meat and meat product

1. (Buffalo Meat) Presented by : Prakash Kumar (Ph.D. Research Scholar, AGFE, IIT-Kharagpur, India) prakashfoodtech@gmail.com

2. Food Product Development: Creating or modifying new food product ultimately increases the sale, give beneficial nutrition to the consumer, maintain competitiveness, filling market gaps , helps in decreasing carbon and water foot prints. This is good for the final food system. Idea Idea screening Development and Testing Marketing Strategies Commercialization Test marketing Pdt Development Business Analysis Success and failure of product depends on the uniqueness of the product, unique benefits to the consumer, superior quality and environment friendly etc. Presentation on new product development CATEGORY: from the buffalo meat (Source from which new product being developed) It is important to know about the source from which new products being developed. PRODUCTS : 1) Meat Biscuits (History and new development) 2) Sausages (innovations and new researches in it)

3. Bhusa Khali (Mustard oilcake) (Wheat straws) Feed Water Gur (jaggery) Daliya (Ground wheat)

4. BUFFALO BY-PRODUCTS Manure Meat processing industry Meat dung Leather industry, skin oil used by cosmetic industry Skin Feed Manufacturing of shaving cream, gelatin , toothpaste, talcum powder etc. Bone Milk Blood Pharmaceutical industry

5. Steak’s Sausage’s Ground Carabeef Meat ham’s Meat Product’s Meat patties Steak sizzler Meat loaf Carabeef ribs

6. For Lean Meat PROTEIN : 19.39 % MOITURE : 76.63% ENERGY : 515 KJ /100g WHY?? pH : 5.42 WHC : 2.39% ASH : 1.08% FAT : 0.84%

7. Meat and Meat Products Overview in INDIA According to Food and Agriculture Organization Statistics (FAOSTAT), the world livestock population is about 195 million buffaloes, 1428 million cattle's, 924 million goat and 1093 million sheep. India has 113 million buffaloes, 211 million cattle's, 157 millions goat and 74.5 million sheep populations, which is 58%, 15%, 17% and 7% of their world population, respectively (According to 2011 livestock census ) From 2001 to 2011, cattle population increased by 11.2%; buffalo by 18.6%; sheep and goat by 23.9% and 26.8%, respectively . The Indian export value of buffalo meat for 1.2 MT is 23000 cr which makes India 3rdbiggest beef (carabeef) exporter after Brazil and Australia. (acc. to APEDA) World average per capita meat consumption 39.8 kg. In India it is about 5.2 kg/year, Developed countries it is 80.3 kg/year.

8. Developing countries average 28.9 kg. 70% of Indian population is non vegetarians. Livestock trading in India is done in Livestock markets regulated by state governments supervised by local authorities like : municipal corporations. Animal farmers are not realizing the full potential of value of their produce due to lack of awareness. The involvement of middle men in several stages is hampering the farmers actual economic returns.

9. In the total Export of meat from India 90 % of Meat is obtained from Buffalo Beef and 3% is obtained from Sheep & Goat. Deboned frozen meat of Buffalo is high in demand in global market APEDA (Agricultural and Processed Food Export Development Agency) Under the Ministry of Commerce is the governing body which regulates the exports. 33 Export oriented modern combined slaughter houses and meat processing plants is registered with the APEDA. 35 Meat processing and Packaging units are present in India out of that 12 is registered wit APEDA

10. 200 processing meat units licensed under MFPO order 1973 The meat of the spent animal is generally tough and thus more suitable for processing to value added products both on economic and quality consideration. Organized development of processed meat sector is important to realize the full benefit from meat animals. Value addition is important for the effective utilization of livestock resources.

11. State wise average carcass yield and breeds of Buffalo

12. Animal product exported from India during April-February 2017-2018 (source: APEDA provisional data) Product quality Quantity (Tonnes) values (Cr) Buffalo Meat 1234288 23774 Sheep / Goat meat 21995 802 Poultry products - 489 Processed meat 237 9 Other meat 997 16 Animal casing 10682 277 Dairy products 86893 1672 LIVESTOCK PRODUCT 1355092 27039 (excluding poultry)

13. State wise overview

14. Buffalo meat value chain

15. Role of different actors in Domestic value chain of buffalo meat production

16. Stages in buffalo meat production for domestic market and cost involved in each stage SP PBM : Sale Price of Buffalo Meat Leg 1 : Farmer rear buffalo and sell them either to traders or at a livestock market Leg 2: Trader transport the purchased animal to a municipal slaughterhouse. Leg 3: Retailer/wholesale meat dealers purchase buffalo meat (carabeef) from municipal slaughterhouse and sell it to consumers. : Sale Price Estimating weight of buffalo is 200kg approx.

17. SLAUGHTER HOUSE PROCESSING

18. Packaging Material used for Carabeef •Vacuum packaging : Oxygen impermeable, moisture impermeable, extends shelf life. •Traditional Overwrap Packaging : Use styrofoam tray, Uses PVC wrap, Moisture impermeable, Oxygen permeable (Allows for bright red color) Disadvantages: Short shelf-life, Exposure to O2 (lipid and pigment oxidation) •MAP(Modified Atmospheric Packaging) : MAP is the removal/replacement of the atmosphere surround the product before sealing in vapor-barrier materials” (McMillin, Huang, Ho, & Smith, 1999). Types of MAP: Vacuum, Oxygen/Nitrogen/CO2, Peel able film etc. •Polymeric films

19. Cost incurred by farmers

20. Cost incurred by traders

21. Cost incurred by exporter Major costs involved in undertaking primary operations in export units after receiving of animals and shipment of final marketable products include : (a) Transportation, (b) Packaging, (c) Service costs, (d) Energy source, and (e) Labor In the entire value chain, transport costs, which consume nearly two fifths of the total expenditure, end up being the most expensive operation category.

22. Environmental concern POLLUTION CONTROL NORMS: According to the zero-discharge policy by CPCB : BOD level should < 30mg/l, COD level should < 250 mg/l, TSS should < 100 mg/l Oil and grease should < 10 mg/l and meat packers are not allowed to discharge any effluent outside Standards to be achieved under water & air (prevention and control of pollution) act 1974 The adequacy and efficacy of the effluent treatment plant/air pollution control devices will be the entire responsibility of the industry. (On average 600-1000 liter water/day is used for buffalo in a slaughter house)

23. Meat biscuits brief history Gail Borden was the man behind the manufacturing of meat biscuit. (He also having patent of condensed milk) high protein, low-fat, nutrient-dense Roughly on 1849, he was experimenting with creation of the dehydrated beef product known as “Meat Biscuits”. He was operating a factory in Galveston, Texas to produce meat biscuits by 1851 and won Great council medal at the 1851 London world’s fair. Within short time his product get huge demand in the market including U.S. Army.

24. 1. Meat Biscuits for Dog’s Dog Biscuits were invented accidentally in London butcher shop during the late 1800 by Carleton Ellis. Shop owner wants to expand his business by creating a new biscuit recipe for his customer. After baking one batch, he tasted them and thought they were terrible. He gave one to his dog, his dog gobbled it right up. This gave him idea of making biscuit especially for dogs. In 1908, F.H. Bennett company was established and they began selling their Dog Biscuits under the name of malatoid. 1911, the recipe granted a patent 1915, the name was changed to Milkbone.

25. 6 % CAGR for the pet food market between 2011 and 2016, according to a Euromonitor International global trends report presented at Global Pet Expo, 2017 The Milkbone Dog Biscuit brand was then acquired by Nabisco Biscuit company and it dominated the dog biscuit market until the late 1960s. Initially, it was marketed as the treat for dog. In their new strategies, they changes their mind set toward the health of the dog to increase the market value of their product, thus created like cleaner teeth and better breath etc. In early 1970s lots of new competitor came out. Nestlé sells pet food as “Supercoat brand” in India.

26. Now, researcher focusing on development of innovative pet functional food products. Challenge of developing such products, and have been produced by combining three different knowledge areas - ‘establishing of an innovative niche market’, ‘functional foods’, and ‘the pet food industry’ - through the building blocks of the Business Model Canvas. Research’s product development is based on 6 factors : •Value propositions : It should be centered around the functionality of the product. •Customer segment : The targeted customer is the future of the product. •Customer relationship : To make the customers to adapt and accept an innovative functional pet food •Channels : Channels concern the means of getting in touch with the specific customer segment. •Cost structure :The cost structure concerns the costs involved in the business model. •Revenue stream :The analysis finds that when developing an innovative functional pet food, value-based pricing is the recommended pricing strategy to use.

27. Product specifications The primary ingredients in a dog biscuit recipe are carbohydrates, proteins, fats and oils, and fiber. Now, researchers focusing on functional ingredients that have a significant effect on the dog biscuit's final characteristics. The ingredients used for dog biscuits are specially for dogs, and are chosen to be nutritious, easily digested, palatable, and economically feasible. Carbohydrates: It is obtained by grinding corn, wheat, or rice into a powder. This powder contains the three main parts of the seeds including the bran, germ, and endosperm. the endosperm is responsible for most of the important baking and shaping characteristics. Chemically, flour is composed of starch and protein. When mixed with water, it creates a mass called gluten that can be cut and formed into the dog biscuit form.

28. Protein : The proteins added to dog biscuits supply the animal with essential amino acids, taurine, improve taste, and in some cases supply energy. Total meat and meat derivatives content is up to 65% for wet food and 39% for dry food They are derived from a variety of sources including animal and plant. Typical plant protein ingredients found in a dog biscuit are such things as corn gluten meal and soybean meal. They are generally less expensive than animal proteins and are therefore used in greater quantities. Ingredients such as poultry byproduct meal, meat and bone meal, and dried liver meal. Milk and egg are also used as a supply of protein. A drawback to plant proteins is that they contain certain indigestible oligosaccharides that can cause undesirable flatulence.

29. Fats and oils : It provide flavor and nutritional energy and texture to the finished product. They are derived from plants, fish and animal sources. Much of the fats and oils used in pet food is obtained from the fast food industry. Fibers : It is important in calorie-controlled recipe. Extra fiber, such as wheat bran or corn bran, is added to improve droppings and water absorption. Other additives and Functional ingredients : Antioxidants are added to prevent the breakdown of vitamins and other nutrients present in the biscuit, and to maintain freshness. Examples of these materials include zinc oxide and manganous oxide. Functional ingredients (on research) to enhance the overall nutritive value. Although dogs are essentially color blind, artificial color additives are added for the benefit of the pet's owner. Finally, preservatives such as BHA are added to prevent microbial growth.

30. Manufacturing Process Ingredient handling Shaping Baking Finishing step Packaging Ingredient handling : •In the first step, the dry ingredients are mixed together. •Water is then added to this blend to bring the moisture content up to about 30%. • This creates a paste-like dough that is next pumped into a conditioner chamber and heated. •Within this chamber, other ingredients such as animal byproducts or other moist ingredients are added. •From this chamber, the batch is moved into an extrusion machine. Shaping : •After extrusion it is sent to the forming dies , which have a variety of shapes such as bones, stars, circles, etc. •Then, laid on drying sheets. The sudden release of pressure causes the entrapped moisture to create an expansion of the biscuit much like exploding popcorn. •From here, the biscuits are transferred to a metal conveyor belt and moved through an oven.

31. Baking : •The baking of the dog biscuits is done in a tunnel oven. •The oven is anywhere from 100-300 ft (30.48-91.44 m) long. •As the biscuits travel through the oven, the biscuit goes through a setting phase where it takes on the shape of the final product. •Next, it is dried out to about 10% moisture content. •The amount of time baking time is controlled by the speed of the moving conveyor belt Finishing steps : •The dog biscuits exit the ovens and travel through a series of conveyors to cool. •Depending on the recipe, additional coating ingredients may be added. These can include fats, vitamins, and other flavor enhancers. They are applied using depositor machines that spray coat the biscuits. If necessary, excess topping removed by forced air or shaker devices. Packaging Dog Biscuits are fragile, the packaging is typically rigid with polymeric packaging inside it. These boxes are put into larger case boxes, stacked on pallets, and shipped to stores

32. 2. Carabeef sausages Sausages are the oldest form of processed meat products known through historical evidence. It is considered one of the most appetizing, nutritious, enjoyable, and convenient meat products. Global hot dogs and sausages market to grow at a CAGR of 3.22% during the period 2017-2021. The report has been prepared based on an in-depth market analysis with inputs from industry experts. The latest trend gaining momentum in the market is Rising demand for organic sausages. With growing health-consciousness, consumers are shifting toward healthier varieties of hot dogs and sausages. Organic production is a sustainable and environmentally safe way of producing. Meats are extracted from animals who are raised without the use of any antibiotics, are fed natural feed, and are not genetically modified. Sausages can be made by grinding meat from beef, pork, poultry, or game meat, mixing with salt and other seasonings followed by stuffing into a container or a casing

34. Ingredients Salt It is necessary for enhancing flavor, preserving the sausage from microbial spoilage, and extracting the soluble meat proteins. Sugar Sucrose (table sugar), brown sugar, dextrose, and corn syrup. The lactic acid produced due to fermentation reduces the pH of the meat and gives sausage a characteristic tangy flavor. Spices Characteristic flavor. Nitrate and nitrite are converted to nitric oxide by microorganisms and combine with the meat pigment (myoglobin) to give the characteristic pink cured-meat color. Less than 2.75 ounces of sodium or potassium nitrate per 100 pounds of chopped meat . Reducing Agents Ascorbic acid or Sodium erythrobate are active reducing agents that react with nitrite to accelerate the curing process. USDA regulations allow the use of up to 7/8 ounce per 100 pounds of meat.

35. Antioxidants are approved for use in fresh sausages to retard oxidative rancidity and protect flavor, including butylated hydroxytoluene (BHT), butylated hydroxyanisole (BHA), propyl gallate, tertiary butylhydroquinone (TBHQ), and tocopherols. Mold Inhibitors The common technique for preventing the growth of mold is to dip the sausage in a mold inhibitor solution, typically 2.5 percent solution of potassium sorbate or a 3.5 percent solution of propylparaben. Binders and Extenders To retain natural juices and reduce the cost of the formulation. These ingredients help may improve the binding characteristics, flavor, cook yield. The most commonly used ingredients of this type are nonfat dry milk, cereal flours, and soy protein products Water To rehydrate the nonfat dry milk and to replace the expected moisture loss during smoking and cooking. Approximagtely 10 % added water typically is used in moist types of cooked sausage.

36. Casings Two types of sausage casings are : 1)Natural casings are obtained from the digestive tract of animals. Now there is innovations in casing of the sausages. 2) synthetic casings made from collagen, cellulose etc. • Collagen casing derived from animal protein, often extracted from beef hides etc. • Collagen is also the main protein present in natural casings. • Synthetic casings come in a variety of forms. • “Skinless” hot dogs are manufactured in cellulose casings (made from inedible plant and tree fibers), which allow smoke to penetrate and moisture to escape during cooking. •These cellulose or fibrous casings have the advantage of being uniform in size (diameter) and generally free of defects

37. References : •http://watermr.com/hide-on-washer/ • http://indianexpress.com/article/india/the-journey-of-a-400-kg-buffalo-cow- slaughter-uttar-pradesh-4644146/ •http://efsonline.uga.edu/wp-content/uploads/2016/08/Basics-of-Sausage- Making.pdf •https://www.peta.org/issues/animals-used-for-food/meat-environment/ •NABARD Consultancy Services (NABCONS) FAO online database, 2011 •http://www.madehow.com/Volume-5/Dog-Biscuit.html •Evaluation of sensory characteristics and texture of an economic Buffalo meat (Bubalus bubalis) sausage and an economic beef sausage with addition of bovine hemoglobin powder. •CPCB (Effluent treatment of slaughter house as per 23rdOct 2017) •Development of innovative functional pet food products by Authors: Lovisa Bengtsson, Gunnel Bildt & Julia Skäremo Supervisors: Stein Kleppesto & Malin Sjoo(http://lup.lub.lu.se/luur/download?func=downloadFile&recordOId=5463978&fileOId=54 63982 )

38. THANK YOU