Cryogenic Meat Processing for Low-Fat Sausage Water Binding
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Solution Overview
Problem
Traditional methods for producing low fat sausages face challenges in maintaining water binding properties and organoleptic quality due to reduced fat content, leading to protein matrix shrinkage and poor distribution of fat particles.
Innovation Solution
A freezer system incorporating a grinder, mixer, and cryogenic processing with liquid nitrogen to maintain low temperatures, ensuring uniform distribution of fat and ice in the meat batter, resulting in a low fat sausage product with improved water binding and texture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If added fat is reduced in sausage formulation, then fat content is reduced, but water binding capacity deteriorates due to protein matrix shrinkage
Solution Approach 1:
The patent applies parameter changes by controlling temperature parameters throughout the processing sequence. The meat is kept at low temperatures (0-4°C) during grinding and mixing, then rapidly cooled with ice slurry, and finally subjected to controlled freezing. These temperature parameter changes prevent protein matrix denaturation and shrinkage that would otherwise occur at higher temperatures, thereby maintaining water binding capacity even with reduced fat content.
Solution Approach 2:
The patent employs preliminary action by adding ice slurry and conducting intensive mixing before the actual sausage formation process. This preliminary cooling and homogenization of the meat batter ensures that the protein matrix is properly prepared and stabilized before cooking, preventing subsequent shrinkage and maintaining water binding properties in the low-fat sausage product.
2Quantity of substance
If meat and water are substituted for fat, then fat content is reduced, but homogeneity of fat distribution deteriorates
Solution Approach 1:
The patent uses parameter changes by maintaining low temperatures (0-4°C) during grinding and mixing operations. This temperature control prevents fat hardening and ensures that fat particles remain pliable and evenly distributable throughout the meat matrix, achieving homogeneous fat distribution even with reduced overall fat content.
Solution Approach 2:
The patent applies preliminary action through intensive mixing with ice slurry before sausage formation. This preliminary homogenization process thoroughly distributes fat particles throughout the meat batter, ensuring uniform fat distribution in the final low-fat sausage product.
3Device complexity
If traditional mixing and freezing methods are used, then processing is simple, but temperature control precision deteriorates leading to poor fat distribution
Solution Approach 1:
The patent employs preliminary action by adding ice slurry and conducting intensive mixing before sausage formation. This preliminary cooling step establishes precise temperature control early in the process, ensuring that the meat and fat remain at optimal temperatures for homogeneous mixing without requiring complex temperature control systems throughout the entire processing line.
Solution Approach 2:
The patent utilizes phase transitions by incorporating ice slurry that melts during mixing, providing continuous cooling and precise temperature control through the phase change from solid to liquid. This simple yet effective method maintains temperature precision without complex equipment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables the production of low fat sausages with enhanced water binding properties and uniform fat distribution, reducing protein matrix shrinkage and improving the overall quality of the sausage product.
Implementation Method 1
adding liquid nitrogen to maintain the temperature of the chopped meat product and fat being chopped between 1° C. and 10° C.
Implementation Method 2
adding liquid nitrogen to maintain the temperature of the meat being chopped below 5° C.
Implementation Method 3
a pump to force coolant flowing through the evaporators
Implementation Method 4
a plurality of evaporators coupled to the payload bay with a multiplicity of coolant tubes in each evaporator
Implementation Method 5
one or more cryogenic valves coupled to the coolant tubes
Data Source
AI summary
A food processor includes a grinder to obtain a ground meat; a mixer to add fat to the ground meat; a payload bay to receive the ground meat; a plurality of evaporators coupled to the payload bay with a multiplicity of coolant tubes in each evaporator, wherein each tube enters and then exits the payload bay, further comprising one or more cryogenic valves coupled to the coolant tubes; a pump to force coolant flowing through the evaporators; and a processor with code for: chopping the ground meat and during chopping, adding salt and ice to the ground meat being chopped and adding liquid nitrogen to maintain the temperature of the meat being chopped below 5° C. to obtain a chopped meat product; adding fat to the chopped meat product and then chopping the fat and adding liquid nitrogen to maintain the temperature of the chopped meat product and fat being chopped between 1° C. and 10° C. to obtain a chopped meat and fat product, wherein the ground meat, added fat, ice and salt are present in amounts so that the chopped meat and fat product has a fat content of from 1% to 20% by weight based upon the weight of the chopped meat and fat product.