REPORT ON THE PRESENCE OF GRANULES AND/OR WHITE CRYSTALS IN VACUUM-PACKED AGED PRODUCTS


Description of the Problem:    samples of prosciutto crudo were deboned and packed. The packages, or bricks, were then vacuum-stored at a refrigeration temperature of 0-4 °C for 60 days. When, after 60 days, they were opened, the product was found to be "grainy" and "sandy" upon tasting and when chewing.
Source of the Defect

the presence of flecks, granules, grains and/or white crystals in vacuum-packed products may be due to phosphate or salt crystals…

REPORT ON THE PRESENCE OF DARK SPOTS IN THE INTERNAL MUSCLE FRACTION OF AGED PRODUCTS


Description of the Problem:    black spots were discovered in the internal muscle mass of aged prosciutto crudo hams, especially those of foreign origin, located alongside the intramuscular and intermuscular fat layers. This defect is characterised by the presence of visible dark spots on the muscle tissue, as early as the end of the resting stage, and noticeable upon opening (e.g. deboning and/or slicing). In products exhibiting this defect, the highest incidence of spots is found in the semitendinosus muscle. They appear less frequently in the semimembranosus muscle and the biceps femoris. It often appears in conjunction with white crystals and a high level of marbling (intramuscular fat) in the muscle.

Source of the defect

1. There is no documented information on the cause of this defect. The hypothesis of a microbiological origin is generally ruled out in favour of one of raw material predisposition (genetic and/or related to breeding) or handling methods during slaughtering/butchering. The effect of the processing itself seems to be less relevant to the incidence of this defect. These are thus haemorrhagic phenomena. Based on genetic analysis, we can reasonably hypothesise that the increased presence of this defect can be traced back to the increase in the number of hybrids available on the market and the use of different breeds for the purpose of crossbreeding (Moro, S. et al., Italian Journal of Animal Science, 2011). 

2. As far as the microbiological hypothesis is concerned, these sorts of spots could be caused by the proliferation of different types of bacteria due to casual contamination (Cantoni et al. 2000, 2001, 2008; Andrade et al. 2012; Eeckaut et al. 2012)… 

SUBSTITUTING NITRATES AND NITRITES THROUGH THE ADDITION OF OTHER CHLORIDE SALTS IN DRY CURED-HAM AND "TRADIZIONE ASSISI" HAM


Why reduce or eliminate nitrates and nitrites:    The World Health Organization (WHO) has stated that pancetta, sausages and processed meats and red meats can cause cancer. 

Processed meat products are made even more harmful to human health as a result of the industrial processes used to produce and preserve cured meats, from salting to the addition of potentially carcinogenic chemical preservatives. 

Products with a long ageing process (> 9 months), such as prosciutto crudo and speck, are made using a natural production process, involving a proper application of salt and the use of controlled temperature and humidity levels in the plants where they are processed. This makes it possible to obtain microbiologically stable products which meet the proper chemical, physical and organoleptic standards without the addition of preservatives. 

When dealing with dry-cured products with a short-to-medium ageing period (4-6 months), such as Sgambato "Tradizione Assisi" hams, Coppa Piacentina, Culatello and other aged products of small size, nitrates and nitrites are used largely to give the product the bright red colour of aged meat and, most importantly, to render it more stable over time, in order to prevent oxidation. As a matter of fact, nitrate, and especially the active form, nitrite, in addition to acting as an antimicrobial against the growth of bacteria that cause spoilage, as well as preventing the growth of the anaerobic bacterium Clostridium botulinum and its toxin production (Sebranek & Bacus, 2007), play other roles in the technology of aged products. These include the impact they have on the products' red colour and the formation of flavour (Flores & Bermell, 1996; Marco, Navarro, & Flores 2008; Noel, Briand, & Dumont, 1990; Olesen, Meyer, & Stahnke, 2004). In addition, they contribute to the oxidative stability of lipids (Stahnke, 1995). 

An aspect that is not positive is the formation of nitrous compounds, created by nitrites reacting with other compounds, for instance the formation of carcinogenic N-nitrosamines, caused by the nitrites reacting with biogenic amines (Corpet, 2011)... 

"SALT REDUCTION" PARMA DRY-CURED HAM AND ENVIRONMENTALLY SUSTAINABLE PLANTS FOR SAFER PRODUCTS


Reasons for reducing the salt in hams and other meat products: Salt and Health    Salt is a compound normally found in nature. All foods, including vegetables, meat, fish, milk, grains and fruit, contain salt in varying quantities (http://www.valori-alimenti.com/cerca/sodio.php). In addition to being naturally present in the raw material, the use of salt is a part of every culinary tradition, and it is also widely used in the food industry as an ingredient to enhance the flavour of foods and give them a longer shelf life. According to the INRAN (the Italian National Institute for Research on Food and Nutrition), 10% of the salt we consume is naturally present in the food and beverages we eat and drink, 36% is added during meal preparation at home, and a full 54% comes from processed food products (both traditionally hand-processed and industrially processed) and from dishes prepared in restaurants (http://www.inran.it) (Figure 1). The American Heart Association (http://www.heart.org) has put together a list of products with a critically high sodium content: pre-packaged sliced bread, cold cuts and cured meats, pizza, chicken and soups (Figure 2).  

Due to the natural presence of sodium in the raw material, but chiefly because salt is added to food as an ingredient to improve flavour and prolong shelf life, our diets are too rich in sodium. According to a number of studies, excessive salt consumption is responsible for arterial hypertension and cardiovascular problems (Gibbs et al., 2000; Sofos et al., 1994; Rohrmann et al., 2013). In order to try and prevent diseases associated with excessive sodium consumption from occurring, the World Health Organization (WHO) has conducted extensive research, which has led to the establishment of a recommended daily per capita salt intake of less than 5 grams (the equivalent of 1 teaspoon), which is equal to 2 grams of sodium (sodium = salt/2.54) (WHO, 2007). In Italy, the daily salt intake per capita is approximately 10-15 grams, in other words, 2 to 3 times higher than the amount recommended by the WHO. The goal is to reduce dietary salt intake by reducing the salt content in foods, while maintaining the variety and quantity of food consumed constant and unvarying. 

    Considering the fact that 100 grams of ham contain 4-6 grams of salt, the equivalent of the recommended daily intake, it is therefore necessary to reduce the amount of salt in this product, in order to make it healthier. However, reaching this goal involves difficulties associated with the essential role that salt plays (as a preservative and adjuvant, and in the formation of organoleptic properties)
In the case of prosciutto crudo ( dry-cured ham), salt plays an essential role in its preservation. Reducing the amount used can lead to problems that would prevent the product's successful production. Moreover, it should be pointed out that, for many types of P.D.O. prosciutto, whose production does not permit the use of nitrates, salt is the only preservative agent. For these reasons it is necessary to study every stage of the production process, review the critical steps and develop suitable modifications to introduce to the processing technology used, in order to obtain a food product with a low sodium content which is biologically stable and whose qualitative features are equal to those of traditionally produced prosciutto... 

REPORT ON THE PRESENCE OF A BITTER TASTE IN DRY-CURED HAM


Description of the Problem:   Types of ham in the prosciutto sgambato family, like speck, had developed a "bitter taste" after 4 months, evident both in the more external muscles (semimembranosus) and in the internal muscle mass (biceps femoris).

Probable source of the defect and possible solutions…

REPORT ON RECEIVING FRESH HAMS (P.D.O. RAW MATERIALS) IN PRODUCTION



Prosciutto is a highly complex product due to the high heterogeneity of its muscular structure.Producers must consider ways in which to promote homogeneity in the properties of prosciutto crudo, and a key factor is to reduce, as much as possible, the number of variablesin play, in addition to those inherent in the product, beginning with weight class.
The first variable is the quality of the hams (thighs) themselves… 

THE SALTING STAGE AND THE CONCENTRATION OF SALT ABSORBED


 At the end of the salting process, the prosciutto crudo has absorbed approximately 60-65% of the salt which has been added to it. 

If we consider a percentage of added salt of approximately 5.5%, applied to a prosciutto crudo ham that weighs about 10 kg: % of salt absorbed = (358/10000) x 100 = 3.58%

The salt concentration in the muscle, which is the "lean" portion of the meat, depends on the amount of salt added and on how much lean there is in the ham. Hams with a particularly large quantity of fleshy portions will have received larger amounts of salt. 

According to a study conducted in Italy on the "Influence of salting procedures on the distribution of salt and water in prosciutto crudo" (Fausto Palmia, Fausto Becchi et al., SSICA – Ferrarini S.p.A.) and one conducted in Spain on the Influence of pre-salting treatments on salt absorption (N. Garcia-Gil, J. Arnau et al., 2012)… 

THE RESTING AND "RECOVERY STAGES"


 Following the salting and the pre-restingstages, the product has already undergone a weight loss of about 10% (4% during the former stage and + 6% during the latter). During the resting stage, the hams are hung in rooms with forced ventilation, where the temperature is maintained at 1-5° C and the relative humidity (RH%) is kept between 70 and 80%. Already during the pre-resting stage and the first week of the resting period, (30 days approximately) the salt absorbed during salting is distributed from the outside to the inside of the ham, thus already beginning to achieve a uniform concentration throughout the ham's entire thickness. 

During the resting stage it is very important to monitor the moisture exchange from the ham to the surrounding environment, because if it occurs to quickly, a crust may form which would prevent the normal ageing process from occurring as it should... 

THE PRODUCTION PROCESS OF "COPPA ARGENTINA"


Introduction:    In Italy it is not permitted to use brine when processing this type of product, while the brine used in the production of "Coppa Argentina" is similar to the kind used to make "Iberian dry-cured loin" or "Coppa Serrana" (Cabecera de Lomo). 

In particular, the production of Coppa Serrana calls, in addition to salt, for garlic, peperoncino (red pepper) and oregano; or otherwise, for pimentón (Spanish paprika) (whole cured Coppa Serrana Paprika Majoral)
After a maximum of 48 hours in refrigeration at a temperature of 4 °C (P. Hernandez et al., Meat Science 51, 1999), the external layers of fat covering the loins are trimmed away. 

The loins are then immersed in a brine (pickling sauce) containing…

PRESENCE OF NITRATE AND NITRITE IN "MATTONELLA" STYLE DRY-CURED PROSCIUTTO CRUDO HAM – AGED 9/10 MONTHS


Description of the Problem:    Nitrate in the amount of 18 mg/kg was discovered in the internal muscle mass (biceps femoris) of "mattonella" style dry-cured prosciutto crudo after 280 days of ageing. 


Taking into consideration the following analysis results: 

Nitrate (expressed as sodium nitrate) = 18 ppm 

Therefore: 

ppm di NO3- = 18/1,37a = 13,14 ppm 
ppm di Na = 18/3,7b = 4,86 ppm 

a) molecular weight of sodium nitrate/molecular weight of a nitrate ion = 84.99/62 = 1.37 (conversion factor); 

b) molecular weight of sodium nitrate/atomic weight of sodium = 84.99/22.989 = 3.7 (conversion factor); Nitrite (expressed as sodium nitrite) = 6 ppmc 

c) LOQ = 6 ppm (limit of quantification). 


These analysis results show very low residual amounts of Nitrate (and non-quantifiable amounts of Nitrite), making it difficult to establish with any certainty whether nitrates or nitrites were added to the product being analysed during its processing. 

With the addition of Potassium Nitrate (E 252) at the beginning of processing, in the amount of approximately 150 ppm, it is possible, upon conclusion of the ageing process, to find in the biceps femoris...

REPORT ON THE PRODUCTION OF SMALL- TO MEDIUM-GRAIN SALAMI WHICH WAS FOUND TO BE UNACCEPTABLE



Description of the Problem:    production of small- to medium-grain salami which was found to be unacceptable. The salami was found to be lacking in firmness, with a texture that did not "meet the required standard"; therefore, problems related to insufficient hardness and difficulty when attempting to chew or slice it.    The Flavour was not acceptable, as a result of multiple factors….