Canning of meat and poultry

Canning of meat and poultry

7

7.1 Introduction The objective of heat-preserving meat and meat-based products is to prolong the shelf life and ensure safety of this high-value, protein-rich food. Meat refers to the edible flesh of all animals (i.e., cows, sheep, pigs, chicken). Fresh meat has pH in the range 5.2–6.5 and is therefore classified as a low-acid food. Meat is extremely rich in nutrients and moisture and is therefore ideally suited to support microbiological growth. Strict hygienic practices must be maintained throughout the processes involved in meat product manufacture. The production of good-quality safe canned meat requires a series of unit operations that must rigorously followed, that is, the animals must be healthy, unstressed, and slaughtered in an appropriate fashion; the raw meat must be stored at the correct temperature and time combination; recipes must be well formulated; processing must be done using good manufacturing practices; thermal processing must be of the correct time and temperature combination to ensure a safe product, but one that is not overcooked; and storage of the product must be at low ambient temperatures to achieve maximum shelf life. Many meat products stored at ambient temperature and packed in hermetically sealed containers (cans, glass jars, retortable pouches) are sterilised products. Some ambient stable meat products are cured and therefore have other hurdles besides heat to ensure that pathogens and food spoilage organisms do not grow under ambient storage conditions. Provided these hurdles are sufficient and well controlled, these meat products can be given the lower-temperature heat process of pasteurisation. Important hurdles for meat canning: ●

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High temperature—Heat treatment Water activity (aw)—Drying, salt, sugar, fat Acidity (pH)—Acidification Redox potentia—Decrease oxygen (vacuum, ascorbate) Preservatives—Sorbate, nitrite, etc.

Meat and poultry processors must be thoroughly familiar with all the requirements of local regulations and laws that apply to meat processing and marketing. Equipment used in meat processing plants should be constructed so that it can be readily kept clean. All surfaces contacting product should be smooth and free from pits, crevices, and scale. Equipment should be constructed either of rust-resisting metal, such as 18–8 (300 series) stainless steel, aluminium, or approved plastic materials. Nonacceptable materials for meat processing equipment are the following: (a) Copper, including its usual alloys, for surfaces contacting meat and fats. (b) Cadmium is not acceptable in any manner or form in equipment used for handling edible product. A Complete Course in Canning and Related Processes. http://dx.doi.org/10.1016/B978-0-85709-679-1.00007-6 Copyright © 2016 Elsevier Ltd. All rights reserved.

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(c) Equipment with painted surfaces in the product zone is not acceptable. (d) The use of containers or equipment made of enamelware or porcelain is not acceptable for any purpose in connection with the handling and processing of product. (e) Plastic materials and resinous coatings should be abrasion- and heat-resistant, shatterproof, and nontoxic and should not contain a constituent that will migrate to the meat or meat product in contact with the material. (f) All gasketing and packing materials should be nontoxic, nonporous, nonabsorbent, and unaffected by food products and cleaning compounds.

The following product formulas and thermal processing conditions are provided for illustrative purposes only. All canned meat products must be thermally processed according to a process schedule recommended by a competent thermal processing authority. All recommended process schedules must be designed to yield safe and stable (commercially sterile) products. Due to variations in formula and methods of procedure that may affect process relationships, meat products should not be packed without directions from a competent processing authority. The sterilisation processes given here for canned meat products should be taken only as approximate, for general guidance, and only for still retorts. As most thermal processes are not designed to kill all thermophilic microorganisms that may be present in a product, immediately after processing, all canned meat products should be water cooled to a centre can temperature between 37 and 42 °C (95 and 105 °F). The following groups of meat products are frequently found as canned products: ●

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Meat preparations such as corned beef, luncheon meat, chopped pork, and potted meat. Cooked whole meat (e.g., ham) Sausages with brine (e.g., Frankfurter-type) Ready-to-eat dishes with meat ingredients such as Beef in Gravy or Chicken with Rice Soups with meat ingredients such as chicken soup or oxtail soup

Luncheon meats are known as cold cuts or deli meats. They are made from fine ground or chopped meat (can be from one type of animal or a mixture of meats) that is presented as a loaf and usually served sliced. There may be cereal in the recipe. Luncheon meat may be cured and pasteurised or sterilised.

7.2 Sterilised meat products Meat is a low-acid food and therefore needs a full sterilisation process, unless other hurdles are incorporated. The temperature time combinations recommended by thermal processing specialists were developed for such a balance between food safety and food quality requirements by measuring and quantifying the summary amount of heat treatment to which a canned product is exposed during the entire sterilisation process. From the microbial point of view, it would be ideal to use a harsh heat treatment that would eliminate the risk of any surviving microorganisms. However, most canned meat products cannot be submitted to intensive heat without suffering loss of sensory quality (e.g., breakdown of texture, jelly and fat separation, discolouration,

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undesirable flavours) and loss of nutritional value (destruction of vitamins and protein components). To comply with the preceding aspects, a compromise has to be reached to keep the heat sterilisation intensive enough for the microbiological safety of the products and as moderate as possible for product quality reasons. The products and recipes listed in this chapter are intended to give some ideas and guidance for the production of canned sterilised meat dishes.

7.2.1 Potted meats Potted meat and potted meat by-products may be prepared from a variety of materials. The formulae are varied and elastic. Beef and pork trimmings, either fresh or cured, tripe, hearts, lips, lungs, cracklings, and so on, may be used together with the trimmings, scraps, and small pieces of product from other canning operations. As a rule, potted meats are rather highly spiced with white pepper, nutmeg, paprika, mustard, and mace. The spicing is influenced largely by the individual taste of the packers and that of their trade. The formula is dependent on what meats are available for the product and is greatly influenced by the price of the various ingredients (Figure 7.1). Cereal may be included in the formula for potted meat. Any good sausage binder or processed corn flour may be used. It is advantageous to use a processed flour, as this flour will absorb water when cold, making it easier to regulate the consistency of the product. Processed flour will absorb about twice as much water as regular flour. The cereal is added when the product is being mixed and ground through the cutter. Processed flour can be added dry. Some ingredients are classified as ‘meat’ and others as ‘meat by-products’. Local regulation should be consulted with regard to labelling regulations. The following is an example of what a formula for potted meat may be:

Figure 7.1  Potted meat filled cold—before processing.

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Basic potted meat recipe Ingredients

Metric amount

Imperial (U.S.) amount

Beef head meat (dry cured), parboiled Hearts, parboiled Pork trimmings, parboiled Tongue trimmings (cured), parboiled Tripe, parboiled Salt White pepper* Nutmeg* Mustard* Paprika*

34 kg 16 kg 20.5 kg 20.5 kg 11.4 kg 0.91 kg 0.45 kg 28 g 57 g 57 g

75 lbs. 35 lbs. 45 lbs. 45 lbs. 25 lbs. 1 lb. 1 lb. 1 oz. 2 oz. 2 oz.

*These ingredients may be replaced with a suitably formulated spice oil.

Usually it is necessary to add water to give the product the desired consistency. Frequently, difficulty is experienced in determining the proper amount of water required. Different meats vary in their absorptive capacity for water. Frequent changing of the formula to include meat on hand causes frequent changing of the amount of water added. Judgment regarding the amount of water a given potted meat will hold and still maintain its consistency is gained largely by experience. The consistency of the product is easier to control when cereal is added. Salt is added so that the finished product contains approximately 1.5% salt. Allowance should be made for the salt content of cured meats when these are used in the formulas. Some cured pork trimmings are usually added to give the product a slight pink colour. Meat packers calculate their formula on the basis of parboiled meat weights because these are subject to fewer variations. The fresh, uncooked meats are parboiled until tender. To do this, the meat is placed in sufficient boiling water to cover it, brought to a boil, and allowed to simmer gently until tender (approximately 60–90 min, depending on the size of the pieces of meat). The cooked meat is ground through a meat grinder using a 9.5 or 22 mm (¾- or ⅞-in.) plate. The quantities of the cooked and ground meats specified by the formula are placed in a cutter and ground to a smooth paste. During this grinding, the salt and spices are distributed uniformly over the product to assist in obtaining a more intimate mixture. Water is added during this grinding to regulate the consistency. Some packers prefer to add a water extract of the spices. This assists in obtaining a better mixture of the meat and spices. The product may be handled by two methods prior to filling into the cans. It may be heated in a steam-jacketed kettle to approximately 66 °C (150 °F) and filled into the cans while hot, or it may be filled cold into the cans (see Figure 7.1) and the cans passed through an exhaust box so that the closing temperature is at least 54 °C (130 °F). Either method is satisfactory if the temperature of the product when the cans are closed is at least 54 °C. A machine is used for filling potted meat.

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During the packing operations, the product frequently gets on the outside of the can. It is advisable to remove this before processing, as it is more difficult to remove after processing. Running the closed cans through sprays of hot water so that the sprays strike the cans on all sides is the most satisfactory and practical method for doing this.

Examples of process times and temperatures for potted meat, in still retorts* Can size

Time

Temperature

¼ lb. (114 g) cans ½ lb. (227 g) cans

75 min 90 min

116 °C (240 °F) 116 °C (240 °F)

*These processes are subject to change as further information becomes available. For latest recommended processes or for processes in other sterilisation systems or in other can sizes, consult with a competent thermal process authority.

Immediately after processing, the cans should be water cooled to 95–105 °F (35–41 °C).

Potted beef Ingredients

Metric amount

Imperial (U.S.) amount

Beef Salt pork Salt Mixed spice*

38.6 kg 9.1 kg 1.4 kg 0.68 kg

85 lbs. 20 lbs. 3 lbs. 1½ lbs.

*A custom blend of essential oils and or oleoresins may be obtained from a spice/seasoning supplier. Mixed spices consist of 0.9 kg (2 lbs.) ground white pepper, 114 g (¼ lb.) cayenne pepper, 28 g (1 oz.) powdered nutmeg, 113 g (4 oz.) powdered cinnamon seed, 57 g (2 oz.) summer savory, 28 g (1 oz.) powdered sweet marjoram, and 57 g (2 oz.) powdered thyme.

Plunge the beef in salted, boiling water, and cook until very tender; cover the pork with cold water, bring to a boil, and cook 2½ h; remove all bones from the beef and skin the pork; grind the mixed beef and pork to a smooth paste, thoroughly incorporate the salt and mixed spices; place in cans; seal and process cans at 116 °C.

Examples of process times and temperatures for potted beef, in still retorts* Can size

Time

Temperature

¼-lb. (114 g) cans ½-lb. (227 g) 1-lb. (454 g) cans

  75 min   90 min 120 min

116 °C (240 °F) 116 °C (240 °F) 116 °C (240 °F)

* These processes are subject to change as further information becomes available. For latest recommended processes or for processes in other sterilisation systems or in other can sizes, consult with a competent thermal process authority.

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Potted ham Ingredients

Metric amount

Imperial (U.S.) amount

Ham Mace* Cloves* Bay leaves* White pepper* Sage, powdered*

4.5 kg 114 g 227 g 28 g 341 g 113 g

10 lbs. ¼ lb. ½ lb. 1 oz. ¾ lb. 4 oz.

Salt

To taste

Water (for boiling) * These may be replaced by a suitably formulated spice oil.

Place ham in kettle, and cover well with cold water; add mace, cloves, and bay leaves. Bring very slowly to a boil, and simmer 4 h. This done, take out and remove the skin and bone, and grind to a paste. Add ground white pepper, powdered sage, and salt, if necessary. Place in cans; seal and process same as beef. If the hams are very fat, use a portion of beef and tongue in place of pork.

Potted tongue Ingredients

Metric amount

Imperial (U.S.) amount

Salted tongue Salted pork Salt Ground black pepper* Powdered cloves* Powdered allspice* Coriander seed* Bay leaves* Onion juice*

35 kg 11 kg 1.4 kg 227 g 43 g 43 g 28 g 14 g 0.5 L

75 lbs. 25 lbs. 3 lbs. ½ lbs. 1 ½ oz. 1 ½ oz. 1 oz. ½ oz. 1 pint

*These may be replaced by a suitably formulated spice oil.

Soak tongues 12 h in cold water; place in kettle, cover with cold water; bring to a boil and simmer 3–4 h, according to size; when done, take out and remove skin; cook the pork and skin; grind very fine and mix with the other ingredients; place in cans, seal, and process same as potted beef.

7.2.2 Tongue Luncheon tongue. The tongues should be parboiled so that they are pliable and the bones may be removed easily. For small tongues, 45 min of parboiling is usually sufficient. After parboiling, the tongues are cooled sufficiently so that they can be handled.

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The bones are removed, and any gristle, glands, and excess fat are trimmed from the base of the tongue. It is desirable that the tongues be handled as rapidly as possible so that they are about 49 °C (120 °F) in the centre when packed. For the ½-lb. (227 g) can, 170 g (6 oz.) of tongue and 28 g (1 oz.) of water or jelly are weighed into each can. For the 1-lb. (454 g) can, 312 g (11 oz.) of tongue and 28 g (1 oz.) of jelly or water are weighed into each can. Smallest tongues are packed into ½-lb. (227 g) cans. The tongues are rolled so the tongue is around the side of the can. If trimmings are added to increase the weight, they are placed in the centre of the can. Either an 8–10% gelatin solution or a 5% agar solution may be used as a jelly. Consult canned meat industry ingredient supplier firms for other jelly formulations. The packed cans are passed through an exhaust box so that the average temperature of the contents is approximately 54 °C (130 °F). The following processes are suggested for luncheon tongue*:

Examples of process times and temperatures for luncheon tongue, in still retorts* Can size

Time

Temperature

½-lb. (227 g) 1-lb. (454 g) cans

90 min 120 min

116 °C (240 °F) 116 °C (240 °F)

*These processes are subject to change as further information becomes available. For latest recommended processes or for processes in other sterilisation systems or in other can sizes, consult with a competent thermal process authority.

Immediately after processing the cans should be cooled in water to 37–42 °C (95–105 °F). Beef tongue. Soak salted or smoked tongue in cold water 12 h; place in kettle and cover with cold water; bring to a boil, and simmer 2–3 h, according to size; take from kettle and remove skin, commencing at tip and stripping back to root. Roll it and place in can; fill can with veal stock.

Examples of process times and temperatures for beef tongue, in still retorts* Can size

Time

Temperature

Small tongues Medium tongues Large tongues

80 min 110 min 160 min

121 °C (250 °F) 121 °C (250 °F) 121 °C (250 °F)

*These processes are subject to change as further information becomes available. For latest recommended processes or for processes in other sterilisation systems or in other can sizes, consult with a competent thermal process authority.

Cured luncheon pork tongue in 6-lb. (2.7 kg) vacuum cans. Pork tongues are chilled and cured in the usual manner. Care should be taken to ensure that the tongues are thoroughly cured before canning or a dark area will be found in the interior of the product.

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The cured tongues are washed to remove the adhering pickle and cooked until soft, usually 105 min of boiling. If less salt is desired in the product, the cooking water is changed. However, the tongues should be in boiling water for 105 min so that they will be sufficiently soft for vacuum packing. From 85 to 113 g (3–4 oz.) of a 5% agar jelly heated to boiling is added to each can. Then sufficient tongue is packed in the cans to give at least 6 lbs. (2.7 kg) net weight. The temperature of the tongues should be at least 54 °C (130 °F), but better results are obtained when the tongues are 66 °C (150 °F) when packed. The tongues should be packed into the cans as tightly as possible and pressed in hard so that a solid pack results. The cans should be closed immediately after packing using a mechanical vacuum closing machine. At least a 68 kPa (20-in. Hg) vacuum should be drawn on the vacuum chamber when the cans are closed. A commercial cook of 4 h at 230 °F (110 °C) has proven satisfactory for this cured product. However, these processes are subject to change as further information becomes available. For latest recommended processes or for processes in other sterilisation systems or in other can sizes, consult with a competent thermal process authority. After cooking, the cans should be cooled under pressure for approximately 1 h (note that the amount of salt and nitrite must be controlled).

7.2.3 Pressed beef Ingredient

Metric units

Imperial units (U.S.)

Beef Ground cinnamon Salt Ground allspice* Ground cloves* Cayenne pepper* Ground mace* Vinegar

45.4 kg 28 g 0.91 kg 28 g 14 g 14 g 14 g 0.71 L

100 lbs. 1 oz. 2 lbs. 1 oz. ½ oz. ½ oz. ½ oz. 1½ pints

*A spice oil with the equivalent amounts of these ingredients many be used.

Place the beef in kettle, cover with cold water, bring to a boil, and cook until well done; remove all bones, cut in small pieces, mix with salt and spices, and pack in 0.45 kg (1-lb.) flat cans. Reduce the liquor in which the meat was cooked to 9.5 L (2.5 gal), add the vinegar, and pour over meat in cans; seal and process 70 min at 121 °C (250 °F).

7.2.4 Beef stew Ingredient

Metric units

Imperial units (U.S.)

Diced beef Soup herbs

45.4 kg 0.9 kg

100 lbs. 2 lbs.

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Powdered onions Parsley Diced potatoes Salt Water Black pepper Flour

0.68 kg 454 g 91 kg 1.8 kg 142 L 454 g 4.5 kg

1 ½ lbs. 1 lb. 200 lbs. 4 lbs. 37½ gal 1 lb. 10 lbs.

Place the beef in steam-jacketed kettle and cover with 123 L (32½ gal) of the water, turn on steam, and bring slowly to a boil; a few minutes after boil commences, the scum of the meat will rise to the top; turn off steam and skim this off; tie the soup herbs in a bag and throw in; add the onions, bring to a boil, and simmer 3 h; then add the potatoes and salt, and cook 10 min after it boils. Add the flour mixed with 19 L (5 gal) water; bring to a full boil and shut off steam; then add the pepper and the parsley very finely chopped. Pack in 3-lb. (1.4 kg) cans, seal, and process 90 min at 121 °C (250 °F). Irish stew. Make and process same as Beef Stew, substituting 91 kg (200 lbs.) mutton for the 45.4 kg (100 lbs.) beef.

7.2.5 Roast beef Cut the beef in can-size pieces, allowing 30% for shrinkage; wrap the pieces with string and place on end in roasting pan. For a 22.73 kg (50-lb.) batch, sprinkle on the beef 28.35 g (1 oz.) ground black pepper, and place in the pan 0.95 L (2 qts.) water in which has been dissolved 227 g (½ lb.) salt. Place pan in a hot oven, and cook 30 min for 0.91 kg (2 lbs.) pieces, 40 min for 1.4 kg (3 lbs.). Turn the meat when half the time has expired, and baste to prevent burning. When done, take out the meat and make gravy from the pan fat. Add boiling water, pepper, and sufficient caramel to produce a rich brown colour. Place the roasted meat in cans, fill with the gravy; exhaust well, close, and process as follows:

Examples of process times and temperatures for roast beef, in still retorts* Can size

Time

Temperature

1 lb. (454 kg) 2 lb. (0.91 kg) 3 lb. (1.36 kg)

70 min 90 min 110 min

121 °C (250 °F) 121 °C (250 °F) 121 °C (250 °F)

*These processes are subject to change as further information becomes available. For latest recommended processes or for processes in other sterilisation systems or in other can sizes, consult with a competent thermal process authority.

Roast mutton. Handle and process same as Roast Beef, but fill cans with melted meat jelly, to which has been added a little of the pan grease. Roast veal. Handle and process same as beef.

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7.2.6 Veal loaf Ingredients

Metric amount

Imperial (U.S.) amount

Boiled veal, boned Boiled ham Bread crumbs Salt Onion juice/essential oil Eggs (or equivalent) Black pepper* Sage* Cloves* Allspice*

31.8 kg 4.5 kg 9 kg 227 g 0.24 L 72 114 g 57 g 85 g 57 g

70 lbs. 10 lbs. 20 lbs. ½ lb. ½ pint 72 ¼ lb. 2 oz. 3 oz. 2 oz.

*A specially formulated spice oil with the equivalent amounts of these ingredients may be used.

Chop the veal and ham very fine; heat the eggs, and add the onion juice; then mix all the ingredients together. Press in moulds of same shape and size as cans; turn out, and brush with new milk; lay in baking pan and place in oven to brown; when coloured, place in cans, seal, and process 1-lb. (454 g) cans 120 min at 116 °C (240 °F). This process may change as further information becomes available. For latest recommended processes or for processes in other sterilisation systems or in other can sizes, consult with a competent thermal process authority.

7.2.7 Jellied veal Ingredients

Metric amount

Imperial (U.S.) amount

Knuckle of veal Onion powder Cloves, whole* Bay leaves* Whole black pepper* Salt Vinegar Worcestershire sauce

45.4 kg 113 g 57 g 28 g 113 g 0.9 kg 0.94 L 0.47 L

100 lbs. 4 oz. 2 oz. 1 oz. 4 oz. 2 lbs. 1 quart 1 pint

* A specially formulated spice blend or spice oil with the equivalent amounts of these ingredients may be used.

Cut the veal into small pieces, place in kettle, and cover with cold water; bring to a boil, and simmer 60 min. Add the onion and allspice enclosed in a bag, and simmer for another 60 min. Take out the meat, remove the bones, and pack in cans. Add the vinegar and sauce to the liquor, strain, and pour over meat in cans. Seal, and process 1-lb. (454 g) cans 60 min at 250 °F (121 °C) and 2-lb. (907 g) cans 70 min at 250 °F (121 °C).

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Examples of process times and temperatures jellied veal, in still retorts* Can size

Time

Temperature

1 lb. (454 kg) 2 lb. (0.91 kg)

60 min 70 min

121 °C (250 °F) 121 °C (250 °F)

*These processes are subject to change as further information becomes available. For latest recommended processes or for processes in other sterilisation systems or in other can sizes, consult with a competent thermal process authority.

7.2.8 Sausage Sausage meat may be canned as pork sausage or meat from other animals or a mixture of meats. The ingredients may include beef trimmings, tripe, poultry, and so on. Each sausage maker has individual formulas or recipes for the sausage. These vary greatly in different localities. The following formulae may be used as a starting point and varied to suit the desires of the trade.

Sausage meat Ingredients

Metric amount

Imperial (U.S.) amount

Regular pork trimmings Tripe Pork or beef head meat Salt White pepper* Mace* Sage*

22.7 kg 11.4 kg 11.4 kg 1.1 kg 227 g 28 g 57 g

50 lbs. 25 lbs. 25 lbs. 2 ½ lbs. 8 oz. 1 oz. 2 oz.

*A specially formulated spice blend or spice oil with the equivalent amounts of these ingredients may be used.

Pork sausage meat Ingredients

Metric amount

Imperial (U.S.) amount

Regular pork trimmings Salt Sage* White pepper* Savory*

45.5 kg 1.1 kg 28 g 198 g 18 g

100 lbs. 2 ½ lbs. 1 oz. 7 oz. 5 ⁄8 oz.

*An especially formulated spice blend.

The meats are ground through a meat grinder, using the. 0.4 cm (5/32-in.) plate. The amounts of each ingredient as specified in the formula are weighed and mixed in the sausage mixer with the salt and spices until thoroughly mixed.

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The filled cans are passed slowly through an exhaust box so that the average temperature of the contents is at least 52 °C (125 °F). The cans should be closed immediately after exhausting.

Examples of process times and temperatures for sausage meats, in still retorts* Can size

Time

Temperature

1 lb. (454 kg) 2 lb. (0.91 kg)

120 min 150 min

116 °C (240 °F) 116 °C (240 °F)

*These processes are subject to change as further information becomes available. For latest recommended processes or for processes in other sterilisation systems or in other can sizes, consult with a competent thermal process authority.

Immediately after processing, the cans should be water cooled to 95–105 °F (37–42 °C). Vienna sausage. Vienna sausages used for canning are especially prepared for that purpose. The cured sausage meat is stuffed in narrow casings, which are not linked, but hung over the smoke sticks forming two lengths of approximately 0.6 m (2 ft.). The sausage is given a good drying and a light smoke in the smokehouse. Too much smoking gives an excessive smoked flavour to the canned product. If the product is not dried sufficiently, splitting of the casings will be observed after processing. The sausage is cut either by hand or machine into suitable lengths for standing on end in the can, allowing for approximately 6 mm (0.25 in.) headspace. The pieces of sausage are packed into the cans by hand to approximately the desired weight and placed on a conveyor, which carries them to the weighers, who adjust the contents to the desired weight. The interstices and headspace of the filled cans are sometimes filled with gelatin, but most canners use only boiling water or brine instead. The latter procedure gives a clear liquor and a very satisfactory product (see Figure 7.2).

Figure 7.2  Canned Vienna sausages.

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The filled cans are passed through a steam exhaust box. The time of the exhaust varies from 3 to 5 min, depending on the size of the can. After exhausting, the centre of the can should be 70 °C (160 °F). From the exhaust box the cans should pass immediately to the closing machine for sealing. There should be no delay between the exhausting and closing of the can. The sealed cans are immediately processed. The following processes are suggested for still retorts:*

Examples of process times and temperatures for Vienna sausages, in still retorts* Can size

Time

Temperature

4 oz. (113 g) 10 oz. (285 g) 24 oz. (680 g)

80 min 130 min 200 min

116 °C (240 °F) 116 °C (240 °F) 116 °C (240 °F)

*These processes are subject to change as further information becomes available. For latest recommended processes or for processes in other sterilisation systems or in other can sizes, consult with a competent thermal process authority.

After processing, the cans should be cooled immediately in cold water until the temperature at the centre of the can has been reduced to between 95 and 105 °F (37 and 42 °C).

7.3 Cured meat products—pasteurised Products like traditional hams and corned beef are cured products and therefore are preserved both by the thermal process that it received as well as the added salts. These salts, typically sodium chloride, potassium chloride, nitrates, nitrites, and other ingredient like polyphosphates and ascorbate, together have antimicrobial properties and assist in rendering the product ambient temperature shelf stable. The levels of these compounds are critical and must be monitored. Sodium chloride lowers the water activity and is the most important ingredient in cured products. This is very important to remember when adjusting recipes to have lower salt (sodium) content—the low-salt version may require a full sterilisation process to be shelf stable. Anaerobic spores are susceptible to the action of nitrites, and the levels of nitrites are very important when thermal processing to a target Fo value of <3. Typically a meat cure required 3–4% sodium chloride in the aqueous phase of the product and 150 ppm nitrite (0.015%). Even distribution of the salts is essential for food safety. The guideline heat process if Fo 1.0–1.5. A competent thermal processing specialist should always be consulted when any process recommendation is required (Betts and Gaze, 1992).

7.3.1 Cured ham It is important to know and understand the regulation and permitted ingredients of the country that the product is being manufactured in as well where it will be sold.

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Figure 7.3  Cured ham in cans before processing.

Canned hams (picnic ham refers to ham shoulder) are treated with a pickling brine by injecting the pickling brine into boneless whole or sectioned hams. The amount of pickup allowed is legislated and is in the region of 8%. There is also a maximum amount of polyphosphate permissible. Local regulations and product specifications must be consulted. An example of the pickling brine is as follows: Ingredients

Metric amount

Imperial (U.S.) amount

Salt Phosphate Sucrose Sodium nitrite Water (make up to)

68 kg 22.6 kg 17.2 kg 0.9 378 L

150 lbs. 50 lbs. 38 lbs. 2 lbs. 100 gal

The pickling brine is pumped into the hams, which are then cured for a defined time period (about 3 days) at approximately 4 °C (see Figure 7.3). Hams are often, but not exclusively, canned in pear-shaped fully lacquered tinplate cans. Up to 28 g (1 oz.) of dry granular gelatin is added to the cans before the cold meat is pressed into them. This solidifies the cooked-out liquor. Cans are vacuum seamed using a chamber vacuum of at least 85 kPa (25 in. Hg). Processing is as for cured meats as described earlier, ensuring that the appropriate levels of salt and nitrites are in place.

7.3.2 Corned beef The meat for corned beef is obtained from the chilled beef carcasses and trimmed free from bruises, cartilage, tendons, blood clots, and excess fat, according to standard practices employed by packing plants. It should be free from bone and skin.

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Figure 7.4  Sliced corned beef.

Two methods of curing (corning) are employed. The first method, known as the quick-cure, is used in most of the larger establishments, having superseded the second or slower method, which has been included for information, so that it is possible to track the development of this product. By using the quick-cure, the meat can be cured in a few hours, whereas the slow-cure method requires from 12 to 15 days. As with all canning, scrupulous hygiene must be employed for product, equipment, and personnel. Some recipes for corned beef are lower in salt and nitrites than required for safe pasteurisation and are therefore treated as low-acid products and sterilised (see Figure 7.4). Method No. 1 (quick-cure). Parboil the cut meat by plunging it into boiling water or broth, promptly bring the liquor again to the boiling point, and allow it to simmer for 25 min. The broth resulting from this parboiling operation may be used several times for parboiling subsequent batches. This practice increases the strength of the broth. It may be subsequently used for beef extract or canned as broth. Meat parboiled in broth has a somewhat better flavour than that parboiled in water. The parboiling liquor should be maintained very near the boiling point. It should not be used for periods in excess of 4 h nor should it be held overnight, or through rest periods or other shutdowns. The meat should be well stirred during the parboiling operation to obtain uniform treatment of all pieces. In the event the meat clumps, these should be broken up. During the parboiling operation there will be a normal shrinkage in the weight of the meat of approximately 35%. Tanks of stainless steel, equipped with an open steam coil with perforations in the cot on the underside, will be found satisfactory for the parboiling operation. The coil should be raised from the bottom of the tank to facilitate cleaning the tank. Aluminium or tin-lined copper steam-jacketed kettles may also be used. Labour may be saved by using crates or perforated baskets; with their charge of meat, they are lifted by means of a hoist and conveyed on an overhead track to and from the parboiling tanks. When such equipment is used, the crates receive their charges of meat directly from the cutter.

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The parboiled meat is cured in a pickle at a temperature of between 49 and 60 °C (120 and 140 °F). Curing may be conducted in the same kettles as are employed for the parboiling operation or in separate similar tanks. When trucks are used for parboiling, the general practice is to also use them for the curing operation. When tanks or kettles are used for parboiling, it is the usual practice to transfer the meat to trucks for curing. The regulation of the country where the product is being packed must be consulted to ascertain what additives are permitted and at what levels. This recipe uses 3.2 kg (7 lbs.) of sodium nitrate to 379 L (100 gal) of pickle as a source of nitrite, and 0.9 kg (2 lbs.) of sodium nitrite to 379 L (100 gal) of pickle at a 10% pump level. The use of nitrites, nitrates, or a combination must not result in more than 200 ppm of nitrite, calculated as sodium nitrite, in the finished product. Cover the parboiled meat in suitable tank or truck with a curing pickle prepared according to the following formula:

Ingredient

Metric amount

Imperial (U.S.) amount

Water Salt Sodium nitrate Sodium nitrite

114 L 8 kg 0.95 kg 28 g

30 gal 18 lbs. 2.1 lbs. 1 oz.

Have the meat and pickle at a temperature of 66–71 °C (150–160 °F). This will be the average temperature at the start of the cure. It will drop during the cooling operation but should be maintained at between 49 and 60 °C (120 and 140 °F) throughout the cure. The curing period is from 6 to 8 h. Stir the meat and pickle constantly at the beginning of the cure and approximately every 15 min throughout the remainder of the curing period. At the end of the cure, remove the scum that has formed on the surface by floating it off with warm water, and drain off the pickle. Wash meat free from excess pickle with lukewarm water of 49 °C (120 °F). Inspect the cured meat for gristle, excess fat, arteries, and other portions unsuitable for the canned product. Pieces of meat to which such objectionable material is attached should be removed to a table for trimming. Transfer the inspected meat from the inspection table or chute to a sausage truck used to convey it to the filling equipment. If smaller cans are being filled, the pieces of meat should be not larger than 3.2 cm (1¼ in.); if larger, they should be recut. Method No. 2 (long-cure). This method is generally known as the long-cure method. It has in most instances been superseded by the quick-cure method. When the long-cure method is employed, the meat should be kept under refrigeration during the boning, trimming, and cutting operations and should be at a temperature of not higher than 4 °C (40 °F) at any time. Prepare a curing pickle according to the following formula, and chill it to a temperature of 2–4 °C (36–40 °F):

Canning of meat and poultry283

Ingredient

Metric amount

Imperial (U.S.) amount

Boiling water Salt Granulated sugar Double refined nitrate of soda

190 L 42 kg 3.4 kg 1.2 kg

50 gal 94 lbs. 7.5 lbs. 2 lbs. 11 oz.

This quantity of pickle should be sufficient to cure from 409 to 454 kg (900 to 1000 lbs.) of meat, using 20 L (5¼ gal) of pickle to 45 kg (100 lbs.) of meat. In a tightly coopered barrel, place approximately 19 L (5 gal) of the pickle. Add approximately 45 kg (100 lbs.) of meat. Continue adding pickle and meat in these proportions until the barrel is nearly full. Head up the barrel, fill with pickle through the bung hole, and seal. Roll the filled barrel into the curing cellar to bring the meat uniformly in contact with the pickle. The temperature of the cellar should be maintained between 2 and 4 °C (36 and 38 °F). After 5 days and again after 10 days, roll the barrel to thoroughly mix the contents. Some packers prefer to transfer the meat and the pickle to another barrel at the end of 5 and 10 days. The cure should be completed in 12–14 days. The meat may be inspected for adequacy of cure by cutting several large pieces. These should be of uniform red colour throughout. After curing, the meat is parboiled and trimmed as described under method No. 1, with the exception that fresh water is used for parboiling each batch of meat to remove excess salt. The meat is filled into the cans by means of a rotary stuffing machine, either a ­single-can or a double-can stuffer. The machines are equipped with hoppers, into which the meat is placed. Plungers force it into the cans, which are placed under the outlet. The desired quantity of meat is either roughly weighed or measured in scoops holding approximately the desired weight. The unit of meat is then placed in the hopper of the stuffing machine, which forces it into the can by means of the plunger. When too much meat is placed in the stuffer, the extra fill may cause the can to be strained. When too little meat is placed in the stuffer, unnecessary labour is employed in completing the fill of the cans. From the filling machine, the cans are transferred to a table, where they are weighed and meat added or removed, as may be required to secure the specified net weight. Corned beef may be canned with or without added jelly. When jelly is used, this is prepared by adding 0.45 kg (1 lb.) of edible gelatin (or equivalent ingredient) to 3.8 L (1 gal) of water. When jelly is used, it is added in the proportion of 1 oz. (28 g) of jelly per pound (0.45 kg) of meat. The jelly is added to the cans prior to filling with meat. It is necessary that the cans be filled without forming air pockets, as the meat adjacent to such pockets will become discoloured. Air pockets are minimised by having the meat at a sufficiently high temperature at the time it is filled into cans. No additional heating is required if the meat is filled promptly after the preceding operation, except in the case of filling of pieces that have been removed for trimming. After weighing, the meat is carefully pushed away from the seam edge so that it will not interfere with the sealing operation.

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The cans are then placed in a mechanical vacuum sealing machine, where the sealing is completed under a vacuum of 70–80 kPa (20–24 in. Hg.). The cans are then passed under a shower of hot water to remove any adhering grease, after which they are placed in retort trucks or crates so that they are not jammed or dented. Spaces should be left among the cans to allow for their expansion during processing. The operations involved in the canning of corned beef should be carried out as a continuous operation to minimise the time elapsing between taking the meat from the cure and processing it in the sealed cans.

Examples of process times and temperatures for corned beef, in still retorts* Can size

Time at 113 °C

Time at 115 °C

No. 1 can No. 2 can 6 lb. can

120 min 150 min 300 min

75 min 90 min –

*These processes are subject to change as further information becomes available. For latest recommended processes or for processes in other sterilisation systems or in other can sizes, consult with a competent thermal process authority.

The process should be immediately followed by cooling the cans in water to an average internal temperature between 95 and 105 °F (37 and 42 °C).

7.4 Poultry products Chicken meat has a pH between 5.7 and 6.0 and is therefore very perishable, Thus, special precautions must be taken during its preparation and processing. Canned chicken is an excellent medium for the growth of heat-resistant microorganisms, and processes sufficient to destroy such organisms must be used to prevent spoilage. Good canning practice dictates that filled, unprocessed cans not be held over 30 min prior to processing. If the lines are operating too slowly to fill a retort in 30 min, each retort crate must be processed as it is filled. Strict sanitation must be maintained throughout the preparation of the product to keep bacterial contamination and build-up as low as possible. Poultry meat is an excellent medium for the growth of bacteria of the Clostridium perfringens group. These bacteria multiply very rapidly and produce large amounts of gas. If cans are held for long periods at a warm temperature after closing, incipient spoilage may occur. Although the bacteria are destroyed by the sterilisation process, the final quality of the product is lower, and the gas that already has been produced will cause buckled or strained ends during the process. The following product formulas and thermal processing conditions are provided for illustrative purposes only. All canned poultry must be thermally processed according to a process schedule recommended by a competent thermal processing authority. All chicken products need to be sterilised, and all recommended process schedules must be designed to yield safe and stable (commercially sterile) products.

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7.4.1 Whole chicken The canning of whole chicken consists of the canning of a dressed and drawn chicken, together with the gizzard, heart, and liver, in a jelly. The can used is one that is adapted to the contour of the chicken, so that the chicken will not be under any pressure from the can because such pressures tend to cause the skin to tear during processing and make the product unsightly. Cans of size A10 (152 mm × 178 mm) or 404 × 700 (46 oz. cans) are commonly used. The chicken to gelatin ratio depends largely on the packing of the chicken into the smallest can that will hold it conveniently because the more chicken that is in the can, the less space remains to be filled with gelatin. Selection. Chickens to be canned are usually selected to weigh about 1.4 kg (3 lbs.). The chicken cans vary in height and are adapted in this manner to hold larger and smaller chickens, 1.4 kg chickens seem to be the size most uniformly canned. The chickens should be further graded into young and old fowl because the young chickens are more tender than old fowl and do not require as long to cook. Some packers prefer older hens as they withstand the sterilisation process better than fryers. Cleaning. The product should be cleaned free from pin feathers, and so on and drawn. The drawn chickens should be washed in cool water to remove adhering dirt and pin feathers together with all blood and serum. If the former is not removed, the appearance of the chicken is poor, whereas the latter coagulates and causes a cloudy jelly, which is unattractive. Processing. Whole chicken may be packed with either brine or broth obtained from the boned chicken operation. To eliminate air entrapped in the bottom of the can, with resultant variation in vacuum and headspace, a portion of the brine or broth usually is added first. The uncooked chicken is hand filled into the cans breast down when A10 cans are used. Broth or water, heated to a temperature of 88–93 °C (190–200 °F), is added to complete the fill of the container, and the cans are topped and closed on a mechanical vacuum sealer under 70–80 kPa (20–25 in. Hg) of vacuum. Following closure, the cans are placed in retort baskets in an inverted position so the breast end is up. That position facilitates circulation of brine in and around the body cavity, on which rate of heat penetration depends in an important manner (Tables 7.1 and 7.2). With an initial temperature of 71 °C (160 °F), the cans are processed for 75 min at 116 °C (240 °F), followed by pressure cooling until the product reaches an average temperature between 37 and 42 °C (95 and 105 °F). Footnotes (a), (b), and (c) given for canned boned poultry (Table 7.3) also apply here. To permit the flesh to become somewhat more firm, some packers allow the processed cans to remain in the retort baskets overnight before casing. Undue agitation in runways and zigzag drops immediately after processing will cause the meat to separate from the bones.

7.4.2 Boned chicken or turkey Canned boned poultry products are a popular item for the preparation of poultry a la king, poultry salads, poultry pies, poultry casseroles, and sandwiches.

Boned (poultry)–solid pack boned (poultry) with natural juices Maximum fillb Net weight (oz.)

Net weight (g)

300 × 106

4

113

303 × 109

5

142

303 × 113 307 × 200

6 7.5

170 213

303 × 406

16

454

404 × 700

50

1417

Time (in min) at:

°F

°C

240 °F (116 °C)

245 °F (118 °C)

250 °F (121 °C)

40 100 160 40 100 160 160 130 160 40 70 100 130 160 40 70 100 130 160

4 38 71 4 38 71 71 54 71 4 21 38 54 71 4 21 38 54 71

60 55 50 70 65 60 65 75 70 120 115 110 105 95 200 195 185 170 155

50 45 40 55 50 45 50 60 55 105 100 95 90 85 180 175 165 150 135

45 40 35 50 45 40 45 55 50 95 90 85 80 75 165 160 150 135 125

a These processes are subject to change as further information becomes available. For latest recommended processes or for processes in other sterilisation systems or in other can sizes consult with a competent thermal process authority. b The maximum fill weights listed with these processes may not be suitable for some operations. In these cases it will be necessary to obtain heat penetration data and resultant processes based on the maximum fill weight expected. If the fill weight critical factor is exceeded for a scheduled process, this constitutes a process deviation that must be evaluated by a competent process authority to determine if a potential health hazard exists. c Minimum initial temperature is the average temperature of the contents of the coldest can in the retort at the time the steam is turned on for the process.

A Complete Course in Canning and Related Processes

Can sizea

Initial temperaturec

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Table 7.1 

Boned (poultry) Maximum fillb

Can sizea

Net weight (oz.)

Net weight (g)

300 × 106

4

113

303 × 109

5

142

303 × 113 303 × 406

6 16

170 454

404 × 700

50

1417

Initial temperaturec

Time (in min) at:

°F

°C

240 °F (116 °C)

245 °F (118 °C)

250 °F (121 °C)

40 100 160 40 100 160 160 40 70 100 130 160 40 70 100 130 160

4 38 71 4 38 71 71 4 21 38 54 71 4 21 38 54 71

60 55 50 70 65 65 65 120 115 110 100 95 195 190 180 165 150

50 45 40 55 50 45 50 105 100 95 85 80 175 165 155 145 130

45 40 35 50 45 40 45 90 85 80 75 70 160 150 140 130 115

a These processes are subject to change as further information becomes available. For latest recommended processes or for processes in other sterilisation systems or in other can sizes consult with a competent thermal process authority. b The maximum fill weights listed with these processes may not be suitable for some operations. In these cases it will be necessary to obtain heat penetration data and resultant processes based on the maximum fill weight expected. If the fill weight critical factor is exceeded for a scheduled process, this constitutes a process deviation that must be evaluated by a competent process authority to determine if a potential health hazard exists. c Minimum initial temperature is the average temperature of the contents of the coldest can in the retort at the time the steam is turned on for the process.

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Table 7.2 

288

Table 7.3 

Boned (poultry) with broth Maximum fillb

Can sizea

Net weight (oz.)

Net weight (g)

4

113

303 × 109

5

142

303 × 113 303 × 406

6 16

170 454

404 × 700

50

1417

Time (in min) at:

°F

°C

240 °F (116 °C)

245 °F (118 °C)

250 °F (121 °C)

40 100 160 40 100 160 160 40 70 100 130 160 40 70 100 130 160

4 38 71 4 38 71 71 4 21 38 54 71 4 21 38 54 71

60 55 50 70 65 60 65 110 105 100 95 85 175 170 160 150 135

50 45 40 55 50 45 50 95 90 85 75 75 155 150 140 130 120

45 40 35 50 45 40 45 85 80 75 65 65 140 135 125 115 105

a These processes are subject to change as further information becomes available. For latest recommended processes or for processes in other sterilisation systems or in other can sizes consult with a competent thermal process authority. b The maximum fill weights listed with these processes may not be suitable for some operations. In these cases it will be necessary to obtain heat penetration data and resultant processes based on the maximum fill weight expected. If the fill weight critical factor is exceeded for a scheduled process, this constitutes a process deviation that must be evaluated by a competent process authority to determine if a potential health hazard exists. c Minimum initial temperature is the average temperature of the contents of the coldest can in the retort at the time the steam is turned on for the process.

A Complete Course in Canning and Related Processes

300 × 106

Initial temperaturec

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Product containing light and dark chicken or turkey meat in quantities other than natural proportions should have a qualifying statement in close conjunction with the name of the product. There is specific terminology for the amount of light or dark meat used in the legislation for some countries. Raw material handling. Poultry canning is usually carried on in conjunction with a fresh poultry processing operation. Under these conditions, poultry canning preparation may proceed without delay. Canning operations not in conjunction with eviscerating plants usually receive frozen eviscerated carcasses. In some cases, if the eviscerating plant is nearby, the poultry may be refrigerated. Frozen poultry carcasses may be used to ensure a readily available supply of poultry. The frozen carcasses are usually thawed by soaking in running water at a temperature of approximately 21 °C (70 °F) for 1–2 h, depending on the size of the carcass. If the poultry carcass is to be precooked, the precooking operation should immediately follow the thawing operation. Precooking. Open kettle cooking of thawed ready-to-cook poultry is most common. Stainless equipment should be used for poultry processing. The poultry is cooked in water at boiling temperatures until the meat can be removed easily from the bones, yet will not fall off the bones by itself. Poultry carcasses averaging 1.8–2.7 kg (4–5 lbs.) are precooked approximately 1½–2½ h. If the precooking operation is to be conducted by steaming in retorts, the carcasses of approximately the same size and quality are placed in a wire basket supported by a container to permit collection of the broth. Heavy carcasses are steamed for approximately 90 min at 104 °C (220 °F) or 60 min at 121 °C (250 °F). The broth from the precooking operation should be held at a temperature of not less than 71 °C (160 °F) if it is to be used in the product. The broth must be placed in a refrigerated room maintaining a temperature not higher than 4 °C (40 °F) for overnight storage. If the broth is to be held longer, the storage temperature should be below 0 °C (32 °F). Boning. The meat is removed from the bones as soon as possible after precooking. The cooked carcasses may be cooled in air, water sprays or flowing water, broth, in contact with ice, or by other approved methods. Contact with the cooling liquids should not exceed 30 min. Boning tables, a merry-go-round, or a conveyor system is used for boning. The boning of whole cooked poultry is done by hand, permitting separation of white and dark meat and skin. Mechanical boning of necks, wings, and backs may be done in conjunction with hand boning. Mixing. Poultry products that contain meat in natural proportions are usually mixed in a mixer to ensure that the natural proportions of light meat, dark meat, and skins are present in each container. The precooked or raw boneless meat that is taken directly from the inspection operation should be of suitable size for filling into the container. The inspected skins are comminuted, usually by grinding through a 3.2 mm (⅛-in.) plate prior to mixing. Salt may be added, either at the time of mixing, or to the broth.

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Cans. Cans made from electrolytic tin plate, fully internally lacquered, are recommended for these products. Filling. The meat portion, after mixing, may be filled into the containers by hand, or by semiautomatic or automatic filling equipment. The cans are check-weighed to a definite fill-in weight of meat. A measured quantity of broth obtained from the precooking operation is used to complete the fill. A better flavoured broth is obtained from liquid in which two to four batches of poultry have been cooked. The broth should be maintained at 71 °C (160 °F) or above. The broth may be filled into the containers by hand or by means of an automatic measuring filler. The poultry fat may be filled into containers in a similar manner. In some operations, the measured quantity of broth and poultry fat is filled into the can prior to filling with meat. Closing. Cans of boned chicken may be closed under vacuum using a mechanical closing machine, by thermal exhausting to a minimum of 60 °C (140 °F), or by the use of hot broth so that the average temperature of the product is not less than 50 °C (120 °F) and with steam vacuum closure. Filled can washing. To maintain clean retorts and to avoid can cleaning after processing, the closed cans should be washed to remove fat and bits of adhering product. Processing. It is important that there be no delay between can closing and the processing operation. Any extended holding time between closing and processing may result in bacterial growth and subsequent spoilage and/or loss of vacuum and buckling of the cans during the processing operation. Because the liquid content will affect the heating characteristics, it is to be regarded as a requirement of the suggested processes. ●

●

●

Boned (Poultry) Solid Pack: 5% or less liquid Boned (Poultry): 10% liquid Boned (Poultry) with Broth: 20% liquid

When a product contains a stabiliser, thickening, or solidifying agent, the suggested processes may not be adequate, and the suggested processes for these products should be obtained from a processing authority. The following is a list of boned poultry products, can sizes, suggested net weights, and suggested processes. Cooling. Immediately after processing, the cans should be cooled in water to an average temperature of 37–42 °C (95–105 °F). Pressure cooling is required for cans of greater than 83 mm diametre to prevent straining or buckling of the ends. Palletising cans when the average temperature of the contents is above 105 °F (42 °C) may produce thermophilic bacterial spoilage, as well as affect the quality of the product. Storage. Canned boned poultry products should be stored in a dry, cool place and not exposed to wide variations in temperature or humidity.

7.4.3 Boned turkey and turkey jelly Same as chicken.

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7.4.4 Chicken in jelly Ingredients

Metric amount

Imperial (U.S.) amount

Chicken Onion powder Bay leaves* Whole mace* Whole cloves* Salt Gelatin

45.5 kg 136 g 28 g 28 g 57 g 1.4 kg 341 g

100 lbs. 0.3 lbs. 1 oz. 1 oz. 2 oz. 3 lbs. ¾ lb.

*A custom blend of the equivalent essential oils may be used.

Draw and clean the chickens, cut each in even pieces, place in kettle and cover with meat jelly, adding the salt and onions and spices in a bag; bring to a boil and simmer until tender; remove the chicken and carefully skin and bone; add the gelatin, which has been soaked in cold water for 1 h, to the liquor in the kettle, and stir until dissolved; then strain; if the liquid is not clear, clarify with white of egg or other clarifying agent. Place the chicken in cans, cover with the liquid; seal and process at 121 °C (250 °F) in No. 1 cans for 30 min; No. 2 cans for 40 min. Processing times and temperatures are for still retorts. Footnotes (a), (b), and (c) given under processes for canned, boned poultry (Table 7.3) also apply here.

7.4.5 Potted chicken Ingredients

Metric amount

Imperial (U.S.) amount

Chicken Salt pork Powdered onion Salt Parsley or equivalent dehydrated Ground white pepper Whole cloves* Mace* Bay leaves*

41 kg 4.5 kg 227 g 1.8 kg 454 g

90 lbs. 10 lbs. ½ lbs. 4 lbs. 1 lb.

227 g 114 g 57 g 28 g

½ lb. ¼ lb. 2 oz. 1 oz.

*A blended mixture of equivalent essential oils may be used.

Cook and skin the pork, draw and clean the chickens, cut into pieces. Place in kettle with 0.91 kg (2 lbs.) of salt, the onions, parsley, cloves, mace, and bay leaves; cover with cold water; bring to a boil. Simmer until tender. Remove from kettle, and remove skin and bone. Grind to a fine paste. Mix in the remainder of the salt and the pepper. Fill into cans. Seal and process same as potted beef. Use the liquor in which the chickens are cooked for chicken soup (see Figure 7.5).

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Figure 7.5  Chicken loaf.

7.4.6 Potted turkey, other poultry, and game birds Make and process same as chicken.

7.4.7 Chicken a la king The usual chicken a la king is very similar to creamed chicken. It is customary to add green peppers and pimentos and sometimes mushrooms. To 45.5 kg (100 lbs.) of properly prepared chicken, add lukewarm water to cover and cook until tender. Add from 0.91 to 1.4 kg (2–3 lbs.) of salt a few minutes before removing the chicken from the kettle. Take the chicken from the kettle, and remove the skin and bones. About 454 g (1 lb.) of fresh mushrooms, should be cooked separately and cut into small slices; 227 g (½ lb.) of green peppers should be sliced and cut into the desired size; and 454 g (1 lb.) of pimentos should be sliced and cut into the desired size. The sauce is made from the chicken stock, which is the concentrated liquid left in the kettle after the chickens have been cooked. Some formulas call for the addition of milk. The butter is melted by heat, and flour is added to the melted butter and stirred to smooth consistency. The cooled chicken stock is added to the flour and butter mixture and cooked until it is of creamy consistency; then add the chicken, peppers, pimentos, and mushrooms. Mix and heat thoroughly and fill into the cans. Close cans in mechanical vacuum closing machine. No. 1 cans should be processed 55 min at 250 °F (121 °C) in still retorts. Footnotes (a), (b), and (c) for canned boned poultry also apply here (Table 7.3).

7.4.8 Chicken and noodles This product is frequently canned in connection with roast chicken and other chicken products. The larger pieces of chicken are canned as roast chicken, and the smaller pieces are canned with the noodles as noodles and chicken.

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The chickens are thoroughly cleaned, drawn, and cut into pieces. These are either sprayed with cold water or soaked in cold water to remove the blood and serum. The pieces of chicken are placed in a kettle, covered with boiling water, brought to a boil, and simmered until the chicken is tender and can be easily separated from the skin and bones and placed in the cans. The following approximate proportions are used: one part of chicken meat, one part of dried noodles, and two parts of hot chicken broth made up as follows: To the liquor in which the chicken was boiled, add the skin and bones and boil to about half the original volume. Strain to remove bones and skins. Add some white pepper and salt. The cans are then preferably exhausted by passing through a steam exhaust box. They are immediately closed using mechanical vacuum closing machines and given a process depending on the size of the can. A guideline process for cans in still retorts: Can size

Can mass

Processing time

Processing temperature

401 × 211 cans 307 × 200 cans

454 g (1 lb.) 227 g (½ lb.)

50 min 45 min

116 °C (240 °F) 116 °C (240 °F)

Footnotes (a), (b), and (c) given for canned boned poultry also apply here. These processes apply only when dried noodles are used. When soaked noodles are used, longer processes are required. Care must be exercised in the selection of the noodles because some noodles have a tendency to become starchy, forming a gummy mass after processing.

7.4.9 Roasted turkey Same as chicken, except that the turkey is roasted whole, then cut in can-size pieces.

7.4.10 Roasted duck Same as turkey, adding to the spices half as much finely powdered sage as there is of pepper.

7.4.11 Roasted goose Same as turkey, omitting the bacon, and using an equal weight of pepper and finely powdered sage. Goose may be packed with sauerkraut; place the desired quantity of goose in the can; then completely fill with kraut, cooked same as for canning.

7.4.12 Roasted guinea fowl Same as chicken.

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7.5 Other meat products 7.5.1 Rabbit meat Rabbit may be canned in two general ways: (a) by picking the meat from the bones and canning the resulting meat, or (b) by cutting the rabbit into suitable sized pieces and canning bone and all. After skinning and cleaning, the rabbit carcass should be thoroughly washed in cold water, care being taken to remove all the blood. It is then placed in a steam-­ jacketed kettle and covered with water. The contents of the kettle are then brought to a boil and simmered gently until tender. The rabbit carcasses are then removed from the kettle, and all the bones are carefully removed. The desired weight of meat is then packed into the cans and the cans filled with a hot broth or jelly, which is made as follows: ●

The water in which the rabbits were cooked is boiled down to approximately half its former volume. Salt is added in the ratio of 227 g (0.5 lbs.) salt to 3.8 L (1 gal) of broth. If a jelly is desired, it can be made by adding 454 g (1 lb.) of best grade gelatin, previously soaked in cold water for 1 h, to 22.7 L (6 gal) of prepared broth.

Most meat products of this kind are packed in flat cans holding 113 g (¼ lb.) to 454 g (1 lb.). The filled cans are passed through a steam exhaust box to remove entrapped air and to heat up the contents to at least 60 °C (140 °F) at the centre and closed immediately.

The following processes are suggested for rabbit meat, in still retortsa,b Can size/mass

Processing time

Processing temperature

½ lb. (227 g) cans 1 lb. (454 g) cans

60 min 75 min

121 °C (250 °F) 121 °C (250 °F)

a These processes are subject to change as further information becomes available. For latest recommended processes or for processes in other sterilisation systems or other can sizes, consult with a competent thermal process authority. b The maximum fill weights listed with these processes may not be suitable for some operations. In these cases, it will be necessary to obtain heat penetration data and resultant processes based on the maximum fill weight expected. If the fill weight critical factor is exceeded for a scheduled process, this constitutes a process deviation that must be evaluated by a competent process authority to determine if a potential health hazard exists.

7.5.2 Canning pieces of rabbit The rabbit carcasses are cleaned as before and are dismembered into pieces of suitable size for the can to be used. The pieces are packed into the can firmly, ⅓ tsp. of salt per 1 lb. of meat is added, and the contents are covered with hot broth or jelly, prepared as described earlier. The cans are then exhausted so that the centre of the contents reaches at least 140 °F (60 °C). They are closed immediately after exhausting and processed. The process described earlier will be satisfactory.

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7.6 Canned meat-based ready meals Many of the ration items originally made for the military have been made into commercial products. Some ideas and guidelines are listed here. They are intended as basic formulas only. All subsistence items are packed to definite specifications, subject to frequent revision. Any canner must, therefore, obtain the specifications and codes of the region the product is being packed in and where it will be sold. Due to variations in formula and manufacturing methods, these products should not be packed without directions from a competent thermal process authority.

7.6.1 Corned beef hash Corned beef hash is usually composed of corned beef, potatoes, and onions, seasoned with salt, pepper, and spices to taste. The formula used depends both on individual tastes and the quality of the product the canner desires to pack. The latter depends largely on the price of the product and the cost of the different ingredients. The following formula may be used as a starting point and varied to suit the individual tastes or conditions. (Water may be added, if desired, to produce a suitable consistency of the product.) The beef is cured and parboiled. The latter is usually done in a stainless steel, steam-jacketed kettle. The meat is boiled until it has lost approximately 25% of its original weight. It is then removed from the kettle and excess fat and gristle trimmed off. It is essential to use a variety of potatoes that do not soften and become mushy when cooked. The potatoes are placed in cold water immediately after peeling and not exposed to the air because exposure to air causes uncooked potatoes to become dark. After all the potatoes are peeled, they are placed in boiling water and boiled for 9–12 min. The meat, potatoes, and peeled onions are cut and mixed in a rotary cutter. The mixed product is then filled into the cans and passed through a steam exhaust box to remove the air and heat the contents to at least 54 °C (130 °F) at the centre. The exhausted cans are closed immediately and processed.

The following processes are suggested for canned corned beef hash in still retorts* Can size/mass

Processing time

Processing temperature

10½ oz. (298 g) 20 oz. (567 g).

120 min 150 min

116 °C (240 °F) 116 °C (240 °F)

*These processes are subject to change as further information becomes available. For latest recommended p­ rocesses or for processes in other sterilisation systems or in other can sizes, consult with a competent thermal process authority.

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7.6.2 Beef stew Ingredients

Metric amount

Imperial (U.S.) amount

Cooked beef Potatoes Carrots Gravy

23 kg 14.5 kg 8.2 kg 23 kg

50 lbs. 32 lbs. 18 lbs. 50 lbs.

Ingredients

Metric amount

Imperial (U.S.) amount

Modified cornstarch/wheat flour Salt Black pepper Water

1.4 kg

3 lbs.

0.81 kg 23 g 2.7 kg

1 lb. 12 oz. 0.8 oz. 6 lbs.

The gravy is prepared according to the following recipe: The meat is cut into 2.5–3.8 cm (1–1½ in.) pieces as nearly uniform in size as is possible, or ground through a plate having holes approximately 3.8 cm (1½ in.) in diametre. The meat is then precooked, with only enough added water to cover the meat adequately in the cooking kettle (not to exceed 23 kg [50 lbs.] of water to each 45.5 kg [100 lbs.] of meat), for such time as is necessary to produce approximately 35% meat shrinkage in the cooking kettle from its raw weight. The precooked meat, vegetables, and gravy are then mixed thoroughly. After mixing, the ingredients are filled into the can in accordance with good commercial practice. The components may be filled into the cans separately, in which case the can shall be inverted before processing. The filled cans are then closed, sealed, processed, and cooled.

7.6.3 Meatballs and spaghetti Ingredients

Metric amount

Imperial (U.S.) amount

Meat Coarsely ground cracker meal Onions, powdered Salt

45.5 kg 6.26 kg

100 lbs. 13.75 lbs.

0.55 kg 1.2 kg

1.2 lbs. 2.75 lbs.

Seasoning

To taste

Meatballs and Spaghetti is a good example of a meal-in-a-can (see Figure 7.6). The beef is ground through a 1.9 cm (¾-in.) plate. If frozen beef is used, the first grind is through a 2.5 cm (1-in.) plate. After thorough mixing with the other ­ingredients,

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Figure 7.6  Canned meatballs and spaghetti.

the mixture then is ground through a plate that will give the necessary consistency for forming balls. The ingredients are formed into balls of uniform size, approximately 22 g each in weight, in accordance with best commercial practice. The meatballs are sufficiently compressed to hold together during cooking and handling. The meatballs are cooked in boiling water for approximately 10 min in accordance with best commercial practice. The tomato sauce is prepared according to the following recipe: Ingredients

Metric amount

Imperial (U.S.) amount

Tomato pulp or paste Cheese Onion powder Sugar Salt Modified cornstarch wheat flour Garlic powder Sweet basil or seasoning to taste Stock (from meatballs) Water (to make up to)

197 kg 25 kg 1.7 kg 10 kg 5 kg 2 kg

433 lbs. 55 lbs. 3.8 lbs. 22 lbs. 11 lbs. 4.5 lbs.

318 g A custom blend may be used.

0.7 lbs.

379 L

100 gal

Blending of the sauce. If dry onions or garlic are used, they are finely chopped or ground through a 6.4 mm (¼-in.) plate. If powdered dehydrated onions are used in lieu of dry onions, the onion powder used is in a ratio of one part, by weight, of onion powder to ten parts, by weight of dry onions. Garlic powder may be used in lieu of dry garlic.

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Figure 7.7  Cans filled with spaghetti and meatballs, ready to be processed.

The cheese is finely ground with water to a thick creamy consistency. Sweet basil is steeped in warm water for about ½ h, and the liquid then strained through a cheesecloth. The flour is mixed with a small amount of cold water to form a thin paste before using. Stock made from cooking the meatballs is placed in a kettle, the onions and garlic added, and cooked for about 4 min. Salt, sugar, tomato pulp and/or paste, and cheese are then added, and the mixture brought to a boil. The flour, sweet basil extract, and enough water is added to bring the total mixture to 379 L (100 gal). The sauce is boiled a few minutes and then passed through a finisher screen, or some other method may be used that will give equivalent results. The quantity of water used in cooking the meat is such that the resultant stock will all be used in preparing the sauce. The stock for the first batch of sauce may be made from fresh beef other than that used for meatballs. Preparation of spaghetti. Care is taken to prevent excessive softening or breaking of the spaghetti. The spaghetti is drained before filling into cans. The spaghetti shall be cooked in water in such a manner that 45 kg (100 lbs.) does not weigh more than 118 kg (260 lbs.) after cooking. Filling. Internally lacquered tinplate cans are filled with a prescribed amount of spaghetti, then a set number of meatballs. The can it then filled with hot sauce (see Figure 7.7). The cans are seamed closed using steam flow closure. Processing must be done according to recommendations by a competent thermal processing specialist.

7.6.4 Chopped ham and eggs Cured and smoked hams are skinned and boned and the outside covering of fat trimmed so that it is not in excess of 13 mm (½ in.) of thickness at any given point. They are then ground through a plate with holes that are approximately 13 mm (½ in.) in diametre. The ground ham and the eggs are then placed in a mechanical mixer in

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equal ­proportions. Pepper is then added at the rate of 7.1 g (¼ oz.) to each 45.4 kg (100 lbs.) of the product. The product is then mixed until all pieces of the ham are coated with the egg. After thorough mixing, the product is filled into a can, closed, sealed, and processed.

7.6.5 Canned hamburgers To each 45.4 kg (100 lbs.) of beef is added 0.7 kg (1½ lbs.) of salt and 50 g (1¾ oz.) of pepper prior to the last grinding operation. The product is formed into patties, which are deep fat fried to approximately a 28% shrink from their raw weight. The weight of the raw hamburgers is such that they will weigh approximately 78 g (2¾ oz.) after they are fried. The fried hamburgers are then thoroughly drained. After draining, two patties are immediately filled into the can, and the net weight of the product should be approximately 156 g (5½ oz.). The cans are closed, sealed, and processed.

7.6.6 Chili con carne Ingredient

Metric units

Imperial units (U.S.)

Lean beef Chili powder Powdered onions Broth Garlic powder Wheat flour/modified starch Tomatoes or tomato pulp Mexican or red kidney beans

45.4 kg 112 g 45 g 15 L 5.6 g 0.9 kg 7.6 L 1.4 kg

100 lbs. 4 oz. 1.6 oz. 4 gal 0.2 oz. 2 lbs. 2 gal 3 lbs.

This product generally consists of a mixture of beef and Mexican or red kidney beans, with various spices and condiments. The preceding formula may be used as a starting point, and varied to meet individual tastes and demands. The beef is cooked with slightly more than 33 L (4 gal) of water in a covered steam-jacketed kettle until well done. The cooking water is drained off and constitutes the broth mentioned in the formula. The cooked meat is ground through a ¼-in. (13 mm) plate of the grinder. The onions, garlic, and chili peppers, if used, are ground or chopped fine. The flour is mixed into a paste with part of the broth from cooking the beef. The ingredients are mixed then with the remainder of the broth and cooked until hot. When more fat is desired, tallow or oleo oil is added. The product is salted to taste, with 224–336 g (8–12 oz.) of salt for the above formula. When beans are added, they are cooked separately until soft and then well washed. They may either be mixed with the other ingredients or weighed into the cans, which are then filled with the other ingredients. If the latter procedure is used, the beans should be hot when canned.

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On small-scale operations, the filling is done by hand, but filling machines can be secured from canning machinery companies that will handle this material. The product should be filled into the cans hot and sealed immediately. The temperature of the product when closed should not be less than 66 °C (150 °F) for smallsize cans and not less than 71 °C (160 °F) for larger cans.

Examples of process times and temperatures for chili con carne, in still retorts* Can size

Processing time at 116 °C (240 °F)

Processing time at 121 °C (250 °F)

No. 1 cans (or smaller) No. 2 cans No. 10 cans

60 min 80 min 180 min

50 min 60 min –

*These processes are subject to change as further information becomes available. For latest recommended processes or for processes in other sterilisation systems or in other can sizes, consult with a competent thermal process authority.

7.6.7 Curried mutton Ingredient

Metric amount

Imperial (U.S.) amount

Boiled mutton, finely chopped Rice Butter Flour Curry powder Salt Boiling water

45 kg 22.5 kg 3.2 kg 2.3 kg 1.1 kg 1.4 kg 24.6 L

100 lbs. 50 lbs. 7 lbs. 5 lbs. 2½ lbs. 3 lbs. 6½ gal

Wash the rice and drop slowly into 151 L (40 gal) boiling water. Cook for 35 min and drain off water. Place butter in kettle and melt. Mix the flour with butter, and add 24.6 L (6½ gal) water. Stir constantly until it boils. Turn off steam, and mix in all other ingredients, including the rice. Fill while hot. Process.

Acknowledgments The author acknowledges with thanks the contributions made to earlier editions of this book by R. Bruce Tompkin, Ph.D., Armour Swift-Eckrich, Downers Grove, IL, and Bruce E. Madden, USDA-FSIS, Washington, DC.

Reference Betts, G.D., Gaze, J.E., 1992. Food Pasteurization Treatments. Campden BRI Technical Manual No. 27.