Understanding Smoke Color

Chad Anderson
Sales Manager
Red Arrow Products

Bob Hanson
VP of Research & Technology
ALKAR - RapidPak
Why do we cook meat?

Primary goal: Kill bacteria

Secondary goal: Quality characteristics
Smoked Sausage, natural casing, 32-34mm, traditional smoke

Step Time Dry-Bulb Wet-Bulb R.H. Dampers Smoke

1 10 min 110º F 100º F 68% Auto

2 90 min 120º F 0º F --- Auto

3 30 min 120º F 0º F --- Closed On

4 30 min 145º F 120º F 47% Auto On

5 30 min 165º F 140º F 50% Auto On

6 to 158º F core 170º F 160º F 78% Auto

Smoke Composition
• Phenols
• Carbonyls
• Acids
Smoke Color
• Carbonyls + amines + dry heat
• Hot, dry conditions promote Maillard
browning
 Maillard Reaction

Reducing Sugar + Protein (N)

R
E
V
E
Schiff’s Base R
S
I
B
L
E
The Amadori Rearrangement
N
O
T
Yield Several Products
including 5 Hydroxymethyl 2 Furaldehyde R
E
V
Different pathways based on the E
ability to dehydrate R
S
I
Brown Pigments B
Melanoidins L
E
Factors Affecting Smoke Color

• Concentration of browning components

• Surface temperature

• Surface dryness
Factors Affecting Smoke Color
Concentration of browning components
– Absorption of liquid smoke
– Application method
• Atomized or drenched
– Concentration of drench solution
• Liquid smoke or Maillose
• Atomization time
– Surface dryness

– Absorption of traditional smoke

– Surface dryness
– Smoke density
Factors Affecting Smoke Color
Surface Temperature & Surface Dryness

– Air velocity
– Dry heat
– Humidity
– Surface drying before smoke application
– Surface drying after smoke application
– Product formulation
– Water content influences surface dryness
– Product shape
Test Equipment and Procedures

Batch Oven
• Air velocity = 100-600 fpm
• Dry-bulb = 120-200oF
• Used typical processes

Belt Oven
• Air velocity = 1800 fpm
• Dry-bulb = 400oF
• Accelerated color development
Test Equipment and Procedures

Batch Oven
• Air velocity = 100-600 fpm
• Dry-bulb = 120-200oF
• Used typical processes

Belt Oven
• Air velocity = 1800 fpm
• Dry-bulb = 400oF
• Accelerated color development
Factors Affecting Smoke Color
Concentration of browning components
– Absorption of liquid smoke
– Application method
• atomized or drenched
– Concentration of drench solution
• Liquid smoke or Maillose
• Atomization time
– Surface dryness

– Absorption of traditional smoke

– Surface dryness
– Smoke density
 15% 30% 45%
Effect of liquid-smoke concentration -- molded hams
Pre-cooked hams: 10-min pre-dry, drench, 10-min final dry
Air velocity = 1800 ft/min Dry-bulb = 400oF
 15% 30% 45%

Effect of Maillose concentration -- Turkey breast

Pre-cooked turkey: 5-min pre-dry, drench, 5-min final-dry
Air velocity = 1800 ft/min Dry-bulb = 400oF
Factors Affecting Smoke Color

Surface Temperature & Surface Dryness

– Air velocity
– Dry heat
– Humidity
– Surface drying before smoke application
– Surface drying after smoke application
– Product formulation
– Water content influences surface dryness
– Product shape
 900 ft/min 1800 ft/min
Effect of air velocity on browning
Pre-cooked turkey: 5-min pre-dry, drench, 5-min final-dry
Dry-bulb = 400oF Concentration = 30% Maillose
Factors Affecting Smoke Color

Surface Temperature & Surface Dryness

– Air velocity
– Dry heat
– Humidity
– Surface drying before smoke application
– Surface drying after smoke application
– Product formulation
– Water content influences surface dryness
– Product shape
 200oF 300oF 400oF
Effect of dry heat on smoke color -- molded hams
Pre-cooked ham: 10-min pre-dry, drench, 10-min final-dry
Air velocity = 1800 ft/min Dry-bulb = 400oF Liq smoke = 30%
 200oF 400oF
Effect of dry heat on smoke color -- turkey breast
Pre-cooked turkey: 5-min pre-dry, drench, 5-min final-dry
Air velocity = 1800 ft/min Dry-bulb = 400oF Maillose = 30%
 Effect of Heat Treatment on Surface Temperatures of Hams
Pre-cooked molded hams, Virginia molds, 6.0"dia x 15.0" , 14 -15 lb

220
Surface temperature
200 400oF process

180

160

140
Temperature oF

120

100 Surface temperature

200oF process
80

60
Process
40 o
1. Pre-Dry = 10-min @ 200 or 400 F dry-bulb temperature
2. Drench = 30-sec in 30% liquid smoke, 90-sec drip-off
20
3. Final-Dry = 10-min @ 200 or 400 oF dry-bulb temperature
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28
Time - Minutes

Effect of dry heat on smoke color -- pre-cooked hams

 Effect of Heat Treatment on Surface Temp of Turkey
Pre-cooked turkey breast, 4.5"x 8"x 10", 9-10 lb

220
200 Surface temperature
400oF process
180
160
Temperature ( F)
o

140
120
100
80
60 o
Process: Pre-dry = 5 min @ 400 F dry-bulb temperature
40 Drench = 30 sec in 30% Maillose, drip-off = 90 secs
o
20 Final-dry = 5 min @ 400 F dry-bulb temperature

0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28
Time (min)

Effect of Dry Heat on Smoke Color -- Turkey Breast

Factors Affecting Smoke Color

Surface Temperature & Surface Dryness

– Air velocity
– Dry heat
– Humidity
– Surface drying before smoke application
– Surface drying after smoke application
– Product formulation
– Water content influences surface dryness
– Product shape
Pre-smoked casings

Oven Cook
Time DB WB RH%
90 min 160 115 26
to 152 180 160 60
10 min shower

Steam Cook
Time DB WB RH%
60 min 130 130 100
to 152 160 160 100
10 min shower

Effect of humidity on smoke color -- boneless hams

Pre-smoked fibrous casings -- steam vs dry cook
Factors Affecting Smoke Color

Surface Temperature & Surface Dryness

– Air velocity
– Dry heat
– Humidity
– Surface drying before smoke application
– Surface drying after smoke application
– Product formulation
– Water content influences surface dryness
– Product shape
Effect of pre-drying on smoke color--atomized smoke
Natural-casing sausage, 32mm, batch oven, atomized liquid smoke

No pre-dry 30-min pre-dry 60-min pre-dry

Time DB WB RH%
0, 30, 60 min 130 90 21
15 min Atomization with Supreme
15 min 145 115 38
15 160 135 50
to 160 180 165 68
10 min shower
Effect of pre-drying time on smoke color
Atomized vs traditional smoke -- natural-casing sausage

Liquid smoke

Traditional smoke

No pre-dry 30-min pre-dry 60-min pre-dry

Effect of pre-drying time on smoke color -- drenching
Skinless smoked sausage, 28mm, cellulose casing, drenched liquid smoke

No pre-dry 15-min pre-dry 30-min pre-dry

Time DB WB RH%
0, 15, 30 min 150 105 22
1 min Drench (30% liquid smoke)
15 min 170 130 32
15 180 150 46
to 165 180 180 100
10 min shower
Factors Affecting Smoke Color

Surface Temperature & Surface Dryness

– Air velocity
– Dry heat
– Humidity
– Surface drying before smoke application
– Surface drying after smoke application
– Product formulation
– Water content influences surface dryness
– Product shape
 Process Steps
1) Drench
2) 10-minute final-dry

1) Drench
2) 20-minute final-dry

Concentration = 15% 30% 45%

Surface drying after smoke application--pre-cooked ham

Air velocity =1800 fpm Dry-bulb =400oF
 Process Steps
1) Drench
2) 10-minute final-dry

1) 10-minute pre-dry
2) Drench
3) 10-minute final-dry

Concentration = 15% 30% 45%

Effect of surface drying -- pre-dry vs no pre-dry

Air velocity = 1800 fpm Dry-bulb = 400oF (pre- and final-dry)
Factors Affecting Smoke Color

Surface Temperature & Surface Dryness

– Air velocity
– Dry heat
– Humidity
– Surface drying before smoke application
– Surface drying after smoke application
– Product formulation
– Water content influences surface dryness
– Product shape
 4.6” 10% Ham 4.6” 20% Ham 4.6” 40% Ham

Time DB WB RH%
2 min Drench (30%)
60, 90, 120 min 160 115 26
to 152 180 160 60

Drying time after smoke application – boneless ham

Process: 60, 90, and 120-minute post-dry, batch oven
Factors Affecting Smoke Color

Surface Temperature & Surface Dryness

– Air velocity
– Dry heat
– Humidity
– Surface drying before smoke application
– Surface drying after smoke application
– Product formulation
– Water content influences surface dryness
– Product shape
 2” 20% Ham 4.6” 20% Ham
Time DB WB RH%
2 min Drench (30%)
60, 90,120 min 160 115 26
to 152 180 160 60

Effect of product shape on smoke color

Process: 60 , 90, and 120-minute post-dry
 Effect of product shape on temperatures of boneless hams
2.0" vs 4.6" diameter, fibrous casings, 20% water-added formula

200
Dry-bulb

160
Surface,
Temperature ( F)

2" hams
o

120

Surface, Wet-bulb
80 4.6" hams

40

0
0 1 2 3 4 5 6
time (hours)

Effect of product shape on smoke color -- hams

Factors Affecting Smoke Color -- Process Variables

Surface dryness

Pre-dry

Humidity

Air velocity

Post-dry

Concentration
Influence of Equipment Design

Batch Oven
• Large cabinet cross-section
• Variation in three dimensions
• Variable air velocity and drying
• Readily over-loaded

Continuous Ovens
• Higher airflow and drying
• Fixed loading prevents over-loading
• Less variable air velocity and drying
• Variation in only one or two dimensions