PLAN FOR MEAT PROCESSING UNIT
3.1.    Components of a Business Plan
3.1.1.    Executive Summary
3.1.2.    Market Analysis
3.1.3.    Operations Plan
 
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3.1.4.    Regulatory and Environmental Considerations
3.1.5.    Organizational Structure and Staffing
3.1.6.    Marketing and Sales Strategy
3.1.7.    Financial Plan
3.1.8.    Risk Analysis and Barriers to Entry
3.1.9.    Sustainability and Growth
3.2.    Challenges of a Business Plan for Meat Processing Units
3.2.1.    High and Unstable Raw Material Costs
3.2.2.    High Operational and Financing Costs
3.2.3.    Thin Profit Margins and Seasonality
3.2.4.    Regulatory Compliance and Food Safety
3.2.5.    Labour Shortages and Skills Gap
3.2.6.    Marketing and Distribution Challenges
3.2.7.    Limited Processing Infrastructure
3.2.8.    Access to Finance
3.2.9.    Supply Chain and Inventory Management
3.2.10.    Sustainability and Animal Welfare
3.3.    Advantages of a Business Plan for Meat Processing Units
3.3.1.    Clarifies Business Goals and Strategies
3.3.2.    Facilitates Access to Financing
3.3.3.    Improves Decision-Making
3.3.4.    Identifies Market Opportunities
3.3.5.    Enhances Operational Efficiency
3.3.6.    Strengthens Competitive Position
3.3.7.    Supports Risk Management
3.3.8.    Guides Expansion and Innovation
3.3.9.    Facilitates Communication and Partnerships
3.3.10.    Monitors Progress and Performance
4.    PROCESSING OF MEAT PRODUCTS
4.1.    Product and Their Processing Techniques
4.2.    Product-Wise Processing Of Meat
4.2.1.    Process of Sausages making
4.2.2.    Process of Ham Making
4.2.3.    Process of Bacon Making
4.2.4.    Process of Meatball Production
4.2.5.    Process of Frankfurters (Hot Dogs) Production
4.2.6.    Process of Salami Making
 
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4.2.7.    Process of Canned Meats Making
4.2.8.    Process of Kebabs/Skewers Making
4.3.    Product-wise Processing Methods
4.3.1.    Fresh and Raw Meat Products
4.3.2.    Comminuted and Emulsified Meat Products
4.3.3.    Cured and Salted Meat Products
4.3.4.    Smoked Meat Products
4.3.5.    Fermented Meat Products
4.3.6.    Dried and Dehydrated Meat Products
4.3.7.    Canned and Shelf-Stable Meat Products
4.3.8.    Ready-to-Eat (RTE) and Fully Cooked Meat Products
4.3.9.    Pickled and Marinated Meat Products
4.3.10.    High Pressure Processed (HPP) Meat Products
4.4.    Main Steps Involved in the Processing of Meat Products
5.    TENDERNESS
5.1.    Pre-Slaughter Factors That Determine Meat Tenderness
5.2.    Post-Slaughter Factors That Determine Meat Tenderness
5.3.        Post-Mortem Storage Conditions, Proteolytic Systems and Meat Tenderness
5.4.    Effect of Post-Mortem Storage on Proteolytic Systems and Meat Tenderness
5.5.    The Role of Collagen in Meat Tenderness
5.6.    Influence of Collagen on Meat Tenderness
5.7.    Thermal Behavior and Cooking Impact
5.8.    Biological and Processing Factors Influencing Collagen
5.9.    Technological and Biochemical Interventions
5.10 Key Points on Collagen and Meat Tenderness
6.    FLAVOUR AND TENDERNESS
6.1.    Simultaneous Flavouring and Tenderzing Action of Molds and Bacteria
6.1.1.    Action of Thamnidium elegans
6.1.2.    Pre-Rigor Mortis Injection of Aspergillus niger Mycelium
6.1.3.    Acid Activation of Thamnidium elegans
6.1.4.    Anta-Mortem injection or Thamnidium and Aspergillus
6.1.5.    Thamnidium and Antibiotic Synergism
 

6.1.6.    Action of Pseudomonas and Achromobacter
6.2.    Combined Action of Flavoring and Tenderizing Agents
6.2.1.    Monosodium Glutamate Eliminates Mutton Flavour
6.2.2.    Application of Dry Tenderizer and Flavouring Materials
6.2.3.    Inhibition of Warmed-Over Flavour
7.    FLAVOURING
7.1.    Meat Hyorolystates and Extracts
7.1.1.    Acid Hydrolysis of Water-Insoluble Meat Residue
7.1.2.    Fractionation of the Flavour Precursor
7.1.3.    Hydrolysis of Meat
7.1.4.    Bone Hydrolysates and Extracts
7.1.5.    Continuous Counterflow Hydrolysis
7.1.6.    Continuous Hydrolysis
7.1.7.    Protein Hydrolysate
7.2.    Synthetic Flavouring
7.2.1.    Cysteine and Glyceraldehyde Base
7.2.2.    Cysteine and Ribose
7.2.3.    Derivatives of Mercapto-Acetaldehyde
7.2.4.    - Ketobutyrate, Inosinate, and Glutamate Base
7.2.5.    Nitrite and Amino Acids
7.2.6.    Cysteine, Sugar, Inosinate, and Protein Hydrolysate Base
7.2.7.    Cysteine, Thiamine and Proteinaceous Substance Base
7.2.8.    Ribose, Glycerol, Proline, Cysteine, and Methionine
7.2.9.    Amino-Carbonyl Complexes from Protein Hydrolysates
7.2.10.    Heat-Treated Slurried Meat and Ascorbic Acid
8.    COLOUR
8.1.    Ante-Mortem Treatment
8.1.1.    Adrenalin and Ascorbic Acid
8.2.    Treatment with Gaseous Atmosphere
8.2.1.    Carbon Monoxide
8.2.2.    Oxygen Under Pressure
8.2.3.    Ammonia
 

8.3.    Hemoglobin Base Colouring Compositions
8.3.1.    Stable Compositions in Liquid and Paste Form
8.3.2.    Compositions in Dry Powder Form
8.4.    Chemical Treatment
8.4.1.    Certified Monoazo Red Dyes
8.4.2.    Ascorbate, Phosphate, and Citrate
8.4.3.    Ascorbate, Gelatin, and Monosodium Glutamate
8.4.4.    Imidazole
8.4.5.    Metal Ions Ashed from Biological Tissues
8.4.6.    Beta-Carotene
8.4.7.    Nicotinic Acid Spray
8.5.    Mechanical Treatment
8.5.1.    Removal of Residual Blood
8.5.2.    Protection of Bone Color of Primal Cuts
9.    PRESERVATION : MOISTURE RETENTION AND
SURFACE PROTECTION
9.1.    Long Chain Hydrocarbon Coating
9.2.    Fatty Alcohol or Fatty Acid Protective Film
9.3.    Preliminary Ice Coating
9.4.    Intermediate Glycerol Layer
9.5.    Intermediate Water Layer
9.6.    Lactic Acid-Fatty Acid Triglycerides
9.7.    Water-in-Oil Emulsion Containing Gum
9.7.1.    Mixture of Mono- and Diglycerides in Oil
9.8.    Acetylated Monoglycerides
9.9.    Plastic Coating
9.10.    Ethylcellulose Plasticized with Mineral Oil
9.10.1.    Ethylcellulose Plasticized with Edible Oil
9.10.2.    Plasticized Cellulose Propionate Containing Glycol
9.11.    Amorphous Polypropylene
9.12.    Chemical and Other Treatments
9.12.1.    Sodium Chloride and Phosphate Solution
9.12.2.    Injection of Water and Citric Acid
9.12.3.    Hydrated Sodium Tripolyphosphate
9.12.4.    Coating Powder Containing Syrup and Starch
10.    PACKAGING AND HANDLING FOR STORAGE
AND TRANSPORTATION
10.1.    Various Methods of Packaging
 

10.1.1.    Vacuum Packaging and Storage Below 5oC
10.1.2.    Hot Carcass Processing and Impermeable Packaging
10.1.3.    Vacuum Packaging and Hot Water Spraying
10.1.4.    Processing of Partially Cooled Carcass
10.2.    Controlled Atmosphere Environment
10.2.1.    Cryogenic Oxygen-Nitrogen Atmosphere
10.2.2.    Carbon Dioxide-Oxygen-Nitrogen Atmosphere
11.    COOKING METHODS
11.1.    Broiling in Oxtgen-Free Atmosphere with Intense Infrared Heat
11.2.    Continuous Steam Cooking of Ground Meat
11.3.    Controlled Electrical Cooking
11.4.    High Pressure Roasting in Air Medium
11.5.    Cooking Between Compressed Plates
11.6.    Roasting in Suspended State
12.    TECHNOLOGY INNOVATIONS IN MEAT PROCESSING
12.1.    Automation in Modern Meat Plants
12.1.1.    Robotic Cutting and Deboning
12.1.2.    Automated Packaging and Palletizing
12.1.3.    Benefits of Automation
12.1.4.    AI-Driven Advancements
12.1.5.    Process Optimization
12.1.6.    Consumer-Centric Innovation
12.2.    Real-Time Temperature Tracking
12.3.    Benefits of IoT
12.4.    Synergy of Automation, AI, and IoT
12.5.    Pros and Cons of Technology Innovations in Meat Processing
12.5.1.    Pros
12.5.2.    Cons
12.6.    How Can Automation Reduce Labor Costs in Meat Processing Plants
13.    GOVERNMENT REGULATIONS FOR
MEAT PROCESSING
13.1.    Introduction
13.2.    Historical Context of Meat Processing Regulations
13.3.    Global Principles Governing Meat Processing
 

13.4.    Regional Regulations
13.4.1.    India
13.4.2.    United States
13.4.3.    European Union
13.5.    Ethical Considerations
13.6.    Emerging Trends in Meat Processing Regulations
13.7.    Challenges in Implementation
14.    EXPORT OF MEAT PRODUCTS
14.1.    Introduction
14.2.    Market Research and Planning
14.3.    Legal and Regulatory Compliance
14.4.    Sourcing and Processing
14.5.    Packaging and Labelling
14.6.    Cold Chain Management
14.7.    Documentation
14.8.    Customs Clearance
14.9.    Logistics and Shipping
14.10.    Marketing and Distribution
14.11.    Post-Sale Activities
15.    BIS SPECIFICATIONS
16.    PLANT LAYOUT DESCRIPTION FOR MEAT PROCESSING AND PRESERVATION BUSINESS
16.1.    Key Components of the Plant Layout
16.2.    Flow of Operations
16.3.    Safety and Hygiene Measures
16.4.    Space Allocation
17.    PLANT LAYOUT AND PROCESS FLOW DIAGRAMS
18.    PHOTOGRAPHS OF PLANT AND MACHINERY
WITH SUPPLIERS CONTACT DETAILS
•    Meat Bowl Chopper
•    Meat Dicer
•    Meat Ball Forming Machine
•    Automatic Hamburger Machine
•    Uv Steriliser Model Gs-1
•    Meat Mincer
•    Marinator
•    Smoke House
 
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•    Breading and Battering Machine
•    Sausage Filler
•    Slaughterhouse Machinery
•    Vacuum Tumbler
•    Frozen Meat Block Cutter
•    Meat Grinding Machine
•    Tunnel freezer
•    Meat Brine Injector Machine
•    Tenderizer Machine
19.    REFERENCES

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