Losing fat, formulating back: not all meat applications are the same; neither are the water-binders, texturizers and fat-mimetics necessary to reduce their fat content

Prepared Foods, Oct, 2004 by Marcia A. Wade

Meat manufacturers can take a hint from innovations in meat analog technology. If a product containing no meat can pass as meat to many consumers, then the quality of extended meat products also can be much better. Formulating low-fat meat products requires an understanding of the mouthfeel, texture and flavor of the original meat product as well as knowledge of how different ingredients can best help to imitate those qualities.

Jack Sprat Could Eat No Fat

Meat extension has been around since the early 1950s, due mainly to economic incentives. Adding water and economical plant proteins to certain formulas increases meat yield at little to no cost to the manufacturer. Since the beneficial nutritional properties of such products often remain little changed, the option is popular for products in school lunch programs, the military and many other foodservice venues. More recently, a demand for fat-reduced meat products has increased among consumers in developed countries. Factors such as weight control concerns and the release of studies showing correlations between saturated fat and risk of cardiovascular disease, certain cancers and obesity (which can lead to Type 2 diabetes) have spurred demand. Even so, perhaps low-fat meat-product launches are stunted due, in part, to their association with negative sensory qualities.

The quality of reduced-fat meat products with starch, gums or proteins and water systems has improved over the years. "We realized regulations that classified [water-added meat] as inferior is counterproductive," says Abe Bakal, president of ABIC International Consultants Inc. (Fairfield, N.J.). For one, the addition of proteins such as soy and whey can increase the biological value of meat.

"Consumers are becoming more knowledgeable about the health benefits of soy," says Mian Riaz, head of the extrusion technology program at Texas A&M's Food Protein Research and Development Center (College Station, Texas). Soy proteins have proven beneficial to heart health, while whey proteins provide the highest source of branched-chain amino acids and leucine, which certain studies have associated with weight loss. Additionally, some ingredients that help reduce fat also can increase a product's fiber content. Nevertheless, with the obesity issue looming over every manufacturer's nutrition label, the most obvious reason to add water to meat is to reduce the fat.

Where's the Beef?

Adding water to lean meat creates a low-fat formulation. Binders "trap" the water and increase the yield. "The challenge lies in maintaining the integrity of the meat product," claims Gil Bakal, managing director of a leading supplier of rice-based food starches. "If you over-extend the meat, it can be unsightly."

Other problems that arise involve freeze/thaw instability and purge in the refrigerator. Additionally, moisture is lost during the cooking process. Such syneresis and drip loss can result in hard, chewy and dry products.

To minimize these occurrences, stabilizers and water-binders are added to retain moisture. Starches of different origins are a notable example. Combinations of these ingredients are injected into or tumbled with the meat as marinades and/or brines.

Cornstarch, with a granule size of 15-25[micro]m, often is used as a basic thickener, but rice starch, wheat gluten, modified potato starch and tapioca also are common. "Some starches won't be stable in the refrigerator or freezer, during cooking or at a low pH," says Gil Bakal.

Water also can be stabilized with soy and whey proteins. Generally, protein isolates have the capacity to bind more water than protein concentrates. Most protein isolates contain less than 1% fat. Both textured vegetable and dairy proteins have a binding capacity similar to isolates.

Protein sources do not have to be limited to soy. "We use peanuts, remove the oil and then texturize the peanuts," explains Riaz, who admits peanut proteins tend to be higher in fat. Although soy is most popular in North America, chick peas and green pea protein concentrates are used by Canadians and Europeans in meat extensions because they are more widely available in those countries.

Hydrocolloid gums like alginates, carrageenan, guar and xanthan make regular appearances in formed meat and fish products but generally are used in combinations with starches and proteins.

In North America, inulin frequently is used in meatless, vegetarian dishes, but not in formed or extended meat and fish products. Inulin, which acts as a dietary fiber, works well with hydrocolloids by facilitating hydration and adding mouthfeel. Inulin's functions in vegetarian dishes easily can be transferred to non-vegetarian dishes.

Another consideration manufacturers should be mindful of is bow fat assists in heat penetration. Consequently, longer cooking time is required to reach the internal temperature of a meat product when water replaces fat. The addition of water also increases the risk of microbiological activity. Sugar alcohols like glycerin, sorbitol and lactitol can be used to reduce water activity and extend the shelflife of meat extensions, notes Abe Bakal.