Commercial proving of spray chilling in Australian beef plants - Phase 2

Spray chilling is the intermittent spraying of carcases with water to minimise carcase weight loss (shrink) during initial chilling.  It is widely used in the USA but has not gained wide acceptance in Australia possibly due to the perception that the shelf life of vacuum-packaged meat is reduced.  JBS Swift Australia commissioned and evaluated spray chilling at the Dinmore plant in order to investigate as processing combinations as possible. 

A system was successfully installed to service one chiller and operational parameters were devised and tested.

The key outcomes were:

• Using a spray system that incorporates nozzles that delivers water flow rates between 19 and 48 litres per minute at 2 bar (200kpi). The water is delivered in a series of spray cycles for a specified time per cycle to reduce dehydration of the carcase during refrigeration eg 8 sprays for 24 seconds each / every 30 mins in the first 3.5 hours. The number of spray cycles per carcase is dependent on the expected duration of chilling, the chilling performance, the type of the carcases and the expected end target.
• Trials have been successfully conducted to introduce spray pattern variations, based on the type of carcases being chilled and the duration of the expected chilling. Depending on the length of refrigeration, carcases have been sprayed. As much as 3 spray cycles and as many as 16 spray cycles. Each spray pattern is delivered for approximately 24 secs. The refrigeration is switched off during spray cycles but do run between spray cycles for 24 - 30 mins. Depending on the chiller size water usage / cycle is approximately 400 litres.
• Water is now delivered via a heat exchanger to deliver spray water at 18'C. There has not been any noticeable change in any chilling, shrink or eating quality standard due to the reduction in spray water temperature.
• Comparative weighing of spray sides against the equivalent opposite sides (conventionally chilled) has again indicated significant reduction in weight loss. Recent trials in Nov 2009, on 4 categories of beef carcases have indicated that greater than 0.5% of HSCW. Reduction is ending up as saleable meat. There were no noticeable increases in the trims and no increase in bone waste.
• There was no detriment to the shelf life, purge or eating quality characteristics of the product as detailed in the final report on P.PIP.0175 prepared & presented by Neil McPhail of CSIRO (Mar 09).
• It is recommended that Swift Australia extend spray chilling to the remaining chillers at Dinmore and consider it at their other similar processing facilities.

Further information on spray chilling is available.

Click here to download a copy of the final report