MEAT PROCESSING (BURGER PATTIES)

1. INSPECTION
- All incoming frozen raw meat must satisfy the Quality Assurance Department prior to being passed to production.

2. THAWING
Meat assigned to the following days patties production run are left overnight to thaw, to an internal temperature of -3C. - the temperature of the thawing room is maintained at 7C.
-

3. EXTRACTOR
- Boneless frozen chunks are deposited into the overhead hopper of the meat extractor from an elevated platform.

- The tumbling motion of the hopper drops the production batch into the extractor, which tears and shreds the meat into smaller portions acceptable for grinding.

4. GRINDER
- Shredded pieces from the extractors are automatically transferred into the grinder.

Example: A 100kg batch of frozen blocks can be ground to size in 15 minutes giving a capacity of 1.2MT an hour.

- The extractor has a maximum storage capacity of 500 kilograms.

5. PACKAGING
- Ground meat oozing from the discharged worm of the grinder falls into waiting plastic crate lined with a polybag. - Processed meats and raw meats packed in cartons on racks are completely frozen within 4 to 6 hours.

OTHER METHOD:
BLENDER based on the specifications given by a client, the production supervisor will add the right proportion of choice meat portions whether ground lean meat, fatty meat, etc.,

and various spices

into the blender.

MINIMAT FORMER -A smaller minimat former with single hole stamping plate forms softer textured products. - Patties from this smaller machine are blast frozen for 30 minutes in the blast freezer.

GYRO FREEZER/BLAST FREEZER

Gyro freezer - Is an 18-level high, spiral conveyor freezer, vertically encircling a cylindrical drum. - Cold air at -30C is blasted directly unto the product as they climb up the top of the spiral.

-The process takes at most 15 minutes, at any one time holding 100kilogram of patties. It is a continuous process - The freezing capacity of the gyro freezer and the spiral conveyors speed is synchronized with the

speed of the former to create an interrupted flow of raw products into the freezing drum. A 24-hour operations will result in approximately 5MT of finished products.

Blast freezer -composed of three tunnels with individual doors at either end of the tunnels. -each tunnel is designed to accommodate 9 carts, giving a total of 27 carts. - The refrigerator system maintains the room temperature at -30C.

QUALITY ASSURANCE

Purpose of laboratory control of food processing operations: To ensure that all products are: safe nutritious compositionally correct

 Protect the end- consumer from foods which are: contaminated Decomposed adultered and injurious when packaged and labeled in false and misleading way.

A. MICROBIOLOGICAL TESTING
1. The bacteriological examination of food and food production facilitates the purpose of protecting the health of the consumer and ensuring the quality of the food.

2. Microbiological testing is a compliment to the traditional sight, smell and touch inspection of facilities. 3. Microbiological indices for food products are used to provide a desirable margin of safety and quality. 4. To analyze for indicator organisms of defective sanitation

5. Test for coliforms, faecal coliforms or Escherichia coli and aerobic plate counts are usually performed as measures of sanitation, in water and product samples. 6. The laboratory also often conducts incubation tests and product sterility test.

B. ENVIROMENTAL SANITATION
All water for the meat operation should be: clear Colorless Odorless Tasteless Free from iron and manganese and of Approved bacteriological quality

Zeolite-softened water: - to obtain better color. - also employed for boiler feed. Note: A food plant has its own deep well and water treatment plant provide and handle its high daily consumption.

QUALITY CONTROL

A. Quality control in Canning Meat

Producer: consider quality in terms of hair color, bone refinement, hide thickness and head size. Packers: refer quality in meat as maturity, marbling, texture, color and muscle firmness.

 Retailer: sees quality in meat color, firmness, texture and marbling. Consumers: think of quality as tenderness, juiciness and flavor on the cooked product.

a.) Microbial Examination of Meat -microorganism play an important role in the quality of meat, before, during, and after processing,by initiating many undesirable biological changes in meat. the age of the animal ration content method of slaughter chilling of the carcasses storage conditions of the meat and the sanitary conditions after slaugther
materially influence the quality of the end product.

b.) Microbial Examination of Equipment - equipment sanitation test are applicable to surface of all types equipment coming in the contact with food. The swab- contact technique may be applied to large or small areas on flat or curved surfaces. Such tests are of particular value in demonstrating effective cleaning and sanitizing procedures. Standard plate count for total bacterial content or differential test such as the coliform test for fecal contamination can also be used.

Hazard Analysis Critical Control Point (HACCP) -is the current preventive system fo Food safety mandated and implemented in the food manufacturing companies in the United States, Europe and in various exporting Asian countries, including Philippines. HACCP program in a company can only succeed and be implemented if GMP(Good Manufacturing Practices) is observed and complied with consistency.

B. Wastes/ Environmental Projects

other parts, especially of the hog are cured and smoked. The fatty portions are converted into lard and commercial grease by rendering process.

 Bones are converted into gelatin glue, fertilizer, animal feeds and other usable products, including pharmaceuticals. Hoofs and horns are used or sold for other purposes. Skin is made into leather or cooked as chicharon.

INDUSTRY UPDATES

MINDANAO- in the south was officially

declared free of foot-and-mouth disease last 2001 and the same status was confirmed in 2002 for the geographicallycentral region formed by the Visayas. Breeding companies have been moving fast to establish themcelves in these 3 large island complexes. - The proportion of all pig present in Mindanao has jumped to 23% from 17% in 1999.

TOP PRODUCING REGIONS Region IV Region III Region Ix TOP PRODUCING PROVINCES Batangas Laguna Rizal

 The National Federation of Hog Farmers, Inc.(NFHFI)- reported that the meat industry is losing Php 21 billion/year brought about by meat smuggling and relentless importation of Indian Buffalo meat.

A. Hazardous effects of broiling and grilling They found out that grilling and broiling cause muscle meats (red meat, poultry, and fish) to produce cancer- causing compounds.

Frying Broiling Barbecuing

Stewing Poaching Steaming

produce more mutagenic activity and HCAs

show little or no mutagenic activity

 Another cancer causing substance forms when fat from meat, poultry, of fish drips onto coals or stones and then, via smoke and flare ups, is deposited onto the food being grilled. PAHs(polycyclic aromatic hydrocarbons)- types of carcinogen formed.

 choose lean, well trimmed meats to grill- they have less fat to drip into the flames. Remove the skin from poultry. Avoid high-fat meats such as ribs or sausages. Pre-cook meats, fish and poultry in the oven or microwave, then briefly grill for flavor.

Keep meat portions small so they need only spend a brief time to grill. Marinating meats before grilling can significantly reduce the amount of carcinogen that might otherwise form.

Marinating foods is effective in reducing the amount of HCAs in some cases, as much as 92% to 99%. Scientist are not sure exactly how marinades act to reduce the formation of carcinogen. There is evidence, however, that marinades may act as a barrier or that their protective powers may lie in their ingredients. Acidic ingredients, like vinegar or citrus juices, or herbs, spices and oils all seem to contribute to the prevention of HCA formation.

B. MAD COW DISEASE

Bovine spongiform encephalopathy(BSE) or Mad cow disease is an incurable, fatal brain disease that affects cattle and possibly some other animals, such as goats and sheep.

It's called mad cow disease because it affects a cow's nervous system, causing a cow to act strangely and lose control of its ability to do normal things, such as walk.

Abnormal proteins called prions (PREons) are found in brain tissue of diseased cattle and appear to be the particle that transmits the infection. The type of protein that causes mad cow disease cannot be removed or destroyed when beef is processed or cooked.

A brain from a person with mad cow disease

How do people get it?

Only certain animals can get BSE people don't actually get mad cow disease. However, if humans eat diseased tissue from cattle, they may develop the human form of mad cow disease known as variant CreutzfeldtJakob Disease(vCJD) or new variant Creutzfeldt- Jakob Disease(nvCJD) .

Variant Creutzfeldt-Jakob Disease

When people have vCJD, cells in the brain die until the brain eventually has a "sponge-like" appearance. During this time, people with the disease gradubally lose control of their mental and physical capabilities. This is due to a type of infectious protein called a prion.

Prions or transmissible spongiform encephaolpathies (TSEs) are not like bacteria or viruses that cause other infectious diseases; rather, they are considered infectious abnormal proteins that are able to "induce abnormal folding of specific normal cellular proteins" according to the CDC.

Tonsil biopsy in variant CJD. Prion protein immunostaining.

 Once infection occurs, there is a long incubation period that typically lasts several years. When prions reach a critical level in the brain.

 Transmission: cannibalism- kuru Transplantation of infected tissue Blood transfusion

Mad Cow Disease and Variant Creutzfeldt-Jakob Disease Symptoms and Signs Symptoms in the animal: change in attitude and behavior, gradual uncoordinated movements, trouble standing and walking,

weight loss despite having an appetite, and decreased milk production Humans: muscle spasms, lack of muscle control, worsening problems with memory.

Treatment
As of 2011 no generally accepted treatment for CJD exists. An experimental treatment was given to a Northern Irish teenager, Jonathan Simms, beginning in January 2003.

 The medication, called pentosan polysulphate (PPS) and used to treat interstitial cystitis is infused into the patient's lateral ventricle The treatment is alleged to slow the progression of the otherwise untreatable disease, and may have contributed to the longer than expected survival.