Ham Production Basics

By Oscar Esquives, Ph.D on 3/1/2008

During ham processing, muscle pieces must be tightly bound to develop a protein matrix that could eventually be sliced and handled without breakage. It is a process in which many details have to be carefully observed to obtain a wholesome finished product.

Specifically, raw material selection, formulation and processing parameters all are critical.


Raw materials
Muscles from the leg are traditionally preferred, although in many places in the world other cuts are also used to produce ham. In the United States, by regulation, all ham meat must come from the ham or leg muscles.

For optimum texture, muscles for ham processing should be lean, free of excessive connective tissue and of normal pH (greater than 5.3-5.5).

Sub-optimal pH in ham muscles could result in a condition commonly known as PSE (pale, soft and exudative) meat with inadequate bind. Hams with a lot of PSE meat can have poor color stability and a very loose texture that will easily rupture upon slicing. It is better to prevent PSE than to correct it. Processors should assess the problem and work out preventive measures with their suppliers.

Meat with excessive membranes, tendons, ligaments or fat will not yield product of the same quality as hams made with lean and denuded pieces of meat. If not-so-lean materials, like pork trim, are used for cost efficiency, it's common to grind them finely and blend them with higher-quality materials as "binder" meat. Particle reduction will maximize the functionality of these binder meats.


Formulation
Adequate slicing ability and bite requires promoting protein-protein interactions. Achieving adequate ionic strength optimizes these interactions; salt concentrations of 4 percent-5 percent are best.

Salt and nitrite (156 ppm) are indispensable for ham processing. Salt solubilizes the myofibrilar proteins that will cement meat pieces together after heat coagulation.

Other important ingredients to consider when formulating a ham are:

Water: Water is the second most abundant ham ingredient after the meat. It needs to be free from microbial and physical contamination. Avoid hard water for optimum performance.

Phosphates: Phosphates may act as sequestrants of heavy metals that might be present in water. They can also moderate the pH to promote maximum water-holding capacity and facilitate the solubilization of myofibrilar proteins. The maximum level allowed is 500 ppm.

Moisture-retention ingredients: Examples include starches, hydrocolloids and non-meat proteins that would bind extra moisture and synergize with meat proteins to strengthen and form an elastic protein matrix.


Processing
Tumbling, massaging and blending are basic in ham processing. All these operations provide enough physical action and friction so protein is extracted and distributed. Vacuum pressure opens up the muscle structure, which facilitates moisture uptake, and removes oxygen from the system. Lower oxygen levels promote color stability and microbial shelf life.

Friction and physical action in a high-protein system may also lead to foam formation that results in product defects, unless an adequate vacuum level is provided (greater than 25 mm HG). Similarly, an increase in temperature due to friction must be controlled during processing to prevent protein denaturation and microbial growth.

Work times from two to eight hours — depending on equipment and extension level — are not uncommon. A resting period of eight to 12 hours for curing also strengthens the protein-protein interactions, promoting a cohesive and firm texture.

Stuffing is another step in ham processing in which vacuum pressure can help prevent air pockets and defects. Ham can be filled in a cook-in bag, in casings or in nets. Positive energy exerted by the stuffing material will be important for enhancing protein-protein interactions and bind.

Cooking completes the process. During the thermal treatment, extracted meat proteins, non-meat proteins and other gels synergize and coagulate to form a tri-dimensional elastic network. The minimum temperature to cook cured ham is 155 degrees F to achieve an adequate kill of pathogenic bacteria.

Finally, the ham is chilled to 27 degrees-30 degrees F for slicing, browning or final packaging, depending on the finished product being manufactured. These low temperatures during the last steps will result in better slicing ability and shelf life.

Texas runs interference on Canada-Mexico cattle trade

The Texas Department of Agriculture (TAD) said Friday that Mexico has offered a new trade protocol to USDA regarding the import of U.S. cattle following the state ag commissioner's announcement that certain Canadian cattle breeds would be prohibited from entering Mexico by way of Texas export facilities due to unfair trade practices.

"Although details of this offer have not yet been shared, the fact an offer has been made is proof of progress," Texas Agriculture Commissioner Todd Staples said in a statement.

Canada and Mexico have signed an agreement allowing the trade of certain dairy and beef cattle less than 30 months of age, including breeding stock. Mexico presently only allows the importation of U.S. dairy heifers younger than 24 months of age, despite international negotiations aimed at including breeding stock, TAD said.

"We must set aside political science and make decisions with our trading partners based upon sound science," Staples said.

Brazilian meatpacker edges out Tyson to acquire Pena Branca

Brazilian meatpacker Marfrig has announced that it acquired a controlling stake in Pena Branca, the largest poultry processor in Sao Paulo state.

Pena Branca gained notoriety in the United States following reports Springdale, Ark.-based Tyson Foods Inc. was trying to buy the Brazilian processor. Though Tyson would not then confirm Pena Branca was its Brazilian acquisition target, Tyson spokesman Gary Mickelson on Friday told Meatingplace.com, "Tyson did have interest in buying Pena Branca, [but] our concerns over some regulatory matters made it difficult to reach a mutually acceptable agreement."

Mickelson added, however, that the company remains, "committed to establishing a presence in Brazil and continues to explore several other opportunities there."

Marfrig acquired Pena Branca, its first poultry venture, for $53 million. Pena Branca processes 300,000 head per day at two slaughter facilities and has 2,140 employees.

The Brazilian meatpacker also acquired a controlling stake in DaGranja Agroindustrial Ltd., a poultry and pork processor, for $58 million.

Marfrig's purchases are still subject to due diligence activities and approval by shareholders.

U.S. pork exports skyrocket in last two decades

U.S. pork exports skyrocket in last two decades
(MEATPOULTRY.com, March 06, 2008)
by Bryan Salvage

DES MOINES, IOWA ― Impressive changes have taken place in U.S. pork exports in the past 22 years, according to research by the Pork Checkoff and University of Missouri, Columbia. U.S. Pork exports have grown from 86 million lbs carcass weight equivalent in 1986 to 3.1 billion lbs in 2007. And the United States has gone from a negative 1.036 billion lbs in net exports in 1986 to a positive 2 trillion lbs in 2007.

Glenn Grimes, an economist with the University of Missouri, Ron Plain, professor at the University of Missouri, and Steve R. Meyer, president of Paragon Economics, are the consultants who conducted the analysis. They discovered the value of pork and pork byproduct exports grew from $1.97 per hog slaughtered in 1986 to $28.91 per head harvested in 2007. The changes in trade have permitted the pork industry to grow at an additional rate of about 0.8% per year on average over the last 22 years.

"In other words, the U.S. pork industry was about 18 million head larger in 2007 than it would have been had pork imports and exports remained at 1986 levels," Mr. Grimes said. "Not only has the increase in the quantity of pork traded allowed the industry to grow without lowering prices, but it has also added to producer' incomes in the years when net exports grew.

"Based on our efforts to calculate the effect of imports and exports on the price of hogs between 1986 and 2007, we believe these estimates are conservative because they show that prices increased only in the year when net exports grew," he added. "We assumed producers reacted to higher prices by increasing the U.S. herd enough to offset any price benefits from net export growth in the following years."

Japan is the largest U.S. pork customer, purchasing nearly 34% of U.S. pork exports in 2007. Mexico is second and Canada is third in tonnage purchased from the United States.

"We believe the total income of all U.S. pork producers has been improved by $7.4 billion over the last 22 years by the increase in exports," Mr. Grimes said.

FAPRI: Commodity prices to remain 'historically high'

FAPRI: Commodity prices to remain 'historically high'
(MEATPOULTRY.com, March 06, 2008)
by Keith Nunes

AMES, IOWA — Continuing high crude-oil prices and new federal bioenergy mandates are expected to sustain prices at historic highs across all agricultural commodities over the next decade, according to the Food and Agricultural Policy Research Institute (FAPRI), whose analysts briefed Congress this week about their new 10-year projections for U.S. and international commodity markets.

Global net trade in ethanol is projected to increase by 2.53 billion gallons, reaching 3.61 billion gallons by 2017. New biodiesel mandates in the Americas and Europe will almost double the price of biodiesel, pushing it to $6 per gallon with the doubling of net trade over the next decade. In the projection for ethanol, FAPRI researchers expect the world ethanol price to fall over the first half of the decade because of strong supplies encouraged by previous price increases. Thereafter, growing demand strengthens the price again through 2017, and it ends at a projected $1.52 per gallon.

The world corn price increased dramatically in 2007/08, to $198.17 per metric ton, because of demand from ethanol, the livestock sectors and sustained exports. FAPRI analysts expect demand will sustain the high price level over the rest of the decade. Similarly, all vegetable oil prices soared in 2007/08 with new biodiesel mandates, and they will continue to increase by 1.28% to 3.60% annually for the rest of the period, according to the group.

All world grain markets were characterized by higher prices during the 2007/08 period because of supply shortages and an increase in demand from the emerging biofuels sector. In particular, the world wheat price increased to $313.55 per metric ton because of production losses due to adverse weather. Adjustments in supply and demand settle the wheat price at $264.05 per metric ton in the 2017/18 period, according to FAPRI.

Other notable forecasts in the FAPRI analysis include:

• The price of sugar will increase by 10.7% over the next decade because exportable surplus will be cut significantly in the European Union as a result of its sugar reforms and in Brazil as a result of increased production of ethanol there from sugarcane.

• Strong demand coupled with the doubling of biodiesel trade will drive up world trade within the soybean complex by 17% to 32%. World soybean production may reach 297 million metric tons by 2017/18. Argentina, Brazil, and the United States are forecast to remain the dominant soybean trio, accounting for 81% of world production. China, the world’s largest importer of soybeans, may expand its import share to 57% of total world imports by 2017/18.

• Palm oil remains the most widely used edible oil, and world consumption increases by 46% over the next 10 years.

• Sanitary and phytosanitary issues continued to affect the world meat market in 2007. FAPRI expects that recovery from the problems, sustained income and population growth will lead to higher per capita meat consumption. Consequently, the group’s projections show meat production reaching 248.5 million metric tons, and meat trade expanding to 20.9 million metric tons by the end of the decade. Recovery in demand, along with strong grain prices, will push all meat prices to high levels. The outlook shows the United States and Brazil gaining significant market shares compared to their average levels in 2003 to 2007.

• Because of strong global demand and limited growth in supplies from major exporters, the world prices of butter, cheese, nonfat dry milk, and whole milk powder increased to record-breaking levels in 2007. Strong prices have encouraged production growth in many countries. World dairy prices are forecast to taper in the mid-term, but strong economic growth and rising population favor higher dairy demand, which puts upward pressure on dairy prices in the long term. Australia, New Zealand and the European Union are forecast to remain the big players in export markets, and Argentina and Brazil may expand their dairy exports to substitute for exports that are declining in the European Union due to policy reforms.

JBS, the new U.S. beef giant, expects deals to pass

JBS, the new U.S. beef giant, expects deals to pass
Wednesday March 5, 1:47 pm ET
By Bob Burgdorfer

CHICAGO (Reuters) - A day after shocking the U.S. meat industry with two big beef company purchases, Brazilian meat company JBS SA (Sao Paolo:JBSS3.SA - News) said on Wednesday it expected U.S. authorities to approve the deals without it having to divest assets.

"We are confident we will be successful. We are not thinking about divesting," JBS President Joesley Batista said in a conference call with analysts and journalists.

On Tuesday, JBS announced a $1.27 billion deal to buy National Beef Packing Co and the beef unit of Smithfield Foods Inc, both in the United States, and the Australian beef company Tasman Group.

"That will certainly raise questions with the Department of Justice," Jim Robb, economist with the Livestock Marketing Information Council, said after learning of the deal.

Batista did not specify when the deals would be completed.

If the deals are approved, the Sao Paulo-based meat company will become the largest beef producer in the United States and in the world, holding about a 32 percent U.S. market share and 10 percent of the world beef market, industry sources said.

Tyson Foods Inc (NYSE:TSN - News) is currently the largest U.S. beef company. It had an estimated 25 percent market share, but that share likely slipped after the company recently ended cattle slaughter at its 4,000-head-a-day plant in Emporia, Kansas.

Once the acquisitions are completed, JBS expects company-wide annual revenue of $21.55 billion, up from its current $12.7 billion.

JBS TO KEEP BEEF PLANTS OPEN

The deal comes at a time when the U.S. beef industry is struggling with an excess of processing capacity, sluggish beef exports, and a slowing U.S. economy.

During the call, Batista said the company did not intend at this time to close any beef plants to bring production capacity down to match the cattle supply. However, that could change later.

"We will be studying what we can do to make this company as efficient as possible," he said. "We don't expect to shut down shifts, but we will be ready to do what is necessary to compete, to save costs, and to make money."

U.S. analysts expect that eventually there will be some closures.

"I assume they will close a plant or two to get capacity in line with supplies," said Rich Nelson, livestock analyst with Allendale Inc.

Nelson said such a closure could be a few years in the future.

DEAL LIFTS MEAT COMPANY SHARES

Shares of Tyson Foods and Smithfield Foods rose on Wednesday after analysts said the JBS deal would be good for both companies.

For Tyson, the deal means fewer beef companies buying U.S. cattle, which should strengthen its bargaining position with cattle producers, Kenneth Zaslow, food industry analyst with BMO Capital Markets, said in a research note.

For Smithfield, the $565 million it will receive for its beef operations will be used to pay down debt, Pablo Zuanic, JP Morgan food analyst, said in a note.

Zuanic also saw the deal as a way for the beef industry to better keep beef production in line with cattle supplies.

Near midday on Wednesday in New York Stock Exchange trading, Tyson's shares were up 7.31 percent, or $1.09, at $16.01 and Smithfield's were up 5.02 percent, or $1.40, at $29.28.

Rosemary derived preservatives can prevent sausage rancidity

According to the Slovenian natural extract company, merguez and chipolata sausages have a high fat content, which makes them particularly susceptible to oxidation. The oxidation process can bring about changes in taste and smell, particularly rancidity.

Typical ingredients used to prevent these changes in sausages are citric and ascorbic acid. But given the current sway against artificial preservatives from consumers - and, as a result, from food producers - there is a call for natural solutions to such problems.

Tests have indicated that the sausages' shelf life can be extended by 65 to 80 per cent compared to sausages with no preservative. A company spokesperson was not available before publication of this article to translate this into actual days.

But Vitiva claims this performance even exceeds that of citric and ascorbic acid.

"Our new formulation offers manufacturers an effective yet natural solution to fight oxidative changes in fresh, traditional merguez sausages, together with a great opportunity to employ a clean label," said Vitiva CEO Ohad Cohen.

The company first started talking about its Vivox range in October 2006, just after the publication of an article in the September 2006 Journal of Food Science which described the potential of the antioxidant and antimicrobial effects of oil-soluble rosemary extracts Vivox 20 and Vivox 4 against lipid oxidation and microbial growth in vacuum-packed chicken frankfurters, compared to a commercially available preservative and a control product made without additives.

Vitiva said that the results expressed as APC (CFU/g) clearly showed both Vivox 20 and Vivox 4 possess antioxidant and antimicrobial properties that may make them suitable for meat applications in the food industry.

Vivox formulations, which are made up mostly of carnosic acid combined with other polyphenols. Other formulations in the line has previously used as natural microbial agents for processed chicken and other poultry products.

In addition, Vitiva has a carnosic acid and antioxidant-based range called Inolens 4, with very low bitterness and rosemary flavour; a rosmarinic acid range called Aquarox used to extend shelf life of prawns and for nutraceuticals, and Ursole, primarily for cosmetic uses.

Last September Vitiva announced the addition of new production lines to its natural extracts facility, giving it 70 per cent more capacity to help meet demand.

It also said it is considering acquiring another company so it can support demand with a second facility.

Whilst Vivox, Aquarox, Inolens and Ursole are its main growth promoters, it is also eyeing opportunities in other extracts, such as high-purity lutein.

Vitiva entered the lutein market last year with the launch of encapsulated VitaLutS, which is said to allow for smaller, more manageable, forms than previous industry standards.