Points To Consider in Starting a Meat Processing Project

 Determination, enthusiasm, and perseverance to start a business.

 Market for the products.
 Good business should be market-driven and not production-driven.
 Sourcing for raw materials, ingredients and packaging materials.
 Availability of simple equipment’s and utensils.
 Capital to start the project.
 Personnel to attend the processing operations.
 Allocate time for processing.
 Identification of product lines.

UTENSILS

 Individual Measuring spoon 1 set

 Individual Measuring cup 1 set
 Graduated Measuring cup (for liquid) 1 set
 Spatula or Rubber scrapper 2 pcs
 Kitchen knives
 Utility knives 2 pcs
 Deboning knives 2 pcs
 Knife sharpener 1 pc
 Kitchen spoon 1 pc
 Wooden ladle 1 pc
 Food tongs 1 pc
 Mixing bowls 1 set
 Trays, plastic or aluminum (rectangular) 6 pcs
 Weighing scale (for spices) 1 unit 0-100 gms. (1kg.)
 Weighing scales (for meat) 1 unit (1-10kgs.)
 Refrigerator (for curing meat products) 1 unit 11 ft3, can cure
 Freezer 1 unit 17 ft3 can store
 Blow torch (kerosene or gasul)
 Polysealer 1 unit (for sealing of plastic bags)
 Meat thermometer 1 unit (for temperature control)
 Styro coolers 2-3 units (for transport of meat)
 Cooking vessels 10-20 kgs. Capacity
 Pressure cooker 1 unit (21 quarts)
 Pressure cooker 1 unit (6 quarts)
 Basic Utensils and Equipment Used in Meat Processing

Important Utensils:

Knives Mixing bowl

Carborundum /steel Utility trays
Weighing Scale (1kg. cap.) Chopping boards
Measuring Cups and Spoons Pots and Pans
Spatula Pails
Syringe and needles Meat Thermometer

Important Equipment to Procure:

Mould (for ham, luncheon meat) Refrigerator

Cooking Vat Freezer
Ice Crusher Tumbler
Tie Linker Impulse Sealer
Bowl Chopper/ Silent Cutter Blow Torch (for emulsified products)
Food Processor Meat Grinder
Cooking Stove Stuffer
Smoke House

MEASURING FOOD MATERIALS

 Meat Processing Ingredients and Functions

CURING MIX:
 Refined Salt Dosage (per kg. meat)
 Sodium Chloride 1Tbsp (12.0 gms)
 Preservative
 Provide desirable flavor
 Extracts myosin from protein in meat which
contribute to the binding quality of meat
 Retains normal moisture content

CURING SALT: (Pink) 1 tsp (2.5-5.0 gms)

 99.4% refined vacuum salt and 0.6% nitrite (NO2)

 Nitrite in combination with vacuum salt reacts
directly to the meat, combines with myoglobin (red
color of the meat) to form nitrosomyoglobin, a
bright red compound and stable upon the reaction of
the heat (ham, tocino, sausages, and emulsified
sausages)
 Powerful anti-oxidants, retarding the development
of rancidity.

PHOSPHATE:

 Relaxes muscle of meat increasing water holding capacity and binding capacity of cured
products.
 Reduces oxidative rancidity.
 Increases product yield.
 Product surfaces are drier and firmer.
 Emulsions become more stable at higher temperature.

VITAMIN C POWDER OR ASCORBIC ACID:

 Speeds up curing reaction in cured products; accelerates color fixation.

 Fights carcinogens present in the preserved meat.

(500 gms) ¼ tsp (0.5 gms)

 EXTENDERS

TEXTURED SOY PROTEIN:

 TVP is the brand name of Aisher Daniels Midland Co. of Chicago Illinois, USA.
 Replace expensive lean meat.
 Soy Protein Concentrate (granules) 70% protein, used in minced products.
 Hydrate in double amount of water.

¼ - ½ cup (10-20 gms)

ISOLATE (SOY PROTEIN ISOLATE): 1 Tbsp (5.0 gms)

 90% protein
 Forms Protein network in meat products
 Add juiciness and volume to the meat product in combination with textured soy
protein.
CARAGEENAN:
½ tsp (1.25 gms)
 Origin: seaweeds
 Increases water holding capacity of meaty (for whole and sliced products)

QUALICEL: ¼ cup (10.0 gms)

 Source: Bamboo fiber

 Use for highly commercial gound products (siomai, embotido, longanisa,
hamburger, and hotdog

FIBRILL:

 Source: Corn Fiber

 For sliced products (like tocino, tapa, steak), dissolve in ½ cup water

¼ cup (10.0 gms)

VERSAGEL:

 Source: Plant Protein

 Use for highly commercial ground products six time the amount of Qualicel
  Qualicel and Versagel are hydrated with textured vegetable protein (1/4 cup) with
1 ½ cups (375 cc) water is 1 ¼ cup

½ cup (60.0 gms)

SEASONINGS

SPICES: Weight

Black / White Pepper (fruit seed) 2.5 gms

Paprika 1-5 gms
 Used in Frankfurters, chorizo de Bilbao, Chorizo de recado
Chili 0.3 – 3.0 gms

For Spicy Products:

A. Pimiento (fruit seed)
 It has an aroma similar to mixture of nutmeg, cinnamon and cloves
 Used in variety of sausages
 Used as partial replacement for black pepper in frankfurters and some smoked
products

B. Mace (flower)
 Used in liner and pork sausages, frankfurters and bologna.\

C. Ginger (root) 0.3-0.5 gms

 Used in pork sausages and frankfurters and similar products

D. Nutmeg (fruit seed) 0.3-1.0 gms

 Used in bologna, minced ham sausages, frankfurters, liner sausage and head
cheese
E. Clove (flower) 0.3-0.5 gms
 Used in bologna, head cheese, blood and liner sausage
F. Cinnamon (bark) 0.1-0.2 gms
 Astringent and sweet, used in martadela and bologna
AROMATIC SEEDS:

A. Cardamon 0.3- 5.0 gms

 Rapid loss of aromatic constituents during storage
 Used in liner sausage and head cheese
B. Celery seed 0.3- 2.0 gms
 Used in fresh pork sausage
C. Coriander Seed 0.3- 1.0 gms
 Contains about 13% of fatty matter and a trace of tannin
 Used in frankfurters, minced ham and luncheon meat
D. Cumin 0.2- .3 gms
 Used for meat specialties with distinct flavor

CONDIMENTAL HERBS:

A. Marjoram 0.5-2.0 gms

 Used in liner and polish sausage and head cheese
B. Tyme
CONDIMENTAL VEGETABLES:

A. Onion (bulb) 2.0- 10.0 gms

 Used in liner sausage, head cheese, sometimes replace garlic
B. Garlic (bulb) 0.1- 0.2 gms
 Used in polish sausages and smoked sausages

OTHER SPICES & SEASONING: Per kg.

A. Beef granules ½ tsp (2.5 gms)

 Added to various meat products using beef to enhance beef flavor.
B. Chicken granules ½ tsp (2.5 gms)
 Added to various meat product using chicken meat to enhance chicken flavor
C. Pork granules ½ tsp (2.5 gms)
D. Shrimp granules tsp (10.0 gms)
 Added to meat products originally using shrimp meat;
 Usage of shrimp granules (siomai, lumpiang shanghai) will bring down the
cost of production.

*The above granules can be used instantly for soup by boiling 4 cups water and add 2
Tbsp of only kind of the above granules and add the following:

Non Dairy Creamer 2 Tbsp

Dried Carrots 2 Tbsp
Shredded Cabbage ¼ cup

OTHER READY MIXES & NON-MEAT MATERIALS

Magic Meat Longganisa Mix
Magic Breading Hamburger Mix
Instamix Chicken Gravy
Non Dairy Creamer Embotido Mix
Spaghetti Mix Afritada Mix
Palabok Mix Menudo Mix
Tocino Mix Bilbao Mix
Tapa Mix

CLASSIFICATION OF MEAT

Used in Meat Processing

Hog Pork
Cattle (over one year old) Beef
Cattle (less than one year old) Veal
Carabao Carabeef
Chicken, duck, quail, goose, pigeon Poultry Meat
Horse Horse Meat
Sheep (over one year old) Mutton
Sheep (less than one year old) Lamb
Goat Chevan
Rabbit Lapan
Deer Vensan

Factors Affecting Fresh Meat Quality

A. Ante-mortem factors
 Age of animals
 Sex of animals
 Genetic and breeding
 Housing
 Feeding
 Veterinary procedure

B. Chemical compositions and histological structure of the meat

Component Percent Weight

Water 75%
Protein 16.21%
Fat 2.5%
Lipids
Connective Tissues
Carbohydrates
Glycogen
Glucose
Lactic Acid
Miscellaneous Soluble
Amino Acids
Inorganic
Potassium Sulfur
Phosphorus Magnesium
Sodium Calcium
Chlorine Iron
C. Rigor Mortis
D. Changes in pH
E. Meat Color
F. Tenderness of Meat
G. Water Holding Capacity (WHC)
H. Binding Capacity
I. Meat Taste and Flavor
J. Nutritive Value of Meat

MEAT QUALITY
What can go wrong?

Solutions

 Dark Meat pH-ultimate meat

 Dry Meat Reduce stress
 Meat tenderness Meat temperature
 Reduce Shelf-life Effective stimulation
 Cold shortening Grain feeding
 Nutrition deficient Ensure minimum fat coverage

RECOMMENDED

Retail cuts for different processed products

Retail Cuts Products

Boston butt (paypay) Ham, Tocino, Sausages

Picnic (kasim) Ham, Tocino, Sausages
Loin (lomo) Canadian bacon, Sausages
Belly (liempo) Slab bacon
Ham (pigue) Chinese style ham, quick-cured ham or
Sweet ham, Tocino, sausages

BEEF CUTTING DIAGRAM

Illustration of where to make primal beef
cuts
 Rib:
Chuck: Round:
Standing
Shoulder Round
Rib Roast
Pot Roast, Loin: Roast Tip:
or Steaks Sirloin:
Bone-in or T-bone & Bone-in or Tip mast or
Sirloin
Boneless Porterhouse Boneless, Sirloin Tip
Short
Chuck Pot Steaks or Rump Kebabs or
Plate: Flank:
Roast, Filler Roast Stir fry
Rib Slab or Flank steak
Bone-in or Mignon Ground strips or
Ground or Ground
Boneless Steaks Beef Ground
Beef cubes Cubes for
Brisket &
for stew Stew
Foreshank
BEEF CUTS
”

Primal Cuts Uses

Tenderloin Tapa, crunchiest
Porterhouse Steak
T-bone Steak
Prime Rib Steak Inihaw, steak
Sirloin Beef steak tagalog, asado
Rounds Sausage, ham
Spareribs Nilaga, kaldereta
Shank Corned beef, nilaga
Chuck Rib Steak Corned beef, sausage, hamburger patties
Ox Stripe Kare-kare
Beef Bones Bulalo, milaga, sinigang
Beef Neck Nilaga, inihaw
Beef Knuckle Steak, roast
Beef Brisket Corned beef, sinigang
Rib Eye Steak Steak, roast
Rump (tapadera) Tapa, crunchies
Short ribs Nilaga, Kaldereta, adobo
 Recommended Methods of Cookery for Retail Cuts Beef

A beef carcass consists of four quarters from a single carcas. The quarters
are produced by seperating the four quarters by cutting between the 12th and 13th ribs
remaining with the hindquarter. The diaphragm may be removed, but if not removed, the
membranous portions shall be removed close to the lean. The thymus gland and heart fat
shall be closely removed.
PRIMAL CUTS FOREQUARTER

1. Paypay (Beef Chuck). The first cut passes across the forequarters between the 5th and
6th ribs and the stemum continuing in a straight linr to the 5 th rib perpendicular to the
first described cut (this cut severs the foreshank and brisket from the square cut).

2. Kadera (Beef Ribs). Portion of the fourquarter reamining after the removal or the
cross-cut chunk (paypay) and a short plate. It is separated from the short ribs 25 cm
(10 inches) from the center or the inside protruding edge of the 6th thoracic vertebrae.
The portion of the diaphragm and practically allof the fat remaining in the ventral
surface of the vertebrae shall be removed.

HIND QUARTER

1. Hita or Pierna Corta y Larga (Beef Round). Portion of the hind quarter remaining
after the removal of the untrimmed loin. A straight cut is made parallel to the outer
skin surface beginning at the juncture of the last sacralvertebrae and the fist caudal
vertebrae passing through a second point which is immediately anterior to the ball or
the femur, exposing the ball or femur and then continuing in the same straight line
completing the cut. No more than two tail vertebrae may remain on the round.
2. Lomo (Beef Loin). Portion of hind quarter remaining after the removal of the round,
flank, hanging tender, kidney knob, and excess fat in the inner surface of the loin.
 Tagiliran Unahan (Short loin). Separated from the loin ansd (sirloin or tagiliran)
by a straight cut perpendicular to the split surface of the lumbar vertebrae through
a point immediately anterior to the hip bone and related cartilage should be left in
the short loin.
 Tagiliran Hulihan (Sirloin). The posterior portion of the full loin and is
separated from the short loin is describe above.
 Solomilio (Full Tender loin). Small spindle-shaped muscle removed from the
full loin intact.

OTHER CUTS FOREQUARTER

1. Kinche sa Unahan (Foreshank). Portion remaining after chuck is removed. It is

seprated from the brislet on or aobut the shank knuckle bones.
2. Punta y Pecho (Brisket). Portion remaining after chuck and foreshank are
removed as described above.
3. Tadyang (Plate). Portion is separated from the rib (kadera) and consists mostly
of ribs.

PORTION CUTS OF BEEF

1. Cubed Steaks. Produced from any boneless meat from beef carcass which is
reasonably free from membrane tissue, tendons and ligaments. The meat is made into
cubed steaks through use of a machine designated for this purpose. The steak must
not break when suspended.

2. Steaks. Unless otherwise specified by purchaser on surfaces where fat is present, the
fat must not exceed an average of 1 ¼ cm. (1/2 inch) in thickness and the thickness of
any one point must not be more than 2 cm. (3/4 inch).

3. Rib. Rib steaks (bone-in or boneless)

Rib eye roll steaks

4. Short Loin. Porterhouse steak is prepared from the short loin. The flank edge on the
individual steaks is removed at a point not more than 10 cm, (4 inches) from the
cutter tip of the loin eyes muscle. The diameter of the tenderloin muscle shall be not
less than 3 cm. (1 ¼ inch) when measured throughb the center of the tenderloin,
parallel to the back bone. T-bone steak is preapared from the short loin. The flank
edge on individual steaks shall be removed at a point, which is not more than 7.5 cm
(3 inches), from the center tip of the loin eye muscle. The diameter of the terderloin
 muscle shall be not less 1 ¼ cm. (1/2 inch) when measured through the center of the
tenderloin, parallel with the back bone.

5. Strip Loin. Steaks are prepared from short loin where the short tenderloin is
removed. It may be bone-in or boneless.

6. Sirloin. Top sirloin butt steaks, boneless; semi-center cut; center cut. Follow
specifications for steaks.

7. Tenderloin. Tenderloin steaks shall be prepared from a full tenderloin. On individual

steaks, when the side strip muscles and underlying fat are not firmly attached, those
must be remoced. Surface fat should be trimmed to an average of 6 cm, (1/4 inch).

8. Ground Beef Potties. Ground beef mechanically formed into round patties of the
size specified. They are arrange in stacks with each patty separated from adjacent
patties by two sheets of wax patty paper except that, when patties are individually
quick frozen, the patty paper may be excluded.

PORK CUTTING DIAGRAM

Illustration of where to make primal pork cuts

Jowl: Belly: Pork leg:

Cut ½ inch below Loin: Between the 2nd
the scapula Picnic Shoulder: From edge of the & 3rd sacral
Between the 2nd tenderloin vertebrae
Boston Butt: & 3rd ribs (posterior) to the
Parallel to the ventral side of Hock:
shoulder cut the scapula Cut through the
through the (anterior) center of the
 PORK CUTS

Primal Cuts Uses

Tenderloin Steak
Pigue Dinuguan, sausage, ham tocino, sausage
Kasim Menudo, sausage, tocino , steak, adobo
Pata front Pata tim, crispy pata, paksiw, sinigang
Pata hind Pata tim, paksiw, sinigang
Skin Chicharon
Rib shoulder Sinigang, nilaga
Pork premium spareribs Kaldereta, inihaw, nilaga
Pork belly with ribs Inihaw, adobo, sinigang
Pork chop, center cut Seaks
Pork rump Tapa, tocino, steaks, asado

Recommended Methods of Cookery for Retail Cuts Pork

Cuts Methods of Cooking

Head (ulo) Roast, stew, boil, lechon, sisig, crispy ulo
Jowl Cook in liquid, broil, pan broil, pan fry
Pig’s feet Cook in liquid, braised; for feet (for crispy pata)
Fore/Hind Shanks Stew, boil, deep fry
Picnic Roast, bake, cook in liquid, pan broil, pan fry
Boston butt Braised, cook in liquid, broil, pan fry, roast
Loin Braised, boil, pan broil, pan fry, cook in liquid
Ham Roast, bake, broil, pan fry, pan broil, cook in liquid
Spare ribs Roast, fry broil, boil
HIND QUARTER

1. Kinche sa Hulihan (Hind Shank). Separated from the round on or about the style
joint.
2. Tapadero (Rump). Separated from the round by a straight cut perpendicular to the
outer skin surface immediately posterior and parallel with the long axis of the
exposed surface of the aitch bone, living no part of the aitch bone in the round. The
separation of the rump from the round is completed by sawing through the roundbone
(femur).

FABRICATED PORK CUTS

1. Chuck Square cut chuck

Square cut chuck, boneless
Chuck roll.
2. Rib Rib, oven prepared
Rib, oven prepared, boneless and tied
Rib, roast-ready boneless
Rib eye role
3. Loin Short, loin short cut
Strip loin (short tenderloin is removed)
Strip loin, boneless
Strip loin, intermediate
Strip loin, intermediate boneless
Strip loin, short cut, bone-in or boneless
Sirloin
Sirloin butt, boneless
4. Round Round boneless
Round, shank off
Round, shank off, 3 way, boneless
(knuckle, top (inside)
Round/bottom round
Eye of the round
DRESSING VALUES OF MEAT ANIMAL

Percent
Cattle (beef)
Dressing Percentage 50-55
Cuts (forequarter)
Foreshank 2.80
Brisket 5.94
Chuck 24.65
Ribs 11.80
Plate 6.45
Short Loin 8.34
Loin End 6.74
Rump 7.14
Round 12.60
Flank 3.60
Hind Shank 4.00
Abdominal Fat Cutting/Chilling 5.84

HOLDING TIMES FOR MEAT STORAGE

Chilled Holding Period

Solid cuts of beef, pork, lamb and veal 2 to 4 days
Ground items and variety meats (liver, tongue) 1 to 2 days
Most cook, processed meat items and cook left overs 3 to 7 days

Frozen
Beef 6 to 12 months
Lamb and Veal 6 to 9 months
Ground Beef 3 to 6 months
Pork 3 to 6 months
Ground Lamb, ground veal and variety meats 3 to 4 months
Ground Pork 1 to 3 months

LIST OF MEAT PROCESSING INGREDIENTS

Extenders and Seasoning According to Functions

Curing Mix:
Refined Salt or Vacuum Salt
Curing Salt
Phosphate
Vitamin C Powder or Sodium Erythorbate
Extenders:
Textured Vegetable Protein (TVP) (from soybean)
 TVP powder (from soybean)
Isolate (from soybean)
Qualicel (Bamboo fiber)
Versagel (plant protein)
Carageenan (from seaweeds)
Fibrill (from corn fiber)
Binder Filler Blend (BF blend)
Seasonings:
Adobo mix
Anisado wine (foe longanisa, tocino, tapa & cooking of ham)
Beef flavor (for hamburger & other beef products)
Beef Aroma (to enhance better aroma in beef products)
Super seasoning
For Corned Beef:
Corned beef seasoning
Garlic Powder
Onion Powder
Mace
Carageenan
Meaty Ginisa & Beef Aroma
For Hamburger:
Celery Powder
Potato Starch /Modified Potato Starch
Hamburger seasoning
Hamburger Mix (Instant mix)
For Ham (Pork, Chicken, Beef):
Cinnamon Powder
Clavo de Corner
Ham spice
Laurel Leaves

Oregano Strands or Oregano Powder

Fried Chicken Seasoning
Garlic Powder
Trehalose
Goyong Powder (for kikiam)
Ground Black Pepper
Luncheon Meat Seasoning
Mace
Meat Enhancer
Monosodium Glutamate (MSG)
Minced Onion
Meaty Ginisa
Paprika
Pork Granules
ShrimpPowder or Shrimp Granules
 Smoked flavor
Sodium Benzoate
White Pepper

Utensils:
Syringe and Needle:
30 ml. capacity
50 ml. capacity
(Needle: 15 inches x 3 inches)
Cotton Thread
Hamburger Molders:
Big: for 50 & 100 grams patty
Small: for 30 grams patty
Funnel for stuffing of longganisa and sausages

Packaging Materials:
Paperlyne (6 inches x 6 inches) (for skinless longganisa and hamburger)
Paperlyne (1 sq. foot) for wrapping of ham
Taupee wrapper for kikiam
Plastic bag (polyethylene bag)
Big (6 inches x 12 inches) for ½ kg. meat products
Medium (6 inches x 8 inches) for ½ kg. meat products
Salted Hog Casing – for sausages; natural, cleaned, salted (keep in freezer)
Wash before using
Collagen Casing
Small
Big
Opaque plastic containers for storage of ingredients

COSTING OF MEAT PRODUCTS

1. Refer to recipe
2. Always record production yield after processing
3. Compute for the direct cost (meat ingredients and packaging materials)
a. Cost meat (pork, chicken or beef)
b. Ingredients: Consider the weight of ingredients (curing mix, extenders
and seasoning) used per kilogram)
c. Compute for the packaging materials
4. Compute for the indirect cost (labor, water, electricity, and transportation
cost).
a. General recommendations 10-12% of the direct cost.
5. Compute for the contingency cost 35% of direct cost.
6. Add the following:
 a. Direct Cost
b. Indirect Cost
c. Contingency Cost
7. Get the total and divide on the yield after production.
8. Marked Up Cost
a. Based on the production cost consider a mark-up from 30-50%
b. Add 30% mark-up to the production cost
c. Production cost plus marked-up cost is equal to the selling price.

Note:
1. Compare your selling price if it is competitive.
2. How to bring down the cost of your processed products.
a. Consider the cost of meat block; for ground products, lean should be 70% and
back fat 30%.
b. Consider meat quality; the higher is the quality of meat the higher is the yield.
Higher yield can be attained using the latest fiber technology in meat by using
various extenders like textured vegetable protein, isolate, carrageenan,
qualicel, versagel and BF (binder filler blend) to enhance water in meat which
is 75%.
3. Instamix, Meaty ginisa and Beef aroma are the latest trends for more aromatic flavor
… mura na masarap pa.