1. Foreword:
Duck meat is rich in nutrients, and the edible protein content of duck meat is about 16%-25%, which is much higher than that of livestock meat. Duck protein is mainly sarcoplasmic and myosin. The other part is the interstitial protein, which contains water-soluble collagen and elastin, in addition to a small amount of gelatin, and the rest is non-protein nitrogen. The fat content in duck meat is moderate, about 7.5%, lower than pork, and is evenly distributed throughout the body. Fatty acids are mainly unsaturated fatty acids and low carbon saturated fatty acids, so the melting point is low, about 33 °C -40 °C, digestion and absorption rate is relatively high. Duck meat is more meat containing B vitamins and vitamin E. 100g edible duck meat contains B vitamins about 10mg, of which 6-8mg is niacin, followed by riboflavin and thiamine; vitamin E90-400μg. Niacin, a component of two important coenzymes in the human body, plays a role in cellular respiration. Duck also contains about 0.8% - 1.5% of inorganics. Different from meat, the potassium content of duck meat is the highest, and 100g edible portion reaches nearly 300mg. In addition, it also contains high iron, copper, zinc and other measuring elements.
2. Ingredients: Fresh, skinless duck breast without any foreign body or blood.
3. Excipients: salt, sugar, monosodium glutamate, sodium nitrite, isoVc-Na, complex phosphate, ethyl maltol, white pepper, pigment, carrageenan (injection), soy protein isolate, starch, potassium sorbate, essence.
4. Basic product formula: duck breast (peeled) 100kg, salt 3kg, sugar 2kg, monosodium glutamate 1kg, complex phosphate 0.5kg, isoVc-Na 0.1kg, sodium nitrite 0.01kg, soy protein isolate 2kg, Cara Plastic 0.4kg, Temptation Red 0.003kg, Ice Water 50kg, Starch 6kg, Potassium Sorbate 0.01kg, White Pepper 0.2kg, Ethyl Maltol 0.1kg, Tianbo Pork Essence 210270.2kg, Tianbo Duck meat flavor DC-40.2kg, Tianbo pork flavor 210110.1kg.
5. Processing technology:
5.1. Selection of Raw Meat: The peeled duck breast that has passed the inspection is naturally thawed to the center temperature of -2°C on the stainless steel plate in the thawing room. Each piece of duck breast is required to be 100-150g.
5.2. Injection preparation:
Formula: (based on 100kg duck meat, injection volume 50%) salt 3kg, sugar 2kg, monosodium glutamate 1kg, complex phosphate 0.5kg, isoVc-Na 0.1kg, sodium nitrite 0.01kg, soy protein isolate 2kg, Carrageenan 0.4 kg, temptation red 0.003 kg, ice water 50 kg, starch 6 kg, potassium sorbate 0.01 kg.
Preparation method: The saline should be prepared 24 hours before the injection. Phosphate should be dissolved in a small amount of hot water first, then add water and salt to make it into salt water. Then add white sugar and MSG to the salt water. Stir well and put in 4 Stored in a refrigerator at °C for 1 hour before use. Add isoVc-Na, sodium nitrite, soy protein isolate, carrageenan, starch, and temptation red 1 hour before use. Stir thoroughly and filter before use.
Injection: According to the above proportion, the prepared pickling solution is injected into a saline injection machine to inject and tenderize the meat to accelerate the penetration and diffusion of salt water in the meat, so that the hair color is even, the pickling time is shortened, and the water retention is increased. The total amount of salt water is 60% of the meat weight, and the injection volume is about 50%.
5.3. Pickling: This process adopts dynamic and static pickling method. The injected raw meat is then added into 10% salt water and poured into a tumbler. The degree of vacuum is -0.08--0.06 MPa and rolled at 4°C. Knead for 12 hours, run for 30 minutes, and pause for 30 minutes.
5.4. Dicing: Cut the kneaded meat pieces into pieces of uniform size of about 50 grams.
5.5. Tumble again: Pour the cut pieces of meat together with pepper, ethyl maltol, and flavor into a tumbling machine and knead for 2 hours. The process is the same as the previous tumbling.
5.6. Filling: Use a vacuum hydraulic casing with a water-permeable and breathable compound casing, filling the length of 15-20cm, weight 300-400g/root. Manual or automatic punching.
5.7. Baking: Baking with a low temperature of 45°C-50°C for 30 minutes first, the purpose is to make the ham evenly colored, and at the same time form a protective layer on the ham surface to prevent moisture loss during cooking.
5.8. Cooking: Cook for 60-90 minutes at 83°C-87°C. The center temperature can reach above 72°C.
5.9. Drying, smoking: Drying at 80°C-85°C for 5 minutes, the purpose is to dry the surface moisture; then smoke for 30 minutes to make the ham bright and give the product a special smoky flavor.
5.10. Cooling: Using air-cooling, turn on the fan for about 20 minutes, until the product center temperature is lower than 10°C, and then pack it into a cold store and refrigerate it.
6. Testing standards:
6.1. Microbiological standards: According to the standard of the Ministry of Health for Western-style ham and smoked ham, the standard of hygiene at the time of delivery is the total number of bacteria <1.0104/g and coliform bacteria <40/100 g. Duck meat ham produced according to the above formula and process was kept at 0°C-4°C for 3 months. The total number of bacteria was lower than the national standard, and E. coli was not detected.
6.2. Sensory index: ham surface is bright, was jujube brown, with a pleasant smoky flavor; good slicing, meat, meat, tight, soft, flexible; roast duck flavor rich.
7. product analysis:
Tianbo duck flavor DC-5 is roast duck flavored meat powder, giving the product a Beijing roast duck flavor; pork flavor 21027 is rich in flavor and has a good concealing effect on the smell of duck meat; pork flavor 21011 has a good smoky flavor. 21027 synergy can increase the flavor of the product while reducing smoke time.
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