410 Chapter 23
impart desired attributes to the fi nal product.
Binders can be used singly or in combination
to achieve a required level of bind; cold - and
hot - set binders can even be used together to
reinforce the binding effect. For instance, in
hot - set restructuring, Activa may be added to
increase the bind strength of the protein
matrix extracted during mixing with salt. In
this chapter, the alginate and transglutamin-
ase (Activa TM ) cold binding systems are dis-
cussed to provide examples of two methods
of cold binding involving gelation and enzy-
matic cross - linking.
An example of a large - scale manufacture
of whole - tissue restructured meat is that of
Bernard Matthews New Zealand (BMNZ,
2008 ). Bernard Matthews New Zealand is an
added - value further processor and marketerdioxide was 63 and 105 days for alginate and
Pearl bound products respectively.
Frozen portioned, raw, cold - set restruc-
tured steaks can be packaged in bags,
pouches, trays, overwraps, and paperboards
similar to their hot - set counterparts.
Formulations for Restructured
Whole - Tissue Meats
Generalized procedures for the manufacture
of restructured whole - tissue meats using hot -
and cold - set binding systems are shown as
fl ow diagrams in Figures 23.3 and 23.4. The
procedures have been simplifi ed to show the
fundamental steps involved. The manufac-
ture can be up - scaled using various types of
equipment, and ingredients can be added to
Tunnel boned whole
lamb leg
↓
Sprinkle 0.2% ActivaTM
↓
Shape
↓
Vacuum pack in regular
vacuum pouch bag
↓
Store at 4°C without
disturbance for 24 hrs to set
↓
Crust or deep freeze
↓
Dice to desired size and
shape
↓
Package
↓
Store chilled at –1.5°C or
frozen at –20°C
↓
EvaluateC
Beef strips (90–95% CL)
↓
Mix the meat in a mixer or tumbler at low
speed
↓
Sprinkle sodium alginate. Mix for 3 min
↓
Sprinkle calcium carbonate. Mix for 1 min
↓
Sprinkle desired amount of GDL. Mix for
additional 1 min
↓
Quickly vacuum pack in regular vacuum
pouch bag
↓
shape
↓
Store at 4°C without disturbance for 24 hrs
to set
↓
Crust freeze
↓
Dice to desired size and shape
↓
Package
↓
Store chilled at –1.5 °C or frozen at –20 °C
↓
EvaluateA B
Boneless whole lamb
shoulder
(Lean 90% and fat 10%)
↓
Sprinkle 0.2% salt
↓
Shape
↓
Vacuum pack in regular
vacuum pouch bag
↓
Freeze at –5°C
↓
Dice using a band saw to
desired size and shape
↓
Individually quick freeze
at –20 °C
↓
Package in foil laminate
bag
↓
Store frozen at –20 °C
↓
EvaluateFigure 23.3. Flow diagrams of whole - tissue restructuring using salt as hot - set binder (A), Alginate (B), and
Activa TM (C) cold - binding systems.