H2020 SLICEWATCH Project: Monitoring meat texture to optimize cutting performance and reduce meat waste on high-speed cutting lines
- Type Project
- Status Filled
- Execution 2016 -2018
- Assigned Budget 1.212.372,88 €
- Scope Europeo
- Main source of financing H2020
- Project website SLICEWATCH
As part of the SliceWatch project, we have developed an industrial solution for noninvasive, piece-by-piece meat texture assessment. The developed scanner checks the electrical properties of meat at different frequencies. Since the texture and tissue characteristics of meat affect the flow of electrical current, the obtained electrical parameters can be used to assess meat texture and detect PSE meat. A key advantage of the SliceWatch solution is that it uses electromagnetic waves to assess meat properties, rather than contact probes. This offers several advantages in terms of robustness, sensitivity, and speed of analysis, while also avoiding the risk of cross-contamination between pieces.
To optimize the performance of the SliceWatch solution, several measures were taken. First, we optimized the scanner's measurement system and worked to maximize sensitivity and operating speed. Based on this design, we manufactured two demonstrators that were tested in two production plants (cured ham and cooked ham). In parallel, we thoroughly investigated the relationship between meat texture and its electrical properties and developed mathematical models to predict it. The developed models proved to be extremely accurate in discriminating meat with poor texture (PSE meat).
In the final phase of the project, the demonstrators were extensively tested in meat processing plants. The tests demonstrated that the SliceWatch solution can be used to effectively detect PSE meat.
The SliceWatch solution was presented under the "Ham-Inspector" brand at the "FOODTECH" International Trade Fair (Barcelona, 2019). This technology has allowed us to expand our range of meat inspection products and offer customers a complete set of tools for evaluating the most important quality parameters (weight, fat content, salt content, and texture).
Regarding the communication of project results, various actions have been carried out, including the presentation of a poster at the World Cured Ham Congress (Toledo, 2017) and participation in various sectoral meetings and technical workshops. In addition, a project website has been developed and is available at www.slicewatch.eu.
The meat industry is a significant sector, with an annual turnover of $360 billion worldwide, including €160.6 billion in the EU-28, and is projected to grow at an annual rate of 14% over the coming years. This positive outlook is associated with the growing demand for processed, ready-to-eat sliced meat products, especially in small packages, which help prevent spoilage and are more convenient for the consumer. In line with this trend, the production of sliced meat products has increased steadily in recent years, and meat companies have made significant investments in the installation of slicing rooms. For example, in Spain, sliced meat products already represent 80% of the total market value of meat products sold in supermarkets and hypermarkets.
Slicing costs are considerable, representing approximately 37% of the final product cost. A significant portion of this cost is associated with meat waste during slicing, which depends on machine performance and meat texture. The presence of textural defects, particularly soft textures and holes, results in broken slices during high-speed slicing, which are either wasted or used to produce low-value products.
Texture defects in meat can be due to poor optimization of the production process. However, they are most often related to the presence of "Pale Soft Exudative" (PSE) meat in the process. This type of meat is characterized by a low water-holding capacity and a low binding capacity of meat tissues, resulting in soft, dry textures that persist even after processing (cooking or curing) and freezing. As a result, when PSE meat is sliced at high speeds (up to several hundred slices per minute), the meat tissue is fragmented rather than cut, generating meat waste, either in the form of small fragments or broken slices.
Even if PSE meat is not cut, it seriously affects the quality of the resulting products, so it is also advisable to establish appropriate procedures for detecting, grading, and processing PSE meat.
The development of the PSE defect depends on complex genetic, nutritional, and animal husbandry factors that are very difficult to control. Therefore, meat processors must manage the presence of PSE meat in their processes. Currently, there is no effective solution to prevent the impact that PSE meat has on production yield and product quality.
As part of the European SLICEWATCH project, we have developed a noninvasive solution for detecting texture defects. This innovative solution is implemented using an industrial scanner that can scan meat pieces piece by piece, at scanning speeds of up to 600 pieces per hour.
The EU-28 meat industry generates an annual turnover of €160 billion, 50% of which is accounted for by SMEs. In recent years, the production of sliced meat products has experienced steady growth, driven by the rising demand for ready-to-eat products such as cooked and cured ham.
Despite significant efforts by processors to optimize the process, around 10% of meat is wasted during slicing, resulting in 72,000 tonnes of meat wasted on EU slicing lines each year.
The presence of soft and exudative (SEE) meat is responsible for a significant portion of meat loss during slicing. On average, SEE represents an annual cost of €180,000 per slicing line and €490 million annually for the EU sector as a whole. Currently, meat processors lack an effective solution to address this problem.
SliceWatch aims to develop a commercial solution for inline, non-invasive, piece-by-piece meat texture assessment. Using a scanning technology developed, demonstrated, and patented by LENZ, meat processors will be able to grade raw meat pieces by texture and reallocate soft-textured meat to products less sensitive to raw meat texture, such as sausages, burgers, and other specialty products. This will allow processors to increase their slicing yield by 4% to 12% and reduce operating costs.
With the support of an approved H2020 Phase I project, LENZ successfully demonstrated the SliceWatch prototype on a pilot meat processing line and developed a business plan. The Phase II project will scale and validate the solution with meat processors to achieve TRL9 before commercialization.
The project is a key part of LENZ's business strategy to develop industrial inspection solutions that deliver cost savings for meat processing companies. SliceWatch represents a unique business opportunity for LENZ: boosting sales, accessing international markets, and helping our customers improve their businesses and achieve environmental benefits.
Currently, there are no commercial online solutions for accurately detecting meat with PSE. The most relevant alternative technologies/methods are based on the use of automated systems that integrate invasive probes. In the case of pH probes, these systems are only effective in detecting PSE during the first three hours postmortem. In practice, these pH measurement systems are difficult to integrate and automate in slaughterhouses and exhibit poor accuracy when used by meat processors between 24 and 48 hours postmortem. Other types of probes based on electrical conductivity and optical reflectance offer limited performance due to the high rate of false positives (up to 95%). More importantly, invasive probes offer very limited robustness during industrial operation due to their wear.
As a solution to the need to monitor meat texture, we have developed a non-invasive technology for meat inspection. The SLICEWATCH solution will enable meat processors to reduce production costs associated with meat waste and line downtime. This will be achieved by grading meat pieces according to their textural properties and selecting those suitable for the production of sliced meat products. The remaining fraction will be used to produce products less sensitive to meat texture. Typically, PSE meat can be ground up and used for the production of sausages or hamburger meat. Alternatively, it can be treated with chemical additives and used in the production of lower-quality products.
SLICEWATCH will significantly improve process efficiency, reduce meat waste, avoid operational issues due to slicing machine and line downtime, and improve final product quality. The presence of PSE meat in the process is a major and growing concern for meat producers, as evidenced by the fact that the incidence of PSE meat on production lines in Spain accounts for up to a third of production.
SLICEWATCH will also bring significant environmental benefits by reducing meat waste and developing more sustainable meat production processes. While pork is the most consumed meat in Europe and an important source of protein, pig farming has a significant environmental impact. Annually, the production of meat wasted during slicing is associated with the emission of 350 million cubic meters of CO2e, the consumption of 400 million cubic meters of water, and 446 GW h of energy.
- LENZ INSTRUMENTS SL
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