Technology: Cooked ham production
A flawless result depends on several factors regarding meat selection and the right technology.1. Meat selection
The first criterion on the list is pH value. A pH value of 5.8 - 6.2 on cooked cured products represents a compromise for the required water retention, curing readiness and shelf life and thus provides each of the following: - good slice consistency
- optimum colour stability
- even colour formation
- good shelf life
2. Brine
The production target must be known before the right additive can be chosen. Depending on the type of end product, it is essential to decide whether to just use reddening agents or to use combis that provide extra binding and flavour.Definition of injection quantity
100 kg meat + 40 kg brine --> 40% injection quantity
Definition of brine (example)
| WIBERG Combi | 5.0 | kg | |
| + | NCS |
6.3 |
kg |
| + | Water |
78.7 |
kg |
| + | Ice |
10.0 |
kg |
| = | Brine |
100.0 |
kg |
Salt content
The salt content of the end product should be about 1.8 - 2.2 % for a mild cooked ham. Depending on how a product is treated and whether or not it experiences a cooking loss, the salt level in the brine will differ according to the end product. Recommended salt quantity with different injection quantities:
| Injection quantity in % |
kg salt in 100 kg brine |
equals salt content of meat + brine (%) |
equals salt content of meat (%) |
|---|---|---|---|
| 20 | 11.0 |
1.83 | 2.20 |
| 30 | 7.8 |
1.80 | 2.34 |
| 40 |
6.3 |
1.80 | 2.52 |
| 50 |
5.1 |
1.70 | 2.55 |
| 60 |
4.5 |
1.69 | 2.70 |
| 70 |
4.1 |
1.69 | 2.87 |
| 80 |
3.8 |
1.69 | 3.04 |
| 100 | 3.3 | 1.65 | 3.30 |
Guideline for injection agents
WIBERG additives are added to the brine in accordance to instructions for use. The following principle applies: Pour liquid additives into the finished salt brine and stir briefly.
Dissolve powdered products in cold water. Then add nitrite curing salt and allow this to dissolve too. Finally, add a certain amount of ice to regulate the end temperature of the brine, and allow it to melt.
Added proteins, thickeners, starches etc. have to be disolved/dispersed well.
End temperature of the brine
The end temperature of the brine is adjusted by adding ice at the end of the brine preparation. The amount of ice to be added must be calculated based on the whole brine quantity and depends on the water temperature. The ideal end temperature of the brine is around 0 °C. Normally, the ice will need to account for about 5 - 15 % of the brine quantity in order to reach the required end temperature. 3. Tumbling
Blended cooked ham:Depending on amount, the brine should be added in 2 - 3 steps. So the meat is longer processed and an optimal water binding can be achieved. If the ingredients are added dry in the tumbler a good distribution and dissolving have to be guaranteed. Vacuum will benefit the colour development and the reduction of air pockets.
Injected cooked ham:
Tumbling should start immediately after the brine injection in order to activate the protein and let the injected additives develop. An overall treatment time under vacuum (approx. 0.6 bar) of 8 - 16 hours is ideal; the tumbling time and rest period differ according to method and machine type. To achieve the best result, tumbling must take place at cold storage chamber temperature (approx. + 2 °C) or in a cooling tumbler.
4. Stuffing and filling
Spread ham forms with WIBERG inlay foil. These provide a smooth ham surface and facilitate unhinging from the form. To minimize the number of air pockets and holes in the cutting surface, the air can be extracted by a vacuum machine before the cover is sealed. When filling casings or foil bags using a filling machine or filling hopper are used, it is important to ensure that the correct casing is choosen. When the cover is peeled off the end product, the surface must not sustain any damage.5. Heating and cooling
Scalding is an important factor to a first-class end product. Depending on the actual product, cooking in stages is the best way to achieve optimum yield and colour formation for ham heated in a certain form. The heating process is divided into different steps. The greater the diameter of the ham, the longer the individual steps.Cook: approx. 1 - 2 hours* at 65 °C
further 1 - 2 hours* at 70 °C
remaining time at 76 - 80 °C, up to core temperature 68 - 72 °C (depending on purpose)
*depending on form size
When smoked cooked cured products are packed in casing, smoke-permeable foil, mesh, or similar, the temperature is raised gradually. Reddening and drying should start at approx. 60 °C and is then raised during the different smoking and drying stages. Roasting and cooking, in turn, should occur at a temperature of max. 76 - 80 °C up to the required core temperature.
Depending on the product/casing composition, the heated ham must either be cooled in a water bath or showered. Cool for at least 12 - 24 hours before removing at 2 - 4 °C.
6. Smoking
Take the cooled-off ham out of the forms, lay it on a grill and rinse it in lukewarm water. Then dry it well in the appropriate facility at about 45 °C and, finaly, smoke at approx. 45 °C until it reaches the right colour. The surface must be evenly dried prior to smoking, to be able to achieve an even smoked colour. Let the ham cool down fully before packing it.INFO: All specified times and temperatures are approximate values only. The exact values must be adjusted to suit the functions of the relevant machinery, the active agents added and the filling quantity.
