Meat and meat products are excellent sources of nutrients for humans. In 2021, around 328 million tons of meat were consumed globally, according to Statista. Appetite for meat is also as high as ever with the Food and Agriculture Organization (FAO) estimating the global consumption of meat proteins over the next decade to increase by 14% by 2030.
However, meat is susceptible to contamination by food-borne pathogens and various spoilage microorganisms because of its high-water activity and nutrient content.
Microbial contamination can cause undesirable changes in quality, and alter colour, texture and flavour, posing not only a health risk to consumers, but possibly an economic loss. This is why meat preservation is a rule and not an exception in the meat processing industry.
From ancient practices of drying and smoking to modern innovations like refrigeration, modified atmosphere packaging and high-pressure processing, the industry has always sought to preserve the quality and safety of one of the most prized delicacies globally. In this article we look at the recent advances in meat preservation technology and their potential benefits for the industry even as the global meat consumption is projected to reach between 460 million and a staggering 570 million tons by 2050.
Advancements in refrigeration technology
Since its 1854 debut, refrigeration has revolutionized meat preservation. By lowering temperatures, it dramatically slows the growth of bacteria, a key culprit in spoilage. This translates to a significant extension of shelf life for fresh meats, typically ranging from 5 to 7 days in the refrigerator. For frozen meats stored at the standard -18°C (-0°F), the shelf life stretches even further: beef for 6 to 12 months, lamb for 6 to 9 months, pork for 6 months, and sausage products for a comfortable 2 months.
Cooling technology supplier Intarcon however notes that temperatures below approximately -2 °C, depending on the type of meat, lead to the formation of ice crystals in the intercellular spaces, causing water to escape from the cells to compensate for the increased osmotic pressure, which leads to drying out of the product and thus to weight loss, as well as alteration of the cell structure. All this results in a lower quality as perceived by the user. To avoid this, cooling technology manufacturers have developed refrigerators with slower freezing time which promote the formation of smaller crystals.
Another primary focus in refrigeration technology has been on improving energy efficiency. This has particularly gathered momentum in the recent pasts as energy costs spiral and pressure mounts on food companies to reduce their environmental impact. Manufacturers have been developing refrigeration systems with advanced compressor technologies, improved insulation materials, and better controls to minimize energy consumption while maintaining optimal cooling conditions for meat storage.
A good example is the modern GEA Grasso compressors which a Belgium-based foodservice wholesaler recently installed and as a result managed to increase energy efficiency by up to 50%. The Grasso compressor also features a new trend; the transition from refrigerants with high global warming potential. It uses ammonia which is considered natural refrigerant with zero ozone depletion potential (ODP) and zero global warming potential (GWP).
CO2 is another refrigerant that gaining popularity for its zero effect on the ozone layer and a low effect on global warming (GWP = 1). German industrial equipment manufacturer Danfoss and her U.S. peer Emerson being among the popular users of CO2 with the latter announcing an expansion of its CO2 compression portfolio with the development of what it calls the refrigeration industry’s first transcritical CO2 screw compressor, which is designed “for the rigors of high-pressure industrial CO2 refrigeration.”
Transport refrigeration brand, Thermo King also joined the environment friendly refrigerant bandwagon in 2022, transitioning to the lower-GWP refrigerant (R452A). The company said the move will reduce the carbon footprint of refrigerants used by its customers’ long-haul, middle-mile and last-mile delivery fleets by nearly 50% or approximately 650,000 metric tons of CO2e annually.
New processes technologies to enhance shelf-life
Novel technologies have been introduced in the meat industry to provide a safer, fresher, more natural or minimally processed and additive-free, products. High-Pressure Processing is among the technologies that many meat producers are increasingly relying on to extend the shelf life of their products. By subjecting packaged meat to high pressures and at lower temperatures of between 5 and 20 degrees, this technology effectively eliminates harmful bacteria, yeasts, and molds, extending shelf life while preserving the nutritional quality and sensory attributes of the meat.
Generally, pressure levels used for pasteurization of meats and meat products range from 400 to 600 MPa, with short processing times of 3 to 7 minutes at room or chilled temperatures. This typically results in an inactivation level of more than a 4-log reduction for the most common vegetative pathogenic and spoilage microorganisms, leading to increased shelf life and improved safety.
Roberto Peregrina, USA Executive Director at HPP equipment manufacturer, Hiperbaric, said: “HPP is able to enhance food safety by controlling pathogens and extend shelf-life, without compromising on quality. Since it is a post-packaging process, it also helps prevent recontamination and recalls”.
Roberto highlighted HPP’s effectiveness by noting that it has allowed one of their customers Demakes to increase shelf life of their pre-sliced organic deli meat from 49 days to 120 days, a 60% increase.
Cutting-edge technologies are revolutionizing the meat processing industry, not just by extending shelf life but also by ensuring transparency and safety. Blockchain, for instance, acts as a digital ledger, meticulously recording every step of a meat product’s journey from farm to fork. This immutable record fosters trust and accountability, allowing for swift identification and removal of potentially contaminated products.
Automation and robotics are also playing a crucial role. While motivated by the desire for efficiency, their ability to minimize human contact during processing has another significant benefit: it reduces the risk of contamination, a major culprit behind shortened shelf life.
Extending shelf-life through natural preservatives and ingredients
To prevent the microbiological contamination of meat, synthetic preservatives, including nitrites, nitrates, and sorbates, have been widely used in the food industry due to their low cost and strong antibacterial activity. However, synthetic preservatives tend to be less preferred by food consumers because of a number of health concerns regarding their side effects. Sorbic acid, benzoic acid, and their salts have been reported to promote mutagenic and carcinogenic compounds. Nitrites and nitrate, used as preservative and coloring agents in meat, have been associated with leukemia, colon cancer, bladder cancer, and others.
Although efforts to have these synthetic preservatives banned are yet to bear fruit, companies are proactively making efforts to switch them out. Dutch food tech company Vaess and Naked Bacon are examples of those who have already eliminated nitrite from their bacon products with a brine compound.
Transition to natural preservatives has stimulated innovation in this area, in 2022, food shelf life extension specialist Kemin Food Technologies developed a nitrite alternative for use in the first stage of emulsified cooked sausages. Kemin says that the Rubinite GC Dry is a label-friendly ingredient offering food safety while maintaining taste and color adding that it is available for food producers in the Europe, Middle East and Africa (EMEA) region. “By developing a nitrite-free solution, we can offer food manufacturers the opportunity to remove ascorbate or diacetate from their formula, thus cleaning up their product labels.”
Corbion, another preservation technology company, has within its product a natural preservative comprised of vinegar and sea salt. Trading as N450, Corbion says its natural meat preservation solution extends the shelf life of 80,000 tons of processed meat in North America for up to 90 days while maintaining the sensory integrity of those goods.
Packaging technologies for extended shelf-life
Africa, with its diverse climates and logistical challenges, has often grappled with preserving meat for extended periods. Factors such as temperature variations, limited cold storage infrastructure, and transportation constraints have historically posed challenges in maintaining the freshness and safety of meat products.
Modified atmosphere packaging (MAP) offers a solution to this. This technique involves altering the composition of the air surrounding the meat, typically by reducing oxygen levels and increasing carbon dioxide. This inhibits the growth of spoilage microorganisms and extends the product’s shelf life without the need for excessive preservatives.
The trio of commonly utilized protective gases in modified atmosphere packaging comprises CO2 (carbon dioxide), O2 (oxygen), and N2 (nitrogen). In the case of red meat, the protective gas composition in modified atmosphere packaging prioritizes O2 and CO2. To maintain the vibrant red hue of the meat, the concentration of O2 must exceed 60%, while the CO2 concentration should not dip below 25% to effectively stifle bacterial reproduction.
For pork, the typical composition of protective gases in modified atmosphere packaging ranges between 60-70% O2 and 40-30% CO2, extending the shelf life to 7-10 days when stored between 0-4°C. Poultry meat, on the other hand, is typically enveloped in a mixture of 50-70% CO2 and 50-30% N2. This configuration grants a shelf life of approximately 14 days under the conditions of 0-4°C in modified atmosphere fresh-keeping packaging
Vacuum packaging meat preservation technique is another alternative that is used to extend shelf-life. This processing technique removes the air from around the meat, creating an oxygen-free environment. This not only slows down the oxidative processes responsible for spoilage but also reduces the growth of bacteria. For this reason, most meats are vacuum packaged, which extends the storage life under refrigerated conditions to approximately 100 days. The exact duration after vacuum sealing varies depending on whether you keep it in a refrigerator, freezer, or pantry. Vacuum sealed and placed in the freezer retains freshness for up to 12 months.
The incorporation of smart packaging equipped with sensors holds potential of revolutionizing meat packaging. These sensors detect changes in temperature, humidity, and other environmental factors, providing real-time data that can provide insights as to whether the meat is stored under optimal conditions or not. This not only enhances shelf life by ensuring optimal storage conditions are observed at all times but also contributes to maintaining quality and safety standards.
Shelf-life extension for a sustainable future
Processed meat and meat products are still very much integral to consumers’ food purchasing, with chilled cuts of meat and sausage being the third and fourth, respectively, most purchased manufactured products among all food and beverage categories.
Demand for meat can only get higher as the world population rises. The rapidly growing world population will be consuming two-thirds more animal protein by 2050 than it does today, according to the FAO. Supply is however constrained by diminishing resources to raise more livestock. The biggest opportunity therefore would be in preventing losses associated with spoilage which is currently estimated at 23% of total production. Saving even half of these losses would not only make sense economically but also reduce the carbon footprint associated with livestock which is also the highest of all food production.
It will also be good for business. A new study conducted by Kerry has revealed that one-third of consumers are willing to switch to brands or products that offer better shelf life. This openness to change is driven by consumers’ strong desire to tackle food waste with 98% of those surveyed found to be actively trying to minimize food waste caused by various factors such as financial concerns, environmental considerations, and mindfulness of world hunger.
Adopting new shelf-life extension methods will also help manufacturers align with consumer demand for foods with natural ingredients. Studies support this shifting mindset, as the Innova Market Insights’ 2019 Consumer Survey showed two out of three European consumers say they specifically want to avoid products with ingredients that are difficult to understand.
These new technologies aren’t just good for companies’ bottom lines; they’re a boon for the planet and our health. By reducing food waste, they tackle greenhouse gas emissions and the environmental impact of food production. For our health, they offer alternatives potentially linked to lower risks of cancers and other diseases. It’s a win-win-win situation with far-reaching benefits.
This feature appeared in ISSUE 60 of FOOD BUSINESS AFRICA MAGAZINE. You can read this and the entire magazine HERE
