Meat Products Production (Roast, Canned Meat, Pastrami, and Sausage)
Prof. Dr. Mehmet Ali Kaşlıoğlu
(Food and Nutrition Science Specialist)
Various preservation methods have been developed to prevent meat spoilage by creating unfavorable conditions for the growth and multiplication of microorganisms. These methods can significantly slow down or stop the effects of physical, chemical, and enzymatic factors that cause spoilage in meat and meat products. Processed meat products are obtained from the meat and organs of slaughtered animals, which are minced and prepared in natural or artificial casings in raw, salted, roasted, boiled, or smoked forms. Maturation or fermentation is one of the most critical stages in sausage production. Temperature and humidity, along with low-humidity air currents, affect product quality.
One of the preservation methods for meat is roasting. After cooking, the meat is placed in suitable containers such as cans or plastic, covered with a layer of fat, and sealed or stored at temperatures below +4ºC. Roast meat is a product produced by packing cooked meat, embedded in melted internal fats from slaughter animals, in special natural or artificial packaging materials, ensuring the entire surface of the meat is covered.
In European or other Christian cultures, meeting the meat needs of Muslims has become a significant issue. Therefore, it is somewhat challenging to find halal slaughtered meat everywhere in Europe. This has made it a necessity to produce meat products such as roast, canned meat, pastrami, and sausage according to Islamic methods, ensuring that Muslim communities can consume them safely.
The durability of meat and meat products is enhanced for the following purposes: During roasting and canning processes in the meat industry, thermal treatments such as pasteurization and sterilization are applied. Chemical and microbiological spoilage can be reduced by heating. The given heat energy kills microorganisms and coagulates enzymes. Afterward, meat durability is ensured by cooling, packaging, and preserving it in a cold environment.
2. Sausage Production
One of the important processing methods for meat products is sausage production. The stages of sausage production generally include raw material selection, preparation of the raw material, sausage dough preparation, filling, maturation, and packaging. A classical sausage formulation uses red meat (18% fat), tail fat, salt, sucrose, garlic, NaNO3 or NaNO2, moderately hot red pepper, ground black pepper, cumin, and allspice.
2.1 Types of Sausages
According to TS-1070, Turkish sausage is made by filling the dough prepared from the meat of slaughtered large cattle into natural and artificial casings, followed by a waiting period for maturation.
According to TS-1070, Turkish sausage is classified based on its fat content:
It is also classified by production method and external appearance into:
- Kangal
- Baton (stick, jump, or staff)
- Finger
- Cooked sausage
After peeling, sausages are sold sliced, and other forms such as buffet sausage, luxury sausage, and extra sausage are also available.
2.2 Properties of Meat and Fat Used in Sausage Production
Due to the low pH content and the difficulty of using buffalo and young cattle meat outside of sausage production, these meats are preferred. The meat should be rested for 1-2 days after slaughter, and its microbial content should be low. It should be well-chilled or frozen. Excessive fat should be trimmed, and tough connective tissues and nerves should be removed. The pH of the meat should be between 5.4-5.8. Sheep tail fat is generally used as fat. Fat from young cattle or internal fats may also be used. The fat mixed into the sausage dough must have a firm consistency.
2.3 Sausage Dough Preparation, Filling, and Maturation
In preparing the sausage dough, meat is first chopped into cubes and placed in stainless steel containers. Sufficient amounts of additives are added, and the mixture is thoroughly mixed in a mixing machine. The mixing process continues until the additives are evenly distributed, and the mixture is stored in a cold storage room (2-4°C) for 12-24 hours. During this time, the salty and spiced water that leaks from the meat cubes helps mature the meat.
After 24 hours, the chopped fats are added to the meat, and the mixture is processed through a meat grinder. The sausage mixture is then mixed and kneaded in special machines to achieve a homogeneous consistency, preparing it for filling. The sausage dough should be kept below +2°C and should not exceed +4°C during the homogenization process.
The sausage dough is filled into natural or artificial casings as tightly as possible, ensuring no air pockets. Afterward, the sausages are hung on ropes, spaced apart to avoid touching, washed with pressurized water, and placed in maturation rooms.
Maturation begins within the first few hours, during which the product dries. Therefore, humidity and air circulation should be controlled. After maturation, if the required flavor and smell have developed, the structural formation is complete, and moisture is within the limits defined by the regulations, the product moves to labeling and packaging stages.
2.4 Characteristics of High-Quality Sausage
According to Turkish sausage standards (TS 1070), sausages are classified based on their fat content:
- 1st class: Fat content ≤ 30%
- 2nd class: Fat content ≤ 40%
- 3rd class: Fat content ≤ 50%
- Very fatty sausage: Fat content > 40%
The sausage should have a moisture content of no more than 40%, a salt content of no more than 5%, and a pH value between 5.4 and 5.8. The protein content in 1st class sausage should be at least 22%, and in 2nd and 3rd class sausages, at least 20%. It should be free from inorganic dyes, and putrefaction tests should be negative. The sausage should not contain internal organs, and the connective tissue content should not be excessive.
3. Pastrami Production
Pastrami is a flavor that emerged from the preservation methods of meat carried by our ancestors during their long rides on horseback in Central Asia. The word "bastırma," which is the root of pastrami, is related to storing meat by pressing it under the saddle of the horse. Pastrami, which is a truly Turkish dish, has traditionally been produced at home, but industrial production has become widespread.
In pastrami production, during the 1st and 2nd stages, animal slaughter and carcass dissection are performed, and the meat for pastrami is separated. In the 3rd stage, medium-sized salt is mixed with nitrate or nitrite and rubbed onto both sides of the meat. Excess salt is shaken off, and the meat is left for 20-30 hours. After this process, excess salt is washed off with cold water. The meat is then hung and dried until its moisture content drops to 40%.
The drying period depends on the thickness of the meat, room temperature, air circulation speed, and relative humidity. After 3-5 days of drying, the meat is placed under pressure for 6-12 hours, depending on its size. Afterward, it undergoes a 2-3 day drying process called "sweaty drying," where the meat is hung in sunny, warm places or in rooms at 35-40°C. During this process, the meat begins to sweat and soften. After drying, the meat is stacked, and special spices such as garlic, red pepper, and ground mustard seeds are prepared by blending them into a paste and applied to the meat. The spiced meat is hung for 10-20 days until the seasoning dries.
Quality Pastrami Features
A high-quality pastrami should have an even and homogeneous marbling pattern. The outer color should be typical of the seasoning, the cut surface should be bright red, and it should be homogeneous on all sides. The texture should be moderate, easy to cut with slight resistance, and not excessively hard or soft. It should be chewable, easy to swallow, and leave no residue in the mouth.
4. Making Roast Meat
Roast is a traditional Turkish meat product. The key to making a delicious roast is undoubtedly the quality of the meat. The other ingredients are fat, salt, and spices. Roasts produced for commercial purposes are made using traditional methods. Beef is the most commonly used meat for making roast, but veal, goat, buffalo, or sheep meat can also be used. Meat that has not been separated from its internal fat is rested at 4°C one day before preparation to get ready for roasting.
Delicious roast can be made from the front legs, buttocks, back, or specific areas of the shoulder of the animal. For the meat to be both delicious and healthy, it should be rested for one day. The type of fat and pan used is also important when making the roast. If possible, it should be made with butter or the animal's own fat.
