Overview of Meat Life Cycle
from Harvest to Consumer
American Society of Animal
Science
Annual Meeting,
San Antonio, TX July 9, 2007
Overview
Meat processing distribution
channels
„ Preservation techniques
„ Define and contrast “freshness”
and “safety”
y
„ Changes in retail meat case implications for industry
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Meat Industry Organization
Packer
Export
Processor
Retail
Distributor
Retail
Store
Purveyor
Hotel
Restaurant
Institution
Fast Food Chain
Distributor
Fast Food
Chain Store
Beef Carcass Processing
Separate hind
& forequarters
18-36 hour chill
Grading &
Sorting
Transfer
rail to fab
Fabricate to
primal cuts
Vacuum
package
boxing
Weigh and label
Fabricate to
subprimals
Chilling
Trim and cut to
specifications
Ship to
distribution
2
History of meat preservation
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Salt
R fi
Refrigeration
ti
Improved sanitation
Improved packaging (canning, aseptic
packaging)
Preservatives / antimicrobials
Vacuum packaging (fresh and processed)
Modified atmosphere packaging
The Conundrum of “Fresh”
1 – 6 days
Trimmings for
Ground beef and
Further processing
Combo packed
~1 – 6 days
Retail Over-wrap
~10 - 12 days
Case Ready High Oxygen
~21 -35 days
Primals for Steaks
/ Chops / Roasts
Vacuum packaged
(2 – ~ 75 days)
18 – 36 hr
carcass chill
Case Ready Low Oxygen
~30 - 45 days
Case Ready Vacuum
~ >180 days
Frozen
~ >180 days
Further
processed
ALL PRODUCTS HAVE SIMILAR SAFETY PROFILE
Which process is likely to produce the “freshest” product?
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Fresh = ???
Just harvested?
„ Never frozen?
„ Great appearance / taste?
„ Safe to eat?
„ Not spoiled?
Or….
„ Just a marketing buzzword?
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Major causes of safety concerns
„ Growth
/ presence of
pathogenic bacteria
„ Presence of chemical hazards
„ Presence of physical hazards
HACCP systems are designed to eliminate, or reduce to an acceptable
level, food safety hazards. Shelf life determination of a given product
assumes that HACCP and prerequisite programs are functioning to
ensure safety.
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Major causes of spoilage
„ Growth
of spoilage bacteria
„ Oxidation of lipids
„ Enzymatic activity
In contrast, the causes of spoilage are mostly unrelated to
factors that influence product safety.
Indicators of safety
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Human observation (subjective measures)
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Implementation
p e e tat o o
of HACCP
CC a
and
dp
prerequisite
e equ s te
control programs in the process
Visual observation of the process for physical
hazards and nodes of potential introduction of
microbiological or chemical hazards.
Instrumental measures (objective measures)
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Pathogen testing of ingredients, raw materials,
finished products, etc.
Chemical testing of ingredients, raw materials,
finished products, etc.
Metal detection, xx-ray, etc.
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Indicators of spoilage
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Human measures (subjective sensorial
changes)
Smell -- odors
„ Touch – visual texture, or feel
„ Sight -- color or texture
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Instrumental measures (objective measures)
Spoilage bacterial enumeration
„ Texture analysis
„ Color analysis
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Factors affecting meat shelf life
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Animal production factors
Genetic differences
Temperature
Muscle chemistry
Muscle pH
Muscle-to-muscle differences
Postmortem age
Ground vs
vs. Whole muscle
Oxygen & other atmospheres
Packaging
Other factors???
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Valued traits for meat processing
and packaging
Fresh raw materials
„ Sanitation, Sanitation, Sanitation
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„ Low spoilage bacteria loads
„ Normal meat pH
„ Temperature control
„ Minimize exposure to O2
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Control of these factors is critical to preserving
product and extending shelf life
Current state of fresh meat
packaging
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National Meat Case Study
„ Conducted
twice, 2002 and 2004
„ 104 retail stores
„ 43 metro markets in 29 states
„ 29,000 linear feet of display case
„ Over 117,000 packages sampled
Sponsored by: Cryovac Sealed Air Corporation, National Cattlemen’ Beef
Association and National Pork Board
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National Meat Case Study
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2002
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69% of linear feet
devoted to fresh
Styrofoam tray, PVC
overwrap, 51%
49% of fresh meat
packages were case
ready
d
9% MAP
2004
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11%
4% „
63% of linear feet
devoted to fresh
Styrofoam tray, PVC
overwrap, 47%
60% of fresh meat
packages were case
ready
d
13% MAP
Case Ready Penetration Increased for
Each Major Specie
Based on Package Counts
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
95%
83%
95%
85%
66%
56%
60%
50%
37%
49%
47%
37% 38%
28%
23%
15%
Beef
Ground
Beef
Pork
Veal
2002
Lamb
Chicken Turkey
Total
2004
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In-Stock Position Was Better in Case
InCase-Ready than StoreStore-Wrap Packaging
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
84%
81%
69%
70%
63%
62%
50%
48%
53%
44% 46%
61%
54%
54%
71%
50%
35%
34%
Beef
Ground
Beef
Pork
Veal
Lamb
Store Wrap
Chicken
Turkey
2002
Total
2004
Total
Case-Ready
In-Stock is 5 or more packages per SKU displayed. Sausage was excluded.
2004 NMCS Research, All Rights
Reserved
Current State: Fresh meat retail
packaging
„
Evolution to case ready
continues
ti
att a measured
d
pace
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Driven largely by
economic influence
“Fresh Meat” case
continues to shrink
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Driven largely by need for
consumer convenience
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Progression of MAP Innovations
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High Oxygen as an industry standard
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Has worked well for a number of years
Some retailers successful in implementation of
this format; others find limited shelf life to be a
challenge
Downside is the rapid development of oxidation
The ultimate in low oxygen
yg p
packaging:
g g
Vacuum packaging
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Consumer acceptance is still an issue due to
appearance and color
Low OxygenOxygen-CO Innovations
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Consumer benefits of lowlowoxygen packaging with
carbon monoxide
„ Major benefit is control of
oxidation
„ Superior flavor over
oxygenated product
„ Removing oxygen
prevents pre
pre--mature
discoloration
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Summary
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Meat processing and distribution systems are
complex, and are designed to meet the needs
of a demanding and increasingly global
marketplace.
marketplace
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Product safety and product freshness (or
spoilage) are measured by different factors
and should be treated independently.
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Management of meat shelf life requires a
balance between science, sanitation and
packaging.
p
g g
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Innovative packaging and processing
technologies will continue to evolve and
change the way the industry delivers “fresh”
product to consumers.
Acknowledgements
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Dr. Darren Cornforth -- Utah State University
Dr. Melvin Hunt – Kansas State University
Scott Eilert, Tim Freier, Brad Down, Anne Rojas -Cargill Meat Solutions
Phil Minerich, Kevin Meyers -- Hormel Foods
Brian McFarlane, Dean Danilson -- Tyson Foods
Mark Franzreb, Charles Barmore, Jerry Kelly, Jim
Belcher – Cryovac
Cryovac--Sealed Air Corporation
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Thank you.
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