Technologies for Further Processing and Value Addition of Organic / Natural Pork

The organic pork market refers to the sector of the pork industry that focuses on the production and distribution of pork products derived from animals raised in accordance with organic farming practices. In this context, “organic” signifies the use of sustainable and environmentally friendly agricultural methods, including the prohibition of synthetic chemicals, antibiotics, and genetically modified organisms in the animal’s diet. The production process emphasizes animal welfare, pasture-based systems, and adherence to strict organic standards, ensuring a more natural and ethical approach to pork production. Consumers of organic pork often seek products that align with their values of sustainability, animal welfare, and environmental consciousness, driving the demand for these premium and responsibly produced pork products.

Opportunities in the organic pork market are multifaceted. Firstly, the rising consumer awareness and preference for organic, ethically sourced, and sustainably produced food contribute to the growing demand for organic pork products. Additionally, the increasing concerns about the environmental impact of conventional farming practices and the desire for healthier, chemical-free diets further propel the market’s expansion. The organic pork sector presents opportunities for farmers to diversify their operations, capitalize on premium pricing, and contribute to the overall sustainability of the pork industry. From a segmentation perspective, the organic pork market can be classified based on product types, distribution channels, and geographical regions. Understanding and strategically addressing these segments enable businesses to tailor their offerings to specific consumer preferences and regional market dynamics, enhancing their competitiveness in the burgeoning organic pork market.

Processing refers to any treatment which brings about substantial physical and chemical changes in the natural state of meat. In broadest sense this includes grinding, curing, smoking cooking, canning freezing, fermentation, dehydration, production of intermediate moisture products and use of certain additives such as seasoning, chemicals and enzymes etc. In processing, properties of fresh meat have been modified, however, the inherent property of “being meat” must remain intact even after processing. Meat technology is the practice of any or all of the applied science that have practical values or industrial use. It is the application of all scientific or modern knowledge for the production of meat in easier methods which include slaughter, processing, transportation, storage and marketing etc. in such a way that has some practical value over traditional way of production.

Prospects of processed pork products

We must aim at technologies and equipments to result in process efficiency for achieving lower production costs and higher yields, product diversification, byproducts utilization, improving shelf life, developing quality control and management systems and providing positive image to meat products. Product diversification is also necessary to minimize imports to the detriment of domestic industry. Small quantities of processed pork products are being produced which is meager in relation to enormous quantity of available pork at cheaper prices. Processing technology should also focus on global competitiveness, energy conservation and socio-ecological friendliness. Meat processing is carried out both in organized and unorganized sectors. Organized processing under the supervision of professionals can make sure that the right kind of product is delivered to the consumers with safety and at affordable price. Meat based fast food industries have great potential in this country. Multinational food companies have already started their business in India. As quantitative restrictions have been removed, the imported meat and meat products may be available in cities and major towns. Globalization promises a wealth of product choices and product value for the consumer. The demand for convenience meat based fast food is ever increasing due to rapid industrialization and urbanization, higher standards of living and increasing number of working women. Rising literacy and increasing health awareness also influence the purchasing pattern of the consumers. The shift in the food consumption pattern from cereals to dairy and meat products and such shift is more prominent is the growing middle class with high purchasing power.

Requirements for processing

For successful processing of meat following infrastructures are required.

1. Constant flow of healthy animals to feed the plant
2. Scientific transportation of live animals
3. Slaughter house with lairage and modern slaughter equipments
4. Modern processing equipments
5. Pork products to be developed with good recipe
6. Scientific packaging, cold storage and marketing facilities
7. By-products utilization facilities
8. Technical manpower

Basic methods of pork processing

Comminution: It is a process by which raw meat is subdivided or reduced into small pieces, chunks, chips or slices etc. Such particle size reduction helps in the uniform distribution of seasoning, enhance the tenderness of meat of old animals and reduces the fuel cost for cooking .Comminution is done with the help of meat mincer and bowl chopper is also used for making fine emulsion.   e.g. Sausage. Non-comminuted meat products are-ham, bacon, corned beef etc.

Emulsion: It is a process where two immiscible liquids are mixed together and one of which is dispersed in the form of small droplets or globules in the other liquid. Thus, emulsion has two phases- a continuous phase and a dispersed or discontinuous phase. These phases remain immiscible due to the existence of an interfacial tension between them. To stabilize the meat emulsion, emulsifying agents are used. Meat emulsion is an oil-in-water emulsion.

Blending/pre-blending: Blending refers to an additional mixing, i.e. mixing of certain chemicals or other products in comminuted meat prior to further processing .e.g.- curing, and seasoning .

Value addition

A variety of non-meat food items are incorporated into products which are commonly referred as extenders, binders and fillers. Purpose of their incorporation in meat products are many and a few are mentioned here viz. to improve emulsion stability, to improve water binding capacity, to enhance flavours, to reduce shrinkage during cooking, to improve slicing characteristics and to reduce formulation cost. Common examples for a) fillers – organically produced soy products, potato, starch; b) extenders – wheat, rice, pea, corn flours and c) binders – milk powers and dried whey.

Formulation of processed pork products

There are hundreds of processed pork products in the world. Some of the very common processed pork products are ham, bacon, salami, sausages, luncheon meat, pickles, patties, loaves, balls, nuggets, slices and pork snack products.

1. The first goal of formulation of the product should be such that it maintains uniform appearance, taste, composition, nutritive value, physical properties. The product should be acceptable to the consumers.
2. The second goal is that it must meet the quality standards.
3. The third goal is that the proportion of meat ingredients like meat, fat and by-products to non-meat ingredients like binders, extenders, fillers, spices salt etc. should be such that the products become stable and cost effective.

Common processing technologies for preparation of value added pork products

Drying: The purpose of drying is to reduce the availability of moisture. It also reduces the water activity of the food products and thus, hinders the growth and multiplication microbes. Rehydration is required before consumption. Used mainly for military purposes. It is not a usual method for preparation of value added pork products.

Salting and curing: High concentration of salt expel out the water by osmosis, thus, microbial growth is restricted. Another purpose is colour and flavour retention. Main disadvantage is that halophilic bacteria may grow. Salting and curing is a part of processing of some of the value added pork products. Unlike normal curing, processors ideally shall not use synthetic chemicals while processing organic processed pork products.

Smoking: Smokes contains formaldehyde, phenol, alcohol, cresol, aliphatic compounds, aldehyde and ketone which have bacteriostatic effect. Smoke is mainly effective against vegetative cells. It also coagulates the surface protein and blocks the entry of microorganisms. Liquid smoke is better. Certain carcinogenic and mutagenic substances like heterocyclic amines (HCA) and polycyclic aromatic hydrocarbon (PAHs). Smoking enhances the flavour and acceptability of the pork products.

Canning: It is a thermal processing method. Processed products are packed in hermitically sealed containers and then treated with heat (at least 121⁰C). Cans are then cooled and stored. Can meats are ready to eat products.

Enrobing: Coating of meat products with edible materials in the form of batter using flours, whole egg and other cereal products is done to produce enrobed meat products. Enrobing imparts the product a crispy texture, increases eating quality. E.g. Pork cutlets, pork patties and nuggets etc.

Restructuring: It is a process where pre cut or comminuted meat is moulded into a shape resembling to a natural streak or intact cut. It is a good method of upgrading value of low quality meat. The pre cut meat pieces are tumbled or massaged and because of this process, protein exudes from the meat surface and thereafter high pressure is exerted to give a restructured new product.

Heat processing (Cooking): Cooking must be done at an internal temperature of not below 65-70⁰C. There are few changes taken place during cooking. There is coagulation and denaturation of protein, connective tissue (Collagen) conversion into gelatine, increasing of tenderness, and development of brown colour and textural changes of meat tissue. Generally meat and meat products are cooked by three methods.

• Dry heat cooking:- Dry heat cooking involves either broiling, roasting or frying. This method is suitable for pork of low connective tissue like pork shoulder, loin cured ham etc.
• Moist heat cooking:- This method is recommended for relatively tough cuts with large amount of connective tissue. Pressure cooking, simmering, stewing and braising are the example of moist heat cooking
• Microwave cooking:-  It is a modern and rapid method. The heating results from the conversion of microwave energy to heat by friction from internal molecular rotation caused by the interaction of molecules with the rapidly fluctuating electromagnetic field. This method is many times faster than conventional method.

Categories of value added pork products

Value added products could be broadly classified based on processing, variety/ convenience and functions and are briefly discussed hereunder.

Comminuted pork products: Comminution is a process for meat particle size reduction and normally includes grinding, flaking, chopping, milling etc. Pork is well suited for comminuted meat products. The processing techniques for high quality pork patties, sausages, loaves, blocks, nuggets and rolls as well as restructured products are available. Incorporation of back fat in these products formulations could improve the juiciness and palatability of the finished products. Further, several low value by-products such as pork rind (skin), head meat, heart meat etc. could also incorporate into these products without much adverse effect on sensory attributes of the products. 

Restructured pork products: Restructuring is a processing technique used for developing convenience meat products with texture in between intact steaks and comminuted products. Some of the modern processing techniques viz. flaking and vacuum tumbling can be used to improve the product yield, binding, texture and sensory attributes of the products.

Enrobed pork products: Enrobing is a technique for coating the meat products with edible materials to improve their cooking yield and provide better protection against oxidative and microbiological deterioration.

Cured and smoked pork products: Curing is one of the oldest methods of preservation technique for pork and pork products and per se it is the addition of salt, sugar and nitrite/nitrate to meat for the purpose of preservation, flavour enhancement or colour development. In the applied concentrations most curing agents are bacteriostatic or fungistatic and more detrimental to gram negative organisms. There are different methods of curing viz. dry curing (ingredients will be rubbed on the meat), pickle curing (ingredients will be dissolved in water and applied either by immersion or injection methods), cold curing (at low temperature) and hot curing (at higher temperature to accelerate the penetration of curing ingredients). The entire curing process may be divided into four different stages viz. curing, salt equilibration/maturation, ageing and smoking. Curing and smoking contributes attractive colour, unique flavour along with shelf life extension of meat products, which makes them popular among consumers.

Shelf stable pork products: Production of thermally processed pork products either in cans or retort pouches with extended shelf life at room temperature promotes distribution and marketing. Simple technology was standardized for developing shelf stable pork sausages using hurdle technology.

Intermediate moisture pork products: Pork products with 15-50% moisture content with moderate juiciness and texture, inhibit growth of bacteria, moulds and yeast, water activity between 0.6 to 0.85, self stable at ambient temperature for a considerable length of time are known as intermediate moisture pork products. A mixture of sodium chloride, glycerin, lactic acid and antioxidants are used in the formulations.

Traditional pork products: Indigenous meat products are very popular because of their ease of preparation and unique sensory attributes, in particular flavour profiles. Considerable progress has been made in standardization of product profile and mechanization of traditional meat products. However, much has to be done to meet the increasing requirements of traditional food products particularly meat products. The demand for traditional meat products is bound to increase further in the coming years due to rapid urbanization and industrialization. The rich heritage of India contributes to wide range of traditional foods and has a role to play in health foods. Indigenous pork products are much popular in North-Eastern Region of India and are unique in their spicy flavour, simplicity and ease of preparation. With many processing methods and tools offered by contemporary food technology along with scientific packaging, the quality and shelf life of traditional pork products can be raised to world class standards. 

Small scale start-ups in organic/natural pork processing

Most small businesses start with an idea which, combined with an entrepreneurial spirit, can be turned into reality. Undertaking a feasibility study and preparing a business plan are the essential first steps for business success and are of vital importance to new enterprises and those considering expansion or diversification. Simply having a ‘good idea’ is not enough. A feasibility study asks questions and provides the information needed to write a business plan. The amount of detail required in the business plan will be related to the size and complexity of the planned business venture and the need for financial support from formal institutions such as banks. However, even a microenterprise, funded by family resources, will benefit greatly from writing a plan and highlighting areas that need investigation.

Steps to start a pork processing business

The following is a list of the basic steps to start a business in meat processing. While each business is unique and subject to specific product requirements, the list below outlines the overall process. The steps are grouped by topic. Keep in mind that each topic affects the others: your product type and packaging will affect your labels; the ingredients to make your product will affect your cost and production plans.

The Product:

1. Develop a prototype. Test it out on family and friends. Collect and incorporate feedback on flavor, texture, and appearance.
2. Determine the market form you would like the product to have: refrigerated, shelf-stable, frozen, smoked, cured, etc.
3. Determine the batch size you will need for commercial operation. A good start-up size for solid meat products will be 200-250 g/packet.
4. Consult an expert or Process Authority to scale up your recipe. Take the following into consideration:

• The formulation may change due to regulatory and food safety requirements.
• Testing (pH, water activity, etc.) may be required for compliance with regulations.
• It may take several attempts to achieve a scaled-up product comparable to the original; ingredient amounts will not change proportionately. 

1. Get approval for your recipe from a Process Authority i.e. Food Safety and Standards Authority of India (FSSAI). This resulting document, a Scheduled Process, will help to avoid product safety and quality issues.
2. Determine the cost of ingredients based on your approved, scaled-up recipe.

Business Planning:

1. Write a Business Plan. It will help you focus your business goals and determine if you need funding.
2. Consider liability insurance. It is affordable and can protect personal assets in the event of a problem with your product.
3. Determine a form for your business: sole proprietorship, corporation, partnership, limited liability etc.
4. Register your business with the Central and State authorities, as applicable. Fill out and submit the required forms to licensing/ registering authorities.
5. Get assistance from business resources: state agricultural departments, state extension organizations, NABARD, local economic development agencies etc.

Labels:

1. Decide on a product name.
2. Determine applicable regulatory requirements. Ask your state regulatory officials for help or contact FSSAI. Consult the FSSAI Food Labeling Guide.
3. Determine what storage information must be on your package: refrigerate, refrigerate after opening, etc.
4. Choose a size and shape, which is compatible with your packaging.
5. Invest as much in your label as possible. They are the first thing customers will see.
6. Make test labels, or labels for small, initial, batches, on a computer printer to cut costs.
7. Decide if you wish to make health or nutrient claims. If you do, you must have nutritional analysis done and invest the time and money for FSSAI compliant nutrition labeling.
8. Decide whether or not to invest in a bar code. The yearly fee is based on the number of products and gross sales, but most large stores and chains will not consider your product without one. If you do not plan to sell to large distributors, you don’t need one.

Market Decisions:

1. Write a Marketing Plan. It is a framework for research on competition, ceiling prices, target markets, etc. and structures your marketing goals and methods.
2. Decide where you will sell your product. Generally, start off small – at farmers markets, fairs, roadside stands, etc. These are also good places to test market your product.
3. Determine a selling price for your product, taking the competition and your financial needs into account.
4. Develop a distribution method: your car, the mail, a fellow specialty food entrepreneur or distributor.

Production:

1. Decide where you will produce your product: commercial kitchen, pilot plant, or co-packer.
2. Obtain all necessary permits and approvals, both Central and State, required for food manufacturing.
3. Find storage space for ingredients, packaging, and the final product.
4. Schedule time with experts at the production facility to learn about equipment.
5. Determine when, based on ordering supplies, you can produce and package product.
6. Schedule time at a processing facility to produce your product.

Pros and cons of starting a pork processing business

The meat processing business can be rewarding and exciting. It can also be a real struggle. Listed below are some pros and cons of starting and running your own meat processing business. The list is intended to provide a realistic picture of meat product processing. Keep in mind that several of the items listed are qualitative, that is, their importance depends largely on how strongly you feel about them.

Advantages:

• Being your own boss
• Creating your own work environment: hours, flexibility, etc.
• Doing something in which you believe
• Reaping the benefits of hard work and long hours directly
• Variety, challenges, and opportunities for creativity, full use of knowledge
• More open earning and growth potential
• Satisfaction of a successful venture, a product well received
• Empowerment

Disadvantages:

• Risk of failure
• Time Commitment – 60-70 hrs per week is normal
• Financial strain as assets become tied to business start up and success
• Strain on family due to financial and lifestyle change
• Emotional burnout
• Unavoidable business roles/requirements you’d rather not fill
• Rejection of your product by consumers

Should you decide to pursue a meat processing business venture, there are a number of things you can do to minimize risk and maximize your chance of success:

• Develop a Business Plan
• Regularly review your business plan to remind yourself of goals and maintain focus
• Develop a marketing plan
• Learn and follow food regulations and requirements
• Maintain accurate, current records
• Analyze your financial status on a regular basis and make necessary adjustments
• Learn to recognize and solve problems promptly
• Draw a line between your personal life and your business life and stick to it.

Marketing considerations for small-scale pork processors

Small-scale meat processors face unique challenges and opportunities when marketing their products. If the venture is to be successful, the processor must decide what market the product will thrive in, what the competition is, and how to market the product given the processor’s available resources. A marketing plan facilitates business success by requiring the processor to address each of these marketing issues through marketing goals and strategies. The research necessary for marketing plan development also prevents entry into an unprofitable business venture.

The marketing goals should meet the following “SMART” criteria:

1. Specific – for example, earn 10,00,000 in net sales
2. Measurable – target date for completion
3. Attainable – not so high that you cannot reach them
4. Rewarding – they reflect the reasons you started the business in the first place
5. Timeline – they should include short term and long term goals

Once goals have been defined, the entrepreneur must research the existing market place and competition (market & competitive analysis). In addition, the entrepreneur must test market the product and evaluate the results. This test will indicate how and if the marketing goals can be reached, given the entrepreneur’s available resources. Analysis of test marketing also provides a basis for a marketing strategy for the product. As part of the market strategy, the meat processor must pursue venues for product introduction to the market place. One of the most cost-effective methods is through direct marketing at local farm stands, farmers markets, and festivals. The product’s reception at these outlets is a good indication of how the product will be received in the larger market place. An added benefit comes from meeting customers face-to-face, providing an opportunity to determine customer preferences and get a sense of the reasons people buy a product. This information can give entrepreneurs new marketing ideas or revise existing ones. Even the most established producers try out new ideas and products at local markets. This is a good time to study the competition, identify trends in local and regional specialty food items, market size, and pricing. Further information on product availability and pricing can be found on the web (on-line) by searching for the product type in your favorite search engine.

            The marketing strategy for a product must be re-evaluated and revised whenever changes in the business, the market, or the product occur. For example, as the business expands, the entrepreneur may decide to hire a co-packer to handle the manufacturing. The entrepreneur may also decide to hand over product distribution to a distributor. This distributor sells to retailers and other distributors, developing new markets for the product. The above changes in the business will affect product price, the product’s position in the market, and the amount of profit the entrepreneur receives from each unit sold. Since the product’s market attributes have changed, a new market strategy is necessary. As the business grows, you will need to research national markets for wider distribution. Attending trade shows for specialty foods will broaden your view of the specialty food business and market in such areas as the gift trade, health food stores, ethnic foods, and the export market. As you expand your marketing views, your marketing plan must expand to include them.