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Effect of Postchill Deboning Time on the Texture Profile of Broiler Breeder Hen Breast Meat1
2003 Poultry Science Association, Inc.
Effect of Postchill Deboning Time on the Texture Profile of Broiler Breeder Hen Breast Meat1 C. E. Lyon,*,2 B. G. Lyon,† and E. M. Savage† *Poultry Processing & Meat Quality Research Unit and †Quality Assessment Research Unit, USDA-ARS, Russell Research Center, Athens, Georgia 30604-5677
SUMMARY Before any significant progress can be made in altering textural characteristics of a meat product, the basic profile of the meat and the possible alterations in that profile due to processing procedures must be known. A number of papers have been published addressing ways to optimize the textural characteristics of broiler breast meat. Changes in broiler processing procedures and processing time lines have been adopted by processors because of the results of these studies. While the number of breeder hens processed annually is much lower than the number of broilers, adding value to the end product could result in new innovative product forms for this niche market meat. The traditional goal for heavy fowl processors has been to remove the muscles, dice or grind the meat and sell it as an ingredient in other products. In an effort to expand the product forms of breeder hen meat, which is usually assumed to be tough and chewy, this study was designed to profile the texture of the meat based on four postchill (PC) deboning times. Instrumental and sensory profiles of the breast meat from hens were determined. There were significant texture differences in the cooked fillets due to deboning time. Cooked yield for the fillets deboned 24 h PC was lower than for fillets deboned 2 or 8 h PC. Key words: texture, sensory attribute, breeder hen, breast meat, deboning time 2003 J. Appl. Poult. Res. 12:348–355
DESCRIPTION OF PROBLEM Utilization and consumption of fowl meat (mature hens) has been limited by poor sensory quality, including toughness. Primary uses for the muscle food are as canned meat for USDA school lunch and military food programs or as diced or ground ingredients in processed combination foods such as canned soups, stews, and patties [1]. In addition, extreme heat conditions used in canning tend to compound fowl meat texture problems [2, 3]. If new prod1 2
uct forms for breast meat from breeder hens are to be successful, then the first step needs to be an accurate flavor and texture profile of the meat. This type of product profile was documented when broiler meat was substituted for the traditionally used fowl meat as a diced ingredient in soups and other products [4, 5]. Shorter chilling times for the broiler carcasses resulted in diced pieces that retained their integrity after retorting, as compared with meat from carcasses that were chilled for longer
Mention of specific brand names does not imply endorsement by the authors or the institution at which they are employed. To whom correspondence should be addressed: [email protected].
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Primary Audience: Quality Assurance Personnel, Researchers, Plant Managers
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TABLE 1. Sensory attributesA and definitions used to profile the flavor and texture of breeder hen breast meat Attribute
Abbreviation
Flavor 1. Broth 2. Chicken/meaty 3. Cardboard 4. Wet feathers 5. Bloody/serum/metallic
brothy chickn cbd wetfeath metal
Aromatic taste sensation associated with: meat stock cooked white or dark chicken muscle cardboard, wet paper wet poultry feathers raw or > rare = lean meat/serum
Basic taste 6. Sweet 7. Salty 8. Sour
swt salt sour
Taste on tongue stimulated by: sugars and high potency sweeteners sodium salts, especially sodium chloride (table salt) acids
Texture 9. Springiness
springi cohes
11. Hardness
hard
12. Moisture release
moisrel
13. Particle size
psize
14. Bolus size 15. Chewiness 16. Toothpack/ residual particles
bsize chewi tpack
Afterfeel/aftertaste 17. Metallic 18. Oily mouthcoat
ametal aoily
Degree to which the sample returns to its original shape after partial compression (low to high) Degree to which sample deforms rather than breaks—first bite (low to high) Force required to compress the sample with molars—first two bites (low to high) Amount of moisture (liquid/fat) coming from the sample during first 10 chews (low to high) Size of meat particles in wad during chewdown (small/mealy to large/fibrous) Size of wad at 25 to 30 chews (small to large) Amount of work required to chew the sample (low to high) Amount of particles left in teeth/mouth after point of swallow (none to much) Sensation of metals in mouth; tinny; iron Feeling or coating detected in the mouth due to oil or grease
Sensory attribute intensities were scored on a scale of 1 = low to 15 = high.
A
times prior to cooking. It was concluded that some texture attributes associated with shorter chilling and aging times, such as fibrousness and cohesiveness of the meat, may be advantageous for products that undergo further heat treatments such as retorting [4]. This information provided processors with optimum chilling and aging periods for processed carcasses when broiler breasts were used as the meat ingredient in the ready-to-eat product.
Under traditional broiler processing schemes, carcass or front-half postchill (PC) aging time is critical to ensure optimum textural characteristics in the cooked breast meat [6, 7]. The relationships between postmortem aging on-the-frame to biochemical changes [8, 9] and texture of the cooked breast meat [10, 11] have been reported. However, for heavy fowl, the processing scheme is not the same as for broilers because the traditional final product
TABLE 2. Raw and cooked weights and cooked yield of breeder hen breast meat deboned at 4 postchill (PC) times PC debone time 2 4 8 24
h h h h
Raw weight (g) 250.5 230.1 237.2 242.9
± ± ± ±
30.8a 26.3b 27.0ab 33.8ab
Cooked weight (g) 194.1 175.1 183.6 182.6
± ± ± ±
25.6a 21.3b 23.4ab 28.3ab
Cooked yield (%) 77.4 76.1 77.3 75.1
Means (n = 24) and SD within a column with no common superscripts are significantly different (P < 0.05).
a,b
± ± ± ±
1.9a 2.3ab 1.9a 3.5b
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10. Cohesiveness
Definition
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form has not been an intact muscle or even strips. The effects of electric stimulation during bleeding on instrumental texture (shear values) and cook loss of mature hen breast fillets deboned at either 2 or 24 h postevisceration were recently determined [12]. Fillets from carcasses that had been electrically stimulated and deboned after a 2 h chill required approximately 50% less force to shear (more tender) and their cook loss was 1.8% less than fillets from nonstimulated carcasses. Fillets deboned 24 h PC exhibited no differences due to the stimulation treatment, indicating that over time the biochemical reactions in the nonstimulated fillets had reached the same level as the stimulated fillets. The objective of this research was to determine the texture and flavor profile of breeder hen breast meat when the muscles were deboned at 2, 4, 8, and 24 h PC. Instrumental
and sensory texture and cooked yields were evaluated.
MATERIALS AND METHODS Broiler breeder hens, 66 wk old, were obtained from the University of Georgia Poultry Farm. Feed was withdrawn 24 h prior to processing. Hens were placed in plastic coops and held for 18 h prior to transport to the pilot plant. Transport time was approximately 10 min. This procedure was repeated for two consecutive days. Forty birds were processed each day, for a total of 80 birds. To accommodate pilot plant processing, hens were processed in groups of five (each treatment group of 10 processed back-to-back as two subgroups of five). The hen’s feet were placed in shackles and the overhead line moved through a stunner (15 V DC, pulsed for 10 s, approximately 10 ma/bird) [13], then the necks were cut with an automated knife [14]. Hens
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FIGURE 1. Warner-Bratzler shear curve attributes (means and SE) for breeder hen breast meat deboned at 4 postchill times. a–cSignificant differences (P < 0.05) among postchill times are indicated by different letters above bars within each attribute box. TA = texture analyzer; WB = Warner-Bratzler.
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TABLE 3. Sensory flavor and texture attribute scores (mean ± SD) for breeder hen breast meat deboned at four postchill (PC) times PC deboning time Abbreviation
2h
4h
Flavor 1. Broth 2. Chicken 3. Cardboard 4. Wet feathers 5. Bloody/serum/metallic 6. Sweet 7. Salty 8. Sour
brothy chickn cbd wetfeath metal swt salt sour
2.9 4.2 2.6 2.8 3.4 2.3 2.0 2.8
± ± ± ± ± ± ± ±
0.8 0.5 0.9 0.7 0.9 0.7 0.6 0.8
3.1 4.3 2.7 2.8 3.4 2.8 2.1 2.9
± ± ± ± ± ± ± ±
1.1 0.6 0.9 0.8 1.1 0.8 0.7 0.8
3.2 4.3 2.6 2.8 3.3 2.4 2.0 2.9
± ± ± ± ± ± ± ±
0.8 0.6 1.0 0.8 1.0 0.7 0.7 0.8
3.0 4.2 2.5 2.7 3.3 2.3 2.0 2.8
± ± ± ± ± ± ± ±
1.1 0.5 0.9 0.7 1.0 0.8 0.7 0.7
Texture 9. Springiness 10. Cohesiveness 11. Hardness 12. Moisture release 13. Particle size 14. Bolus size 15. Chewiness 16. Toothpack/residual particles
springi cohes hard moisrel psize bsize chewi tpack
4.7 6.3 5.8 3.4 3.9 4.5 5.6 3.6
± ± ± ± ± ± ± ±
0.9ab 1.5a 0.9a 0.8 0.9a 1.1a 1.2ab 1.0
4.9 6.0 5.8 3.6 3.9 4.7 5.9 3.7
± ± ± ± ± ± ± ±
0.9a 1.3a 1.3a 1.0 1.2a 1.4a 1.3a 0.9
4.3 5.6 5.4 3.6 3.5 4.2 5.2 3.8
± ± ± ± ± ± ± ±
1.2b 1.1ab 1.1ab 0.8 0.9ab 1.0ab 0.7bc 1.0
4.1 5.2 4.9 3.3 3.3 3.7 4.8 3.7
± ± ± ± ± ± ± ±
1.2b 1.2b 1.0b 1.0 1.1b 1.2b 0.8c 1.0
Afterfeel/aftertaste 17. Bloody/serum/metallic 18. Oily mouthcoat
ametal aoily
3.5 ± 1.1 1.1 ± 0.8
3.3 ± 0.9 1.1 ± 0.9
8h
3.3 ± 0.9 1.3 ± 1.1
24 h
3.2 ± 1.1 1.0 ± 0.9
Means (n = 27) and SD within a row with no common superscripts are significantly different (P < 0.05).
a–c
were bled for 120 s, and the carcasses were transferred to a separate overhead line for scalding and feather removal. Carcasses were immersed in 134°F, agitated water for 2 min in the single section of a commercial scalder (2,000 L capacity). Feathers were removed by passing the line through a five-banked commercial picker for 30 s [15]. After exiting the picker, heads and feet were removed. Carcasses were eviscerated manually and then rinsed inside and out with tap water. Carcasses were identified with color-coded wing tags and chilled in agitated ice water (34 to 36°F) for 30 min [16]. Each treatment group (two subgroups of five) was initially processed and placed into the chillers in 15 min increments. The 15 min from initiation of bleeding through placement in the chillers, plus the 30 min chill time, totaled 45 min postmortem for each group. After chilling, carcasses were placed in a 35°F cooler and covered with ice until time to remove the breast muscles. Both breast fillets were removed at the appropriate PC time (2, 4, 8, 24 h) by using the technique of Hamm [17]. Each skinless fillet
was individually placed in a labeled heat-andseal bag and put on a tray in a −30°F freezer. After freezing, the fillets from each deboning time treatment were held in the −30°F freezer until evaluated. For instrumental and panel evaluation, the fillets were removed from the freezer, and the raw weight of each fillet in its bag was recorded. To derive the individual fillet weight, 10 empty bags were weighed, and the average bag weight was subtracted from the combined frozen fillet and bag weight. The bags of fillets were arranged in a single layer on a tray and thawed in a commercial refrigerator at 36 to 38°F for approximately 20 h. Eight fillets at a time (four fillets per container) were cooked for 35 min on a commercial range in two stainless steel vessels filled with 2 gal of water heated to 185°F. Water temperature was monitored with a thermocouple. A time of 35 min had been determined in preliminary trials to result in adequate cooking. The endpoint temperature of the heaviest fillet was measured (minimum 175°F) to ensure adequate cooking for each sample set [18]. After
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Attribute
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FIGURE 2. “Spider web” illustration of the sensory texture profile of breeder hen breast meat deboned at four postchill times. Rays extending from the center point represent truncated 15-point line scales for each texture attribute. Mean sensory scores for each attribute are plotted on the line scales and connected to create a profile of the texture of each sample. Springi = springiness; cohes = cohesiveness; hard = hardness; moisrel = moisture release; p size = particle size; b size = bolus size; chewi = chewiness; tpack = toothpack.
cooking, the fillets were tempered for 5 to 8 min. Fillets were then removed from the bags and cooked weights recorded. Two parallel strips, 0.75 in wide, were removed from each fillet [19]. One strip was used for shear value analysis, and the other strip for panel flavor and texture evaluation. Assignment of the two strips within the breasts was alternated between replications for instrumental and panel tests.
Warner-Bratzler (W-B) shear values were determined for each breast fillet by using one of the 0.75-in. strips. Attributes associated with the instrumental shearing procedure were force to shear, gradient, area under the curve, and force to shear multiplied by sample dimensions [20]. Sensory flavor and texture profiles were determined by using the other 0.75-in. strips re-
LYON ET AL.: BREEDER HEN BREAST MEAT
RESULTS AND DISCUSSION Weights and Cooked Yield There were significant differences in raw and cooked fillet weights by deboning time (Table 2). Raw weights for the treatment groups ranged from 250 g (8.8 oz) for the 2-h fillets to 230 g (8.1 oz.) for the 4-h fillets. This weight trend was also noted in the cooked fillets, which ranged from 194 g (6.8 oz.) for the fillets from the 2-h PC deboning group to 175 g (6.17 oz.) for the fillets from the 4-h deboning group. The fillets deboned 24 h PC exhibited a significantly lower cooked yield (75.12%) than fillets deboned 2 or 8 h PC (77.39 and 77.29%, respectively). The fillets deboned 24 h PC were not significantly different from the yield for fillets deboned 4 h PC. Instrumental Texture, W-B Shear Attributes Shear values indicate the maximum force needed to cut through the sample and relates to the firmness or hardness of the samples. The kg/cm2 calculation represents the shear physical force measurement expressed on a sample dimension basis. This attribute is especially helpful if sample test pieces are not the same size. Gradient is the slope of the curve and measures the change in force perceived over the time as the blade shears through the sample (kg/s). Area of the shear curve indicates work
or the distribution of force across time. Higher values mean more work is needed to shear the sample and relates to an overall measurement of sensory “toughness.” There were significant differences in the instrumental texture attributes due to PC deboning time (Figure 1). The fillets deboned 4 h PC exhibited the highest shear values (both as kg of force and kg/cm2), and the highest gradient and area values followed, in order, by the 2, 8 and 24 h PC deboning times. These differences were statistically significant (P < 0.05) for all of the instrumental attributes except gradient (P < 0.06). Attributes noted in Figure 1 illustrate that the direction of the textural changes for all the samples is consistent. Since all the strips used for instrumental evaluation were cut to the same width and height (0.75 in × 0.75 in), the dimensions were equal across the treatments, and the effects are reflected as the reaction of the fibers to time of removal from the frame. Early broiler breast muscle removal (immediately PC or shortly thereafter) induces fiber contraction, which is, for the most part, irreversible and results in elevated shear values (i.e., tough meat) [6, 8, 11]. It is interesting to note that the 2 h PC treatment resulted in significantly lower WB shear attributes compared with the 4 h PC treatment (Figure 1). These results illustrate the variation that can be noted during the initial 2 to 4 h postmortem times. For example, it has been reported that W-B shear values for broiler breast fillets did not change between 1 and 2 h in the chiller but decreased significantly after 3 h [22]. In another study, shear values from broiler fillets were lower immediately after a 45 to 50 min chill, then increased at 0.5 and 1 h PC before decreasing at 1.5 h PC [23]. Sensory Flavor and Texture Attributes Deboning time did not have a significant effect on any of the eight flavor attributes evaluated by the descriptive panel (Table 3). All 18 values were in the slight to moderate range on the 15-point intensity scale. Although there were no differences in flavor attributes associated with deboning at the 4 PC times, the basic flavor profile indicates some similarities to broiler breast flavor profiles, in that “broth,” “chicken,” “cardboard,” and “bloody/serum/
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moved from the fillets. Sample strips cut from the breast were placed in prewarmed glass cups that were fitted in styrofoam bowls to maintain serving temperature. Sample containers were coded with three-digit numbers and presented to eight panelists in individual sensory workstations equipped with computers for data collection using the Compusensefive Sensory Analysis System [21]. The panelists evaluated the sample attributes for intensity and marked the response on 15-point line scales, where 1 = low to 15 = high. Sensory flavor, basic tastes, texture, and afterfeel/aftertaste attributes and definitions used by the descriptive panel to rate breeder hen breast meat are detailed in Table 1. The flavor and texture lexicon had been developed by the trained descriptive sensory panel during orientation sessions. The evaluations were replicated three times.
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characteristics. The sensitivity of the trained panel is evident in differences noted in the six attributes of the texture profile: springiness, cohesiveness, hardness, chewiness, particle size, and bolus size. The other two attributes that were significantly affected by PC deboning time were particle size and bolus size, and both of these are directly related to the behavior of the muscle fibers to deboning time [24]. Generally, the earlier the breast muscle is removed from the skeletal frame, the more pronounced the contraction of the individual fibers. The greater degree of contraction equates to differences in toughness and tenderness in the cooked meat. For instrumental procedures, such as W-B shear, early deboning means higher values for force to shear. But for the trained panel, it means significant differences in many more of the attributes studied, including larger particle size and bolus size for meat from the early deboned fillets. The “spider web” graphic illustrates the differences in texture based on PC deboning time. Generally, fillets from the 2 and 4 h PC deboning times and fillets from the 8 and 24 h treatments grouped close together for the significant attributes. This same grouping would be expected for broiler breast meat and is a reflection of the postmortem time and rate of biochemical changes that relate to ultimate texture characteristics when birds are processed under traditional schemes. The visual results can be an easier way to interpret the profile, especially when determining the effects of a treatment such as deboning time.
CONCLUSIONS AND APPLICATIONS 1. Cooked yield was increased when the breast fillets were deboned earlier (2, 4, 8 h). 2. The basic flavor profile (eight attributes) was determined for breast meat from breeder hens. The PC deboning times had no influence on the flavor profile. However, changes due to ingredients and/or other processing treatments can now be compared to this basic profile. 3. Both instrumental and sensory texture attributes were significantly affected by the PC deboning times. Earlier deboning resulted in higher force to shear values, and significant differences in six of the eight descriptive sensory texture attributes.
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metallic” are major perceived notes. A major difference between broiler and hen is the inclusion of “wet feathers” as a flavor note in cooked hen meat. Basic tastes of sweet, salt and sour were also present in hen as in broiler. These data establish a baseline flavor profile for the hen breast meat processed and cooked under the conditions of this study. Similar profiles determined with broiler breast meat, spent layer meat, and various levels of nonmeat ingredients, as well as alternative processing schemes (electric stimulation, extended chilling) are being used by quality control and R& D personnel to optimize end product characteristics [24, 25, 26, 27]. The “spider web” in Figure 2 illustrates a baseline profile of sensory texture attributes of the breeder hen breast meat at the PC deboning times. The rays extending from the center point represent the 15-point line scales for attribute intensity. Each attribute is represented by a ray. Mean scores for each attribute were plotted on the rays, and then points were connected to provide the visual profile. Six of the eight sensory texture attributes were significantly affected by the PC deboning time (Table 3). Typically, sensory texture data exhibit a more complicated picture than the one-dimensional shear value based on an instrument that records force, distance, time, or some combination of the three. The “human instrument”—in this case the descriptive panel—also integrates aroma, appearance, data collected during chewing, as the sample, teeth, tongue, and saliva all interact to yield many impressions that relate to sample
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REFERENCES AND NOTES 1. Lyon, B. G. 1983. Effects of salt and phosphate treatments on deboned meat from light and heavy fowl. Poult. Sci. 62:321–330.
17. Hamm, D. 1881. Unconventional meat harvesting. Poult. Sci. 60(suppl.1):1666. (Abstr.).
2. Lyon, B. G., and A. A. Klose. 1980. Sensory profiling of canned boned chicken: Comparison of retail, school lunch, and military canned bone chicken. J. Food Sci. 45:1336–1340.
18. A Barnant hand-held thermometer was inserted through the bag into the fillet. A minimum temperature of 175°F was obtained.
3. Lyon, B. G., and A. A. Klose. 1981. Effect of heat processing in cans and retort pouches on sensory properties of fowl meat. J. Food Sci. 46:227–230, 233. 4. Lyon, B. G., C. E. Lyon, and J. P. Hudspeth. 1994. Texture profiles of canned boned chicken as affected by chilling-aging times. Poult. Sci. 73:1475–1478. 5. Lyon, B. G., and C. E. Lyon. 1996. Texture evaluations of cooked, diced broiler breast samples by sensory and mechanical methods. Poult. Sci. 75:812–819.
7. Lyon, C. E., D. Hamm and J. E. Thomson. 1985. pH and tenderness of broiler breast meat deboned various times after chilling. Poult. Sci. 64:307–310. 8. McKee, S. R., E. M. Hirschler, and A. R. Sams. 1997. Physical and biochemical effects of broiler breast tenderization by aging after pre-rigor deboning. J. Food Sci. 62:959–962. 9. Walker, L. T., S. D. Shackelford, S. G. Birkhold, and A. R. Sams. 1995. Biochemical and structural effects of rigor mortis accelerating treatments in broiler pectoralis. Poult. Sci. 74:176–186. 10. Lyon, C. E., C. M. Papa, B. G. Lyon, and M. C. Robach. 1992. Broiler tenderness: Effects of post-chill deboning time and fillet holding time. J. Appl. Poult. Res. 1:27–32. 11. Papa, C. M., and C. E. Lyon. 1989. Shortening of the pectoralis muscle and meat tenderness of broiler chickens. Poult. Sci. 68:663–669. 12. Dickens, J. A., C. E. Lyon, and R. J. Buhr. 2002. The effects of electrical stimulation during bleeding on shear values and cook loss of breast fillets from mature chickens deboned at two or twentyfour hours post-evisceration. J. Appl. Poult. Res. 11:111–116. 13. SF-7000 pre-stunner brine cabinet. Simmons Engineering, Dallas, GA. 14. SK-5 automated knife. Simmons Engineering, Dallas, GA. 15. Johnson Food Equipment Co., Kansas City, KS. 16. Two prototype paddle chillers, 35-gal capacity, paddles rotating at 4 rpm. Chiller temperature ranged from 34 to 36°F.
20. Shear attributes were determined using the Texture Analyzer TA-XT2. A 25-kg load cell was fitted to the TA-XT2, and a traditional Warner-Bratzler blade was used at a test speed of 4 mm/s. The height of each strip was trimmed to be no more than 0.75 in, so the sample height and width (0.75 in) were known. The height at the point of shearing was noted prior to initiating the test. Each strip was sheared twice, and the values were averaged. The curve attributes and their definitions are 1) shear value—maximum force (kg) recorded as the blade cuts through the sample; 2) gradient—(kg/s)—slope of the curve calculated from contact of sample to peak of the curve; 3) area under the curve—area under the shear curve from the point of sample contact with the blade through the complete shearing of the sample; 4) shear value by sample dimensions (kg/cm2)—force in kilograms based on height × width of the strips. 21. Compusensefive Sensory Analysis System. Compusense Inc., Guelph, ON, Canada. 22. Dickens, J. A., and C. E. Lyon. 1995. The effects of electricstimulation and extended chilling times on the biochemical reactions and texture of cooked broiler breast meat. Poult. Sci. 74:2035–2040. 23. Lyon, C. E., B. G. Lyon, and J. A. Dickens. 1998. Effects of carcass stimulation, deboning time and marination on color and texture of broiler breast meat. J. Appl. Poult. Res. 7:53–60. 24. Lyon, B. G., and C. E. Lyon. 1997. Sensory descriptive profile relationships to shear values of deboned poultry. J. Food Sci. 62:885–888, 897. 25. Lyon, B. G., C. E. Lyon, and J. P. Hudspeth. 1994. Texture profiles of canned-boned chicken as affected by chilling-aging times. Poult. Sci. 73:1475–1478. 26. Lyon, C. E., B. G. Lyon, W. E. Townsend, and R. L. Wilson, Jr. 1978. Effect of level of structured protein fiber on quality of mechanically deboned chicken meat patties. J. Food Sci. 43:1524– 1527. 27. Lyon, B. G., C. E. Lyon, and W. E. Townsend. 1978. Characteristics of six patty formulas containing different amounts of mechanically deboned broiler meat and hand deboned fowl meat. J. Food Sci. 43:1656–1661.
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6. Dawson, P. L., D. M. Janky, M. G. Dukes, L. D. Thompson, and S. A. Woodward. 1987. Effect of post-mortem boning time during simulated commercial processing on the tenderness of broiler breast meat. Poult. Sci. 66:1331–1333.
19. Lyon, B. G., and C. E. Lyon. 1991. Shear value ranges by Instron Warner-Bratzler and single-blade Allo-Kramer devices that correspond to sensory tenderness. Poult.Sci. 70:188–191.
Effect of Postchill Deboning Time on the Texture Profile of Broiler Breeder Hen Breast Meat1 C. E. Lyon,*,2 B. G. Lyon,† and E. M. Savage† *Poultry Processing & Meat Quality Research Unit and †Quality Assessment Research Unit, USDA-ARS, Russell Research Center, Athens, Georgia 30604-5677
SUMMARY Before any significant progress can be made in altering textural characteristics of a meat product, the basic profile of the meat and the possible alterations in that profile due to processing procedures must be known. A number of papers have been published addressing ways to optimize the textural characteristics of broiler breast meat. Changes in broiler processing procedures and processing time lines have been adopted by processors because of the results of these studies. While the number of breeder hens processed annually is much lower than the number of broilers, adding value to the end product could result in new innovative product forms for this niche market meat. The traditional goal for heavy fowl processors has been to remove the muscles, dice or grind the meat and sell it as an ingredient in other products. In an effort to expand the product forms of breeder hen meat, which is usually assumed to be tough and chewy, this study was designed to profile the texture of the meat based on four postchill (PC) deboning times. Instrumental and sensory profiles of the breast meat from hens were determined. There were significant texture differences in the cooked fillets due to deboning time. Cooked yield for the fillets deboned 24 h PC was lower than for fillets deboned 2 or 8 h PC. Key words: texture, sensory attribute, breeder hen, breast meat, deboning time 2003 J. Appl. Poult. Res. 12:348–355
DESCRIPTION OF PROBLEM Utilization and consumption of fowl meat (mature hens) has been limited by poor sensory quality, including toughness. Primary uses for the muscle food are as canned meat for USDA school lunch and military food programs or as diced or ground ingredients in processed combination foods such as canned soups, stews, and patties [1]. In addition, extreme heat conditions used in canning tend to compound fowl meat texture problems [2, 3]. If new prod1 2
uct forms for breast meat from breeder hens are to be successful, then the first step needs to be an accurate flavor and texture profile of the meat. This type of product profile was documented when broiler meat was substituted for the traditionally used fowl meat as a diced ingredient in soups and other products [4, 5]. Shorter chilling times for the broiler carcasses resulted in diced pieces that retained their integrity after retorting, as compared with meat from carcasses that were chilled for longer
Mention of specific brand names does not imply endorsement by the authors or the institution at which they are employed. To whom correspondence should be addressed: [email protected].
Downloaded from http://japr.oxfordjournals.org/ by guest on March 23, 2015
Primary Audience: Quality Assurance Personnel, Researchers, Plant Managers
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TABLE 1. Sensory attributesA and definitions used to profile the flavor and texture of breeder hen breast meat Attribute
Abbreviation
Flavor 1. Broth 2. Chicken/meaty 3. Cardboard 4. Wet feathers 5. Bloody/serum/metallic
brothy chickn cbd wetfeath metal
Aromatic taste sensation associated with: meat stock cooked white or dark chicken muscle cardboard, wet paper wet poultry feathers raw or > rare = lean meat/serum
Basic taste 6. Sweet 7. Salty 8. Sour
swt salt sour
Taste on tongue stimulated by: sugars and high potency sweeteners sodium salts, especially sodium chloride (table salt) acids
Texture 9. Springiness
springi cohes
11. Hardness
hard
12. Moisture release
moisrel
13. Particle size
psize
14. Bolus size 15. Chewiness 16. Toothpack/ residual particles
bsize chewi tpack
Afterfeel/aftertaste 17. Metallic 18. Oily mouthcoat
ametal aoily
Degree to which the sample returns to its original shape after partial compression (low to high) Degree to which sample deforms rather than breaks—first bite (low to high) Force required to compress the sample with molars—first two bites (low to high) Amount of moisture (liquid/fat) coming from the sample during first 10 chews (low to high) Size of meat particles in wad during chewdown (small/mealy to large/fibrous) Size of wad at 25 to 30 chews (small to large) Amount of work required to chew the sample (low to high) Amount of particles left in teeth/mouth after point of swallow (none to much) Sensation of metals in mouth; tinny; iron Feeling or coating detected in the mouth due to oil or grease
Sensory attribute intensities were scored on a scale of 1 = low to 15 = high.
A
times prior to cooking. It was concluded that some texture attributes associated with shorter chilling and aging times, such as fibrousness and cohesiveness of the meat, may be advantageous for products that undergo further heat treatments such as retorting [4]. This information provided processors with optimum chilling and aging periods for processed carcasses when broiler breasts were used as the meat ingredient in the ready-to-eat product.
Under traditional broiler processing schemes, carcass or front-half postchill (PC) aging time is critical to ensure optimum textural characteristics in the cooked breast meat [6, 7]. The relationships between postmortem aging on-the-frame to biochemical changes [8, 9] and texture of the cooked breast meat [10, 11] have been reported. However, for heavy fowl, the processing scheme is not the same as for broilers because the traditional final product
TABLE 2. Raw and cooked weights and cooked yield of breeder hen breast meat deboned at 4 postchill (PC) times PC debone time 2 4 8 24
h h h h
Raw weight (g) 250.5 230.1 237.2 242.9
± ± ± ±
30.8a 26.3b 27.0ab 33.8ab
Cooked weight (g) 194.1 175.1 183.6 182.6
± ± ± ±
25.6a 21.3b 23.4ab 28.3ab
Cooked yield (%) 77.4 76.1 77.3 75.1
Means (n = 24) and SD within a column with no common superscripts are significantly different (P < 0.05).
a,b
± ± ± ±
1.9a 2.3ab 1.9a 3.5b
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10. Cohesiveness
Definition
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form has not been an intact muscle or even strips. The effects of electric stimulation during bleeding on instrumental texture (shear values) and cook loss of mature hen breast fillets deboned at either 2 or 24 h postevisceration were recently determined [12]. Fillets from carcasses that had been electrically stimulated and deboned after a 2 h chill required approximately 50% less force to shear (more tender) and their cook loss was 1.8% less than fillets from nonstimulated carcasses. Fillets deboned 24 h PC exhibited no differences due to the stimulation treatment, indicating that over time the biochemical reactions in the nonstimulated fillets had reached the same level as the stimulated fillets. The objective of this research was to determine the texture and flavor profile of breeder hen breast meat when the muscles were deboned at 2, 4, 8, and 24 h PC. Instrumental
and sensory texture and cooked yields were evaluated.
MATERIALS AND METHODS Broiler breeder hens, 66 wk old, were obtained from the University of Georgia Poultry Farm. Feed was withdrawn 24 h prior to processing. Hens were placed in plastic coops and held for 18 h prior to transport to the pilot plant. Transport time was approximately 10 min. This procedure was repeated for two consecutive days. Forty birds were processed each day, for a total of 80 birds. To accommodate pilot plant processing, hens were processed in groups of five (each treatment group of 10 processed back-to-back as two subgroups of five). The hen’s feet were placed in shackles and the overhead line moved through a stunner (15 V DC, pulsed for 10 s, approximately 10 ma/bird) [13], then the necks were cut with an automated knife [14]. Hens
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FIGURE 1. Warner-Bratzler shear curve attributes (means and SE) for breeder hen breast meat deboned at 4 postchill times. a–cSignificant differences (P < 0.05) among postchill times are indicated by different letters above bars within each attribute box. TA = texture analyzer; WB = Warner-Bratzler.
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TABLE 3. Sensory flavor and texture attribute scores (mean ± SD) for breeder hen breast meat deboned at four postchill (PC) times PC deboning time Abbreviation
2h
4h
Flavor 1. Broth 2. Chicken 3. Cardboard 4. Wet feathers 5. Bloody/serum/metallic 6. Sweet 7. Salty 8. Sour
brothy chickn cbd wetfeath metal swt salt sour
2.9 4.2 2.6 2.8 3.4 2.3 2.0 2.8
± ± ± ± ± ± ± ±
0.8 0.5 0.9 0.7 0.9 0.7 0.6 0.8
3.1 4.3 2.7 2.8 3.4 2.8 2.1 2.9
± ± ± ± ± ± ± ±
1.1 0.6 0.9 0.8 1.1 0.8 0.7 0.8
3.2 4.3 2.6 2.8 3.3 2.4 2.0 2.9
± ± ± ± ± ± ± ±
0.8 0.6 1.0 0.8 1.0 0.7 0.7 0.8
3.0 4.2 2.5 2.7 3.3 2.3 2.0 2.8
± ± ± ± ± ± ± ±
1.1 0.5 0.9 0.7 1.0 0.8 0.7 0.7
Texture 9. Springiness 10. Cohesiveness 11. Hardness 12. Moisture release 13. Particle size 14. Bolus size 15. Chewiness 16. Toothpack/residual particles
springi cohes hard moisrel psize bsize chewi tpack
4.7 6.3 5.8 3.4 3.9 4.5 5.6 3.6
± ± ± ± ± ± ± ±
0.9ab 1.5a 0.9a 0.8 0.9a 1.1a 1.2ab 1.0
4.9 6.0 5.8 3.6 3.9 4.7 5.9 3.7
± ± ± ± ± ± ± ±
0.9a 1.3a 1.3a 1.0 1.2a 1.4a 1.3a 0.9
4.3 5.6 5.4 3.6 3.5 4.2 5.2 3.8
± ± ± ± ± ± ± ±
1.2b 1.1ab 1.1ab 0.8 0.9ab 1.0ab 0.7bc 1.0
4.1 5.2 4.9 3.3 3.3 3.7 4.8 3.7
± ± ± ± ± ± ± ±
1.2b 1.2b 1.0b 1.0 1.1b 1.2b 0.8c 1.0
Afterfeel/aftertaste 17. Bloody/serum/metallic 18. Oily mouthcoat
ametal aoily
3.5 ± 1.1 1.1 ± 0.8
3.3 ± 0.9 1.1 ± 0.9
8h
3.3 ± 0.9 1.3 ± 1.1
24 h
3.2 ± 1.1 1.0 ± 0.9
Means (n = 27) and SD within a row with no common superscripts are significantly different (P < 0.05).
a–c
were bled for 120 s, and the carcasses were transferred to a separate overhead line for scalding and feather removal. Carcasses were immersed in 134°F, agitated water for 2 min in the single section of a commercial scalder (2,000 L capacity). Feathers were removed by passing the line through a five-banked commercial picker for 30 s [15]. After exiting the picker, heads and feet were removed. Carcasses were eviscerated manually and then rinsed inside and out with tap water. Carcasses were identified with color-coded wing tags and chilled in agitated ice water (34 to 36°F) for 30 min [16]. Each treatment group (two subgroups of five) was initially processed and placed into the chillers in 15 min increments. The 15 min from initiation of bleeding through placement in the chillers, plus the 30 min chill time, totaled 45 min postmortem for each group. After chilling, carcasses were placed in a 35°F cooler and covered with ice until time to remove the breast muscles. Both breast fillets were removed at the appropriate PC time (2, 4, 8, 24 h) by using the technique of Hamm [17]. Each skinless fillet
was individually placed in a labeled heat-andseal bag and put on a tray in a −30°F freezer. After freezing, the fillets from each deboning time treatment were held in the −30°F freezer until evaluated. For instrumental and panel evaluation, the fillets were removed from the freezer, and the raw weight of each fillet in its bag was recorded. To derive the individual fillet weight, 10 empty bags were weighed, and the average bag weight was subtracted from the combined frozen fillet and bag weight. The bags of fillets were arranged in a single layer on a tray and thawed in a commercial refrigerator at 36 to 38°F for approximately 20 h. Eight fillets at a time (four fillets per container) were cooked for 35 min on a commercial range in two stainless steel vessels filled with 2 gal of water heated to 185°F. Water temperature was monitored with a thermocouple. A time of 35 min had been determined in preliminary trials to result in adequate cooking. The endpoint temperature of the heaviest fillet was measured (minimum 175°F) to ensure adequate cooking for each sample set [18]. After
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FIGURE 2. “Spider web” illustration of the sensory texture profile of breeder hen breast meat deboned at four postchill times. Rays extending from the center point represent truncated 15-point line scales for each texture attribute. Mean sensory scores for each attribute are plotted on the line scales and connected to create a profile of the texture of each sample. Springi = springiness; cohes = cohesiveness; hard = hardness; moisrel = moisture release; p size = particle size; b size = bolus size; chewi = chewiness; tpack = toothpack.
cooking, the fillets were tempered for 5 to 8 min. Fillets were then removed from the bags and cooked weights recorded. Two parallel strips, 0.75 in wide, were removed from each fillet [19]. One strip was used for shear value analysis, and the other strip for panel flavor and texture evaluation. Assignment of the two strips within the breasts was alternated between replications for instrumental and panel tests.
Warner-Bratzler (W-B) shear values were determined for each breast fillet by using one of the 0.75-in. strips. Attributes associated with the instrumental shearing procedure were force to shear, gradient, area under the curve, and force to shear multiplied by sample dimensions [20]. Sensory flavor and texture profiles were determined by using the other 0.75-in. strips re-
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RESULTS AND DISCUSSION Weights and Cooked Yield There were significant differences in raw and cooked fillet weights by deboning time (Table 2). Raw weights for the treatment groups ranged from 250 g (8.8 oz) for the 2-h fillets to 230 g (8.1 oz.) for the 4-h fillets. This weight trend was also noted in the cooked fillets, which ranged from 194 g (6.8 oz.) for the fillets from the 2-h PC deboning group to 175 g (6.17 oz.) for the fillets from the 4-h deboning group. The fillets deboned 24 h PC exhibited a significantly lower cooked yield (75.12%) than fillets deboned 2 or 8 h PC (77.39 and 77.29%, respectively). The fillets deboned 24 h PC were not significantly different from the yield for fillets deboned 4 h PC. Instrumental Texture, W-B Shear Attributes Shear values indicate the maximum force needed to cut through the sample and relates to the firmness or hardness of the samples. The kg/cm2 calculation represents the shear physical force measurement expressed on a sample dimension basis. This attribute is especially helpful if sample test pieces are not the same size. Gradient is the slope of the curve and measures the change in force perceived over the time as the blade shears through the sample (kg/s). Area of the shear curve indicates work
or the distribution of force across time. Higher values mean more work is needed to shear the sample and relates to an overall measurement of sensory “toughness.” There were significant differences in the instrumental texture attributes due to PC deboning time (Figure 1). The fillets deboned 4 h PC exhibited the highest shear values (both as kg of force and kg/cm2), and the highest gradient and area values followed, in order, by the 2, 8 and 24 h PC deboning times. These differences were statistically significant (P < 0.05) for all of the instrumental attributes except gradient (P < 0.06). Attributes noted in Figure 1 illustrate that the direction of the textural changes for all the samples is consistent. Since all the strips used for instrumental evaluation were cut to the same width and height (0.75 in × 0.75 in), the dimensions were equal across the treatments, and the effects are reflected as the reaction of the fibers to time of removal from the frame. Early broiler breast muscle removal (immediately PC or shortly thereafter) induces fiber contraction, which is, for the most part, irreversible and results in elevated shear values (i.e., tough meat) [6, 8, 11]. It is interesting to note that the 2 h PC treatment resulted in significantly lower WB shear attributes compared with the 4 h PC treatment (Figure 1). These results illustrate the variation that can be noted during the initial 2 to 4 h postmortem times. For example, it has been reported that W-B shear values for broiler breast fillets did not change between 1 and 2 h in the chiller but decreased significantly after 3 h [22]. In another study, shear values from broiler fillets were lower immediately after a 45 to 50 min chill, then increased at 0.5 and 1 h PC before decreasing at 1.5 h PC [23]. Sensory Flavor and Texture Attributes Deboning time did not have a significant effect on any of the eight flavor attributes evaluated by the descriptive panel (Table 3). All 18 values were in the slight to moderate range on the 15-point intensity scale. Although there were no differences in flavor attributes associated with deboning at the 4 PC times, the basic flavor profile indicates some similarities to broiler breast flavor profiles, in that “broth,” “chicken,” “cardboard,” and “bloody/serum/
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moved from the fillets. Sample strips cut from the breast were placed in prewarmed glass cups that were fitted in styrofoam bowls to maintain serving temperature. Sample containers were coded with three-digit numbers and presented to eight panelists in individual sensory workstations equipped with computers for data collection using the Compusensefive Sensory Analysis System [21]. The panelists evaluated the sample attributes for intensity and marked the response on 15-point line scales, where 1 = low to 15 = high. Sensory flavor, basic tastes, texture, and afterfeel/aftertaste attributes and definitions used by the descriptive panel to rate breeder hen breast meat are detailed in Table 1. The flavor and texture lexicon had been developed by the trained descriptive sensory panel during orientation sessions. The evaluations were replicated three times.
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characteristics. The sensitivity of the trained panel is evident in differences noted in the six attributes of the texture profile: springiness, cohesiveness, hardness, chewiness, particle size, and bolus size. The other two attributes that were significantly affected by PC deboning time were particle size and bolus size, and both of these are directly related to the behavior of the muscle fibers to deboning time [24]. Generally, the earlier the breast muscle is removed from the skeletal frame, the more pronounced the contraction of the individual fibers. The greater degree of contraction equates to differences in toughness and tenderness in the cooked meat. For instrumental procedures, such as W-B shear, early deboning means higher values for force to shear. But for the trained panel, it means significant differences in many more of the attributes studied, including larger particle size and bolus size for meat from the early deboned fillets. The “spider web” graphic illustrates the differences in texture based on PC deboning time. Generally, fillets from the 2 and 4 h PC deboning times and fillets from the 8 and 24 h treatments grouped close together for the significant attributes. This same grouping would be expected for broiler breast meat and is a reflection of the postmortem time and rate of biochemical changes that relate to ultimate texture characteristics when birds are processed under traditional schemes. The visual results can be an easier way to interpret the profile, especially when determining the effects of a treatment such as deboning time.
CONCLUSIONS AND APPLICATIONS 1. Cooked yield was increased when the breast fillets were deboned earlier (2, 4, 8 h). 2. The basic flavor profile (eight attributes) was determined for breast meat from breeder hens. The PC deboning times had no influence on the flavor profile. However, changes due to ingredients and/or other processing treatments can now be compared to this basic profile. 3. Both instrumental and sensory texture attributes were significantly affected by the PC deboning times. Earlier deboning resulted in higher force to shear values, and significant differences in six of the eight descriptive sensory texture attributes.
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metallic” are major perceived notes. A major difference between broiler and hen is the inclusion of “wet feathers” as a flavor note in cooked hen meat. Basic tastes of sweet, salt and sour were also present in hen as in broiler. These data establish a baseline flavor profile for the hen breast meat processed and cooked under the conditions of this study. Similar profiles determined with broiler breast meat, spent layer meat, and various levels of nonmeat ingredients, as well as alternative processing schemes (electric stimulation, extended chilling) are being used by quality control and R& D personnel to optimize end product characteristics [24, 25, 26, 27]. The “spider web” in Figure 2 illustrates a baseline profile of sensory texture attributes of the breeder hen breast meat at the PC deboning times. The rays extending from the center point represent the 15-point line scales for attribute intensity. Each attribute is represented by a ray. Mean scores for each attribute were plotted on the rays, and then points were connected to provide the visual profile. Six of the eight sensory texture attributes were significantly affected by the PC deboning time (Table 3). Typically, sensory texture data exhibit a more complicated picture than the one-dimensional shear value based on an instrument that records force, distance, time, or some combination of the three. The “human instrument”—in this case the descriptive panel—also integrates aroma, appearance, data collected during chewing, as the sample, teeth, tongue, and saliva all interact to yield many impressions that relate to sample
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REFERENCES AND NOTES 1. Lyon, B. G. 1983. Effects of salt and phosphate treatments on deboned meat from light and heavy fowl. Poult. Sci. 62:321–330.
17. Hamm, D. 1881. Unconventional meat harvesting. Poult. Sci. 60(suppl.1):1666. (Abstr.).
2. Lyon, B. G., and A. A. Klose. 1980. Sensory profiling of canned boned chicken: Comparison of retail, school lunch, and military canned bone chicken. J. Food Sci. 45:1336–1340.
18. A Barnant hand-held thermometer was inserted through the bag into the fillet. A minimum temperature of 175°F was obtained.
3. Lyon, B. G., and A. A. Klose. 1981. Effect of heat processing in cans and retort pouches on sensory properties of fowl meat. J. Food Sci. 46:227–230, 233. 4. Lyon, B. G., C. E. Lyon, and J. P. Hudspeth. 1994. Texture profiles of canned boned chicken as affected by chilling-aging times. Poult. Sci. 73:1475–1478. 5. Lyon, B. G., and C. E. Lyon. 1996. Texture evaluations of cooked, diced broiler breast samples by sensory and mechanical methods. Poult. Sci. 75:812–819.
7. Lyon, C. E., D. Hamm and J. E. Thomson. 1985. pH and tenderness of broiler breast meat deboned various times after chilling. Poult. Sci. 64:307–310. 8. McKee, S. R., E. M. Hirschler, and A. R. Sams. 1997. Physical and biochemical effects of broiler breast tenderization by aging after pre-rigor deboning. J. Food Sci. 62:959–962. 9. Walker, L. T., S. D. Shackelford, S. G. Birkhold, and A. R. Sams. 1995. Biochemical and structural effects of rigor mortis accelerating treatments in broiler pectoralis. Poult. Sci. 74:176–186. 10. Lyon, C. E., C. M. Papa, B. G. Lyon, and M. C. Robach. 1992. Broiler tenderness: Effects of post-chill deboning time and fillet holding time. J. Appl. Poult. Res. 1:27–32. 11. Papa, C. M., and C. E. Lyon. 1989. Shortening of the pectoralis muscle and meat tenderness of broiler chickens. Poult. Sci. 68:663–669. 12. Dickens, J. A., C. E. Lyon, and R. J. Buhr. 2002. The effects of electrical stimulation during bleeding on shear values and cook loss of breast fillets from mature chickens deboned at two or twentyfour hours post-evisceration. J. Appl. Poult. Res. 11:111–116. 13. SF-7000 pre-stunner brine cabinet. Simmons Engineering, Dallas, GA. 14. SK-5 automated knife. Simmons Engineering, Dallas, GA. 15. Johnson Food Equipment Co., Kansas City, KS. 16. Two prototype paddle chillers, 35-gal capacity, paddles rotating at 4 rpm. Chiller temperature ranged from 34 to 36°F.
20. Shear attributes were determined using the Texture Analyzer TA-XT2. A 25-kg load cell was fitted to the TA-XT2, and a traditional Warner-Bratzler blade was used at a test speed of 4 mm/s. The height of each strip was trimmed to be no more than 0.75 in, so the sample height and width (0.75 in) were known. The height at the point of shearing was noted prior to initiating the test. Each strip was sheared twice, and the values were averaged. The curve attributes and their definitions are 1) shear value—maximum force (kg) recorded as the blade cuts through the sample; 2) gradient—(kg/s)—slope of the curve calculated from contact of sample to peak of the curve; 3) area under the curve—area under the shear curve from the point of sample contact with the blade through the complete shearing of the sample; 4) shear value by sample dimensions (kg/cm2)—force in kilograms based on height × width of the strips. 21. Compusensefive Sensory Analysis System. Compusense Inc., Guelph, ON, Canada. 22. Dickens, J. A., and C. E. Lyon. 1995. The effects of electricstimulation and extended chilling times on the biochemical reactions and texture of cooked broiler breast meat. Poult. Sci. 74:2035–2040. 23. Lyon, C. E., B. G. Lyon, and J. A. Dickens. 1998. Effects of carcass stimulation, deboning time and marination on color and texture of broiler breast meat. J. Appl. Poult. Res. 7:53–60. 24. Lyon, B. G., and C. E. Lyon. 1997. Sensory descriptive profile relationships to shear values of deboned poultry. J. Food Sci. 62:885–888, 897. 25. Lyon, B. G., C. E. Lyon, and J. P. Hudspeth. 1994. Texture profiles of canned-boned chicken as affected by chilling-aging times. Poult. Sci. 73:1475–1478. 26. Lyon, C. E., B. G. Lyon, W. E. Townsend, and R. L. Wilson, Jr. 1978. Effect of level of structured protein fiber on quality of mechanically deboned chicken meat patties. J. Food Sci. 43:1524– 1527. 27. Lyon, B. G., C. E. Lyon, and W. E. Townsend. 1978. Characteristics of six patty formulas containing different amounts of mechanically deboned broiler meat and hand deboned fowl meat. J. Food Sci. 43:1656–1661.
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6. Dawson, P. L., D. M. Janky, M. G. Dukes, L. D. Thompson, and S. A. Woodward. 1987. Effect of post-mortem boning time during simulated commercial processing on the tenderness of broiler breast meat. Poult. Sci. 66:1331–1333.
19. Lyon, B. G., and C. E. Lyon. 1991. Shear value ranges by Instron Warner-Bratzler and single-blade Allo-Kramer devices that correspond to sensory tenderness. Poult.Sci. 70:188–191.