DESC:The present invention relates, in general, to a method for preparing Mutton chukka (Deep fried meat with some spices is locally called as chukka) by using a retort process, which has excellent taste and flavour even without adding any artificial preservative, is able to be preserved at normal room temperature for a long time. The package which is easily portable and compact.
The retort pouch is perhaps the most significant advance in food packaging since the development of the metal can (Mermelstein, 1978). A retort pouch is flexible, laminated pack having sufficient and heat resistance to allow it to be replaced metal can for the heat processing and storage of food products. The flexible laminated food package that can withstand thermal processing and made from three materials viz an outer layer of polyester for strength, a middle layer of aluminium foils as a moisture, light and gas barrier and an inner layer of polypropylene as heat seal and food contact material.
The precooked meat is furnished and cooked with the following ingredients such as Pepper, Turmeric, Groundnut oil, Ginger, Garlic and Cashew nuts.
SUMMARY OF INVENTION
This invention relates to methods or processes for Retorted cooked meat, and more particularly to the retorting of meat products like lamb meat. It is an object of the invention to provide improved methods for retorted meats which are completely precooked with spices, wherein the retorted product in condition for use or consumption is preserved as to identity, texture, taste and flavour. More specifically, it is an object of the invention is the meat slices maintain their original shape, size and sensory character and without crushing, mashing or disintegration, even when subjected to a complete sterilization process. The standardisation of time and temperature inside the processing equipment is very important too.
A further object of the invention is the selection of parts of the lamb meat which is subjected to cooking. Retorted lamb meat is preferably selected and cut from the Shank (front leg) and rolled boneless back leg. These cuts are possessed of the most desirable characteristics of connective tissue, strong muscle fibre bonding and low fat for enabling the meat pieces to withstand the retort processing, without deterioration or disintegration.
The different cooking ingredients of the dish makes the product tasty and flavour was delicious. Fennel, cinnamon, Groundnut oil, Turmeric powder and specific ratio of Chilli, Pepper and Coriander powders are the important ingredients of the product.

Rolled Back Leg Shank
F0 VALUE
Retort processing temperature was determined based on the values obtained from the experiment conducted with laboratory model overpressure retort machine. Laboratory model was supplied by M/s Lakshmi Engineering having a capacity of 150 kgs of capacity. Sealed pouches were subjected to thermal processing by maintaining the retort temperature at 121.10C. Pressure was maintained at 20 psi throughout the process by using steam-air mixture during heating and water-air mixture during cooling. The pressure was adjusted based on the requirement at time interval. The product core temperature and the lethal rates (F0 value) were noted and the F0 value was calculated by the following formula (Stumbo, 1973).
Lethal rates/ F0 value (min) =
Where PCT= Product Core Temperature
Product core temperature was noted for every minute till the product was processed and the F0 value was calculated by adding all the lethal rates noted every minute.

Commercial sterility test
The commercial sterility study was done according to the Bureau of Indian Standards, 1971.
Sensory evaluation
Sensory evaluation was assessed by subjecting the samples to sensory scores of appearance, flavor, juiciness, tenderness and overall acceptability by a trained and semi-trained taste panel, by a 9-point hedonic scale.

Microbial analysis
Total viable count, anaerobic, coliform, staphylococcal, clostridia and yeast and mould counts of processed samples were determined at NABL Certified laboratory, Enviro care, Madurai.
Method of Cooking
High perishability of meat and meat products is a serious problem in developing countries including India due to climatic condition and limited refrigeration facilities. It is necessary to develop shelf stable product to attract consumers. With proper processing or value addition the tough meat can be converted in to acceptable meat product and thereby can increase the meat market in the country.

Retort processing
Retort pouches are constructed as four-ply laminates of different packaging films that can with stand high process temperature and pressure. The typical retortable pouches consist of 12 µm polyester, 15µm nylon, 9 µm aluminium foils, 80 µm cast-polypropylene Outer polyester (polyethylene terephthalate) layer is for heat resistance and printability, an aluminium foil layer as a barrier for oxygen and light, biaxial oriented nylon for resilience, and an inner layer of cast poly propylene for pack sealing. (Sabapathy, Ramakrishna, & Srivastava, 2001)
Prepared Mutton chukka was carefully filled in four laminated retort pouches. The hermetically sealed pouches are loaded in the trays. To assess heat penetration studies, a sample pouch was fixed with thermo couple glands through which thermocouple was inserted into meat pieces for recording the core temperature during heat processing. The filled and sealed pouches (along with sample pouch) were subjected to thermal processing at 121.1ºC and 7.5. F0 value for 36 min. Pressure was maintained at 20 psi throughout the process. Rapid cooling was done to 55 0 C. The processed retort pouches were stored in cool dry place at ambient temperature (35 ± 2 o C).
Processed Meat Product

Processed Retort Meat

Sealed pouches opened for Sensory Evaluation

Retort Processed Mutton Chukka (Deep fried lamb meat)

Nutrient Analysis
Nutritional analysis is the process of determining the nutritional content of food. It is a vital part of analytical chemistry that provides information about the chemical composition, processing, quality control and contamination of food. It ensures compliance with trade and food laws. There are a variety of certified methods used for performing nutritional analysis. The analysis accounts for the changes in nutritional value that occur due to the cooking and processing of the food. This is of extreme value as calories tend to increase or decrease during the cooking process depending on the method used. For example, added fats increase calorie content during frying. Moreover, salt can be added during food preparation which increases the final sodium content of the dish.

Nutrient composition of the Retorted Mutton chukka
Parameters Results Test method Specification as per Codex Standards
Energy (Kcal) 218 PCAF – 9th Edition Not more than 2000
Carbohydrates (%) 8.5 IS 1656 Not more than 300
Fat (%) 12.6 AOAC 20th Edn. Chapter 32.920.85 Not more than 65
Saturated Fat (%) 1.5 Lab Internal Method NA
Protein (%) 17.6 AOAC 20th Edn. Chapter 32.920.87 Not more than 50
Salt (%) 6.2 FSSAI Manual 4:2015 NA
Calcium (PPM) 2.9 AOAC 19th Edition Chapter 32.944.03 Not more than 1300
Vitamin C (mg/100g) 1.86 IS 5838 Not more than 90
Dietary Fibre (%) 6.7 FSSAI Manual 2016 NA
pH 6.08 FSSAI Manual 2016 NA
Acidity (%) 0.4 FSSAI Manual 2016 NA
Sodium (PPM) 46.2 AOAC 20th Edition 2012, 966.16 Not more than 2400
Potassium (PPM) 192.4 FSSAI Manual 2016 Not more than 2000
Iron (PPM) 3.7 FSSAI Manual 2016 Not more than 22
Vitamin A (µg) <0.1 Lab Internal method NA
Vitamin D (IU) <0 1 Lab Internal method NA

Microbial load of the Retorted Mutton chukka
Parameters Units Results Test method Codex Standards
Total plate count CFU/g < 10 IS5402
NA
E.coli CFU/g Absent IS5887: Part1
NA
Salmonella P/A Absent IS 5887: Part3 Absent

The results shows that, sample having a high quality protein source, providing all essential amino acids to your body needs for growth and maintenance. It also contains varying amounts of fat mostly saturated fat, which has several health benefits. In addition to these, it contains number of other vitamins and minerals in good amounts.
The microbiological results show that, the product is nutritionally safe for human consumption and there is no growth of the microorganism in the sample. The high process temperature and controlled pressure in a specified time meets the food safety standards and quality of the product.
From this study report, it can be concluded that retort processing of mutton chukka in retort pouch at 120 °C for 30 min resulted in microbiological safe and sensory acceptable product, which can stored up to one year under room temperature condition.
Development of retort pouch processed shelf stable mutton chukka can be preserved for long term storage, increasing their commercial scope and viability.
The clinical studies show that saturated fats originating from foods increase levels of LDL cholesterol, while monounsaturated and polyunsaturated fats can help in reduce LDL cholesterol and increase levels of HDL cholesterol in the blood. Based on these findings, it can be argued that the goat meat helps reduce blood cholesterol levels and thereby reduce the risk of atherosclerosis and coronary disease (Correa, 2011).
When it comes to fat, goat meat is leaner than other meats. It also has far lesser calories, which means it is ideal for those trying to stick to a diet. While red meat is known to be high with saturated fat that increases cholesterol levels and leads to heart disease, goat meat is said to have very low levels of saturated fat and will pose no harm to your heart health. The low levels of saturated fat in goat meat is said to improve blood cholesterol levels and ease inflammation.
With cholesterol levels shooting through the roof in most households, it is important to watch your diet. Goat meat comprises very little cholesterol and hence, can be consumed regularly. Goat meat also contains higher levels of iron than chicken. Iron is an important nutrient especially for women a lack of iron reserves is known to cause anaemia.
The meat is also packed with proteins another important nutrient the body needs on a daily basis. Goat meat comprises Vitamin B, which is known to help one effectively burn fat. So, a little portion of the meat is good for those wanting to lose some weight. It is packed with Vitamin B12, which is known to help you get healthy skin.

,CLAIMS:CLAIMS
I claim,
1. A method of processing of a method of preparation of ready-to-eat (RTE) retort processed mutton involving the following the steps:
i. Retorted lamb meat is preferably selected and cut from the Shank (front leg) and rolled boneless back leg
ii. In a cooking vessel , mutton pieces and turmeric powder is added
iii. Pour a cup of water in it and boil it until the meat is cooked
iv. Heat a pan on high heat and add unrefined groundnut oil to it.
v. Add fennel and cinnamon and let it crackle.
vi. Add onions , curry leaves, green chilly and ginger garlic paste and sauté it for a minute
vii. Add tomatoes and cook till mushy. It will take around 5 minutes
viii. Now add the mutton pieces along with stock.
ix. Now add in masala mix with specific ratio (chilli powder:pepper powder: coriander powder) and mix well
x. Keep stirring till the gravy gets thick and the masala coated on all the mutton pieces
xi. Use coriander leaves as toppings and serve
2. A method of processing of a method of preparation of ready-to-eat (RTE) retort processed mutton as claimed in claim 1 wherein , the processed Mutton chukka (Deep fried meat with some spices is locally called as chukka) in retort packaging material would extend the shelf life of the product with minimum changes in the chemical composition.
3. A method of processing of a method of preparation of ready-to-eat (RTE) retort processed mutton as claimed in claim 1 wherein, the meat slices maintain their original shape, size and sensory character and without crushing, mashing or disintegration, even when subjected to a complete sterilization process.
4. A method of processing of a method of preparation of ready-to-eat (RTE) retort processed mutton as claimed in claim 1 wherein, the mutton chukka (Deep fried meat with some spices is locally called as chukka) is prepared by using a retort process, which has excellent taste and flavour even without adding any artificial preservative, is able to be preserved at normal room temperature for a long time.
5. A method of processing of a method of preparation of ready-to-eat (RTE) retort processed mutton as claimed in claim 4 wherein, prepared Mutton chukka was carefully filled in four laminated retort pouches.
6. A method of processing of a method of preparation of ready-to-eat (RTE) retort processed mutton as claimed in claim 5 wherein ,to assess heat penetration studies, a sample pouch was fixed with thermo couple glands through which thermocouple was inserted into meat pieces for recording the core temperature during heat processing.
7. A method of processing of a method of preparation of ready-to-eat (RTE) retort processed mutton as claimed in claim 5 wherein, the filled and sealed pouches (along with sample pouch) were subjected to thermal processing at 121.1ºC and 7.5. F0 value for 36 min. Pressure was maintained at 20 psi throughout the process.
8. A method of processing of a method of preparation of ready-to-eat (RTE) retort processed mutton as claimed in claim 5 wherein, rapid cooling was done to 55 0 C. The processed retort pouches were stored in cool dry place at ambient temperature (35 ± 2 o C).
9. A method of processing of a method of preparation of ready-to-eat (RTE) retort processed mutton as claimed in claim 1 wherein, the sensory evaluation was assessed by subjecting the samples to sensory scores of appearance, flavor, juiciness, tenderness and overall acceptability by a trained and semi-trained taste panel, by a 9-point hedonic scale.
10. A method of processing of a method of preparation of ready-to-eat (RTE) retort processed mutton as claimed in claim 1 wherein , the mutton chukka in retort pouch at 120 °C for 30 min resulted in microbiological safe and sensory acceptable product, which can stored up to one year under room temperature condition.