LOURDES S.RIVERA “Guru of Meat Processing” Born in the province of Laguna, Mr. Filomeno Filomeno N. Rivera saw the need of his people from the time he learned the value of living specially those time wherein the only source of income is the land. He graduated at the University of the Philippines as Agriculturist. Working with the government gives him all the opportunity to meet all kinds of people and businesses. And in 80’s he became a meat processor together with his wife, LOURDES CANLAS SANTOSRIVERA to generate additional income for the family. Being exposed into this line of business, he decided to put up his own store for the meat processing ingredients. And in 1997, Spices and Foodmix House was established with the mission of promoting food grade and unadulterated ingredients for the meat processors. The company’s vision is to be able to deliver safe food on every household thru meat processing One-Stop Shop for your Nego Needs Meat Processing Baking Courses Non-Food Courses Business (P) in the Meat Industry Live Animals Example Hog (80 kgs) Farmer (4 months) Carcass (60 kgs) By products Head. Legs & Blood (20 kgs) Market Meat Shoppe Supermarket Profit P 1.400.00 .00 P 2.200. PRIMAL CUTS . PRIMAL CUTS . . RETAIL CUTS WET MARKET MEAT SHOP SUPERMARKET . MEAT PRODUCTS (Value Added Cost) MEAT PROCESSING . carbohydrates. and 5% fat. & assorted proteins. .MEAT Meat is mostly the muscle tissue of an animal. Most animal muscle is roughly 75% water. 20% protein. Muscles are made of bundles of cells called fibers. MEAT WHOLE MEAT HAM TOCINO SLICED MEAT PORK BBQ . GROUND MEAT NUGGETS MIXES (NO CURING) EMBOTIDO HAMBURGER Premium Commercial Highly Commercial (MDM) SIOMAI . CURED PRODUCTS LOCAL LONGGANISA LUZON VISAYAS MINDANAO - ILOCOS LUKBAN CABANATUAN PAMPANGA CEBU CHICKEN LONGGANISA INTERNATIONAL SAUSAGE CHORIZO PEPPERONI ITALIAN SALAMETTI GERMAN SAUSAGE HUNGARIAN SAUSAGE HOTDOG (Emulsified Products) . 21% Protein 75 % Water Binding Quality Color Taste Aroma P MEAT Processing (Value Added Cost) P Meat Block Lean Backfat Value Added Cost Market Meat Shop Super Market Fabricated Cuts Retails Cuts Consumer A B C D .FRAMEWORK OF MEAT PROCESSING BUSINESS Live Animals Hog Cattle Chicken Goat Ducks 16 . 4% v.6% nitrite) Phosphate (relaxes the (Lagkit) muscles of the meat) Vitamin C Chilled Water PROCESSING 2 Extend Extenders Textured Veg.) 1 Ground Whole Sliced Shredded Preserve Curing Mix Refined Salt (Vacuum) Curing Salt (99.2 -.2.0 kg -. Bango. Katas Beef Aroma Pork Aroma Isolate (soybean) Meaty Ginisa Carageenan (seaweeds) Binder Filler Blend Fibrill (corn fiber) (BF Blend) Qualicel (bamboo fiber) Versagel (plant fiber) Chilled Water bulk.0 kgs.salt + . increased in weight . 3 Seasonings Sarap .1. Protein (soybean) water absorption.Weight increase (1. Meat Processors / Caterers Source of Meat Imported Various 1. 4. 2. 3. Kinds of Meat Beef Pork Chicken MDM (Mechanically Deboned Meat) . Urgent Problems to be Solved by the Meat Processors Sourcing of Meat • Local • Higher Cost • Hygienic Handling Imported • Lower in Cost • More hygienically slaughtered . Chicken) Backfat * MDM (Mechanically Deboned Meat) .Formation of Meat Block Meat (Pork. Longganisa. Nuggets. • Live Animals (pork/chicken) are slaughtered (80-90 kgs. a paste like products produced by forcing beef.Mechanically Deboned Meat MDM is a mechanically separated meat. Siomai) . Embotido.) • 75% of live weights is called carcass (60 kgs.) • Carcass Primal Cuts Retail Cuts • Meat + Bones MDM is used for various ground products to replace meat in various amount (Hamburger. Hotdogs. pork. turkey or chicken under high pressure to separate the bone from edible tissue. Pink MDM P 80. Light Pink Texture Course (ground) Paste like 16-21% 10-12% --- --- 75% 85% Real taste of meat Lacks taste of meat Protein Content Fat combine Water content Taste .00 / kg.Mechanically Deboned Meat (MDM) Comparison of Meat and MDM Price Color Pork / Chicken P 180.00 kg. 000 grams Add: M1 + 2 To make meat tacky . Now: A.Sample of Meat Block Before: 700 grams LEAN 300 grams BACKFAT 1.) 500 grams MDM 300 grams LEAN 200 grams BACKFAT 1.000 grams = 1 kg. 000 grams 1.000 grams / 1 kg.) C.Sample of Meat Block Now: B.) 800 grams MDM 100 grams LEAN 100 grams BACKFAT 1. Pure MDM . Problem: Taste Flavor goes down .Extenders are added in producing a higher yield to bring down cost. etc.PROBLEMS Meat Processors Competitive Price • Add extenders to get higher yield Ex. Hamburger.2.0 kg to 1. masarap pa) . 1.0 kgs • Higher yield • Shrinkage • Taste (improve taste) (add fibers) (mura na.8 . Longganisa. Siomai. PROBLEMS Caterers Competitive Price Keeping quality of cooked recipes Number of serving portions (shrinkage of meat) . . TM TREHA (Trehalose from Hayashibara) is a crystalline saccharide containing two water molecules per molecule of trehalose . Stucture of Trehalose (dihydrate) . 01 0. Only a few are listed in the graph below. Shitake Mushroom Yeast Beer Bread Soybeans 0.Trehalose in Nature Many common natural foods contain trehalose.1 1 10 Trehalose constent on dry solid basis (%) 100 . Malaysia. Singapore. United States. Belarus. Mexico. Cuba. Croatia. Canada. Iceland. United Arab Emirates and Ukraine (as of May 31. Thailand. Indonesia. Taiwan. Brazil. Norway. Russian Federation. India. Israel. South Africa. Switzerland. Hong Kong. Argentina. Australia. China. Chile. Turkey. 2013) .TREHA Is a trademark for trehalose and a registered trademark of Hayashibara in Japan. Philippines. New Zealand. European Union. Republic of Korea. This process includes specific purification steps which yield high purity trehalose crystals. .Production of TREHA TM TREHA is manufactured from starch by an enzymatic process under strict quality control. STARCH SLURRY PREPARATION LIQUEFACTION SACCHARIFICATION DECOLORIZATION DEIONIZATION CONCENTRATION CRYSTALLIZATION CENTRIFUGATION DRYING TREHATM . TREHA is a saccharide with excellent stability TM . Physical Properties Sweetness Treha is only 38% as sweet as a 5% solution of sucrose SUCROSE GLUCOSE TREHATM 100 61 38 . Solubility Treha has good solubility in water. but is generally lower than sucrose . While some Maillard reaction are desired. Trehalose is a non-reducing sugar and will not contribute to Maillard reactions. . it is also one of the major causes of food discoloration and off-flavors. that chemically react with proteins or amino acids. Maillard Reaction The maillard reaction (non-enzymatic browning) is caused by saccharide. including sugars. . Heat/Acid resistance Treha is exceptionally stable to heat and acid. . . Vitrification Property is a phenomenon in which is a liquid substance does not crystallize but solidifies in an amorphous state. This usually occurs during a rapid change in temperature or drying. it is known that saccharides and proteins contained in food can become vitrified. which can contribute to the improvement of the stability and quality of foods. In the field of food science. TREHA has the highest glass transition temperatures in disaccharides commonly used in food manufacturing. . Low Hygroscopicity Treha is resistant to moisture absorption. . Digestibility/Absorption Treha is digested and absorbed in the small intestine in essentially the identical manner as sucrose and maltose. . it is an excellent source of energy (4 kcal/g). Since it contains two glucose molecules and is completely digested. TREHA is effective in preventing the denaturation of proteins. which leads to lower quality food.Prevention of protein denaturation Proteins can denature during manufacturing. storage and distribution. . .No Addition Sucrose Corn Syrup Maltose TREHATM 0 20 40 60 80 Denaturation (%) Various saccharides were added to egg white at a final concentration of 5%. Mixtures were stored frozen at -200C for 5 days. Growth of a single ice crystal during the freezing process. .Reduction of damage during freeze/thaw Ice crystals can damage the structure of the food and results in significantly lower quality upon thawing. Trehalose has been shown to reduce size ice formed the freezing process. . Restaurants. Canteen Operators Try our new products TREHALOSE .In summary. ALL MEAT PROCESSORS. Bacon. then processed to mixing .TREHALOSE SOURCE: FOR: TAPIOCA STARCH Ham. Siomai. Embotido and others USAGE: 2 Tbsp TREHALOSE (10 grams) plus 2 Tbsp WATER (20 grams) Apply directly to meat before using. . Tapa. Hamburger. Tocino. Longganisa. Brighter color More binding quality Increased juiciness More water holding capacity Acts as anti-oxidant Prevents freeze-thaw Higher yield .Advantages: Accelerates reaction of all ingredients applied to meat. . . . . . . . . . . . . . . . . . . . . . . . 00 2.00 0. boneless.00 3.00 5.00 2. refined Curing salt Sugar.50 30 cc .00 12. skinless-on (1 kg) Ingredients: Weight (gms) 1000 g. Meat): Water. Household Measure Weight (gms) Pumping pickle solution (1.75 20. chilled Salt.00 10. refined Phosphate Vitamin C powder Hamspice TREHALOSE BF Blend Smoked Flavor Honey (added at the last mixing) ½ cup 1T ½t 1T 1t ¼t ½T 2T 1t ¼t 2T 125.50 3.QUICK CURED HAM Meat Material: Pork pigue.0 Kg. 00 96.2 cups ½ cup 1 .00 2.5 pcs. refined Sugar Phosphate Vitamin C powder 2½T 1½T ¼T ¼ t 30.70 230.00 * Ingredient that minimizes shrinkage in ham and promotes better sliceability.00 240.50 2 cups 3 cups 1 . .00 5. 3 .2 pcs. Bottle 500.00 356.4 strands 1t 1 med.Dry Cure Mixture: Salt. 3 .00 Cooking Ingredients: Water Brown sugar Pineapple juice Anisado wine Bay leaves Clavo de comer Oregano dried Cinnamon powder 7-up 1.25 0. ** Hamspice may be substituted in the amount of 1 tablespoon. 7. Boil until it thickens. Carageenan. Select good quality raw materials. 2. Cool. Trim and weigh. Put brown sugar of fat portion and caramelize. Inject pumping pickle into the lean portion. only one inch apart (½ cup pickle per kilo of meat). 9. Massage for even distribution of pickle. 8. 5. Use of blow torch. Caramelization Process: 1. Temperature is 350 ºF for 20 minutes until golden brown. Procedure 1. 4. Thick syrup is prepared by boiling 1 cup cooking solution.. Add ½ tsp. Pack and store in freezer. Cure at refrigeration temperature for 2-7 days. Boil the mixture at simmering temperature for 10 minutes. 5. Traditional hot syense on top of the fat portion with brown sugar. 2 cups brown sugar and ¼ cup pineapple juice. Use of thick syrup to be poured on top of the fat portion. 4. Prepare 50º pumping pickle and dry cure mixture. 3. Wash for 90 seconds and tie with abaca twine or ham net. Cook with recommended ingredients for 2 ½ hours at the middle of the cooking time invert. Apply dry cure mixture into the fat and lean portion. 2. Use of turbo with brown sugar on top of the fat. 6. 10. dissolve in 1/4 cup water Ham Sauce: 1 cup Cooking Solution (from cooking of Ham) 1 cup Brown Sugar ½ tsp Carageenan dissolved in ¼ cup water. for form a shape or put in ham net or ham sock. Oven at broiling temperature for 20 minutes with brown sugar on the fat portion of the meat. Remove abaca twine or ham net and caramelize with brown sugar. . 3.V. 00 Household Measure 1T ½t 1T 1t ¼t 1T 2T 1T 1t ¼t ¼ ½ cup 1/2 t 1t 2T 5.50 0.50 15.50 15.50 1.00 125. refined Curing salt* Sugar.50 20.HOME MADE BACON Meat Material: Pork belly or liempo. skinless. . Ingredients: Salt.00 0.00 5. sliced 1/8 inch thick or Loin. ** Added in the last mixing.00 *These two ingredients minimize shrinkage in bacon and promotes better sliceability. refined Phosphate Vitamin C powder Bacon powder TREHALOSE Isolate Carageenan Meat enhancer Smoke Flavor Water chilled MSG BF Blend (Binder Filler) Honey** Weight (gms) 10.00 30. boneless.00 2. boneless. skinless. sliced 1/8 inch thick Weight (gms) 1000 gms.00 5.00 2. Apply ingredients previously dissolve in water with honey added in the last mixing. 3. Freeze. Select good quality raw materials. Pack in styropore with cling wrap. Cure at refrigeration temperature for 8-10 hours with cover. . (34-360F) 4. (Arrange symmetrically). 2.Procedure: 1. pigue or kasim. with or without skin Boneless.TOCINO I. II. Meat Material Pork. INGREDIENTS: Curing Mix Household Measure Salt. 2 Tbsp (20 grams) dissolve in 20cc or water Add to meat before mixing the ingredients.00 .00 2. refined 1 Tbsp Curing salt ½ tsp Phosphate 1 tsp Vitamin C powder ¼ tsp Chilled Water* ¼ cup * to dissolve the four ingredients Extenders Isolate Carageenan Fibrill Water chilled* * to dissolve the 2 ingredients 1 Tbsp 1 tsp ¼ cup ½ cup Weight (gms) 12.00 3.50 100. sliced ¼ inch thick TREHALOSE Weight (gms) 1000 gms.50 62.00 2.00 0.00 125.50 5. per kg. From this solution get 1-2 tsps.50 5. ** Prepared by dissolving 1 tsp.00 24. ***Add in the last mixing . which is equivalent to 10 grams.00 2.Seasonings Sugar. refined Garlic.0 * Garlic powder maybe substituted in the level of 2 tsp.00 24.00 1. of food color in ½ cup of water. This serves as the stock solution to be kept in the refrigerator.00 60.22 3. chopped finely* Anisado wine Pineapple juice Vetsin (MSG) Food color (allura red)** Meat enhancer Meat tenderizer Meaty Ginisa BF Blend *** (Binder-filler) 1 cup (16T) 2 Tbsp 2 Tbsp ¼ cup ½ tsp 1 tsp ½ tsp 1 tsp ½ tsp ½ tsp 160.50 1. Measure and weigh all the ingredients. 4. ½ kg.003 inch 0. Size: 4 inches x 8inches 6 inches x 10 inches Thickness 0.Styrofoam containers to be wrapped on top with cling wrap. Dissolve in ¼ cup of water. Select good quality raw materials. phosphate and Vitamin C. Packaging materials: . Pack in polyethylene bag in ¼ or ½ kg. package.003 inch . 2. curing salt. Add the rest of the ingredients and mix again. Cure at room temperature for 8-10 hours or refrigeration temperature for 8-12 hours 6.PROCEDURE: 1. Mix Trehalose (20 grams + 20cc water) and add to the meat before adding the curing mix.Polyethylene bags ¼ kg. Add the extenders and mix well until it dries up. 5.extenders and seasonings. Mix meat with first four ingredients: Salt. . Store in freezer. Slice the raw materials. Trim and weigh. 3. Seasonings: Sugar, refined Black pepper, ground Garlic, chopped (or Garlic powder) Vetsin (MSG)/Super Seasoning Meat enhancer Onion, chopped finely or Onion Powder Celery powder Hamburger seasoning Milk or whey powder or Non-Dairy Creamer 1½ T 1 T 2 T (2 t) ½ t ½ t ¾ cup 2 tsp ½ t 2 t 3 T 2 T Egg, fresh medium Bread crumbs Potato starch Beef Aroma Meaty ginisa BF Blend (Binder Filler) (added in the last mixing) 1 pc. ½ cup 4 T 1/2 tsp 1/2 tsp 1t 15.00 5.00 24.00 4.00 1.50 1.00 109.00 0.75 5.00 56.00 26.00 COMMERCIAL HAMBURGER Meat Material: Mechanically Deboned Meat (MDM) Pork lean, ground finely Pork backfat, ground finely TREHALOSE - Weight (gms) 500.00 300.00 200.00 1,000.00 kgs. 2 Tbsp (20 grams) dissolve in 20cc or water. Mix to meat block before mixing with curing mix, extenders and seasonings Ingredients: Curing mix: Salt, refined Phosphate (Dissolved in ¼ cup water) Extenders: TVP (Textured Veg. Protein) Qualicel Versagel Water Household Measure Weight (gms) 1¼T 1t 15.00 5.00 ¼ cup ¼ cup ½ cup 1½ cup (if Beef) 1¼ cup (if Pork or Chicken) 18.00 10.00 60.00 375.00 Procedure: 1. Select good quality raw materials.Grind meat and fat finely. Mix Trehalose to the meat block. 2. Add salt and phosphate (dissolve in ¼ cup water). Mix until tacky. 3. Add extenders: TVP, versagel and qualicel. Mix again until homogenous mixture is attained. Add seasonings and remix. 4. To attain firm patties, chill mixture for 1-2 hours in the refrigerator. 5. Form into the patties with the use of hamburger molder (50 grams per patty), 1 kg. should contain 20 pieces. For 30 grams patty – 1 kg. should contain 33 pieces. 7. Freeze patties before packing. Store in freezer. Cook with little amount of fat. Yield: 1 kg. = 1.5 to 1.8 kgs.