Courtesy of MSA – Bacharach.
Reliable temperature control is essential in the industrial meat processing sector to ensure that meat products are safe and enjoyable for consumption, with optimal texture and taste.
Inadequate refrigeration and freezing techniques can lead to several problems, including microorganism growth, freezer burn, bone taint, and cold shortening, as well as ensuring the quality and safety of meat products. One key area that impairs temperature control is refrigerant leaking from the system, whereby temperatures can no longer be maintained through failing equipment.
Meat processing temperature requirements
Adequate cooling and freezing protocols, including the use of freezer-safe packaging, storage at optimal temperatures, and adherence to recommended freezing times, are necessary to minimise these problems and ensure the production of high-quality meat products.
Microorganism growth: Temperature is an important factor when it comes to inhibiting the growth of microorganisms and bacteria. Pathogenic bacteria growth such as Campylobacter, Salmonella, and Listeria is seriously impeded in temperatures under 38°F (3°C) and so it’s meat products should be stored at temperatures as low as possible.
Freezer burn is caused by dehydration and oxidation of the surface of the meat, which can result in a tough and unpleasant texture, as well as a loss of flavour. To prevent freezer burn, meat should be wrapped tightly in freezer-safe packaging to prevent air exposure and stored in the coldest part of the freezer.
Bone taint is another issue that can arise when meat is not frozen correctly. This condition refers to the unpleasant odour and taste that can develop in meat when it comes into contact with bone during storage or transportation. The bone releases compounds that can be absorbed by the meat, resulting in the development of bone taint. Proper temperature control during storage and transportation is critical to prevent this from happening. Careful temperature control is also necessary to avoid the problem of bone taint turning bones red.
Cold shortening is a condition that affects the texture of meat when it is frozen too quickly, resulting in a tough and dry texture. This can occur when the temperature of the meat drops rapidly, causing ice crystals to form within the muscle fibres, which can then break down the cell structure. To prevent cold shortening, meat should be cooled gradually before being placed in the freezer.
Industry and regulatory guidelines for the handling, storage, and shipping, including specific temperature and time requirements for different stages of meat processing are well regulated. In the US, the Food Safety and Inspection Service (FSIS), an agency of the Department of Agriculture, provides regulatory information responsible for ensuring the US supply of meat, poultry, and egg products are safe. In Canada, similar regulations are handled by the Canadian Food Inspection Agency (CFIA). In South Africa, the Department of Agriculture, Land Reform and Rural Development (DALRRD) has responsibility for agriculture, and food safety (https://www.dalrrd.gov.za/). In the UK the Food Standards Agency (FSA) outlines legal requirements for meat establishments as:
During cutting, boning, trimming, slicing, dicing, wrapping, and packaging, meat should be maintained at not more than 3°C for offal and 7°C for other meat by means of an ambient temperature of not more than 12°C or an alternative system having an equivalent effect.
Each regulatory body provides resources for the handling, storage, and processing of various types of meat, whilst maintaining regional variations. It is important to note that these guidelines may be subject to change and it is always best to consult the most up-to-date guidance from the relevant regulatory bodies.
Impaired temperature control through refrigerant leaks
When refrigerant leaks occur, they can lead to decreased cooling capacity, increased energy consumption, and potential damage to the refrigeration system. Leaked refrigerant can also have a negative impact on the environment, as many refrigerants are known to contribute to ozone depletion and climate change. Additionally, some refrigerants are hazards for personnel, so personal safety should also be considered.
Common types of refrigerant used in meat processing plants include hydrofluorocarbons (HFCs) such as R-404A and R-507A, as well as ammonia NH3 and carbon dioxide (CO2). HFCs have been widely used as refrigerants in the past, but they are known to have a high global warming potential and are being phased out in many countries. Ammonia and CO2 provide a natural refrigerant alternative and are becoming increasingly popular due to their lower environmental impact. However, they require special handling and safety precautions due to their flammability and toxicity.
Refrigerant leak detection solutions
For meat processing, finding and fixing refrigerant leaks quickly is critical for product safety and quality, and also for minimising environmental harm, ensuring regulatory compliance, and enhancing energy efficiency. To support a rapid leak detection, notification, and consequential repair to assist in minimising refrigerant emissions, there are a number of solutions that can be categorized as background monitoring, localised leak detection, and integrated IoT solutions to improve efficiencies. For large scale meat processing sites, an aspirated detection system would be the most effective and efficient considering the high sensitivity, wide coverage and remote sampling functionality:
High sensitivity: Aspirated systems, also known as active air sampling systems, can detect even very low concentrations of refrigerant gases. They use a pump to continuously aspirate air samples, ensuring high sensitivity and quick response to leaks.
Wide coverage: Aspirated systems are designed to cover larger areas. They use a network of sampling points, allowing them to monitor extensive spaces effectively. This feature makes them suitable for large supermarkets with complex refrigeration systems.
Remote sampling: Aspirated systems can sample air from various locations, which is particularly useful in supermarkets where refrigeration units might be dispersed across different sections of the store.
A further integration that would help support a rapid refrigerant leak response and repair would be to integrate the detection equipment with a cloud-based solution. Cloud-based monitoring solutions collect data from the fixed leak detection hardware installed within the meat processing facility. This connected solution then provides secure, remote access, allowing authorized personnel to monitor the system’s status from anywhere. Cloud platforms often come with analytics tools that provide insights into system performance and trends. BMS software can integrate refrigerant monitoring as part of its functions. BMS continuously monitors various building systems, including refrigeration. It provides real-time data and can be configured to send alerts via email, SMS, or in-app notifications when leaks are detected.
References:
National Library of Medicine, ‘Microbial Communities of Meat and Meat Products: An Exploratory Analysis of the Product Quality and Safety at Selected Enterprises in South Africa’ (https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7997435/)
United States Department of Agriculture (USDA), ‘Beef from Farm to Table’ (https://www.fsis.usda.gov/food-safety/safe-food-handling-and-preparation/meat-fish/beef-farm-table), ‘Fresh Pork from Farm to Table’ (https://www.fsis.usda.gov/food-safety/safe-food-handling-and-preparation/meat-fish/fresh-pork-farm-table), and ‘Lamb from Farm to Table’ (https://www.fsis.usda.gov/food-safety/safe-food-handling-and-preparation/meat-fish/lamb-farm-table)
MSA Safety, ‘New Rules of Refrigeration Leak Protection: What You Should Know’ (https://blog.msasafety.com/new-rules-of-refrigeration-leak-protection-what-you-should-know/)
Environment Agency, United Kingdom, ‘How to comply with your environmental permit Additional guidance for: The Red Meat Processing (Cattle, Sheep and Pigs) Sector (EPR 6.12)’ (https://assets.publishing.service.gov.uk/media/5a7c5180e5274a1b00422f54/geho0209bpja-e-e.pdf)
Register for free to gain access the digital library for Cold Link Africa publications