10 Feb 24
Eben van Tonder

Introduction

Meat bones are not a product in Nigeria. Bones are discarded. I first had to conceptualise the output of beef bones with tendons and other items from the deboning hall to the production freezer where it will be stored for production, for a maximum time of 7 days from input into the freezer. The packaging of the bones had to be considered: Optimal Storage Practices for Beef Bones: Ensuring Quality for Future Processing. I had to consider how the freezers will be cleaned: Comprehensive Guidelines for Cleaning and Maintenance of -18°C Freezers with Temperature Management.

The comprehensive strategy for handling these freezers has been discussed in Optimal Strategy for Freezer Management and Other Areas Often Neglected in Meat Plants

Recipe for Beef Bone Broth

Now it’s time to look at how we are going to process the bones and what we are going to do with the resultant broth. First, we need a recipe for the broth.

Ingredients:

• 100 kg beef bones (mixture of marrow bones, knuckle bones, and meaty bones)
• 40 liters water
• 10 kg onions, roughly chopped
• 5 kg carrots, roughly chopped
• 5 kg celery stalks, roughly chopped
• 1 kg leeks, roughly chopped
• 1 kg garlic cloves, smashed
• 20 bay leaves
• 1 bunch fresh thyme
• 1 bunch fresh parsley
• 500 g whole black peppercorns
• Salt, to taste

Instructions

1. Preheat the oven to 400°F (200°C). Place the beef bones on large baking sheets and roast them in the oven for about 2 hours, or until they are deeply browned and caramelized.
2. Transfer the roasted bones to large stockpots or kettles. Add the water, onions, carrots, celery, leeks, garlic, bay leaves, thyme, parsley, and black peppercorns.
3. Bring the mixture to a boil over high heat, then reduce the heat to low and simmer, partially covered, for at least 24 hours, preferably 48 hours. Skim off any foam or impurities that rise to the surface.
4. After simmering, strain the broth through fine-mesh sieves or cheesecloth into other large pots or containers. Discard the solids.
5. Let the broth cool to room temperature, then portion it into clean 20-litre drums for long-term storage. Seal the drums tightly and store them in a cool, dark place or refrigerate them if possible.

Usage of Beef Bone Broth

Once the broth has been created, now we must consider where we will use it.

1. Sausages: Incorporate the beef bone broth into sausage formulations to enhance flavour and moisture retention. For example, for every 10 kg of ground meat, use 1 kg of beef bone broth in the sausage mixture.
2. Fresh Meat Products: Use beef bone broth as a liquid component in fresh meat products such as meatballs, meatloaf, and burgers to improve juiciness and flavour. Use approximately 10% of the total meat weight as beef bone broth in these formulations.
3. Bacon and Hams: Utilize the beef bone broth as a brine solution for curing bacon and hams to add richness and depth of flavour. Replace water with beef bone broth in the brine solution, following standard curing ratios and procedures.
4. Small Goods and Delicatessen: Use the beef bone broth as a base for soups, sauces, and gravies in the production of small goods such as pâtés, terrines, and sausages. Adjust the amount of broth according to desired flavour intensity and consistency in each recipe.

These applications of beef bone broth will enhance the flavour, moisture, and overall quality of your factory’s products, providing added value and customer satisfaction.

Storage of Broth

The optimal way to store beef bone broth in a freezer is to follow these steps:

1. Portioning: Divide the broth into manageable portions that are suitable for your production needs. For example, pour the broth into smaller containers or bags, ensuring that each portion is properly sealed to prevent freezer burn and contamination.
2. Cooling: Allow the broth to cool to room temperature before transferring it to the freezer. Rapid cooling can be achieved by placing the containers in an ice bath or using a blast chiller.
3. Freezing: Place the sealed containers of broth in the freezer, ensuring they are arranged in a single layer for even freezing. Leave some space between containers to allow for expansion during freezing.
4. Labelling: Clearly label each container with the date of production and contents to ensure proper inventory management and rotation.
5. Storage: Store the broth in the coldest part of the freezer, maintaining a consistent temperature of 0°F (-18°C) or below.

Thawing Procedure

When thawing beef bone broth for use in production, follow these steps:

1. Refrigerator Thawing: The safest method is to transfer the frozen broth from the freezer to the refrigerator and allow it to thaw overnight. This gradual thawing process maintains the quality and integrity of the broth.
2. Cold Water Thawing: If time is limited, submerge the sealed container of frozen broth in cold water. Change the water every 30 minutes to ensure it remains cold. This method will thaw the broth more quickly than refrigerator thawing but requires more attention to prevent bacterial growth.
3. Microwave Thawing: Thawing broth in the microwave is not recommended as it can result in uneven heating and potential food safety risks.
4. Thawing in Production: If immediate use of the broth is required, it can be thawed directly in the production process. Ensure that the broth is heated to a safe temperature (above 165°F or 74°C) to kill any potential bacteria before use.

Storage Duration

Beef bone broth can be stored in the freezer for up to 6 months without significant loss of quality. However, for optimal flavour and freshness, it is best to use the broth within 3 months of freezing. Proper storage and handling practices, such as maintaining a consistent freezer temperature and minimizing exposure to air, will help prolong the shelf life of the broth.

Storage Containers

Storing beef bone broth in sealed drums is a practical and efficient method for long-term storage. Here’s how you can do it:

1. Portioning: Divide the beef bone broth into manageable portions suitable for your production needs. Pour the broth into food-grade plastic bags or containers that are specifically designed for freezer use.
2. Sealing: Ensure that each bag or container is properly sealed to prevent leakage and contamination. For bags, use a heat sealer or twist tie to securely close the opening. For containers, use tight-fitting lids that form a complete seal.
3. Arranging in Drums: Once the broth is portioned and sealed, place the bags or containers inside clean and sanitized 20-litre drums. Arrange them in layers, ensuring that there is sufficient space between each container to allow for proper airflow and freezing.
4. Labelling: Clearly label each drum with the date of production, contents, and any other relevant information such as batch number or expiration date. This will facilitate proper inventory management and rotation.
5. Sealing Drums: Seal the drums tightly to prevent air and moisture from entering. Use sealing tape or locking rings to secure the lids in place and ensure a tight seal.
6. Freezing: Place the sealed drums of beef bone broth in the coldest part of the freezer, maintaining a consistent temperature of 0°F (-18°C) or below.

By storing beef bone broth in sealed drums, you can ensure that it remains fresh and flavorful for an extended period, ready to be used in various meat products whenever needed.

Conclusion

In summary, the discussion surrounding beef bone broth has shed light on its importance in the meat industry, particularly in the production of sausages, fresh meat, bacon, hams, and other small goods. By utilizing a carefully crafted recipe and production process, beef bone broth serves as a versatile ingredient that enhances flavour, moisture retention, and overall quality in various meat products.

The optimal recipe for beef bone broth involves simmering a mixture of beef bones, vegetables, and aromatics for an extended period to extract maximum flavour and nutrients. This rich and flavorful broth can then be stored for long-term use in sealed drums, ensuring its freshness and integrity.

Furthermore, the versatility of beef bone broth extends to its usage in a wide range of meat products, including sausages, fresh meat, bacon, hams, and small goods. Whether used as a liquid component in formulations or as a base for soups, sauces, and gravies, the beef bone broth adds depth of flavour and nutritional value to the final products.

In conclusion, the production, use, and storage of beef bone broth are essential aspects of meat processing operations, contributing to the overall quality and satisfaction of consumers. By following proper recipes, production techniques, and storage practices, meat manufacturers can harness the full potential of beef bone broth to elevate their products and meet the ever-evolving demands of the market.