GOOD MANUFACTURING PRACTICES IN PROCESSED MEATS MANUFACTURE

A - Guidelines for blending (Meat based products):

  1. Mince the meat and fat through either a kidney or 13 mm plate. Keep fat separate.
  2. Mince the meat and fat through the final preferred plate size.
  3. Add minced meat to a blender, sprinkle curing salt of Ready Pack (pink salt) over the meat. Blend for 2-3 minutes.
  4. Add 2/3 of the water/ice. Blend for 3-5 minutes while switching the direction of the blender every 2 minutes if possible.
  5. Add last 1/3 water/ice, Soya, and Seasoning pack from Ready pack. Blend for 3-5 minutes while switching direction of blender every 2 minutes if possible.
  6. Add fat/ fat emulsion/ rind emulsion. Blend for 3-5 minutes while switching the direction of the blender every 2 minutes if possible. Ensure the product is uniform.

B - Guidelines for blending (MDM based products) :

  1. Mince MDM through 13 mm plate or run through flaker.
  2. Add MDM to a blender (4°C). Sprinkle curing salt of Ready Pack (pink salt) over MDM. Blend for 2-3 minutes.
  3. Add 2/3 of the water/ice. Blend for 3-5 minutes while switching the direction of the blender every 2 minutes if possible.
  4. Add last 1/3 water/ice, Soya, and Seasoning pack from Ready pack. Blend for 3-5 minutes while switching direction of blender every 2 minutes if possible.
  5. Add fat/ fat emulsion/ rind emulsion. Blend for 3-5 minutes while switching the direction of the blender every 2 minutes if possible. Ensure the product is uniform.

C - Guidelines to blending and emulsifying MDM based products using an emulsifier

  1. Coarse mince MDM through 13 mm plate.
  2. Add MDM to a blender (-4°C to 2°C) and sprinkle curing salt of Ready Pack (pink salt) over the MDM. Blend for 1 minute.
  3. Add 2/3 of the water/ice. Blend for 2 minutes while switching the direction of the blender every 1 minute if possible.
  4. Add last 1/3 of water/ice, Soya, and Seasoning pack from Ready pack. Blend for 2 minutes while switching direction of blender every 1 minute if possible.
  5. Add fat/ fat emulsion/ rind emulsion. Blend for 3 minutes while switching the direction of the blender every 1 minute if possible. Ensure the product is uniform.
  6. Open blender hatch and run through emulsifier at no less than 0°C. Ensure there are no air pockets before switching on the emulsifier. Output temperature should be between 8°C and 12°C. Run product for a second time if output temperature was not reached.

Note: for products containing ‘show meat’; add emulsified product back into blender with show meat. Do NOT run through emulsifier again.

D - Bowl Cutter guidelines (MDM based products)

  1.  Coarse mince the frozen MDM through 13 mm or 20 mm plate or flake.
  2.  Place minced/flaked MDM in a well-functioning bowl cutter with recently sharpened knives.
  3.  At slow speed, sprinkle curing salt (pink salt) of the Ready Pack over MDM. Switch to high speed and cut until mince starts binding (+- 30 seconds).
  4.  Add 2/3 of the water and cut until no loose water is observed and the emulsion is uniform.
  5.  At slow speed, add last 1/3 water, Arcon® SM/SJ, and seasoning from the ready pack.
  6.  Switch to high speed and cut to 8°C.
  7.  Add fat emulsion or rind emulsion. Cut to 10°C
  8.  At slow speed, add starch. Switch to high speed and cut to 12°C to 14°C.

E - Reddening cycle

  1.  Set chamber temperature at 50°C and RH at 90%.
  2.  Ensure that product is spaced well, allowing air to move through all products.
  3.  For a 20 - 22 mm caliber product set time for about 15 - 20 minutes.
    For a 32 - 40 mm caliber product set time for about 30 minutes.

F - Smoking and Cooking guidelines for Viennas or similar products (equipment dependant)

  1. Ensure viennas or similar products on the smoker trolley are well spaced to ensure free movement of air and heat inside the smoker chamber.
  2. Run drying cycle for 15 - 20 minutes. Set: Temperature at 50°C; Humidity at 0%; Core temperature: n/a.
  3. Run smoking cycle for 10 minutes. Set: Temperature at 50°C; Humidity 0%; Core temperature: n/a.
  4. Run drying cycle for 5 minutes. Set: Temperature at 55°C; Humidity 0%; Core temperature: n/a.
  5. Run smoking cycle for 10 minutes. Set: Temperature at 55°C; Humidity 0%; Core temperature: n/a.
  6. Run drying cycle for 3 minutes. Set: Temperature at 55°C; Humidity 0%; Core temperature: n/a.
  7. Run cooking cycle. Set: Temperature at 80°C to 85°C; Humidity 96%; Core temperature at 72°C. (Note: Never cook product using time, only use attainment of core temperature. Ensure calibration test on temperature probes are done daily.)
  8. Run evacuation for 3 minutes. Set: Temperature at 60°C; Humidity 0%; Core temperature: n/a.
  9. Cold shower product after cooking to ensure minimum further weight loss.

G - Smoking and Cooking guidelines for Russians or similar products (equipment dependant)

  1. Ensure Russians or similar products on the smoker trolley are well spaced to ensure free movement of air and heat inside the smoker chamber.
  2. Run drying cycle for 20 - 30 minutes. Set: Temperature at 50°C; Humidity at 0%; Core temperature: n/a.
  3. Run smoking cycle for 15 minutes. Set: Temperature at 50°C; Humidity 0%; Core temperature: n/a.
  4. Run drying cycle for 5 minutes. Set: Temperature at 55°C; Humidity 0%; Core temperature: n/a.
  5. Run smoking cycle for 15 minutes. Set: Temperature at 55°C; Humidity 0%; Core temperature: n/a.
  6. Run drying cycle for 3 minutes. Set: Temperature at 55°C; Humidity 0%; Core temperature: n/a.
  7. Run cooking cycle. Set: Temperature at 80°C to 85°C; Humidity 96%; Core temperature at 72°C. (Note: Never cook product using time, only use attainment of core temperature. Ensure calibration tests on temperature probes are done daily.)
  8. Run evacuation for 3 minutes. Set: Temperature at 60°C; Humidity 0%; Core temperature: n/a.
  9. Cold shower product after cooking to ensure minimum further weight loss.

H - Smoking guidelines for Bacon or similar products (equipment dependant)

  1. Ensure injected meat on the smoker trolley is well-spaced to ensure free movement of air and heat inside the smoker-chamber.
  2. Run drying cycle for 45 - 60 minutes. Set: Temperature at 50°C; Humidity at 0%; Core temperature: n/a.
  3. Run smoking cycle for 15 minutes. Set: Temperature at 50°C; Humidity 0%; Core temperature: n/a.
  4. Run drying cycle for 5 minutes. Set: Temperature at 55°C; Humidity 0%; Core temperature: n/a.
  5. Run smoking cycle for 15 minutes. Set: Temperature at 55°C; Humidity 0%; Core temperature: n/a.
  6. Run drying cycle for 5 minutes. Set: Temperature at 55°C; Humidity 0%; Core temperature: n/a.
  7. Run smoking cycle for 15 minutes. Set: Temperature at 60°C; Humidity 0%; Core temperature: n/a.
  8. If a core temperature of 45°C was not reached. Run the cooking cycle. Set: Temperature at 60°C; Humidity 70%; Core the temperature at 45°C. (Note: Never cook product using time, only use attainment of core temperature. Ensure calibration tests on temperature probes are done daily.)
  9. Run evacuation for 3 minutes. Set: Temperature at 60°C; Humidity 0%; Core temperature: n/a.
  10. Cool smoked bacon down to 4°C, pack neatly in crates to minimize cutting losses. Freeze products.
  11. Thaw to -4°C before slicing.