Production methods and product characteristics of jerky produced by small and very small meat processing businesses

Midwestern meat processors were surveyed to determine whether consensus existed among industry processing practices for jerky production. Seventy-eight plants were contacted, 37 responded and 33 plants sent 61 samples consisting of whole muscle (56%) or chopped and formed (44%) jerky. Samples had mean water activity, salt (NaCl) and pH of 0.74, 6.85% and 5.85, respectively. Plants used either smokehouses (34) or commercial ovens (3). Nine plants measured wet bulb temperature, and one used a relative humidity instrument. However, 35 plants claimed that they were able to control humidity. Controls included closing dampers, steam injection, direct addition of water, placing a pan of water in the house, or a combination of methods. Plants used sodium nitrite (32), sodium erythorbate (15) and potassium sorbate (5), and vacuum (78%), no vacuum (32%) and gas flush (14%) packaging. Most products were stored at room temperature (38%) or refrigerated (32%); or a combination of methods was used. Because of the high variability of processing times and temperatures, processing environment relative humidity, and methods to control humidity used by small and very small plants, there is a need to educate these processors about jerky processing parameters and the need for routine product analysis. Lack of processing knowledge and equipment capabilities also highlights the need for lethality studies in this area in addition to education on jerky process control and food safety for processors. On the basis of the averages from this study, lethality studies should target Aw 0.74 (Food Safety Inspection Service requires an Aw of [less-than or equal to]0.85), NaCl 6.85% and pH 5.85. Lethality studies should be conducted with cure for most studies. Marinade pH and length of time held in marinade prior to thermal processing as well as packaging effect and subsequent shelf life on pathogen lethality during storage should be considered. This research information could potentially decrease plants' operating costs while helping ensure food safety and public health protection.