Development and Innovation in Cooked Ham Produced in Spain
Abstract
:1. Introduction
2. Definition of Cooked Ham
3. Innovation and Development in the Choice of Raw Materials
4. Innovation and Development in the Elaboration Process
- Reception of raw hams. Raw hams are usually received chilled or frozen at 3–4 °C or at −18 °C, respectively. In the case of the production of high-quality cooked ham, prior freezing of the raw material is discouraged because it negatively affects the quality of the final product. Freezing causes the following problems: protein oxidation, the loss of red colouring and hardness [4].
- Polishing. The polishing of the hind leg consists of the complete removal of all bones, tendons, and all or part of the skin and the subcutaneous fat, keeping the muscle bundles intact. The level of polishing of the raw material is according to the quality or category of the final product [5] and is carried out by specialised staff.
- Weighing of the piece. This stage is important so that the percentage of brine to be injected in the subsequent stage is known. It is usually carried out automatically, in line with the weighing system.
- Brine injection. Currently, the most used form of brine injection is a multi-needle system. It is carried out at temperatures between 3 and 8 °C, since an increase in temperature promotes the penetration of the salt but reduces the microbiological stability of the piece [5]. It is advisable to replace the brine every 24 h to prevent the loss of antioxidants and nitrites due to the brine’s high reactivity, and to prevent microbial growth. Multi-needle injection systems allow the homogenisation of the brine and are grouped into two types: low pressure and spray effect. Spray effect systems have the particularity of being able to dose the volume of brine with a spray or atomiser effect. In other words, once the needles have completed their journey through the piece of meat, the brine is injected with a spray effect at high pressure, between 6 kg/cm2 and 10 kg/cm2, guaranteeing homogeneity [6]. In addition to the injection system, the percentage of brine injected can be optimised. The most commonly used ranges from an industrial point of view are very wide, between 25 and 40% of the piece weight [7], affecting the quality of the final product.
- Tumbling massaging or malaxing. The main objective of this step is to distribute the brine and solubilise the meat proteins that facilitate the binding of the product. It is performed in rotating cylinders for several hours depending on the amount of brine injected, interspersed with rotation and rest phases at temperatures of 3–6 °C under vacuum to avoid foam formation during the process [8].
- Maturation of meat. The introduction of this stage is recommended in the production of high-quality cooked ham because it influences the organoleptic characteristics, mainly texture. In this stage, the protein extraction carried out during malaxing will be completed and higher levels of water retention, muscle bonding, and a homogeneous colour will be also achieved [6]. Maturation consists of keeping the ham at refrigeration temperatures for normally between 12 and 18 h, sometimes up to 48 h. The inclusion of this stage in the process influences its cost-effectiveness [6].
- Moulding. The ham is placed in a cotton mesh or plastic bag, and then in stainless steel moulds that give it the characteristic shape to be sold on the market. They are usually oval, rectangular or mandolin shaped. They can also be placed in heat-shrinkable bags, which retract as the ham does, forming the final packaging in which it will be sold.
- Pressing and/or resting. The cooking mould is closed and at the same time, is pressed and left to rest in order to ensure the absence of any remaining air, whether occluded in the mass or that which may remain between the product and the packaging material.
- Cooking. This is a delicate stage of the process that requires good control. It is important to reach pasteurisation temperature values in the centre of the piece that are usually between 65 and 72 °C [9]. The aim of this is the destruction of the viable cells of microorganisms and producing enzymatic inactivation, without altering the sensory characteristics of the ham. The microorganisms naturally present in ham are various (lactobacilli, staphylococci, enterococci and micrococci), and the treatment conditions are set according to the most heat-resistant microorganisms (enterococci) [10]. On the other hand, the minimum temperature to achieve the destruction of Trichinella spiralis is stipulated as being 58.3 °C [9].
- 10.
- Cooling. Pasteurisation eliminates the viable cells of microorganisms, but it does not eliminate spores from spore-forming bacteria, which can germinate if immediate chilling (4–5 °C) is not carried out after cooking in order to ensure the product’s stability before consumption. This process can be performed by using air shocks, immersion or water showers. The decrease in the temperature is the most crucial part and should be limited to less than 4 h [13,17].
- 11.
- Final stages. The cooked ham is unmoulded, sliced, packaged and finally stored and distributed. Whole pieces are vacuum packed. A squirt of gelatine is usually introduced into the bag before sealing, which uses a vacuum in order to cover gaps and to homogenise the appearance. When the cooked ham is sliced, modified atmospheres without oxygen (normally a mixture of N2/CO2) are used for packaging. Slicing can only be performed in clean rooms with extremely hygienic air quality. Market storage is between 2 and 4 °C.
5. Innovation and Development in the Use of Ingredients and Additives
5.1. Ingredients
- Water. The added water is used to dissolve the rest of the ingredients and additives injected in the form of brine. After meat, it is the second most abundant component in a cooked ham, and it is desirable that the water used as a brine matrix is weakly mineralised. The presence of metal ions can affect other additives; for example, traces of iron or copper can partially destroy ascorbate, which destabilises the colour of the final product, and also poses a toxicological risk [18].
- Common salt. Common salt or sodium chloride (NaCl) provides a salty taste, firmness, aroma (by interaction with other components) and a reduction in water activity, inhibiting the growth of microorganisms and enabling preservation [19]. It also contributes in other ways, as it possesses the ability to increase the water holding capacity (WHC) of the ham at an alkaline pH through the solubilisation of meat proteins, resulting in increased binding between muscles. This is due to the ionic strength of the salt, which is able to weaken the electrostatic bonds between amino (NH4+) and carboxyl (COO−) groups in the quaternary structure of proteins [20,21]. In addition, it promotes lipid oxidation. Although the mechanism is not fully elucidated, it is quite possible that the initiation of lipid oxidation is due to the formation of radicals by high hydrostatic pressure [22]. Studies point to several pro-oxidative mechanisms of NaCl, indicating that it is due to the following: (i) its ability to penetrate cell membranes that facilitate the entry of oxidising agents; (ii) the release of iron ions from haemoprotein molecules; and (iii) the inhibition of antioxidant enzymes such as catalase, protease, peroxidase and superoxide dismutase [22]. In low-salt cooked ham, part of NaCl is often replaced by KCl and the taste of the product is slightly affected [23].
- Sugars. Although their use is not essential, they can be added to cooked ham. However, like salt, the amount used by the industry continues to decrease over the years, according to the recommendations of the WHO and the European Commission; these are in line with the NAOS Strategy (2005), which has been working with different sectors to reduce the levels of salt, sugar, fat and calories in food products. Sugars are used in cooked ham for two reasons: (i) to increase the bacteriostatic power by decreasing the activity of water and (ii) to improve the flavour of the ham by providing some sweetness [2,24]. Saccharose and dextrose are the most common sugars in the cooked ham industry. Saccharose contributes to the taste of the finished product, but its ability to reduce water activity is limited by its sweetening power, as limit values of only around 0.8–0.9% can be achieved. However, the most suitable concentration would be around 0.5%. Dextrose has a higher sweetening capacity than saccharose and a higher osmotic pressure; in finished products, 3% can be reached in the brine without affecting the taste too much. The main problem is that, as it is a monosaccharide, it is digested more quickly by microorganisms [18]. Resconi et al. [25] proposed the use of fructo-olysaccharides as a healthier substitute for dextrose in cooked ham, concluding that there was no significant sensory difference. Therefore, it might be suggested as an alternative to reduce sugar content.
5.2. Additives
- Preservatives. These are a series of chemical substances that are used to minimise the deterioration caused by microorganisms (mainly moulds and bacteria), avoiding economic losses to a company. Improvements in the cold chain and in the production stages, together with strict legislation and public opinion against their use, are leading to a reduction in the use of these chemical agents. There are several chemical substances with preservative properties that are used in cooked ham: sorbic acid (E-200), sodium benzoate (E-211), natamycin (E-235) or parahydroxybenzoates (E-218), which are still used in some countries (not in Spain). Meanwhile, sodium lactate, potassium lactate and sodium diacetate (E-325, E-326 and E-262, respectively) are used to a very limited extent or not at all in Spanish territory. It is important to mention the existence of plant extracts with antimicrobial functions that could allow the elimination of additives from the label. These drawbacks are related to the presence of allergens, the need to add bacteria with nitrate reductase activity, and the need to add vegetable flavourings and pigments [26]. There are several types of preservatives on the market, but the most widely used in Spain is undoubtedly sodium nitrite, which appears in practically all commercial brands of cooked ham. Nitrites (NO2−), and also nitrates (NO3−), are salts that have been used in the meat industry for many years, due to several functions: colour stabilisation, their inhibition of Clostridium botulinum, their contribution to the preservative effect of salt, and their contribution to the taste and aroma of the ham [26]. It is very important and necessary to control the amounts added, otherwise they can reach toxic levels. Therefore, in Regulation (EU) No. 1129/2011, the use of nitrates (E-251 and E-252) is not authorised in heat-treated meat products. In the case of nitrites, their use is limited to a maximum added amount of 150 ppm.
- Antioxidants. Antioxidants are reducing substances that prevent the oxidation of other substances by oxidation–reduction reactions. The most used antioxidants in cooked ham are ascorbic acid/sodium ascorbate (E-300, E-301), its isomer isoascorbic acid, which is also called erythorbic acid/sodium erythorbate (E-315, E-316), sodium citrate (E-331) and sodium lactate (E-270). Sodium citrate and lactate play a reinforcing role, the former as a chelating and buffering agent and the latter as a depressant of water activity and inhibitor of lactobacilli [27,28]. The use of these reducing agents is permitted by European authorities in their acid form and in the salts they form with various cations [29,30]. Because of their greater prevalence in the meat industry, we will focus on ascorbic acid and its salts, as erythorbic acid and sodium erythorbate have the same functions [31]. Ascorbic acid is an organic compound that is highly soluble in water, but not in lipid media. In fact, its efficacy with respect to the inhibition of lipid oxidation is low, as reported by several authors [32,33]. Its use is frequent in the meat industry as it participates in the reduction of nitrite to nitric oxide, facilitating the formation of nitrosomyoglobin and, therefore, facilitating the stability of the pink colour in cooked ham [34]. It is also involved in preventing the appearance of nitrosamines, although the reaction mechanism has not been fully elucidated; however, it possibly blocks nitrosating agents [35,36]. It is recommended that it is added to the brine in its salt form and at an alkaline pH because otherwise, it may react with the nitrites and form irritating vapours.
- Stabilisers. According to Real Decreto 142/2002, “stabilisers are substances that make it possible to maintain the physicochemical state of a foodstuff”. They include substances that allow the maintenance of a homogeneous dispersion of two or more immiscible substances in a food (emulsion), substances that stabilise, retain or intensify an existing colour in a food, and substances that increase the binding capacity of foods, including the formation of cross-links between proteins that allow the binding of food pieces In the reconstituted food product. The function of stabilisers in cooked ham is to reduce free water, improve or increase viscosity, and improve the functionality and physical stability of the product by providing firmness due to the reduction in or elimination of holes in the product. Among the most frequently used stabilisers in the cooked ham industry are locust bean gum, guar gum, xanthan gum, carrageenans, sorbitol or sorbitol syrup and phosphates (E-410, E-412, E-415, E-407, E-420 and E-451/452, respectively), the latter being the most present in practically all cooked ham put on sale.
6. Innovation and Development in Labelling
7. Discussion
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Commercial Name | Commercial Category | Moisture/Protein Ratio | Collagen Free Protein | Total Soluble Sugars (g glucose/100 g) | Added Protein (g/100 g) | Starch (g glucose/100 g) |
---|---|---|---|---|---|---|
Cooked ham | Extra | ≤4.13 | - | ≤1.5 | Absence | Absence |
Cooked ham | ≥14.0 | ≤2.0 | ≤1.0 | Absence | ||
Fiambre | ≤5.0 | ≤3.0 | ≤10.0 |
Brand | Quantity of Meat (%) | Salt | Saccharose | Dextrose | Aroma | Stabilisers | Antioxidants | Preservatives |
---|---|---|---|---|---|---|---|---|
E1 | 90 | X | X | X | E-407—Carrageenans E-508—Potassium chloride | E-326—Potassium lactate E301—Sodium ascorbate | E-250—Sodium nitrite | |
E2 | 90 | X | X | X | E-407—Carrageenans E-451—Triphosphates | E-250—Sodium nitrite | ||
E3 | 88 | X | X | X | E-407—Carrageenans E-410—Xanthan gum E-415—Locust bean gum E-420—Sorbitols E-451i—Pentasodium triphosphate E-508—Potassium chloride | E-316—Sodium erythorbate | E-250—Sodium nitrite | |
E4 | 82 | X | X | X | E-407—Carrageenans E-410—Xanthan gum E-415—Locust bean gum E-420—Sorbitols E-451i—Pentasodium triphosphate E-508—Potassium chloride | E-316—Sodium erythorbate | E-250—Sodium nitrite | |
S1 | 69 | X | X | X | E-407—Carrageenans E-410—Xanthan gum E-415—Locust bean gum E-420—Sorbitols E-451i—Pentasodium triphosphate E-508—Potassium chloride | E-316—Sodium erythorbate | E-250—Sodium nitrite | |
S2 | 75 | X | X | E-412—Guar gum E-450—Diphosphates E-451—Triphosphates E470a—Sodium, potassium and calcium salts of fatty acids | E-316—Sodium erythorbate | E-250—Sodium nitrite | ||
S3 | 70 | X | X | X | E-407—Carrageenans E-420—Sorbitols E-451—Triphosphates | E-316—Sodium erythorbate E-331—Sodium citrate | E-250—Sodium nitrite |
Per 100 g | Applicable Nutritional Claims | Terms of Use | Conditions in Cooked Ham | |
---|---|---|---|---|
Energy, kcal | 114 | |||
Water, g | 75.6 | |||
Proteins, g | 21 | Source of proteins High in protein | ≥12% energetic value ≥20% energetic value | energetic value of 84% from proteins |
Fats, g | 3 | Low-fat | ≤3 g fat/100 g | |
Saturated fats | 1.1 | Low-saturated fat | Ʃsaturated fatty acids and trans-fatty acids ≤ 1.5 g/100 g Ʃsaturated fatty acids and trans-fatty ≤ 10% of energy | energetic value of 8.7% from saturated fats |
Monounsaturated fats | 1.4 | |||
Polyunsaturated fats | 0.36 | |||
Carbohydrates, g | 0.4 | Sugar free | ≤0.5 g per 100 g | |
Cholesterol, mg | 50 | |||
Vitamins | ||||
Thiamine (B1), mg | 0.46 | Source of thiamine High in thiamine | ≥15% of NRV Twice value of “source of” | 41.8% of NRV |
Riboflavin (B2), mg | 0.18 | |||
Niacinamide equivalents (total) (B3), mg | 11.4 | Source of niacinamide High in niacinamide | ≥15% of NRV Twice value of “source of” | 71.3% of NRV |
Pyridoxine (B6), mg | 0.2 | |||
Folic Acid (B9), µg | 0.2 | |||
Vitamin B12, µg | 0.7 | Source of vitamin B12 | ≥15% of NRV | 28% of NRV |
Vitamin C, mg | 19 | |||
Vitamin A, µg | Trace | |||
Vitamin D, µg | 0.7 | |||
Vitamin E, mg | 0.08 | |||
Minerals | ||||
Calcium, mg | 9.6 | |||
Iron, mg | 2.1 | Source of iron | ≥15% of NRV | 15.1% of NRV |
Potassium, mg | 270 | |||
Magnesium, mg | 17.5 | |||
Sodium, mg | 970 | |||
Phosphorus, mg | 239 | Source of phosphorous High in phosphorous | ≥15% of NRV Twice value of “source of” | 34.1% of NRV |
Iodine, µg | 10.9 | |||
Selenium, µg | 11 | Source of selenium | ≥15% of NRV | 20% of NRV |
Zinc, mg | 2.8 | Source of zinc | ≥15% of NRV | 28% of NRV |
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Arenas, C.B.; García-Béjar, B.; Santos, A.; Soriano, A. Development and Innovation in Cooked Ham Produced in Spain. Foods 2023, 12, 1360. https://doi.org/10.3390/foods12071360
Arenas CB, García-Béjar B, Santos A, Soriano A. Development and Innovation in Cooked Ham Produced in Spain. Foods. 2023; 12(7):1360. https://doi.org/10.3390/foods12071360
Chicago/Turabian StyleArenas, Cristian B., Beatriz García-Béjar, Ana Santos, and Almudena Soriano. 2023. "Development and Innovation in Cooked Ham Produced in Spain" Foods 12, no. 7: 1360. https://doi.org/10.3390/foods12071360
APA StyleArenas, C. B., García-Béjar, B., Santos, A., & Soriano, A. (2023). Development and Innovation in Cooked Ham Produced in Spain. Foods, 12(7), 1360. https://doi.org/10.3390/foods12071360