Identifying Critical Control Points Key to Proper Bacon Processing
The following are some guidelines finalized several years ago by a bacon processing task force as a guide to control critical points in bacon processing.
Since meeting the requirements of 120 ppm (parts per million) of nitrite and 550 ppm of ascorbate is judged on the basis of the percent pump retained after a drain time that is specified, percent pump and drain time is the first step in critical control point processing procedures for pumped bellies. This may be any period of time up to 30 minutes after the pump.
In deciding the number of gallons of pickle to make at one time, processors must consider their equipment; size of holding tank; usage per hour, per shift or per day; and their ability to weigh and measure.
As the brine warms, agitates, ages, and goes through the pumping machine, the effective amounts of nitrite and ascorbate are reduced-sometimes drastically.
Recommendations include trying to formulate batches of pickle that are as small as possible yet give economy of operation; not recirculating pickle back to the mixing tanks; not saving pickle overnight (as a general rule); and using standardized quantities to simplify procedures.
In calculating the pickle formula, the 120 ppm of nitrite and 550 ppm of ascorbate is obtained by a combination of correct amounts of nitrite and ascorbate in the pickle with a designated percent pump. Here are some guidelines:
-- The percent of nitrite needed in the bacon is .12 percent.
-- The percent of ascorbate needed in the bacon is .055 percent.
-- Decide on the percent salt wanted in the bacon.
-- Decide on the percent sugar wanted in the bacon.
-- Decide on the percent phosphate wanted in the bacon.
-- Decide on the percent of any other flavorings wanted in the bacon.
-- Figure the amounts needed by weight of other ingredients (3 to 6) in the pickle that will equal the percentages wanted for each in the bacon.
-- Add all of the previously mentioned amounts, subtract from the total number of pounds of pickle to be made, and that amount is the amount of water to use.
Weigh each ingredient
In preparing the pickle, carefully weigh each ingredient and completely dissolve them in water.
The water should be as cold as possible (if using ice, be sure to account for its weight); dissolve ingredients in proper sequence; don't over-agitate; avoid air agitation; excess agitation (especially air and steam) dissipates ascorbate and nitrite; and if whole cartons or bags of an ingredient are used, check the stated net weight.
While sorting bellies, evenness of pump depends to a large extent on uniformity of the bellies in addition to pump setting.
The belly temperature also affects pump retention. Bellies graded for uniform thickness will improve controls and benefit further processing.
There are indications that uniformity of weight and ratio of fat to lean also affect uniformity of pump.
Bellies should never be below 40 F, and those pumped at any one time should not vary more than 4 degrees. Frozen bellies should be removed from the freezer and tempered to the desired temperature prior to pumping. Never thaw frozen bellies in hot water exceeding 100 F.
Set pump, pump bellies
To set pump and pump bellies, adjust the pump settings; start the pumps; allow pumping machines to run for a few minutes prior to running bellies; pump bellies; drain for stipulated time (up to 30 minutes according to a company's approved procedure); check to determine if desired pump is attained; re-check pump regularly (at least every 30 minutes); and adjust as necessary.
Pumping must be capable of producing bellies within 20 percent of targeted pump. If more than one pump is utilized, they must each be checked to see that the pump is uniform. If the bellies' skin is pumped, reduce pump by 10 percent of target for skinned bellies since skin retains practically no pickle and approximates 10 percent of the belly weight.
In lot identification, mark each shift's production, and carry it through to the smokehouse, chiller, slicer and packager.
Processors are urged to smoke at time, temperature and humidity specified in their processes. Maintain day-to-day uniformity, and weigh bellies into and out of the smokehouse. Maintain time and temperature records for each batch.
The cooler shrink should be controlled so that end products are as alike as possible, and processors should attempt to maintain the same yields.
Ceiling fans should be provided for the air velocity needed to promote uniform chilling.
In slicing and packaging, use cards to identify the steps of production. Be sure to carry identification through to packaging.