The situation before ActiMeat

David, Manufacturing Manager

of a leading brand
I have to deal with the same comment regularly – «Where is the meat in the Bolognese sauce»?  I see that when I put the ingredients into a pot the pieces of meat break up, even though they make up 18% of the recipe. I am prepared to pay a little bit more if the result is convincing. 
Do you have a solution.
The manufacturer uses any form of beef meat supplies, in 25kg (3.94 stone) blocks, consisting just of muscle. Following defrosting, it minces the meat into pieces with a diameter of 8mm (0.31 inches) and then puts the ingredient into a pot in which vertical mixing using a scraper takes place in a mix of oil and flavourings before tomato sauce is added. Once the mix reaches the right temperature, the pot filling and sterilisation operations begin.
 ActiMeat was consulted regarding a sauce range as regards their national brand recipe,with a view to supplying the manufacturer with 900 tonnes.
actimeat‘s solution

Resistance of
the pieces

ActiMeat studied the principles
of extrusion, of compression and
of density of the meat in order to
resolve this problem.

The know-how developed by us
resides in a twin grinding process
which ensures that hard substances
in the meat are turned into smaller
pieces and then controlled
compression which forms the pellets
of meat. Thus, we obtain raw minced
beef meat with a density within the
bracket determined in conjunction
with the client.

of the meat

In order to increase the standard
of quality as perceived by the end
consumer, we supplemented the
shaping process by cooking and
cooling the meat pellets.

Our process enables us to roast
the meat and it means that the
cooking juice will be reabsorbed
during quick cooling prior to IQF
freezing. Thus the protein which
was modified ensures maintenance
of the structure of the pellets of
cooked minced meat.

Measurements & Checks
during the process

All of our deliveries undergo
the most stringent of tests and
our client has strengthened its
position as leader in the market.

A predictive resistance test has
been developed to simulate, in
an acid environment, the mixing
which takes place as part of the
industrial manufacturing and
sterilisation process. The test entails
the observation and calculation of
the percentage of pieces visible,
guaranteeing the sales promise.