Christian Hansen - Bactoferm Meat Manual Vol. 3 - 2013
Christian Hansen - Bactoferm Meat Manual Vol. 3 - 2013
Christian Hansen - Bactoferm Meat Manual Vol. 3 - 2013
3
Dry-cured meat products with Chr. Hansen
starter cultures
Contents
Production of dried cured meats 2
Introduction 2
General process 2
Raw material 3
Initial bacterial count 3
Temperature 3
pH-value 4
Other aspects 4
Ingredients 5
Salt 5
Nitrite 5
Nitrate 5
Sodium ascorbate 5
Spices 6
Starter cultures 6
Sugars 6
Processing 7
Curing 7
Dry curing 7
Pickle curing 8
Injection curing 9
Post salting (ripening in storage) 9
Maturation (ripening) 10
Procedures of raw ham production 11
Microbiological stabilization 11
Color formation 11
Flavor formation 13
Benefits of starter cultures 15
Product examples 16
Parma ham 16
Serrano ham 17
Bündnerfleisch and Bresaola 18
Coppa 19
Westphalian ham 20
Coburg ham 21
Schwarzwälder ham 22
Holsteiner Katen ham 23
Bacon (“Gelderländer”) 24
Pancetta 25
Literature 26
Troubleshooting 27
Texture 27
Apperance and color 28
Flavor 30
The information contained herein is presented in good faith and is, to the best of our knowledge and belief, true and reliable. It is offered solely for your
consideration, testing and evaluation, and is subject to change without prior and further notice unless otherwise required by law or agreed upon in
writing. There is no warranty being extended as to its accuracy, completeness, currentness, non-infringement, merchantability or fitness for a particular
purpose. To the best of our knowledge and belief, the product(s) mentioned herein do(es) not infringe the intellectual property rights of any third party.
The product(s) may be covered by pending or issued patents, registered or unregistered trademarks, or similar intellectual property rights. Copyright (c)
Chr. Hansen A/S. All rights reserved.
Production of dried
cured meats
Introduction Due to difference in animal species, meat cuts and
applied technology, there is a multitude of
The preservation of whole pieces of meat through commercial cured meat types. In Germany the name
salting, curing and potentially smoking is an ancient ham/Schinken always indicates that the meat is
technique dating back to times when salting was from the rear legs of a pig. For all other products,
the primary means of preservation, and it may animal species or the part of muscle used must be
be even older than the procedure for fermented mentioned.
sausages.
Furthermore, particular aspects of the product types
The products are often defined in national or even are expressed by the name of the product e.g.
regional regulations or standards of identity. designation of origin (Prosciutto di Parma, Parma
An example are the German basic principles ham), special technology (“Katenschinken”) or
(corresponds to GMP in Anglo-Saxon countries) simply the name of the particular muscle used in the
which defines dried cured hams as raw meat process (ham from muscle longissimus dorsi would
products, which are stabilized by salting and drying. be called “Lachsschinken”).
The curing process uses ingredients like salt, nitrate
and/or nitrite to obtain a preservation effect.
Cured hams are smoked or non-smoked pieces
General process
of meat of stable color, typical flavor and of a The industry uses different methods to introduce salt
consistency, which makes slicing possible. and curing agents into the core of a raw, compact
piece of meat. The three most widespread methods
In the European Union (EU) many of the cured
are:
meats are protected within the Protected
Geographical Status (PGS) framework. Three • Dry curing
regimes exist within this framework which came • Pickle curing
into force in 1992 (EU 2081/92, EU 501/2006): • Injection curing
Protected Designation of Origin (PDO, most strict),
Protected Geograical Indication (PGI, less strict) and The next step in the process would be a “ripening in
Traditional Speciality Guaranteed (TSG, least strict). storage” or post salting step (“brennen” in German).
PDO and PGI apply to food and certain agricultural This step is necessary to even out the difference in
products, and the products must meet both origin salt concentration between edge and centre zones
and quality requirements, whereas TSG does not of the ham. The ham obtains its typical flavor and
impose any geographical restrictions. appearance by the further maturation and drying
steps. Depending on product type, a smoking
The use of meat cultures may not be defined in process can follow. The finished ham is sold without
some of the PDO and PGI products. further treatment or as a sliced and pre-packed
ready-to-eat product.
Raw material
Sometimes very big differences in meat quality are Initial bacterial count
found between hams. And the choice of meat and
fat quality is key to an optimal end product. A few The initial bacterial count of the meat must be low.
parameters should be applied as indicators of meat This can be expected when the animals are rested
quality e.g. initial bacterial count, fast cooling of the before slaughtering and the slaughtering is done 2|3
carcass and of the meat. without any stress. In addition, the meat should be
chilled as fast as possible.
MATURATION Temperature
To keep the bacterial count low the temperature in
the core of the meat has to be brought below +4°C
AIR DRYING SMOKING
(39.2°F) as fast as possible. For pork this cooling
has to be achieved within 24h.
Figure 1. Flow diagram of dry cured meat processing The best temperature for inhibition of bacteria
growth is a temperature near -1°C (30.2°F) (meat
freezes at –1.6°C (34.9°F)!). Frozen meat may
have a positive effect on water loss when drying,
but it also releases bacteria when thawed. The
resulting juice is an ideal substrate for proliferation
of microorganisms. The thermometer should be
checked regularly (simple method: put ice and water
into a small vessel and allow for 1 minute waiting
time and stir. The temperature is 0°C (32°F) until
all ice has melted).
pH-value Other aspects
The pH-value should be below 5.8 in chilled meat Besides the three parameters for the meat quality
(pH-value 24h post mortem). The pH-value is the the condition of the fatty tissue or the age of the
most important hurdle (together with the chilling animals play a decisive role. The texture of the fat
process) to impede the growth of micro-organisms. mainly depends on the saturation of the fatty acids.
At pH-values above 5.8 the water binding capacity The higher the quantity of unsaturated fatty acids,
of the meat is higher and the water loss is slower the more liquid and soft is the texture (low melting
throughout salting and post salting. The reason for point). The soft texture of the pork fat can be
this water binding effect at high pH is the swelling explained mainly by the presence of oily acids. The
of muscle fibers at high pH-values. This “closed” proportion of unsaturated fatty acids in the fatty
structure of the meat slows down the penetration of tissue can be influenced by feeding. Oil-seeds or
salt and curing agents. Every piece of meat must be their pulps make the fat softer. More solid fat is
controlled. Therefore meat with a pH-value higher obtained by feeding of e.g. coconut oil.
than 5.8 is unsuitable for dry cured ham and must
The age of the animal is important as well. Meat of
be discarded. In practice, people often experience
old animals has a high content of myoglobin. This is
problems with determining the pH-value.
an advantage for the formation and stabilization of
Therefore the following recommendations should the curing color.
be followed:
Furthermore, various residues can influence the raw
• Measure in muscle tissue, not in the fatty ham production negatively, e.g. antibiotic residues
tissue or sinews are able to suppress the desired bacterial flora in
the meat.
• Measure in several spots. It is not
sufficient to measure only in the
recommended measuring spot of the leg
(muscle semimembranosus). Check as
well the pH-value of the “thick flank”
(nut) since this can be 1.0 units higher
Starter cultures
To get an excellent flavor and to improve and
stabilize the color, it is positive to use starter cultures
in the curing process. In this case primarily coagulase
negative Staphylococci are used. Furthermore,
Lactobacilli can be used, depending on desired end
product and raw materials available. The desired
feature when using Lactobacilli is a slight drop in
pH, ie increased acidity. The inoculation with mould
cultures like Penicillium strains gives advantages
for the surface treatment. Addition of sugar in
combination with Lactobacilli must be handled
carefully to avoid “sour ham”.
Processing
Curing Shortly after salting, meat juice starts to drip from
Three different methods are used to distribute the the meat as a result of the high difference in salt
salt and curing agents into the raw, compact piece concentration between the outside and the inside of
of meat: the meat (osmotic pressure). This brine is drained
and collected (or not) beneath a grid. It contains
• Manual or mechanical application of dry curing agents, salt soluble proteins, muscle pigment
curing agents to the meat (dry curing) and other substances of meat origin. The diffusion of
the curing salt ions into the core of the meat as well
• Marinating the meat in brine (pickle curing)
as the color development take places while the
• Injecting the brine into the meat (injection meat juice is running off. To ensure a better salt
curing) distribution and approximately the same pressure
for all pieces of meat during the curing process,
the meat should be repacked from time to time 6|7
Dry curing depending on their sizes. When repacked, the hams
must be put into the curing container in reverse
Dry curing is the oldest curing process. It starts with
order. The upper layers of hams go down and vice
rubbing the mixture of curing agents (common salt,
versa.
nitrate/nitrite, sugars, sodium ascorbate and starter
cultures) onto the meat. For large pieces, salting by
hand is recommended. In this case the meat is less
damaged. For small pieces, a tumbler can be used
because this has less effect on texture and helps to
rationalize the process. Afterwards, the pieces of
meat are packed side by side in curing containers.
The pieces of meat should be packed in the curing
containers in such a way that the desired shape of
the product is already obtained at the beginning
of the treatment. The meat is soft and easier to
form than at a later stage of production. The use of
stainless steel separators and sheets are well-proven
means. The bottom of the curing container should
allow drainage of the leaking liquid from the meat.
This can be obtained by installing a grid approx.
20 cm above the bottom of the container.
The hams must be treated with the curing salt Pickle curing
mixture once more when repacking takes place.
For this reason the salt mixture must be divided In the pickle curing process the meat is marinated
into different batches with respect to the number of in brine, which can also contain curing agents and
repacking steps. To avoid a loss of curing agents the spices together with common salt. The salt
salt mixture should always be freshly prepared. This concentration of the brine depends on the kind of
is also advisable from a hygienic perspective. Spices desired ham product. It is often between 10% and
should always be added during the last salting. 20%. Meat with a bigger diameter always requires
higher concentrated brine. The diffusion of salt into
The curing process must take place at temperatures the meat and the outflow of meat juice into the brine
below 4°C (39.2°F). The aw-value inside the meat is lead to a dilution of the brine. Due to the declining
higher than 0.96 and therefore the product is not salt level and the high protein content the brine
microbiologically stable at this stage. An aw-value of can spoil. The salt concentration of the brine can
0.96 approximately corresponds to a salt content of be determined by a density measurement with an
about 4.5 %. The curing time depends on the size of “aräometer”. The value is shown as a °B (degrees
the hams. A rule of thumb says that the curing time Baumé). The real amount of salt in the brine is 0.5
for fresh meat is 2 to 2.5 days/kg. This rule of thumb % lower than the determined °B. This knowledge
is confirmed by a mathematical approximation called makes it easy to prepare the brine with the required
the first law of diffusion developed by Fick: salt concentration. The required salt content of the
dm = D * (dc * dA * dt) / dl brine for a given ham technology can be calculated
dm = quantity of curing salt as follows:
dA = cross-section of the ham Cf = Cl * A / (Q * A + 1)
D = diffusion constant Cf = salt concentration in the meat
dt = time Cl = salt concentration in the brine
dc = gradient of ionic concentration Q = meat brine relationship
dl = diffusion distance A = amount of solution of the meat
This equation explains that the amount of curing A = (1 – fat % / 100) * 0,74
salt,which must diffuse into the piece of meat, is The factor 0.74 reflects the water content of pure
proportional to the gradient of ionic concentration, meat (e.g. 74% water). During pickle curing a
to the cross-sectional area, to the time and inversely temperature below 4°C (39.2°F) is very important.
proportional to the diffusion distance. The diffusion The ratio of meat:brine is also very important.
constant depends on several factors. One is surface A meat:brine relationship of 1:1 to 2:1 is generally
structure of the meat and another is pH-value, the approved. In this context the density of the laminar
third is temperature. Sinews between single muscle layer (between meat and brine) is of importance
groups slow down the diffusion and furthermore (as a diffusion barrier).
affect the evenness of the diffusion over the cross-
section.
Fig. 2. Relation between meat and brine to achieve optimal salt diffusion.
Close to the meat surface the brine is diluted by the Injection curing
diffusion of salt into the meat and by the outflow of
meat liquids into the brine. The factor of density of In the dry and pickle curing methods the salt and the
the laminar layer (as a diffusion barrier) indicates curing agents move from the outside of the meat
that the salt concentration decreases proportionally to the inside by diffusion. With injection curing the
with the distance to the meat surface. The low salt and the curing agents penetrate the meat by
concentration is closer to the meat and the high injection. The injection can be done directly into the
concentration is closer to the brine within the muscle tissue (injection at random with a multi–
laminar layer. needle injector) or indirectly into the blood vessels
(artery injection) and the diffusion distance of the
The wider the laminar layer, the slower the salt curing agents becomes fundamentally shorter and
diffusion and vice versa. This barrier can be reduced therefore the curing process is sped up considerably.
by creating turbulences in the brine (pumping) or by The injection curing has a positive effect on the
moving the meat (stir/overhaul). Even when applying microbiological stability because the curing agents
those measures the curing time is approx. 2 days/kg are very quickly present in the core of the product
of meat. Consequently, a process shortening is and can impede the bacteria in the core. On the
generally not possible as opposed to the dry curing other hand spoilage micro-organisms can be injected
method. However, a bigger disadvantage of pickle accidentally into the meat. In this ase the
curing is the inability to shape the product in the aw-value is very high and therefore a curing
very beginning of the curing process. temperature below 4°C (39.2°F) is necessary.
Meticulous hygiene of the injectors is very
important. The needles have to be regularly checked 8|9
C
for corrosion as well, because corroding needles can
D2 lead to discoloration in the injection spots.
Fig. 4. Hurdle effects during the manufacturing of dry cured ham (Leistner, 1986)
+oxygen
Myoglobin Oxymyoglobin
(red) - oxygen (cherry red)
oxidation
+ NO red ox
reduction
Nitrosylmyoglobin ox - NO Metmyoglobin
(dark, stable red) red + NO (brown)
(simple system)
STRECKER/MAILLARD
TASTE REACTION 12 | 13
VOLATILE COMPOUNDS
AROMA
DRY CURED HAM
PHOSPHOLIPIDS MUSCLE
PHOSPHOLIPASES
Fig. 7. General scheme showing flavor generation during the processing of dry-cured ham (Fidel Toldrá 2002)
Cystein-cystin redoxsystem:
-2H20
2 HNO2 + R1-SH + HS-R2 2 NO + R1 - S- S- R2
Enzyme redoxsystems:
NADH2 NAD+
NO-2 + Cyt. -c (red.) NO-Cyt. - c (ox.) NO + Cyt. -c (red.)
C-P-77 Staphylococcos carnosus Color formation and stability, tenderizing, improving flavor
Table 1. Selection of Chr. Hansen cultures for dry cured meat products
Product examples
Parma ham
The true Parma ham/prosciutto di Parma or and older than 10 month. Parma hams are seasoned,
prosciutto di San Daniele are from northern Italy’s salt-cured and air-dried but not smoked. The real
province of Parma. The special diet of chestnuts Parma cured ham goes through at least 14/18
and “whey” (from the cheese-making process) that months of maturing. This long treatment results in
Parma pigs enjoy results in an excellent quality of the special mild, nutty taste. Most Parma hams have
meat. The pigs have to be a weight of 140 kg at least PDO status.
Washing in salt-water
18 | 19
Westphalian ham
Westphalian ham comes from the Western region of dried or smoked over beech wood dust. Depending
Germany and has a very long tradition. This kind of on the quality there is a 3–8 month ripening phase.
ham is made from pork leg including bones. After The final weight is usually 4–5 kg. The bones remain
the dry salting and post salting stages the ham is air in the ham until the end of maturation.
Originally this protected ham type was established whether the ham will be used for a smoked ham or
by pigs from the Fränkisch area. The Coburg ham is an air-dried Coburg ham. Before the ham is sold, it
a raw ham which is cut from the main item of the must mature for at least six months. It then weighs
ham (topside and subshell). It depends on the curing approx. 2.5 to 3.0 kg and the taste is mild and soft.
The “Pape” is the item part of the ham. The “Blume” is the lean part of the ham. The “Kappe” is the “rump” of the ham with a
little bit more fat.
Washing
Washing
Pancetta
Pancetta is Italian bacon that is cured with salt, It is usually used as a flavoring for dishes, added to
pepper, and other spices and dried for about 3 sauces, stuffings, etc. In Italy, there are numerous
months, but it is not smoked. Pancetta is only from recipes called “all’amatriciana,” meaning “with
the belly and is often rolled up like a large sausage. pancetta.” It is often found as an ingredient in
pastas, on pizzas, etc.
2. Fidel Toldrá 2002. Dry-cured meat products. Publications in food science and nutrition.
Food & Nutrition press, INC. Trumbull, Connecticut 06611 USA.
3. Werner Frey 1986. Die sichere Fleischwarenherstellung. Leitfaden für den Praktiker. Hans Holzmann
Verlag, Bad Wörishofen.
4. Joachim E. Reichert 1983. Die Wärmebehandlung von Fleischwaren. Grundlagen der Berechnung und
Anwendung. Schriftenreihe Fleischforschung und Praxis Band 13. Hans Holzmann Verlag, Bad
Wörishofen.
5. Bundesanstalt für Fleischforschung 1985. Mikrobiologie und Qualität von Rohwurst und Rohschinken.
Kulmbacher Reihe Band 5. Institut für Mikrobiologie, Toxikologie und Histologie der Bundesanstalt für
Fleischforschung, Kulmbach.
6. Bundesanstalt für Fleischforschung 1990. Sichere Produkte bei Fleisch und Fleischerzeugnissen.
Kulmbacher Reihe Band 10. Institut für Mikrobiologie, Toxikologie und Histologie der Bundesanstalt für
Fleischforschung, Kulmbach.
7. Georg Moiser, Werner Nass, Oswald Oberländer 1979. Fachkunde für Fleischer. Georg Westermann
Verlag, Braunschweig.
8. Keim, Weichert 1976. Das Fachwissen des Fortschrittlichen Fleischers. Verlagshaus Sponholz,
Frankfurt am Main.
9. H.-D. Belitz, W. Grosch 1992. Lehrbuch der Lebensmittelchemie. Springer Verlag, Berlin Heidelberg.
10. Achim Stiebing 1993. Vorlesungsscript im Fach: Technologie der fermentierten Fleischwaren.
Studiengang: Fleischtechnologie, Fachhochschule Lippe Lemgo.
12. Ternes 1990. Naturwissenschaftliche Grundlage der Lebensmittelzubereitung, Behr’s Verlag, Hamburg
13. Norbert Frank 1996, Schinken. Hugo Matthaes Druckerei und Verlag, Stuttgart
Troubleshooting
TEXTURE
TOO SOFT
Raw material Use of meat with high pH-value, badly chilled meat
Ingredients Amount of salt is too low
Technology Injection of too much brine when injection curing
Unfortunate ratio of brine to meat when pickle curing
The temperature during the curing process has been too high
The relative humidity during “burning” step has been too high
Ripening The temperature during smoking has been too high
Storage The temperature during storage has been to high
The relative humidity during storage has been too high
Packing Packing of ham with a too high pH-value
Packing of insufficiently matured ham (too fresh)
26 | 27
TOO FIRM, RIM TOO FIRM
TOO DRY
COLOR UNSTABLE
DRY RIM
Technology The relative humidity at the “burning” room has been too high
Ripening The temperature and relative humidity during ripening and smoking
have been too high
Storage The relative humidity during storage has been too low
Technology The relative humidity at the “burning” room has been too high
Ripening The temperature during smoking has been too high
The relative humidity during smoking has been too high
Strong development of carbon black during smoking
FLAVOR
SPOILED, STICKY/MOIST AND SOFT SURFACE
RANCIDITY
FATTY
MOLDY, SMELLY
Denmark
Chr. Hansen A/S
Boege Allé 10-12
DK-2970 Hoersholm
Danmark
Phone: +45 45 74 74 74
Fax: +45 45 74 89 94
Germany
Chr. Hansen GmbH
Giessener Strasse 94
D-35415 Pohlheim
Germany
Phone: +49 6403 950 10
Fax: +49 6403 950 130
USA
Chr. Hansen, Inc.
9015 West Maple Street
Milwaukee, WI 53214
USA
Phone: +1 414 607 5700
Fax: +1 414 607 5959
www.chr-hansen.com