MXPA06001933A - Integrated continuous meat processing system - Google Patents

Abstract

An integrated system for continuous production of processed meat products utilizing a continuous mixing system is disclosed. Meats and other meat product constituents may be forced into a mixer having rotating elements for directing the constituents through a housing of the mixer. A system and method for providing information to a control system may be provided for regulating the formulation of a meat product is disclosed. The control system may recei ve information prescribing the formulation of the meat product, analyze characteristics of incoming constituent streams, and adjust the flows based on the final product formulation. The control system may further provide feedback regarding the final product formulation relative to the incoming constituent streams.

Description

INTEGRATED SYSTEM, CONTINUOUS PROCESSING OF MEAT Field of the Invention The invention relates to a method and apparatus for processing meat, which may include a control system. Background of the Invention In commercial systems for making certain processed meat products such as Bologna sausage and sausages, raw meat in the form of pieces or pieces and other ingredients such as spices are ground, split and / or otherwise physically mixed. with one or more salt or brine solutions to provide a mixture that can subsequently be formed into a stable meat emulsion or protein matrix. Similar steps of grinding, splitting and / or otherwise working are also employed in making coarser ground products such as pepperoni, whole muscle products such as processed ham and processed turkey, and other processed meat products. In each case, the protein forms a matrix to hold or link the separated pieces together. A stable protein matrix requires protein bonds that are suspended or bound with fat and water. The creation of protein bonds in this context require a process commonly known as protein extraction. In this process, salt-soluble or heat-coagulable proteins such as myosin, actomyosin, and actin bind water, swell and become sticky as a result of working or physically mixing the meat in the presence of a salt or a solution of salt . The proteins are subsequently seated when heated to create a bond. Other micro-fibrillar proteins, as well as sarcoplasmic or soluble or extractable proteins in water, can also play a role in binding. Salt solutions that can be used in protein extraction include, but are not limited to, sodium chloride, pyrophosphate or sodium diphosphate, potassium chloride, sodium lactate, and potassium lactate. In protein extraction as described herein, the mechanism believed to be primarily responsible for the creation of the linkages involves binding proteins, salts, fats, and / or water and subsequent protein swelling, rather than protein solutions. . More precisely, it is believed that the salt solution releases binding sites in the proteins to bind with each other, as well as with water and fat. The particles of the cooked product are linked together by the proteins to provide integrity to the final meat product. As used herein, a stable meat protein matrix refers to a mixture that retains a large percentage of its components during further processing, including cooking, and during shelf life as a final product. For example, an emulsion is considered stable if less than 2% of the weight of the product is lost due to cooking fat from the cooking stage. If the protein matrix is unstable, either it or the final product will lose excessive amounts of water or fat. An unstable protein matrix leads to yield losses and to a final product that is not able to maintain sufficient integrity over its desired shelf life. Conventional batch processing is a long process requiring a number of discrete steps. Initially, several meats are provided by a supplier with specific contents. More specifically, the meats are provided with a protein, fat, and / or water content, typically a percentage by weight. A batch sheet is provided to processing plant personnel indicating that a mixture of meat, water, and additives will be combined for one of a variety of meat products. Although the acquisition is made outside the processing plant, the batch sheet is based on knowledge of the meats currently on hand in the plant. However, the lot sheet often needs to be adjusted. For example, a particular provider can provide meat valued at 70% protein, while the current meat may have slightly different content such as 68% protein. Because the batch sheet is based on the procurement and evaluation of meat provided by the supplier, plant personnel often have to adjust the meats selected for the meat product based on the formula desired for the final product. The final product mixture is carefully controlled. For example, a particular product, such as sausages, may have no more than 30% fat by weight. If a particular meat is used where the fat content is greater than what the batch sheet asks for, the final product may have an excessive amount of fat. To avoid this, plant personnel will increase the protein provided by other means to balance the fat content. Unfortunately, this is not necessarily a sufficiently precise approach. Each meat, as well as each piece in a batch of meat, can vary significantly from a sample taken and assumed to be average. Once water and other additives are mixed in the batch, it can be difficult to alter the balance. Sometimes, the resulting batch is determined to be mixed inaccurately, and remedial procedures must be taken such as mixing the batch with additional correction materials. To reduce the likelihood of an inaccurate lot, relatively large quantities of meat are provided for a single lot while waiting to minimize or average the composition deviation resulting from a portion of meat with an aberrant content. A typical amount of a particular meat for a batch is approximately 2,000 Ib. Batch processes to physically mix meat and other ingredients and extract protein are well known. A known method for achieving protein extraction and physical mixing of ingredients for whole muscle products such as processed turkey and processed ham involve puncturing whole muscle meat with hypodermic needles, injecting brine through the needles, and using a processor. or batch mixer to work the meat for approximately 45 minutes under vacuum to remove air, as discussed above. For coarsely ground and emulsified products, meat is milled and added to the processor in batches with water, salt solution, spices, and / or other ingredients and is worked with or without vacuum for up to one hour, or, for example, 15 to 45 minutes. A large batch mixer can process approximately 6,000-12,000 pounds per hour. The constituents of the meat product including the meats and the additives are combined in the batch mixer with low cutting effort. This mixing step typically requires 30-60 minutes of mixing. It is during this time that the constituents are transformed into a mixture that will form a stable protein matrix. A stable protein matrix is formed when mixtures for each of the whole muscle products, coarsely ground products, and emulsified products allow the salt solution to reach the extractable protein with salt. This process, known as curing, achieves the extraction of protein.

For whole muscle products, injection with needles inserted into the pieces of meat to deliver the brine solution is a relatively inaccurate method to try to reduce a distance of the meat through which the salt solution must diffuse. The curing step typically requires 24-48 hours for satisfactory diffusion, and the batches are stored in vats placed in refrigerators for the curing time. Once the protein extraction has occurred, the mixture can then be processed further. Input constituents are calculated to result in a specific amount of cooked product. If excessive water or fat is lost after mixing such as during the cooking stage, the carefully regulated water, fat, and meat ratios will be off target. If grease is lost prior to the cooking stage, it often remains in the machinery or pipes through which the mixture is processed. This can result in downtime for the machinery, probability of damaged machinery, and greater labor in cleaning the machinery. Moreover, cooked emulsified products depend, to some degree, on non-protein or non-bound materials to provide the proper texture. The proteins bind to form a matrix with each other and, in the absence of enough fat or water, these bonds can form a larger, stronger matrix, which leads the product to become somewhat rubbery. Conversely, if there is too much water, the cooked product may be too soft, and may lack integrity. As used herein, the term "additives" can broadly refer to brine solution, unsalted water, a species slurry, nitrite, or other additives. Although the brine and meat solutions themselves include each water, the balance for the final product is typically adjusted with a quantity of water. The species slurry provides, for example, flavors. An additive is typically nitrite, which is used as a preservative and to provide a desired color. Other inert additives, such as corn starch or non-functional proteins, may also be included. As the mixing constituents are beaten in the mixer for up to one hour, contact with air may produce a foam on the surface of the pieces of meat. A final product having visible air may be unacceptable. In some cases, the product must be re-processed and mixed with subsequent batches. Air in the product may appear as surface bubbles, or as surface holes. Trapped air can also lead to product swelling during cooking, or it can lead to the product having visible air bubbles inside it. Air affects the product in other ways, too. For example, some proteins are denatured by the presence of air, which reduces the functionality of the meat to bind with fat and water. The air can also react with the nitrite to delay the development of the appropriate color. The resulting color may then be undesirable or objectionable by consumers. To prevent air from being stirred into the mix, vacuum pressure can be applied during the mixing process. This requires extensive configuration including the vacuum itself and seals to maintain pressure. The vacuum system and seals require maintenance, and occasionally leak which results in degraded product. Although such mixers have been used commercially for many years, they have significant drawbacks. For example, one of the problems is that air can be undesirably carried to the product. Other drawbacks for mixers include their space and cost requirements due to their large size, labor costs, the length of time required to process each batch, losses from tank handling and transfer performance, and the associated time and cost with cleaning of the device. SUMMARY The invention relates to improved methods and apparatus for use in making processed meat products that provide significant advantages with respect to the size of the apparatus, the time required for processing, process control, and / or other aspects of the manufacturing process. In one embodiment, a method and apparatus provide for accelerating the formation of stable meat mixtures for meat products. Streams of input constituents such as meat, water, salt solution, spices, and other ingredients are fed into a mixer. The constituents are subjected to high cutting force in the presence of a brine solution. The high cutting force distorts the shape and can reduce the size of the pieces of meat such that immediate contact of protein and salt solution can occur. Intimate contact results in effective and efficient protein extraction and mixing of the constituents at a relatively short stay or residence time in a mixer, which may be of the order of less than one minute. In this way, a stable and functional meat protein matrix is produced rapidly for each of the emulsified products, coarsely ground products, and whole muscle products. In another embodiment, a method and apparatus are provided to reduce the time for diffusion of ingredients in the meats. The input constituents including the meats are worked and deformed under high cutting force such that the protein strands become unraveled and porous, thus making them susceptible to infusions of the salt solution and the ingredients. This results in a reduced time to process the meat while achieving proper dispersion and diffusion of the ingredients, including the salt solution necessary for protein extraction.

According to embodiments of the present invention, the preferred apparatus includes rotating elements located in at least one mixing device capable of rotating located within a housing. Each mixing device may comprise a plurality of rotating mixing elements such as vanes, blades or screws, or may consist of a single element such as a single screw, blade or vane. The mixing devices can be supported removably in one or more arrows. To facilitate complete cleaning of the apparatus without disassembly, the elements are preferably integral with their associated arrows. In some embodiments, the mixing and arrow elements may be welded together or formed as a unitary machined part, in one piece. A mixer according to embodiments of the invention comprises a plurality of rotating mixing elements that force some or all of the mixture through one or more spaces of about 0.08"between the mixing elements and the interior of the housing of mixer, and between several pairs of mixing elements and the interior of the mixing housing, and between several pairs of mixing elements, as the mixture advances through the apparatus.The system preferably achieves sufficient protein extraction, physical mixing, and in some cases maceration in less than 5 minutes of processing time, and it is believed that it is capable of achieving sufficient protein extraction, physical mixing, and maceration in less than one minute In a particular embodiment, the processing time is about 45 seconds The average time required for a given mix portion to pass through the processor is around 10-60 seconds Within that time, the mixer is capable of forming ingredients comprising pieces or pieces of raw meat, together with salt solution, water, spices, etc., into a mixture that, when cooked, will form a self-processed meat product -supported, cohesive, without extra protein extraction or maceration, also referred to as a stable protein matrix that retains a predictable and acceptable amount of fat and water. It should be noted that for some products, eg, Bologna sausage and sausages, additional processing steps may take place that incidentally involve additional protein extraction. In some embodiments, the mixing can take place at a pressure equal to or greater than the atmospheric pressure without the meat mixture suffering from aeration. The constituents are fed into the mixer, and the time spent in it is relatively short. Since the mixture is in a relatively anaerobic environment, aeration of the mixture does not occur. This eliminates the problems with air being present in the meat product, and eliminates the need for a vacuum system for the mixer. In other embodiments, the mixing operation can take place in a vacuum environment of, e.g., 25-29 inches Hg vacuum. In a further embodiment, the process produces low fat or fat-free emulsified products with a texture similar to that of whole fat products. The use of high shear stress processing for a short period of time results in a product that does not form the protein structures that impart an undesirable texture to typical low fat or non fat products. The process can be used without the need to add inert ingredients or water to prevent the formation of protein structures. The meat emulsion produced forms a stable emulsion with optimal protein binding to produce a desired texture. The process can prevent the formation of a visible protein exudate in whole muscle products and coarsely milled. The use of high shear stress processing for a short period of time helps eliminate exudate from the surface of meat or meat products. Additionally, the elimination of a curing period, as described herein, helps to eliminate exudate. Protein exudate is not formed when meat mixtures are not allowed to rest for a significant period of time. The method and apparatus, in some embodiments, utilizes a single piece of machinery for grinding, mixing, and low speed, high volume emulsion formation. The single piece of machinery can combine initial size reduction, mixing and grinding of the constituents, protein extraction, and final emulsion formation. Continuous processing of the constituents is allowed by such a system. In some embodiment, the method comprises feeding a plurality of input food ingredient streams comprising one or more streams of meat ingredient, measuring at least one component of at least one stream of meat ingredient, and controlling feed rates. relative flow of input meat ingredient streams based on the measurements using forward feed analysis to maintain a percentage of at least one component in the combined stream within a predetermined range. Where two streams of meat ingredient are employed, they can be differentiated by fat content, with one having a significantly higher fat content than the other. In addition to one or more meat ingredient streams, other inlet streams may comprise water, salt solution, species, preservatives, and other ingredients, separately or in combination. The preference control system includes at least one on-line analyzer for measuring a compositional characteristic of at least one meat input stream and regulating one or more input flow rates in response to output data from the analyzer (ie ). The system can directly measure a compositional characteristic such as fat content. it can measure a related characteristic such as moisture content from which the fat content can be estimated. The control system may include a plurality of on-line analyzers to analyze the compositional characteristics of a plurality of inhomogeneous input streams. The preferential control system operates one or more pumps or valves for each feed inlet stream. The flow can be regulated by varying the pump speed, by intermittent pump operation, by opening and closing one or more valves, by varying the flow rate with one or more metering valves, or by other means. The control system can thus control both the combined flow rate and the relative flow rates of the input currents. The relative flow rates can be adjusted by the control system based on analysis of the composition characteristics by the analyzer. Feed forward composition analysis can allow rapid adjustment of flow rates of inlet streams to allow control of fat content, protein content, moisture content, and / or other variables of the combined stream without the need to depend on a feedback cycle based on measurements of components in the combined stream. By introducing the controlled components into desired proportions at the input end, the forward feed control system can also improve the processing time by eliminating delays associated with adding and mixing additional ingredients to correct deviations from the desired content levels. The forward feed control system can thus allow a physical mixture or mixture to have a desired composition to be produced from the ingredients introduced at the inlet end and flowing through the processor in one step, without recycling any of the processor output. Another embodiment reduces the necessary number of meat processing equipment components by providing a single interconnected system. The materials can be placed in incoming feed tanks or the like, and each feed tank is fed through an inlet line to the mixer. The input rates are controlled in a stable state manner such that the proper balance of materials is fed to the mixer. This control is done by a system controller receiving the prescribed formulation, such as batch-sheet data or formulation rules, for a particular meat product. The system controller is then able to consider the composition of the materials in relation to the desired output composition and, using the desired formulation for a meat product from the batch sheet, controls the pumps, the mixer, and others. devices to comply with the formulation. The mixer reduces and combines the input materials, maceration and mixing, and removes proteins for fat and water binding with the meat proteins to form a stable mixture. The mixture can then be automatically passed for additional processing. The additional processing can be a step of encapsulation or filling of form, and / or of cooking or thermal treatment. In a further embodiment, the automatic and interconnected system can be used as part of a start-to-finish program for the production of meat products. The control system can collect and download the analysis data and usage data for further analysis. The data can be examined to determine the current input formulation in the current composition of each material or meat used in the formulation, or the system controller can carry out this function and provide this information to a database. This information can be used to compare the yields of final product to input materials, and to examine the fat / meat / water meats relationships for trends including, but not limited to, trends from specific suppliers. Moreover, this information can be used to provide an accurate picture of the consumption rate of various materials, and to allow for effective and precise material ordering. Brief Description of the Drawings Figure 1 is a schematic representation of a continuous mixing processor according to an embodiment of the invention. Figure 2 is a perspective view of a mixing apparatus used in an embodiment of the invention, shown with a portion of the housing removed. Figure 3 is a front elevational view of a component of the apparatus of Figure 2; Figure 4 is a front elevation view of another component of the apparatus of Figure 2; Figure 5 is a front elevation view of another component; of the apparatus of Figure 2. Figure 6 is a fragmentary side view of a segment of a rotating element according to an embodiment of the invention. Figure 7 is a flow chart depicting a process according to an embodiment of the invention. Fig. 8 is a flow chart depicting a process according to an embodiment of the invention. Figure 9 is an amplified image of a piece of meat showing protein striation. Figure 10 is an enlarged image of a piece of meat after a high shear processing step. Figure 11 is an enlarged image of a piece of meat after a curing step in the presence of salt solution. Figure 12 is an enlarged image showing a piece of meat after the high shear processing step in the presence of salt solution. Figure 13 is a table listing configurations of rotating elements for the apparatus as described herein and data relevant thereto. Fig. 14 is a graphical representation of an emulsion stability measurement for the configurations of Fig. 13. Figs. 15-20 are schematic representations of the configurations of Fig. 13. Fig. 21 is a representation in graphical coordinates showing orientations of components inside the device. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS With reference initially to FIG. 1, the apparatus for making processed meat products according to an embodiment of the invention is shown diagrammatically at 10. The illustrated apparatus comprises a motor 12 and a band drive 14 transmitting energy to one or more mixing devices 16 located in a housing 20. Ingredients such as pieces or pieces of meat, one or more salt solutions, water, flavorings such as spices, and preservatives are entered through of intake lines, including pumps 84, directly into the housing 20. The inlet line pumps 84 and mixing devices advance the mixture through the housing while the mixing device applies a high shear rate to the mixture for achieve protein extraction from the meat components. The mixing devices are preferably made of stainless steel or other material that is wear resistant and suitable for contact with food product components. Although a single elongated screw as shown in Figure 1 can be used as a mixing device in some embodiments, other embodiments employ other types of mixing devices. The embodiment illustrated in Figure 2 employs a twin arrow arrangement with a relatively short feed screw 17 used in combination with a longer array of mixing elements 18 on each arrow 19. As the ingredients are forced through the housing 20, the rotary mixing elements 18 macerate and / or mix the ingredients, and subject the ingredients to high cutting force by urging them between the mixing elements 18, and between the mixing elements 18 and the inner walls of the housing 20. The minimum spaces or voids between the mixing elements 18 of an arrow 19 and the mixing elements of a second mixing device 16, as well as between the mixing elements 18 and the housing 20, are preferably between 0.06 and 0.12 inches. In some embodiments, the spaces are 0.08 inches. As the arrows rotate, the distance between mixing elements 18 in respective arrows will also vary such that, for example, portions of muscle are forced through without being split or ground. Forcing the mixture through these spaces applies high cutting force and results in rapid protein extraction. Meat, water, salt solution and other additives such as a slurry of species are fed simultaneously into the mixing device. The present protein extraction involves an intimate contact between the salt solution and the extractable proteins with salt and breaking up of the meat structure to separate protein strands, breaking the own protein strands, or unraveling the proteins. The mixing device applying the high cutting force mechanically provides this intimate contact, opposite to the diffusion used in typical batch processes. One mechanism for this is simply by reducing the mass transfer or diffusion distance. By reducing the pieces of meat to relatively small pieces, the salt solution needs to spread only over a short distance, if at all. In other words, the work applied to the meat in the presence of salt or brine solution forces the salt solution into the structure of the pieces of meat. This accelerates the process, thereby promoting the necessary chemical reactions where chloride ions or other ions occupy binding sites of the protein strands. Moreover, to the extent that the protein strands remain intact, the process deforms the pieces of meat, which promotes unraveling of the protein strands. Figure 9 shows a piece of representative unprocessed meat under amplification. As can be seen, the meat shows a regular pattern of striated muscle protein, the regions of high protein density being darker. The insert of Figure 9 illustrates a portion of the piece of meat under increased magnification such that regions high in protein can be observed distinctly separated by regions of low protein density, or other material such as fat. By applying cutting force to a piece of meat to deform or grind the meat, the protein strands also deform, flatten, stretch, and twist. This opens the structure of proteins, making it more porous, and promotes the penetration of the ingredients, including the brine solution. As the dispersion is more uniform, uniform diffusion of the salt solution and other ingredients and additives, for example, are increased significantly by use of high shear force. Referring now to Figure 9, a representative piece of meat that has been processed with an apparatus as described herein in the absence of other constituents or ingredients is shown. Although still showing a regular striated pattern, the piece of meat has regions of high protein density, dark, much smaller, and much wider areas of lighter color. In addition, the striated pattern and the dark and light regions are less distinct, displaying a somewhat broken structure. Compared with FIG. 9, it is clear that the application of cutting force has opened and made the piece of meat more porous. Accordingly, the piece of meat is more capable of accepting or susceptible to diffusion of other ingredients within it. This process causing rapid diffusion through the application of high cutting force eliminates the need to cure, as has been described as the time for the salt solution to diffuse through the pieces of meat. Due to the need to cure, typical processing methods are necessarily batch oriented. That is, the processing of certain meat products requires diffusion of salt solution into the meat for protein extraction to occur. After mixing or injection with salt solution, typical processes require a curing or diffusion time for the large pieces of meat, during which time the meat is set aside to allow satisfactory diffusion. The curing stage requires an accumulation or inventory of meat inside the plant, which is eliminated to allow use and reception of product just in time, and reduced storage needs in the processing plant.

A representative piece of meat that has undergone a static batch process curing period is shown in Figure 11. The piece of meat was injected in a conventional manner for batch processing with a solution of sodium chloride (NaCl) and It allowed him to heal for a typical enough period for the type of meat. By comparing the piece of meat of Figure 11 with those of Figures 9 and 10, the piece of cured meat shows a striate pattern and colors similar to those of Figure 10 where the dark regions are reduced in size from the piece of unprocessed meat of Figure 9, and the light regions showing open or unraveled protein with ingredients diffused therein. Through the application of high shear force in the presence of a salt solution, a piece of meat displays a physical structure combining both the curing and the unraveling of the protein strands. Figure 12 shows a piece of meat that has been processed with the apparatus in the presence of a sodium chloride solution. As can be seen, the patterns and colors are further distorted, indicating the unraveling and porosity of the protein strands, as well as the infusion and diffusion of the ingredients within and between the protein strands. The apparatus 10 is capable of working with meat ingredients and extracting proteins from them much faster than batch processes of the state of the art. Specifically, the processing time is reduced from 30-60 common minutes to approximately 10-60 seconds and, preferably, 10-45 seconds. In general, this period of time is related to the rate of return. As discussed herein, the rate of yield is mainly dependent on the speed of the pumps forcing the constituents or ingredients within the mixer. Additionally, the mixing apparatus need not be used in conjunction with a vacuum environment. Although vacuum can be applied to the blender, final cooked product made with processed constituents without a vacuum applied to the mixer does not display the visible air characteristics described above for meat that has been stirred in a typical mixing tub, nor does it expand when cooked due to trapped air. During use, the interior of the mixer is generally filled with solid and liquid constituents, and is substantially devoid of air. Little or no air is forced into the constituents. Little or no air that may be present in the mixer is mixed with the constituents because the mixture is not beaten, and because the mixing time is short. By eliminating the vacuum system for the mixer, the process can be simplified, equipment removed with concomitant cost savings, maintenance costs can be reduced, and product loss can be reduced. It should be noted that other processing steps, such as cover filling, can advantageously utilize a vacuum system. Through the effective use of high shear force applied over a small meat area or volume, a stable protein matrix is produced. Protein extraction is quickly and easily controlled, and the protein binds to the mixed water and fat molecules. The protein is then able to bind with water and fat to form a protein / water / fat matrix. The other additives can be bound, in suspension, or dissolved in them. This effectively reduces losses of fat and water to either an irrelevant level or at least to an acceptable level. Thus, the mixing device and other appliances do not suffer from grease being left in the equipment. The composition of the final product is more easily controlled without significant fat or water being lost. The texture of the final product is desirable. Test methods, such as the Ronge Method using a centrifuge to measure quantities of fat escaping from the mixture, will show that the stability of a mixture made by this method is equal to or exceeds the stability of mixtures processed in conventional batches. This system also controls the formation of protein matrix in emulsified products referred to as fat-free products having 1% or less of fat, an example being a Bologna sausage. These products are typically a physical mixture of meat / additive with water. In typical formulation, the physical mixture lacks the fat that otherwise tends to break down the protein matrix. Proteins are capable of forming strong gel-like structures with strands of reticulated, long proteins, forming a large matrix, as mentioned. This results in a rubberized texture which is undesirable for consumers who expect a texture similar to that of whole fat meat products. Typically, this protein matrix problem in fat-free products is handled with the addition or selection of ingredients, although so-called fillings are generally not allowed. One method for decomposing matrix formation is to add inert additives such as starch or non-functional proteins for example. Although water binds to the protein to delay matrix formation, excessive water results in a mild product that does not stay together well, and that can have excessive amounts of water bleeding. Moreover, water can be expelled during the cooking and post-cooking stages. Fat-free products, it is believed, suffer from this problem mainly due to the mixing times of conventional batch processes. It is believed that such batch processing requires such extensive mixing times that this excessive protein binding is able to occur, and the matrix structures begin to form during this mixing time. Analysis of the final baked product using the present method and apparatus has shown that there is a marked fracture in the matrix structure. It is further believed that the high cutting effort of the method and apparatus of the present invention prevents or interferes with the ability of the proteins to bind as such, and / or the rigorous reduction in mixing time of the present method and apparatus reduces or eliminates the ability of proteins to form these long matrix bonds. In any case, Bologna sausage and other so-called fat-free or low-fat products produced using this method do not require any inert additive to reduce or avoid the large matrix formation while still producing a product with the desired texture characteristics of a whole fat meat product. For whole muscle and coarsely ground products, another benefit of the present apparatus and method is the removal of 1 commonly known visible protein exudate that forms on the surface of the meat. More specifically, in certain batch processors, a combination of protein, salt solution, and water forms protein exudate, a sticky, viscous material, as the meat rests in a curing vat for batch processing. This must be broken prior to additional processing steps, such as delivering through pumps. Because the present system uses continuous processing, this exudate does not have the opportunity to be formed. It is believed that the protein exudate results from long mixing time periods. That is, since a period of time must elapse before all the constituents have enough protein extraction, some portions of the constituents will allow excess proteins to be extracted. By reducing and controlling the extent of protein extraction through the constituents, the exudate is reduced or eliminated. Since the mixture discharged from the mixer is delivered relatively quickly for further processing, such as padding or thermal processing, the mixture does not continue to cure and extract additional proteins. In other words, the residence time within the mixer is less than that required for the formation of a visible protein exudate, and the removal of proteins substantially ceases once discharged from the mixer. Although it has been suggested that the exudate is in fact responsible for binding the meat product, the removal of the exudate has not shown any detrimental effects on the final product created as described herein. In some cases, it may be desirable to control the temperature of the mixer housing. For example, it is believed that cooling the mixer housing is beneficial in forming coarse ground articles. It is also believed that the internal temperature of the mixture during the mixing process remains optimally below a threshold level, or a maximum rise in internal temperature during processing. As it has been found that increased cutting work in the mixer improves the mixing stability, reduce the temperature of the mix by cooling the mixer housing or entering ingredients (such as cold water) at points along the length of the mixer it can allow the residence time to increase, or allow the revolutions per minute (RPMs) of the mixing elements to increase. More specifically, cooling the mixture may allow increased cutting work while maintaining the temperature of the mixture below the threshold level. It should be noted that varying the size of the outlet, in the form of a discharge gate opening, necessarily affects the residence time for mixing within the mixer. The opening can be in the range of an eighth of an inch to two inches. An example of a commercially available mixer such as the one described is a Twin Arrow Continuous Processor manufactured by Readco Manufacturing, Inc., of York, Pennsylvania, United States, having mixing elements 18 of 5 inches diameter in arrows rotating in opposite directions 19, and output of around 6,000 lb / hr at around 200 rpm. In the operation, the arrows can have adjustable speeds. Successful operation of the system can be achieved with revolving speeds of, eg. , 100-600 rpm. For the present system, the rotation speed determines the amount of work, including cutting, applied to the mixture. To drive the mixture therethrough, the mixing elements 18 and / or the system pumps for entering the constituents can be used. It should be noted that any pumping force is not what is determined by "high pressure" such that the structural integrity of pumps, pipes, and other components are generally not in danger of failure. The pressure does not force the grease to separate from the mixture. In other embodiments, larger or smaller mixers may be used, e.g., 8 inch diameter mixers having output of at least 20,000 lb / hr, and up to about 25,000 lb / hr. The output can vary depending on the downstream processes, such as filling or filling in shape or baking. Typically, the thermal processes of cooking or cooling determine the output rate of the current mixing device that can be handled downstream. As shown in Figures 2-5, each of the illustrated mixing elements 18 has a bore 200 through which an arrow can pass. To couple each mixing element to the arrow for rotation with it, each mixing element has a non-circular perforation therethrough and the arrow has a cross section of the same figure. In the illustrated embodiment, each mixing element has a generally square perforation, and the arrow accordingly has a square cross section. More specifically, the mixing element 18a (FIG. 3) has a square hole where two corners of the square align with the tips of the mixing element 18a itself. In contrast, the mixing element 18b (FIG. 4) has a square hole where two sides align with the tips of the mixing element. The mixing element 18a is referred to as a "diamond" mixing element, while the mixing element 18b is referred to as a "square" mixing element. Thus, the perforation in a mixing element can be rotated 45 degrees from a second mixing element which is otherwise identical. As you can see in figure 21, the mixing elements 18a, 18b can thus be oriented around the arrow with essentially four different initial positions or orientations when viewed from the output end of the mixer. A first orientation aligns the mixing element tips through vertically aligned positions labeled "1". A second orientation aligns the tips with the positions labeled "2", 45 degrees counterclockwise from the first orientation, while the fourth orientation aligns the tips with the positions labeled "4", 45 degrees in clockwise of the first orientation. The third orientation aligns the tips through generally horizontal positions labeled "3". However, it should be noted that the initial positions of the elements in the arrow can vary infinitely as desired around the axis of the arrow. As described, the mixing elements can be placed in different rotating orientations and different orders, i.e. configurations can vary the cutting speed, the output speed, and / or other process parameters. The mixing elements can also be interchanged with mixing elements of different configurations. In other embodiments, to facilitate cleaning and sterilization of the apparatus, the mixing elements can be formed integrally with the arrow as a unitary, one-piece rotor, or can otherwise be supported for rotation therewith. In the illustrated embodiments, the mixing element 18a (FIG. 3) and the mixing element 18b (FIG. 4) have a generally oval shaped profile similar to that of a football, with a very sharp point or radius of curvature. small on each end. The illustrated mixing elements 18a, 18b have flat, parallel faces, 206 and arcuate peripheral edge surfaces 204. As illustrated in Figure 3, the mixing elements 18a have an edge surface 204 perpendicular to the faces. For the mixing elements 18b, illustrated in Figure 4, the edge surface 204 is angled relative to the faces, and the faces are offset angularly slightly relative to each other, such that the rotation of the mixing elements provides a movement toward forward or reverse when pumping the mixture through the housing. One or more of the mixing elements 18b may be provided to assist the screws 17 in pumping the mixture forward through the housing. Alternatively, one or more of the mixing elements 18b may be inverted such that they urge the mixture back. This can create regions of increased flow resistance or reverse flow such that the dwell time or mixing for the mixture or for particular portions of the mixture is increased, and the work imparted by the mixing device is increased. An additional mixing element 18c is illustrated in figure 5. This mixing element 18c has a generally circular or disc-like shape. Each mixing element 18a and 18b can have a width of half an inch to an inch, and the mixing element 18c can have a width of 1 to 2 inches. Separators can also be placed between each element. In each arrow 19, each of the mixing elements 18 has a cleaning action relative to one or more mixing elements in the opposite arrow to avoid accumulation of ingredients in the mixing elements. This self-cleaning feature helps maintain the flow of ingredients through the mixer, and helps maintain good ingredient distribution. The arrow 19 is preferably a one-piece unitary article that can be removed from the housing 20. A modified screw element 30 that can be used in conjunction with or instead of one or both of the screw elements 17 and the mixing elements 18 described above is shown in Figure 2. The screw element 30 has a helical outer edge 34 disposed at a predetermined radius of the screw shaft, and separated from the interior of the housing by a narrow space of, eg, about 0.08 inches. On the face 32 of the screw a plurality of protrusions or blocks of sharp edges 40 are provided for puncturing whole muscle meat components of the mixture to facilitate protein extraction. Each of the illustrated protuberances 40 has five exposed faces. Each of the illustrated protuberances comprises two pairs of generally parallel quadrilateral side faces 41 and a quadrilateral end face 43. The end faces are rectangular, and in particular, square, and are perpendicular to the side faces. The end faces and the side faces are substantially planar. The arrangement of the mixing elements can be constructed in different ways for different amounts of time of stay, as well as for different amounts and types of work to be applied. For example, an initial section may be spiral flute or screw elements that can be used to pump through the housing. The screw elements can also be used to provide some initial size reduction of the incoming pieces of meat, for example, reducing the size of a piece that measures as large as several pounds to pieces measured in a few ounces or less. This can be achieved by, for example, the edges of the flutes providing a cutting or tearing edge, and / or from the faces of the flutes being provided with surface characteristics to achieve the same, similar to that described herein. for the element 30. As the mixture passes through the mixing elements 18, a first group of mixing elements can be arranged to provide a first level of application of shear force which is mainly for mixing or for allowing the reactions described occur between the protein and the salt solution, as examples. Then, the mixture can pass through a second group of mixing elements imparting a second, higher level of application of cutting force for the purposes described herein. There may be an additional grouping to apply a lower cutting force than the second level for additional mixing, followed by a final group of mixing elements for final high-cut application, such as for reduction or shredding to final size. The use of the mixing device in this manner allows for continuous processing, as the mixture forms a stable mixture that is drawn at one end as new material to be processed enters the entrance. Pre-entry feed tanks including one or more mills can be used to feed the meat entry lines and for some amount of meat-size reduction to facilitate the pumping of the meat into the mixing device. In this manner, meats and other constituents can simultaneously be fed into a continuous processor such that size reduction, mixing, milling, protein extraction, and emulsion can occur continuously and in a single piece of equipment. Thus, the amount of equipment is reduced, the floor space required for the equipment is reduced, cleaning is simplified for the equipment, and the opportunity for contamination of the mixture is reduced. The configuration of the rotating mixing elements such as the mixing elements can be adjusted depending on the type of product being mixed or being produced. For example, finely chopped products resulting in a smooth, fine paste, such as Bologna sausage, can be produced. Thicker chopped products such as salami can also be produced. In addition, whole muscle products such as turkey or ham can be processed. Figures 15-20 show a series of configurations for elements arranged in arrows within the mixer housing. In figure 15, a mixer 200 is illustrated having inlet feed screws FS arranged at an inlet end 202 of the mixer 200 and providing a mixing zone. Along a first arrow two series of mixing elements F, discussed previously as flat mixing elements 18a, and mixing elements H, previously discussed as helical mixing elements 18b, are arranged to provide an application zone of cutting effort. A second arrow (not shown) would be placed parallel to the first arrow and would carry screws FS and mixing elements H, F, the selection of which corresponds to those in the first arrow. As illustrated, the mixing elements H and F are provided with a first number 5-28 to indicate their position in the series, and the orientation of each mixing element H, F is designated by a second number corresponding to the relative positions shown in Figure 21. As shown, liquid injection dampers can be provided along the length of the mixer to provide liquid streams therein. As discussed above, the input feed screws FS are mainly low shear stress elements for forcing the constituents through the mixer 200, while the mixing elements H, F are high shear stress elements for applying work to the constituents within the mixer 200. In this configuration, each arrow has six feed screws FS, eleven helical mixing elements H, and twelve flat mixing elements F. A mixing element in the form of a reverse helix RH provides close to the outlet to force the mixture out of an outlet wall 204 near the outlet of the mixer 206.

Figure 16 shows a mixer 300 similar to that of mixer 200. However, mixer 300 shows a second series of screws FS downstream of a series of screws FS at an inlet end 302. In this manner, mixer 300 provides two mixing zones corresponding to the screws FS, and provides two areas of application of shear stress. In addition, this configuration provides each arrow with six feed screws FS, ten helix-shaped mixing elements H, and thirteen planar mixing elements F. The helix-shaped mixing elements H promote the movement of the mixture through the mixer 300, as discussed above. By reducing the number of helical mixing elements H in the mixer 300 as compared to the number in the mixer 200, the cutting force applied in the configuration of the mixer 300 is greater. Figure 17 shows a mixer 400 having two mixing zones, provided by the feed screws FS, and two areas of application of shear stress. Mixer 400 includes eight helical-shaped mixing elements H, and fifteen flat mixing elements F. Again, with a reduction in the number of helically-shaped elements as compared to mixers 200 and 300, the force of Cut applied in this configuration is increased. Figure 18 shows a mixer 500 having a single mixing zone near the inlet 502, while the rest of the mixer applies cutting force. In this configuration, elements numbered 4-6 and 9-11 are flat, half-sized mixing elements, in pairs, F, where each of the pair is rotated 45 degrees from those mixing elements immediately adjacent to it. This series allows more work, and thus more cutting force, to be imparted to the mix as it moves through such a region. Moreover, three helical, inverse, additional, RH mixing elements are provided. As the helix-shaped mixing elements H promote the mixture to move through the mixer, the reverse helix-shaped mixing elements RH delay this movement and provide a backward force to the mixture. This single action increases the applied work in comparison with flat or helical mixing elements, but also increases the residence time, thereby also increasing the work and the cutting force applied to the mixture. The number of feed screws FS is reduced to four, thereby allowing more high shear stress elements to be placed on the shaft. This configuration uses only three helix-shaped mixing elements H, and 15 flat mixing elements F, in addition to medium-sized mixing elements and inverse helix-shaped mixing elements RH. An even greater force application magnitude is achieved with the configuration of Fig. 19. A mixer 600 is provided similar to that of mixer 500. However, a blister ring BR is provided, discussed above as mixing element 18c . To accommodate the blister ring BR, there are only fourteen flat mixing elements F and two helical mixing elements H. The blister ring BR applies more cutting force than any of the helical, flat mixing elements or inverses. Figure 20 shows an even higher level of application of shear force. For a mixer 700 illustrated in FIG. 20, the helix-shaped mixing elements H have been removed, and a total of 4 reverse helical elements are provided. In comparison with each of the previous configurations illustrated in Figures 15-19, the mixer 700 provides an even greater amount of cutting force and work to the mix. Tests were carried out to determine the emulsion stability of various mixtures using a product formula for beef sausages. When the mix leaves the mixer, and as a batch processor or apparatus as described herein, the mixture will be processed by other machinery and forces. Accordingly, the mixture should not lose stability during this downstream processing. As noted above, an emulsion is considered stable if it loses less than 2% of the final product due to overcooking of fat during cooking. With reference to the table of figure 13, test results for a number of conditions corresponding to the configurations of figures 15-20 are presented, and conditions 5 and 16 represent control batches made from mixing system by conventional lots. The test was made such that the mixture produced from each condition was placed on a separate piece of machinery that applies a cutting force many times greater than the cutting force of the apparatus described herein. After each minute of additional cutting effort being applied, a sample was removed and cooked. It is generally considered that an emulsion is sufficiently stable if three minutes of additional cutting effort does not result in the emulsion having over-cooking greater than 2% of the product, by weight, of loss due to overcooking. The tests determined that control mixtures withstand additional cutting force for approximately 6-8 minutes before additional work results in overcooking of fat and excessive water, and become unstable for longer periods of time. As can be seen in Figure 13, each of the other conditions resulted in a mixture that withstood at least three minutes of application of additional cutting force. For mixers 500, 600 and 700, the emulsion stability was comparable or better than the emulsion stability of the batched mixture. The point at which the application of additional cutting force causes the emulsion to lose stability is referred to as Time to Break, and the results of these tests are presented graphically in Figure 14 to show the Break Time for each condition. It should also be noted that no significant difference was noted in the final appearance for the baked product resulting from each condition. Preferred ingredients are pumped through the inlet lines into the mixer, although an inlet feed tank 62 can also be used alternatively, as shown in Figure 1. As noted previously, pre-entry feed tanks 68 can be provided as storage within which plant personnel load a quantity of materials. In addition, a mill or physical premixing device 64 may be provided prior to or within the feed tank 62 to provide an initial mixing, grinding, or physical mixing action, and / or to assist in pumping the inlet streams downwardly through the feed tank. Ingredients are supplied as input streams by a plurality of input assemblies 66. The input streams may include a first stream comprising predominantly lean meat or muscle content, a second stream comprising predominantly fat content, a third stream comprising one or more salt solutions such as sodium chloride dissolved in water as well as any species or flavoring agent, a fourth stream comprising an aqueous nitrite solution, and a fifth stream consisting essentially of water. Additional ingredients including flavorings such as species, preservatives, and / or other ingredients may be introduced in additional streams, or may be incorporated into one of the five streams described above. Some meat products may use more than two meats, and in some of these cases the system may include additional input sets. In other cases, some of the meat products require small amounts (relative to the overall mix), such as in the range of 2-5%) of a plurality of particular meats, and these can be pre-mixed and delivered to the mixer with a single inlet to measure them at a relatively low rate. Each entry line may be provided with the feed tank 68 or tank which may retain a pre-mixed amount of its respective constituent. For example, a relatively low rate of nitrite solution is used, such that a single pre-mixed amount in a cell measured through an inlet line is sufficient for continuous processing. A line of leftover pasta can also be provided to return pasta to the mix to rework. In the embodiment of Figure 1, each of the input assemblies 66 includes a feed line 80 for bringing an ingredient to the input feed tank 62, a content analyzer 82 on the feed line, and a pump measuring 84 or downstream valve from the analyzer on the power line. In other forms of feeding, e.g., the feeding form of Figure 7, content analyzers are used in some but not all of the input sets. As a stream of ingredients passes through an associated content analyzer 82, the stream is analyzed to determine, for example, fat, moisture and / or protein content. To achieve balance among the various ingredients in the desired ratio, a control system receives input from a plurality of analyzers, and regulates the performance rates of the metering pumps 84 such that the ingredients flow into the input feed tank 62 in the desired ratio, as specified by the product formula. Several methods can be used to analyze the content of fat, moisture, and proteins. Known methods include the use of microwave energy or infrared light. Commercially available online analyzers can be programmed to analyze the characteristics of a wide variety of substances ranging from, eg, petrochemicals to processed cheese. Examples of such analyzers include in-line analyzers GMS # 44 and GMS # 46 manufactured by Weiler and Company, Inc. of Hite ater, Wisconsin, United States, and Process Quantifier manufactured by ESE Inc. of Marshfield, Wisconsin, United States. These analyzers typically must be calibrated for each individual application, either by the manufacturer or by the end user. Figure 7 illustrates a process carrying out the invention comprising a control system 100 by balancing the flow rates of a plurality of input streams to maintain composition parameters within desired ranges using forward feed analysis. In the process of Figure 7, there are two meat inlet streams 102 and 104. In other embodiments, the process may employ only one meat inlet stream, or three or more meat inlet streams. The preference process employs one or more additional inlet streams to supply moisture, flavor improvers, preservatives, and / or other ingredients. In the process of Figure 7, there are three non-meat inlet streams comprising an input stream of physical species / water mixture 106, a water inlet stream 107, and an inlet stream of aqueous nitrite solution 109 Other embodiments may employ more or less non-meat input streams. To produce a mixture with desired moisture, protein and fat content levels, the control system 100 regulates the flow rates of the inlet streams by adjusting the speed of a pump or valve associated with each inlet stream. In the embodiments of Figure 6, metering pumps 110 and 112 regulate the flow rates of physical meat mixture inlet streams, and additional pumps or valves 114, 115 and 117 are used to regulate flow rates of other input currents. Adjustments are made using a forward feed method whereby the pumps and valves provide the appropriate relative amounts of the inlet streams based on upstream analysis. To determine the need for adjustments to the various flow rates, the control system 100 uses the content analyzers 82 to determine the levels of protein, fat and / or moisture content of the inlet streams of ingredients 102, 104 upstream of the metering pumps 110 and 112. In some forms embodiment, for each element of input current being analyzed, analysis is completed before the element reaches the metering pump associated with the input current such that the flow rate of the associated input current can be adjusted as necessary to maintain the desired composition parameters of the combined output stream continuously within the target range. In other embodiments, analysis may take place after the element has passed through the metering pump, and flow rates may be adjusted as necessary to count for the delay. Thus, the percentages of protein, moisture and fat entering the mixer are preferably regulated such that adjustments to variations in input current characteristics are made as the inlet streams flow into the feed tank, rather than in response to Characteristics of the mixture measured downstream of the mixer 10. More specifically, the control system 100 initially receives a prescribed formulation for the meat product, such as from a database. The control system 100 then receives information regarding the composition (i.e., fat content, water content, etc.) of the meats passing through the analyzers. The control system solves a set of simultaneous material balance equations to determine if the materials passing through the analyzers are in the proper relationships for the final meat product. To the extent that the materials are out of an average balance for a short period of time, the control system 100 will adjust the speed of one or more pumps to maintain the material balance within a tolerable range. These equations can be the same equations that would otherwise be solved by plant personnel to adjust input materials based on the batch sheet, discussed above. By providing the control system 110 with known standard parameters for a mixture that will produce the desired final meat product, the control system 100 can automatically, continuously, and dynamically adjust the mixture such that the output is consistent and appropriately balanced. Also as previously noted, in typical batch systems, the only sample that can be made is from the mixing tank, at which point it is difficult and tedious to adjust the balances. The control system 100 and mixing device allow controlled mixing in composition to be consistently and uniformly produced, and narrower composition control can result in increased product yields and improved product quality. The mixer 10 preferably includes an outlet gate 122 for discharging the mixture, and may include an outlet feed tank 124 for receiving the mixture and channeling it to a delivery pump 126. If it is desired to maintain the process at sub-atmospheric pressure , one or more vacuum lines may be in communication with the apparatus at one or more points. Figure 1 illustrates a vacuum line 120 in communication with the input feed tank 62. In other embodiments, vacuum lines can be connected to other locations in addition to or in place of the input feed tank. For example, vacuum lines can be connected to the output power tank, at points between the input and output feed tanks, and at points downstream of the output power tank. Since the extraction of protein is a function of time and force of cut in the presence of a salt solution, the power drive 12 can be a variable speed motor such that the constituents are contained within the housing 20 to mix for a time necessary to allow both infusion of salt solution and shearing force action.

In connection with detection of fat, moisture and protein content of meat components, it has been found that the moisture content can be correlated with the fat and protein content. It is believed that the correlation may be sufficient to allow the moisture content of meat components from a known source to be used as a prediction of fat and / or protein content with sufficient precision for the fat content and / or Protein can actually be measured simply by measuring the moisture content. Accordingly, in certain embodiments of the invention, the step of measuring fat and / or protein content may consist of measuring the moisture content after having calibrated the moisture meter appropriately. The control system can then control the entry of fat and / or protein based on the moisture content readings of one or more inlet streams. By using the system described herein, plant personnel can receive a batch sheet from a database for the formulation of a particular meat product. Plant personnel can then select appropriate meats to enter the system based on fat, protein and / or water content. However, the precision with which they are selected does not need to be so precise, to the extent that the ratings provided by the provider can generally be reliable. Moreover, the system allows the pieces of meat to be delivered directly into the pre-entry feed tank 68 which may or may not carry out the initial size reduction, thereby eliminating the need for the injection and feed stages. Cured and their companion tanks. At this point, the control system 100 takes the processing of the meat and other constituents. The control system 100 automatically receives or pulls the batch sheet from the database and calculates the necessary material balance equations. As described, the control system 100 monitors and adjusts the system including the pumps and mixing device to produce a stable protein matrix of generally uniform composition. The output stream of the meat product mixture from the mixing device can first proceed to a peak feed tank to take into account minor imbalances in the system, and can then easily and simply be transported to additional processing steps, such as coating processes or filling of form and cooking / thermal. The peak feed tank is filled from the bottom to the top, so that there is very little mixing or aeration problems as a result of its use. The control system analyzes the composition needs and what is present, and adjusts accordingly. Thus, human interaction is reduced to provide the constituents, such as by loading meat into the supply tanks 68, and responding to alarms or alerts from the system by providing notice that there is a problem such as a constituent ending. The result is a reduction in labor, more precise and higher yields (lower loss of yield), greater food safety and reduced contamination probability due to the substantially closed system and lack of transfer, reduced space requirements after elimination of tanks and chillers, improved product uniformity, and reduced maintenance due to the elimination of tank and transfer traffic, as well as savings from the elimination of the tanks themselves and the injection stages. The communication between the control system 100 and the corporate database is directed in both directions. That is, the control system 100 can receive the base formula batch sheet, formulation rules (such as maximum fat content), and directly finished paste targets., as well as providing feedback to the database regarding the current materials used. Since the database may have a non-current or inaccurate formulation, the information of the control system 100 may be loaded to correct the formulation. In addition, the control system can provide information detailing the current composition rating compared to the vendor-specific rating to which a small sample estimate is generally. This allows a historical view of a specific supplier and can show trends of changes in the meats provided by specific suppliers. This feedback can be used by the database to evaluate materials at hand and purchase requirements, as well as compare the results of performance to use of materials. The data collection allowed by this system can show tendency of several aspects of the operation to look for inefficiencies and mark for improvements in them. In previous systems, the database tends to have a static formulation, while the present control system allows dynamic re-positioning of that formulation. The control system does respond to changing materials, compensates for unavailable materials, and provides feedback to re-configure the formulation in the database. From the foregoing, it should be appreciated that the invention provides a new and improved method for effecting protein extraction and mixing of meat components for certain processed meat products. The term "meat" is broadly used herein to refer to meat such as beef, pork, poultry, fish and meat by-products, including cuts or pieces that are all or mainly all fat, as well as lean cuts or pieces that they have a relatively higher protein content. The terms "meat product" and "meat ingredient" are widely used herein to refer to products or ingredients that contain meat, alone or in combination with other components.

The preferred embodiments described above relate to continuous processes, i.e. processes in which ingredients are input during unloading of a combined output. In these processes, the entry and / or exit steps may be interrupted periodically or may be intermittent. Preferred embodiments of the invention are believed to be effective in achieving fast protein extraction and mixing of meat components in a much smaller apparatus than that used in certain batch mixing processes of the prior art. In addition to reducing floor space requirements, preferred embodiments of the invention also cost and time of cleaning compared to those processes and apparatuses of the prior art. The invention can also result in significant cost savings by allowing more precise control of the composition of the combined output stream. Although specific embodiments have been described above, the invention is not limited to those embodiments. The invention is further described in the following claims.

Claims (33)

1. CLAIMS 1. A system for processing meat to produce a continuous output of a stable meat mixture, the system comprising: inputs to provide constituents to the system, the constituents including meats and additives; a mixer for continuously receiving and processing the constituents in a mixture, the mixer having a housing containing rotating mixing elements located on a pair of rotating shafts to work the constituents, working including at least one of grinding, deforming, macerating, and mixing the constituents, the rotary mixing elements forcing the constituents through the mixer, the mixer having an inlet to receive the constituents and an outlet for discharging the mixture; a thermal process step for receiving the mixture from the outlet and heating the mixture to solidify the mixture to a final meat product form which is a self-supporting, cohesive processed meat product. The system of claim 1, further including storage tanks for retaining and delivering the constituents to the inlets and a feed tank for receiving the constituents from the inlets and delivering the constituents to the mixer. The system of claim 2, wherein the storage tank includes a mill to provide an initial size reduction to the meats prior to the mixer. The system of claim 3, wherein the inputs include input lines through which constituents are delivered, each input line including a pump for forcing the constituents through the entry line and for helping to force to the constituents through the mixer. The system of claim 4, further comprising a forming apparatus for receiving the premix prior to the thermal process step, wherein the forming apparatus provides a predetermined figure to the finished cooked meat product. The system of claim 5, further comprising a cooling apparatus for cooling the meat product to final form. 7. A method for continuous production of processed meat product including the steps of: providing inputs for constituents of meat product; - provide a continuous process mixer; enter the constituents inside an entrance of the mixer; process the constituents in the mixer, including: combine salt solution with protein strands of the meat to extract protein; mixing the constituents in a mixer having a housing containing rotating mixing elements; advancing the constituents through the mixer at least in part using the rotating mixing elements within the mixer housing; forming a stable meat mixture from the constituents; and discharging the mixture from one outlet end of the mixer. The method of claim 1, further comprising the steps of: providing constituents in storage tanks to deliver the constituents to the inputs; pump the constituents from the storage tanks through entry lines to the entrances. The method of claim 8, wherein the constituents of meat product includes at least one first meat in the form of pieces of meat including protein, and the method includes the step of reducing the size of the pieces of meat in a tank of pre-feed to the inlet end of the mixer housing. The method of claim 9, further comprising treating the mixture in a thermal process step after leaving the outlet end of the mixer by applying heat to the mixture to solidify the mixture in a self-supported processed meat product, cohesive. 11. A method for reducing the formation of protein exudate in meat mixtures, the steps including: providing a mixer having a plurality of rotating mixing elements within a mixer housing; entering a plurality of the meat mixture constituents into the mixer; applying a high cutting force to the constituents using the rotating mixing elements to extract protein from the meat mixture; mix the constituents; and removing the mixture, where the period of time to apply the cutting force and mixing is sufficient for protein extraction to occur to form a stable meat mixture, and the period of time is relatively short. The method of claim 11, wherein the removal step is carried out prior to extensive binding of protein bonds in the mixture. The method of claim 12, wherein the time period is between 10 and 45 seconds, the time period being less than that required for protein extraction to produce visible exudates, and where the extracted proteins are used to bind the mixture during a thermal process. The method of claim 13, further including the step of processing the mixture after removing it from the mixer, the step of further processing including at least one of filling the mixture into a cover and delivering the mixture to a shape. 15. The method of claim 14, wherein the extraction of protein substantially ceases when the mixture is removed from the mixer. The method of claim 11, wherein the mixer housing is closed and further including the steps of: providing a plurality of input lines for inputting the constituents into the mixer; and pumping the constituents through the entry lines under pressure and into the closed housing of the mixer. The method of claim 16, wherein the mixing step is carried out substantially in the absence of air and at a pressure of at least equal to atmospheric pressure, and wherein the step of mixing comprises first mixing in a first zone with a First rate of shear stress, then mixing in a second zone at a second rate of shear stress greater than the first rate of shear stress, then mixing in a third zone at a third rate of shear stress less than the second rate of shear stress, then mixing in a fourth zone at a rate of shear stress greater than the third rate of shear stress. The method of claim 11, wherein the stable meat mixture is a low fat meat mixture having the texture of a whole fat meat mixture. 19. An apparatus capable of reducing the formation of protein exudate in meat mixtures, the system including: a mixer to apply a high cutting force; a plurality of entries to deliver constituents of meat mixture, including meat having protein strands, to the mixer, the mixer extracting an amount of protein strands from the meat sufficient to form a stable meat mixture and the mixer having a housing with an inlet end and an outlet end, the mixer having a pair of rotating arrows located within the housing, each of the arrows having a plurality of high shear mixing elements to extract at least some of the protein strands of the flesh; and a mixer discharge, wherein the constituents form a stable meat mixture in a relatively short period of time within the mixer. 20. The apparatus of claim 19, wherein the high shear mixing elements rotate within one-eighth of an inch of the inner surface of the housing and the other mixing elements. The apparatus of claim 20, wherein the relatively short period of time is less than one minute. 22. The apparatus of claim 19, wherein the mixer housing is substantially anaerobic, the time period is insufficient to allow air to mix within the constituents and the inlet lines are under pressure using a pump to force the constituents to its through. 23. An apparatus capable of processing meat based on a predetermined formulation for a final meat product, the apparatus including: a control system for receiving the formulation; i a plurality of input lines to deliver streams of constituents of the meat product, streams including a stream of salt solution and streams of meat containing pieces of meat having protein strands, the input lines each including a pump and a analyzer to provide a content value to the control system, the content value being based on one or more of fat, water, and protein, and the control system communicating with the analyzers and calculating content relationships for a combination of the currents of constituent; and a mixer receiving the constituents and processing the meat in a stable meat mixture. The apparatus of claim 23, wherein the control system adjusts the pumps to adjust a rate of constituent streams across the input lines, and such adjustment is made with respect to the contents ratios so that the combination maintain a content value for the combined constituent stream within a predetermined range based on the formulation. The apparatus of claim 24, wherein an initial formulation for unprocessed constituents and having the final product target formulation is recovered by the control system from a central database and the control system also sends information to the central database with respect to the production of meat product. 26. The apparatus of claim 25, wherein the pieces of meat have an initial content rating, and the information sent by the control system to the central database including one or more of the amount of constituent used, the amount of final meat product, and a formulated formulation based on the current quantities of processed constituents. 27. The apparatus of claim 26, wherein the control system provides values to the central database for a modified initial formulation to produce the final product target formulation. 28. The apparatus of claim 23, wherein an operating pressure in the mixer is equal to or greater than the atmospheric pressure and the mixer is substantially anaerobic, the mixer including mixing elements for processing the meat and providing at least one mixing zone and at least one mixing zone. less a zone of high shear stress, where the high shear stress forces the salt solution towards the protein strands, and a thermal processing step to receive the mixture from the mixer outlet. 29. The apparatus of claim 28, wherein the mixing elements contort the meat pieces and the salt solution diffuses rapidly within the contorted pieces of meat and the high shear zone by extracting proteins to form a stable emulsion. . 30. The apparatus of claim 29, wherein the constituents are in the mixer for a period of time which is insufficient for the formation of visible surface protein exudate. The apparatus of claim 23, wherein flute-shaped spiral elements disposed of the mixer direct the constituents at least partially through the mixer and provide an initial size reduction to the pieces of meat, and where the mixer includes zones of effort of high cut and low alternating. 32. The apparatus of claim 28, wherein the zone of high shear stress grinds the constituents. 33. The apparatus of claim 23, wherein the mixer is a single piece of equipment.