FROZEN BEEF

PROCESSING,PACKING & TRANSPORT

INTRODUCTION
• Freezing is an effective way to preserve beef and extend its shelf life. By freezing beef, the growth of bacteria,
mold, and other microorganisms that can spoil the meat is slowed down, which helps to maintain the quality
and safety of the beef.
• Many beef producers freeze their products to make it easier
to transport and store. Frozen beef can be shipped and stored at much lower temperatures than fresh beef,
which helps to reduce the risk of
spoilage and contamination during
transport.
• Freezing beef can be a cost-effective way to preserve it for longer periods of time. This can be particularly
useful for beef producers who need to store large quantities of beef for extended periods.
• In some cases,beef may be frozen to preserve it during periods of seasonal availability.For example, if beef is
only available in certain regions during specific times of the year, producers may freeze it to make it available
to consumers throughout the year.
When beef is frozen, the ice crystals that form inside the meat can cause damage to its structure, which can result
in a loss of texture and flavour. However, if beef is properly frozen and thawed, the impact on its quality can be
minimized.
PROCESS FLOW CHART
PRIMARY MEAT PROCESSING
Meat production from food animals is the process whereby healthy, live animals are humanely stunned, bled, dehided/dehaired and
eviscerated. In India cattle, buffalo, sheep, goat, pigs and poultry are the common meat animals. The following are brief description
about various steps involved in slaughter and dressing of food animals.

• Rest and fasting: The animals intended for slaughter are rested for minimum period of 12 to 24 hours. Ample drinking water
during rest should be provided as it lowers the bacterial load in intestines, and facilitates dehiding procedure. Animals awaiting
slaughter should be fasted for 12- 24 hours. Fasting improves appearance of the carcass and helps in dressing.
• Ante mortem inspection: Ante mortem inspection of food animals is carried out by a qualified veterinarian with the object of
providing wholesome meat to the consumers by deciding their fitness for slaughter. The live animal examination should be done
within 24 hours prior to slaughter to detect communicable disease like Anthrax, Foot and Mouth disease, sheep pox, swine fever
etc. Diseases like Tetanus, Rabies are detected only in ante mortem examination. It should be carried out in adequate lighting in
the lairage.
• Stunning: Stunning is the first step in the slaughter procedure. This must be done in a way that complies with the humane
slaughter act. In conventional slaughter methods in most developed countries, it is normal practice to render the animal
insensible by stunning, except in Jewish and Muslim methods and then to kill it by bleeding. Stunning induce an immediate state
of insensibility and produce sufficient immobility to facilitate the sticking process to initiate bleeding. Electrical, mechanical and
gaseous stunning are three important methods.
• Sticking and bleeding: It is desirable to keep the animal live, but stunned, in order to eliminate the blood. Therefore bleeding can
be achieved when the heart and respiratory functions are still working. In the slaughter of animals, bleeding is usually carried out
by an incision in the jugular furrow close to the head, severing both carotid arteries and jugular veins and blood drains, causing
death through exsanguination. Bleeding should be complete, and continued to a minimum period of 6 minutes. The efficiency of
bleeding has greater impact on the subsequent keeping quality of the carcass.
• Dressing of meat animal: Following bleeding, carcasses are dressed and excess fat, viscera and offals are separated from the
bones and the edible tissue.
• Deheading: The head as well as front and rear feet are removed after completion of bleeding. Prior to hide removal, care is
taken to tie the oesophagus and bung to prevent faecal contamination later in the process. In case of pigs, the head, skin, feet
and tail are left attached to the carcass.
• Dehiding: The hide/skin is removed by down and side pullers and fisting off the pelt (sheep and goats). In case of pigs and
poultry, skin is edible and is retained with carcass. In these animals, after bleeding, carcasses are scalded with hot water at (55-
65°C) to remove the hairs/ feathers.
• Evisceration: Carcasses are sprayed with pressurized water to eliminate external contamination. Evisceration involves opening
of pelvic, abdominal and thoracic cavities and removing the internal organs. Adequate precaution should be taken to segregate
edible and inedible parts of the carcass in such a way that the contamination of the
edible parts is strictly restricted.
• Post mortem inspection: The carcass and internal organs should be inspected for safety. The internal organs are removed and
inspected for internal parasites and signs of disease. Lymph nodes are examined for signs of systemic disease. If any
pathological condition is detected, part of or carcass as a whole should be condemned and sent for destruction.
• Carcass washing & decontamination: Then the carcass is washed with pressurised potable water to remove the external
contamination and also reduce the body temperature. Decontaminants like chlorinated water, lactic acid, etc employed to
minimize the microbial load
• Chilling: Carcasses of freshly slaughtered animals have surfaces that are warm and wet and thus provide a perfect substrate for
the growth of pathogenic and spoilage organisms. Chilling immediately post-slaughter reduces the surface temperature to a
value below the minimum growth temperature for many pathogens. The combination of low temperature and surface drying
inhibits the growth of spoilage bacteria. Hence, carcass sides should be cooled as soon as possible after weighing. Meat
fabrication is generally carried out after the carcass has been cooled for 18 hours or more in chilling rooms at the temperature of
0 to 5°C and 85-95% relative humidity to attain 5.8-6 pH to prevent the growth of microorganisms and reduce meat deterioration.
Chilled meat has shelf life of 2-3 days.
• Fabrication: Fabrication refers to creating the various cuts from the chilled carcass to produce particular types of products.
Primal or wholesale cuts are made first. The carcass is then cut into smaller piece for further processing. The temperature should
be maintained at 32°F to 40°F (0°C to
4°C) during this process.
• Ageing of meat: In the absence of microbial spoilage, holding of unprocessed meat above the freezing point is known as
conditioning or ageing and it has long been associated with an increase in tenderness and flavour. Immediately after death and
before the onset of rigor mortis, muscles are pliable and tender when cooked. With the onset of rigor mortis, the muscle
becomes inextensible and is tough when cooked. As conditioning proceeds, the muscle becomes pliable once more and
increasingly tender on cooking. time for completion of rigor mortis depends on animal, species and even muscle. In case of beef
it is 18 to 24 hours.
• Further processing: The beef is then further processed into various products such as ground beef, sausages, and beef jerky.
The temperature should be maintained at 32°F to 40°F (0°C to 4°C) during this process.
• Preservation: The meat is then preserved through various methods, such as curing, smoking, or freezing.Curing involves
adding salt and other ingredients to the meat and keeping it at a temperature of around 4°C (39°F) for several days. Smoking
involves exposing the meat to smoke from burning wood chips or other materials. Freezing involves lowering the temperature of
the meat to -18°C (0°F) or lower.
• Packaging: Meat needs to be packaged to prevent contamination, color deterioration, loss of moisture, odour pickup, oxidative
rancidity etc. It also helps in easier transport, display of necessary information and to convince consumers. Packaging is one
factor effecting the shelf life of meat.
• Storage:Old storage should be pre-tested to ensure temperature transmission and rapid treezing of products. A pallet should
contain no more than 6 lavers of cargo. It is recommended to use 30 pounds 13.6 kilograms) carton/pallet 27.2 kilograms)
Carton/pallet.The meats is desired to be stored for longer time quick freezing is aways a desirable process to retain the natural
quality of meat and to avoid deterioration due to process.. Blast freezers are widely used for meat of all type and suits for
freezing whole sides, primal cuts and irregular shaped products.
PRESERVATIVES

Preservatives are not typically added to frozen beef as it is not necessary to extend its shelf life or maintain
its quality.Frozen beef is usually packaged and frozen without the use of preservatives.However, some pre-
packaged beef products, such as sausages and meatballs, may contain preservatives to extend their shelf
life and prevent bacterial growth. The preservatives commonly used in these products include sodium nitrite,
sodium erythorbate, and citric acid. It is important to read the labels of prepackaged beef products to
determine whether any preservatives have been added.
PACKING

Preservation of meat by freezing, offers the greatest advantages of increase in shelf-life, inhibition of bacterial growth and
preservation of fresh texture and flavour. If frozen meat is not properly packed there is continuous dehydration from the surface
resulting in freezer burn. This condition affects the surface texture and colour. Meat fat is also prone to the development of oxidative
rancidity if a good oxygen barrier is not used. Hence, frozen meat needs protection against:

• Dehydration and loss of surface texture

• Moisture loss
• Temperature fluctuations
• Rancidification
• Pick up of odours / flavours
• Expansion and contractions which occur during freezing and thawing.
PACKAGING REQUIREMENTS

A suitable packaging material must, therefore, have a very low moisture vapour and oxygen transmission rate. The
material should also be durable at freezer temperature, have very high wet strength and be impermeable to dour and
flavours. Packaging Materials Plastics are amongst the most commonly used materials for packaging of frozen meat
Generally, low density polyethylene (150 - 200 gauge) is used for this purpose as it provides adequate clarity and is
stable at low temperatures and is available at low cost. Polyester or Nylon / PE laminates and heat shrinkable low
density polyethylene and PVC / PVDC co-polymer films also provide functional properties, besides giving neat
appearance to the frozen meat cuts.Shrink packaging also allows convenient handling of the product. Frozen meat
may be in the form of chunks, minced or various cuts. The unit packs consist of 1, 2, 4 or 8 lbs in LDPE bags of 250 -
350 gauge. After placing the meat in the bags, the bag is folded and then the packed product is blast frozen at - 40°C
for a period of 4 to 12 hrs depending upon the size and shape of the package. After freezing, unit packages are
packed and stored in corrugated boxes made of either paper or plastic, which are either waxed internally, or on both
the surfaces. These boxes are stored at -20°C and the expected shelf-life for the product is around one year.
VACCUM PACKING
• Using a vacuum or protective gas during the packaging process is one of today’s most common methods for hygienically
packaging fresh meat, sausage goods and convenience products in portioned packaging with a long shelf life that is
attractive to consumers

• Meat can be packed in various formations, like vacuum packaging,MAP modified atmosphere packaging, or VSP vacuum skin
packaging. For industrial large scale meat production, vacuum packaging is the most utilized method.

• Vacuum packaging removes the oxygen from the meat. This reduces the activity of bacteria that require oxygen and
significantly increases shelf life. Removing the oxygen drastically slows the meat maturation process and the meat
quality is maintained for a longer period.
TRANSPORT
Transportation temperature and conditions are critical to maintaining the quality and safety of frozen beef during transit.
• Temperature control: Frozen beef should be transported at a temperature of -18°C (0°F) or below to prevent spoilage and
bacterial growth. The transport vehicle should have a temperature monitoring system to ensure that the temperature is
maintained throughout the journey.
• Packaging: Frozen beef should be packaged in a way that prevents contamination and maintains its quality during transport.
Vacuum-sealed plastic, shrink-wrapped plastic, and insulated containers are commonly used for transporting frozen beef.
• Handling: Frozen beef should be handled with care during transport to prevent damage to the packaging and ensure that it
remains frozen. It should be loaded and unloaded quickly to prevent exposure to warmer temperatures.
• Storage time: Frozen beef should be handled with care during transport to prevent damage to the packaging and ensure that it
remains frozen. It should be loaded and unloaded quickly to prevent exposure to warmer temperatures.
• Sanitation: The transport vehicle should be clean and free from contamination to prevent the spread of bacteria and other
pathogens. It should be sanitized before and after each use to ensure that it is free from dirt, debris, and other contaminants.
frozen beef should be transported at a temperature of -18°C (O°F) or below, packaged appropriately, handled carefully, transported
for the shortest possible time, and stored in a clean and sanitized transport vehicle.Following these guidelines can help to maintain
the quality and safety of frozen beef during transportation.
MICROBIOLOGICAL TESTING
• Total Plate Count: This test determines the number of viable bacteria present on the surface of the
meat. A high total plate count can indicate that the meat is contaminated and may not be safe for
consumption.
• Coliform testing: Coliform bacteria are commonly found in the intestines of animals and are used
as an indicator of feacal contamination. Testing for coliform in beef can indicate whether the meat
has been exposed to animal waste during processing.
• Escherichia coli (E. coli) testing:E. coli is a type of bacteria that can cause serious illness in
humans. Testing for E. coli in beef is important to ensure that the meat is safe for consumption.
• Salmonella testing: Salmonella is a type of bacteria that can cause food poisoning in humans.
Testing for Salmonella in beef is crucial to prevent outbreaks of illness.
• Listeria testing: Listeria is a type of bacteria that can cause serious illness, particularly in
pregnant women and immunocompromised individuals. Testing for Listeria in beef is important to
ensure that the meat is safe for consumption.

• These tests are typically conducted by taking swab samples from the surface of the beef and
analyzing them for the presence of bacteria. If any of these tests come back positive, it may
indicate that the beef is contaminated and should not be consumed.
Thank you.