6/25/2015

Chilling Effects on Pork Thanks to our Sponsor

Carcasses and Meat
Quality

MAX ENGLAND, CARGILL PORK

68th RECIPROCAL MEAT CONFERENCE 68th RECIPROCAL MEAT CONFERENCE

Pork Carcass Chilling AGAIN?? Topics to Discuss

People
New students
New people to the industry (sales, marketing, purchasing)
Predominant methods of chilling
Process
Similar base technologies available today some with
improvements
New facility construction is easier to optimize design and Considerations for larger carcasses
performance
Retrofitting into older plants can be challenging
(considerations if/when visiting facilities)
Findings of published work
Products
Some recent research has raised questions
Carcasses are bigger than those from 20 years ago Business implications of results conveying the appropriate message

68TH RECIPROCAL MEAT CONFERENCE 68TH RECIPROCAL MEAT CONFERENCE

Predominant Methods of Chilling Predominant Methods of Chilling

Conventional
Typical temperature is around 1oC with air velocity of 1.5 to 3 feet per second
Normal turn around on this format would be approximately 24 hours (Ham
temperature to release for cut targets 4.4oC)
Often considered the benchmark to measure quality from (testing alternative
methods of chilling)
Ham, loin, belly, shoulder temperature decline
Normal pH decline
Carcass shrink
Might be considered the baseline to measure from
Losses up to 2% may be observed in this setting
Spray
Typical temperatures can range from 1 to 5oC with air velocity of 1.5 to 3 feet per
second
Normal turn around on this format is 24 hours
Cold water sprays are set on intermittent schedules (may spray for 1 minute every 15
minutes)
Timing of the spray schedule can be up to 10 hours after filling the cooler
Anticipated changes from Conventional
Will experience a slightly more rapid temperature decline than conventional
Limited color change
pH declines will be more similar to Conventional
Carcass shrink
Will be lower than Conventional close to 0% in some cases
Can be variable depending on overall chilling format

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Predominant Methods of Chilling Predominant Methods of Chilling

Blast/Snap Blast/Snap
Temperatures can range from -20 to -40oC, with air velocity of 10 Anticipated changes from conventional
to 16 feet/second Will experience a more rapid temperature decline than
Conventional and Spray Chilling
Dwell times can range from 1 to 3 hours, with many at
approximately 90 minutes Depending on blast settings, differences may not be observed until
exit of blast
When loaded in equilibration, can be managed in different ways Rate of pH decline will typically be slowed, and 24 hour pH will
Hold at -1 to 0oC for several hours (4-8), and then run at 3 to 4oC for often be slightly higher doesnt mean its done dropping
the next 10 to 14 hours to confirm skin and shank condition
Different variations of this can be utilized Carcass shrink will be lower than Conventional, with
differences from Spray depending on equilibration bay
Normal turn around is 24 hours, but can also effectively set up management
same day cut Could be similar to spray
Equilibration managed with more aggressive temperature and
tempering
Could be slightly higher than spray under 1%

68TH RECIPROCAL MEAT CONFERENCE 68TH RECIPROCAL MEAT CONFERENCE

Predominant Methods of Chilling

Todays Carcasses
Blast/Snap Blast is not just a blast Carcasses are notably heavier today consider mean and standard deviation
Time to get to blast chill from harvest (retro fitting into older plants vs new construction)
Genomic technology has helped control Halothane Gene, but there is still
Time in blast chill (time/temperature interaction and the impact on pH decline) discussion on color and needs for improvement
Configuration of blast chill (rooms/areas with different configurations/duct configurations) National Pork Board initiatives are promoting improved loin color session right now
Reciprocation session this morning is discussing ham color (outer surface of outside,
Equilibration management
not the inner surface of the inside)
How aggressively this is run and timing to convert over to tempering
There is a difference between light color and PSE
Set point vs actual air temperature and air velocity
Is there truly a color issue (understand issues of past vs future needs)
Ability to achieve set points
Frost build up between cleanings
Different plants may have different schedules
Understand these when collecting data Continuous improvement in animal welfare efforts have also made an impact
Carcass spacing Hook format carries carcasses at set spacing improper handling can negate quality improvement technologies
Energy costs Cost vs Reward

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Published Work Chilling and

Todays Carcasses Tenderness
Carcass Loading Considerations
Optimal Chilling Rate of the
Blast chill chain configurations
Loin (Honikel, 1999)
Air flow at different points of carcass (duct positioning and fan velocity) 40
Temperature oC

Carcasses per ton of refrigeration (can vary either add refrigeration 30

capacity or reduce carcasses per ton) 20
10
Carcass spacing (8-10 centers, rail weight considerations per linear foot)
0
Maintaining temperature targets at key points in the chill process 0 2 4 6 8 10 12 14 16 18 20 22 24
Hours Postmortem

Safety Considerations The concept promotes the prevention of cold shortening

Rated load capacities of rails and support structure
Pounds per rail or linear foot
Employees will look at structural indicators for consistency in loading rails
Having a loin temperature that is above 15oC while ATP is present
Hot boning increases the vulnerability of muscles to this condition
Not typically applied to butcher carcasses
Not chilling below 5oC while the pH is above 6.0
What does this curve mean to ham? Shoulder?

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Published Work Chilling and Published Work Chilling and

Tenderness Tenderness
Chilling rate effects on pork loin tenderness in commercial processing plants Chilling rate effects on pork loin tenderness in commercial
(Shackelford, et. al. 2012) processing plants (Shackelford, et. al. 2012)
Hot carcass weights were 98-99 kg Both blast chill treatments resulted in higher slice shear force than the
Three different plant scenarios CO2/spray treatment
CO2 stun and spray chill Electric stun/blast had 7.5% of samples with SSF greater than 25kg
Electrical stun and blast chill (75 minutes at -30oC to -25oC) CO2/blast had 14.7% of samples with SSF greater than 25kg
CO2 stun and blast chill (135 minutes blast at -22oC to -15oC) CO2 stun/spray chill had 1% of samples with SSF greater than 25kg
Equilibration air temperature ran warmer for the spray chill carcasses at 3 hours Depending whats being done with finished product, is this tolerable?
post harvest
Loin temperatures in the blast chill treatments ran colder than
Equilibration air temperature ran colder for the CO2 stun/blast treatment Honikels recommended rate of decline (both treatments below 15oC
(approx. 4oC) at 3 hours vs Honikels recommended 27oC)
Common source of genetics (consistent farm and genetic source) SO WHAT??

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Published Work Chilling and Published Work Chilling and

Tenderness Tenderness
Chilling rate effects on pork loin tenderness in commercial processing plants Stepwise chilling: Tender pork without compromising water-holding capacity
(Shackelford, et. al. 2012) (Rosenvold, et. al. 2010)
Insightful data was gained in a controlled genetic scenario to understand differences Control
between 2 stunning and 3 chilling scenarios 75 minutes at -22oC
The authors also call out to consider blast chill parameters and resulting temperature 4oC until fabrication
declines Step 10
This publication also raised a number of questions, resulting in customer inquiries 69 minutes at -22oC
and the merit of blast chilling 6 hours at 10oC
Despite a wide degree of variation on blast chill technologies (time/temperature), 12 minutes at -22oC
these processes have helped alleviate a number of quality issues in other facilities 4oC until fabrication
Color improvement
Step 15
Purge loss improvement 47 minutes at -22oC
Improved processing yields on finished cooked products 6 hours at 15oC
Doesnt mean all blast chills are unacceptable 24 minutes at -22oC
In this case, the company may have decided to back off the blast? Comparable quality at 4oC until fabrication
reduced energy output? Maybe no changes as product met their desired product mix?
KNOW YOUR TECHNOLOGY, PROCESS, AND PRODUCTS
68TH RECIPROCAL MEAT CONFERENCE 68TH RECIPROCAL MEAT CONFERENCE

Published Work Chilling and Published Work Chilling and

Tenderness Tenderness
Stepwise chilling: Tender pork without compromising water-holding capacity Stepwise chilling: Tender pork without compromising water-holding capacity
(Rosenvold, et. al. 2010) (Rosenvold, et. al. 2010)

Carcass weights ranged from 100 to 106 kg Again, similar trends to those observed in the previously mentioned studies slower
rate of decline improving loin tenderness
Cooler shrink was 2% on all treatments except for Step 15, which was 3.1% BUT AT WHAT COST?

Similar rates of temperature decline were observed on the loin for the first hour,
with a notable plateau in temperature decline through 8 hours for the Step 10
and even more pronounced for Step 15
Warner Bratzler Shear Force was lower for Step 15 vs the Control (3.1 vs 4 kg in
the LM)
No differences in processing yields
Shrink was 2 to 3%
Compared to less than 1% for Blast and Spray in previous work, consider
215# carcass losing an extra 1% of weight now weighs 212.85
Figure worst case $0.20 on value lost (estimates on skin) on 16,000 head/day large plant
$0.43 per head of opportunity, or $6880 per day, or $1.8 million per year on 270 days
Shelf life
Unknown implications vs current customer expectations

SO WHAT?? No processing yield gain

KNOW YOUR TECHNOLOGY, PROCESS, AND PRODUCTS
68TH RECIPROCAL MEAT CONFERENCE 68TH RECIPROCAL MEAT CONFERENCE

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Key messages Key messages

Considerations for todays carcasses
Predominant Methods of chilling
3 Main Types Conventional, Spray, Blast/Snap Variations
Be conscious of set point vs actual temperatures, air flow throughout the
process
Utilize additional recorders to track air temperatures if needed
Understand air flow
Understand operating conditions of freezers and coolers (defrost cycles, etc.)
Be conscious of probe placement and measurement lack of attention to
detail in this area can result in variable results
And if collecting data in a commercial plant, be aware of both food safety
and personal safety expectations
Collect the same number of probes with all parts and pieces still attached
Understand the potential population and capture the appropriate variation
Take note of loading and spacing when conducting research
Spacing on blast chains
Spacing on trolley centers
Ask about refrigeration loads
Be diligent on probe placement temperature and pH
By carcass weight, look at relationships between primals
Are there ratios to consider between temperature decline curves by primal
(loin/ham/shoulder/belly)
Understand that companies may have different needs depending on their
product mix and brands
What makes them most competitive
Less focus on one quality attribute for another might make that company more competitive

68TH RECIPROCAL MEAT CONFERENCE 68TH RECIPROCAL MEAT CONFERENCE

Key messages Key messages

Findings of published work Business implications of results conveying the appropriate message
Be aware of the potential audience For research, Id challenge everyone to consider the business case for their findings when
possible (sometimes its worth the investment, sometimes not)
Academia, Processors, Retailers, Food Service, Consumers
Results of publications make it to different segments Understand potential customers and consumers does the technology investment create
value for the chain
Consider if statistical differences might be truly recognizable to the consumer or end user
Dont minimize the finding of the research
Understand there may be unintended consequences if testing parameters are too narrow
Does it represent a broad view of the industry, or is it narrowed to a given set of parameters
(genetics/stun/chill)
Maintain awareness of what is being correlated
24 hour pH is not always ultimate pH
18 hour pH is not always 24 hour pH
Which measurement is being correlated to quality attributes

68TH RECIPROCAL MEAT CONFERENCE 68TH RECIPROCAL MEAT CONFERENCE

Thanks to our Sponsor References

Honikel, K. 1999. Influence of chilling of pork carcasses on physical
quality traits. National Pork Producers Council Chilling Workshop.
National Pork Producers Council. Des Moines, IA.
Murray, A. 1999. Pork Chilling: Canadian Research Update. National
Pork Producers Council Chilling Workshop. National Pork Producers
Council. Des Moines, IA.
Rosenvold, K., U. Borup, and M. Therkildsen. 2010. Stepwise chilling:
Tender pork without compromising water-holding capacity. J. Anim. Sci.
88:1830-1841.
Shackelford, S.D., D.A. King, T.L. Wheeler. 2012. Chilling rate effects on
pork loin tenderness in commercial processing plants. J. Anim. Sci.
90:2842-2849.

68th RECIPROCAL MEAT CONFERENCE 68TH RECIPROCAL MEAT CONFERENCE