Custom Meat Formulation

There was a time when food was eaten to satisfy hunger and fuel up for the day. Today, product developers are busy formulating foods and beverages that meet consumer demands for flavor, nutrition and low-to-no levels of fat, sugar, sodium and gluteneven meat-containing products like pizza, soups and appetizers.

Burke Corporation, a supplier of fully cooked meat productsincluding sausage, pork and beef toppings; pepperoni; meatballs; chorizo; and shredded beef, pork and chickenincreasingly is being asked by foodservice operators and food manufacturers for custom meat products that satisfy the healthy-food trend.

Customers often seek us out for a variety of custom fully cooked meats as they respond to market trends, says Dawn Canon, food scientist. Recently, we have been receiving myriad requests for gluten-free, reduced-sodium, clean ingredient statements, natural and organic labels, and more. Gluten-free and reduced-sodium currently top the companys list of healthy custom formulation requests.

Gluten-free. Most of the companys products are inherently gluten-free, but others, such as meatballs, do contain gluten, due to breadcrumbs in the mixture. In addition, some starches and other additives are wheat-based.

While gluten-free is generally a viable option, it does include significant challenges such as flavor contribution in the final product, texture changes and cost increases, says Canon. Gluten is a functional ingredient in many products, but a combination of gluten-free flours, starches and gums can usually be found to replace the functionality. These options can provide similar results in product texture without the intolerance symptoms.

The Burke R&D team has tested pea protein and rice to replace traditional gluten-containing ingredients, and also uses amaranth, buckwheat, quinoa, millet, potato, tapioca, coconut flour and other gluten-free alternatives.

Reduced-sodium. Reducing sodium in processed meat products presents a number of challenges, including loss of flavor, tenderness and juiciness, as well as minimized yield.

While a variety of sodium-reduction options are available, there are a number of challenges to finding the right solution, Canon says. Potassium chloride has been a longstanding alternative, but it contributes a bitter flavor. Fortunately, additional ingredients to mask this bitter flavor are now available. Flavor enhancers can also be used to provide improved sensory qualities in low-sodium products. Other salt-replacement alternatives have longer and less friendly ingredient statements. However, in spite of these challenges, more and more products are becoming available to help reduce the sodium in meat products, while maintaining the quality of the end product.

Custom formulation. Canon says there are three basic stages to the custom-formulation process: concept communication and clarification; laboratory development and testing to optimize size, flavor and texture; and production testing in the end-product. The process requires excellent communication and diligent testing, but ultimately, she says, the rewards are worth the time spent at the bench.

Custom formulation allows individualized food products to fulfill specific customer needs for functionality or flavor profiles, both of which are important for quality and differentiation, Canon says.

Burke Corporation

1516 South D Avenue

P.O. Box 209

Nevada, IA 50201

Phone: 800/654-1152

Fax: 515/382-3955

Website: burkecorp.com