BACKGROUND OF THE INVENTION A growing trend in the food industry, including the meat industry, involves the production of value-added products. These food products are characterized by their high quality and convenience of use. Products which are ready to consume with little preparation, such as portion sized products are one type of value-added product. Specifically, there has been a growing demand for meat products which are portion controlled, easy to prepare and, of course, healthy and aesthetically pleasing and tasty.

One of the problems associated with such easy to prepare, portion sized meat products is their expense. Complex preparation processes are usually necessary to prepare such products and much meat is wasted in selecting and trimming a prime cut of meat.

Pork products provide a less expensive alternative to expensive cuts of meat such as prime rib or steak. However, previous attempts to utilize a muscle portion of pork such as the inside, outside, or knuckle portion of the ham either required blending the intact muscle with other parts of the animal or non-meat filler, or required a complex multi-step curing or smoking process. These complex treatment steps were required because of the dark red color and perceived unappealing nature of these intact muscle portions.

It would therefore be desirable to create healthy, tasty and relatively inexpensive pork products which are portion controlled, fresh (not cured or smoked), and easy to cook at the consumer or retail level. The present invention is directed to this need. Specifically, the present invention provides processes for preparing edible pork products, and the pork products themselves, which are made from a less expensive, intact muscle portion of pork.

The processes are relatively simple and yet produce uniform, organoleptically superior, low- fat products which are easy to prepare by the retail establishment or consumer.

SUMMARY OF THE INVENTION The present invention provides processes for preparing edible pork products made from intact inside, outside, or knuckle portions of a ham. The invention comprises selecting a fresh cut from any of the three major muscle groups of the ham of a pig including the inside, outside and knuckle portions of the ham, trimming excess fat and connective tissue from the muscle, treating the meat with a liquid and tumbling the meat under vacuum. Preferably the meat is then formed into a desired size and shape, and allowed to temper prior to slicing or serving.

The combined use of specific pork starting materials, specifically whole muscle portions, and the processes by which they are prepared produces fresh pork products, including pork sandwich core products, which are aesthetically pleasing, low fat, tender, and yet, relatively inexpensive.

In a preferred embodiment, the pork products are made from the intact knuckle portion of the ham. In an especially preferred embodiment, the knuckle portion of the ham is trimmed of excess fat and connective tissue; injected with liquid such that the liquid is

present in a concentration range of about 5 to 20 percent and most preferably about 10 to 14 percent of the amount of weight of the knuckle; tumbled under a preferred pressure range of about 15 to 30 inches and most preferably about 18 to 25 inches of mercury (Hg), formed into a desired shape and size and tempered at a preferred temperature range of about 15 to 30°F and most preferably about 22 to 26°F or, alternatively, crust frozen. Most preferably, the knuckle is from a pig whose deoxyribonucleic acid (DNA) does not contain the halothane gene.

In another embodiment, the present invention provides pork products prepared by processes comprising the steps of : providing an intact muscle of a ham selected from the muscle group consisting of the inside, outside, and knuckle portions of the ham; trimming the muscle to remove connective tissue, external fat, and non-uniformly colored portions of the muscle; treating the muscle with a liquid; tumbling the muscle under vacuum; forming the muscle into a desired shape and size; and tempering the muscle. In a preferred embodiment, the muscle is the knuckle portion of the ham. In a most preferred embodiment, the knuckle is from the ham of a pig whose DNA does not contain the halothane gene.

BRIEF DESCRIPTION OF THE DRAWINGS Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings in which: FIG. 1 is a schematic flow diagram illustrating the steps of the process of this invention; and FIG. 2 is a drawing showing the muscle groups in a whole ham portion of a pig.

While the invention will be described in connection with certain preferred embodiments, it is not intended to limit the invention to the specific exemplary embodiments.

On the contrary, it is intended to cover all alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.

DESCRIPTION OF THE PREFERRED EMBODIMENTS This invention concerns processes for preparing fresh, whole muscle pork products, such as core sandwich products, finger-style products, cutlets or filets, which are made from a sub-primal cut from the fresh ham of a pork carcass. These whole muscle pork products are not cured or smoked, but rather are fresh, such as core pork sandwich products, are easy to cook, wholesome, and healthy. Most processed ham products are cured. Curing consists of the application of salt, nitrite or nitrate ions, seasonings and several other additives to develop unique properties and resistance to rapid deterioration. Two main ingredients must be used to cure meat: salt and nitrite, but other substances are added to accelerate curing, stabilize color, modify flavor and texture and reduce shrinkage during processing. In addition, a series of lengthy and severe mechanical action steps, like injection, tumbling or massaging are necessary to insure disruption of the muscle tissue structure and hasten distribution of cure ingredients. Most cured products are also smoked and cooked.

The present invention creates healthy, tasty and relatively inexpensive whole muscle pork products which are minimally processed, portion controlled, fresh (not cured and smoked) and easy to cook at the consumer or retail level. In addition, this invention concerns products made according to the processes described in detail below.

Turning now to the drawings, FIG. 1 is a schematic flow diagram illustrating the steps of the processes of this invention. Step one involves selecting a fresh, intact, boneless muscle (sub-primal cut) from the ham portion (primal cut) of a pork carcass. A unique feature of this product is that it is made from whole, intact muscle processed in a specific way to yield an organoleptically superior product. Organoleptic qualities refer to the aesthetic qualities associated with the taste, smell, and appearance of the meat. Specifically, the pork products of the invention, including core sandwich products, when cooked are nearly as pale as chicken breast, are very tender, juicy, and low in fat. Additionally, the processes by which the products of this invention are made are relatively simple, saving time, energy, and money.

FIG. 2 shows the muscle groups in a whole ham portion of a pig. The muscle groups of the primal cut of ham 10 can be roughly broken down into three major portions denoted the inside 12, outside 14 and knuckle 16. The inside 12 contains the biceps femoris 18 and the semitendinosus 20 muscles. the outside 14 contains the gracilis 22, pectineus 24, adductor 26 and semimembranosus 28 muscles. The knuckle portion 16 contains the sartorius 30 (also known as the"thumb"), vastus medialis 32, vastus intermedius 34, rectus femoris 36, and vastus lateralis 38 muscles. The femur 40 is also shown.

While the intact inside 12, outside 14 or knuckle 16 portions of the ham may be used in the processes of the instant invention, it is preferable to utilize the knuckle portion.

Turning back to FIG. 1, step 2 involves trimming the knuckle 16, inside 12, or outside 14 to remove connective tissue, external fat, and non-uniformly colored portions of muscle.

For example, trimming the knuckle 16 involves removing the sartorius 30 or thumb portion and the three major connective tissue strips. One connective tissue strip attaches the thumb and the other two connective tissue strips are located between the three major vastus muscles.

All muscle portions (knuckle inside or outside) used for these products are trimmed free of external connective tissue, and on specific muscles, internal connective tissue and external fat. Any"dark"or non-uniform colored sections are removed.

Step 3 involves treating the selected trimmed muscle with liquid, such as a marinade, for example, by injection of liquid into the chosen muscle. For example, liquid marinade is injected to a preferred pump target concentration range of 5-20% and preferably about 10- 14% of marinade by weight of muscle portion. This percentage range of liquid marinade can vary by a few percentage points on either side of the range. A twelve percent concentration by weight of marinade is especially preferred. A typical marinade includes salt, phosphate and other ingredients. Examples of specific marinades may include a spicy cajun type marinade, a smoky marinade, a Japanese style teriyaki type marinade among others. The inside 12, outside 14 or knuckle 16 portions are injected using a multi-needle injector.

Step 4 involves tumbling the inside 12, outside 14, or knuckle 16 portions under a vacuum. The vacuum tumbling process helps to extract proteins from the muscle and helps the marinade to bind to meat proteins insuring a tender and juicy product. Tumbling also physically manipulates the muscle pieces and softens the muscle, enhancing the binding process. Typical time and tumbling parameters are about 45 to 75 minutes at about 10-20 revolutions per minute (RPM). The processes of the instant invention are especially attractive because of the short length of time necessary for the tumbling process. Prior art processes require several hours of tumbling or massage to achieve an appropriate tenderness, flavor, taste and juiciness. In addition, the vacuum of the tumbling step need only be at an atmospheric pressure of about 15 to 30, and preferably about 18-25 inches of mercury (Hg).

Many typical commercial products, especially blended products, require an atmospheric pressure of 36 or more inches Hg to adequately marinate and tenderize the meat product.

Step 5 involves forming the muscle product into a desired shape and size. Typically, the whole muscle product is stuffed into a plastic or other suitable casing, pulled tight, and clipped closed. The casing material is preferably a shape-determining encasement which has a uniform cross section from end to end. This uniformity insures that each individual pork product when sliced into sandwich type slices will be of roughly the same size. An example of a typical casing product is a four inch plastic casing from Vista International Packaging of Kenosha, Wisconsin.

In Step 6, air bubbles are evacuated from the package and the product is tempered.

The product can be tempered in a salt water and ice brine to a temperature range of between about 15-30°F, and most preferably between about 22-26°F or crust frozen in a freezer at a temperature of approximately 10°F. The tempering process insures that the encased pork product may be easily sliced into portion sized, typically, sandwich-type core products.

The consumer, likely a restaurant or"fast-food"retail food outlet, may then simply slice the frozen prepared knuckle product to an appropriate size and cook the product. The pork products may be grilled, deep fried or even broiled. The sliced pork products will be uniform in appearance, taste, and fat content. The accessory"thumb"portions of the products which are removed in the trimming step may themselves be processed and conveniently fried or otherwise prepared as"finger style"foods.

The preferred pork products made according to the processes of the instant invention are especially juicy and tender and otherwise organoleptically superior to other pork products because the preferred genetic source of the pigs is carefully chosen. Specifically, in a

preferred embodiment, all of the pigs from which the knuckle, inside or outside portions of the ham are taken lack the halothane gene. Pigs lacking this"stress"gene have tissue that holds moisture very well which results in a better, more tender pork product. These halothane gene-free pigs and pork products are available from Pig Improvement Company, Franklin, Kentucky.

The specific processes by which the pork products of the invention are made also contribute to the superior organoleptic qualities of the instant invention. In addition, the processes require less time and energy than typical processes used to prepare value-added meat products. Specifically, typical commercial production processes for cuts of meat such as prime rib or ham require that the meat be tenderized by tumbling or massage for about 6-8 hours, while the instant process requires only about 45 to 75 minutes of tumbling.

In addition, most processes require that vacuum tumbling be performed at an atmospheric pressure of about 36 or more inches Hg versus the 18-25 inches of the instant invention.

Previously, the knuckle, inside or outside portions of a ham were treated via a complex and relatively expensive smoking or curing process to yield an edible product.

Alternatively, the knuckle, inside or outside portions were blended with filler, a laborious process.

Fresh intact knuckle, inside or outside portion of the ham has been an under-utilized and inexpensive cut of pork. Thus, by utilizing the processes of this invention, combined with the choice of pork starting material, these cuts of pork are significantly upgraded in quality. Specifically, significant value is added to the pork products of this invention by the processes of trimming, treating with liquid, for example, marinating the muscle via injection

of liquid into the muscle, tumbling under vacuum, and tempering the products. The processes of this invention utilize an under-utilized (and under-rated) whole intact muscle portion of the ham to produce fresh, 97% fat free, tender, juicy, healthy, white meat pork products.

The following examples are presented to describe preferred embodiments and utilities of the present invention and are not meant to limit the present invention unless otherwise stated in the claims appended hereto. For instance, although the examples involve use of the knuckle portion of the ham, the methods of the examples and of the invention in general can also be applied to the inside and outside portions of the ham.

EXAMPLE 1: Processing for Sandwich Core Product 1. Trim knuckles to specifications, removing dark portions ("thumb"and accessory muscle) and 3 major connective tissue strips.

2. Mix marinade system with cold water in Hobart mixer with whisk attachment (Model N-50 mixer, Hobart Corporation, Troy, Ohio).

3. Inject knuckle using multi-needle injector to a 12% pump target (add residual amount to tumbler if short of target pump level).

4. Tumble under vacuum (20 inches Hg) at 36°F for 1 hour in a vacuum tumbler (Model 50 Vacuum Tumbler, Hollymatic Corporation, Countryside, Illinois) at-14 RPM.

5. Stuff lengthwise into clear 4 inch diameter plastic casing (SCF 4 inch plastic casing, Vista International Packaging, Kenosha, Wisconsin).

6. Pull stuffed casing tight using-35 psi on a Tipper Tie machine and clip.

7. Evacuate air bubbles to slightly loosen bag for forming.

8. Temper in a salt water and ice brine at 26°F or crust freeze in a freezer (10°F) using a pressure mold to form product (similar to a pressed ham mold).

9. Slice 10 mm thick on a deli slicer (Model 2500, Globe Machine Company, Canton, Georgia).

EXAMPLE 2: Processing For Finger Product 1. Hand cut'thumb"and accessory trim into 2.5 to 3 inch strips weighing 18-25 g (average=21 g).

2. Add strips to vacuum tumbler at a 15% target level.

3. Apply coatings.