BPI's process begins with fresh USDA inspected beef trimmings from the fabrication lines of approved establishments that meet BPI's raw material specifications. Raw materials are further inspected by trained BPI employees to ensure their consistency and quality prior to introduction into our production process. These raw material specifications and inspection processes are fundamental elements of BPI's Quality Assurance Program.

The selected trimmings are transported by conveyor to a material accumulator, which feeds into a de-sinewing device. Here, virtually all non-functional protein is removed, including cartilage, sinew, connective tissue, or bone chips.

The trim is then tempered to near post-mortem temperature to facilitate the separation of lean from fat by centrifugal force. By managing raw materials and attention to processing applications, we are able to closely match finished product fat and moisture content to customer specifications, typically achieving a 94% lean or better finished product.

At this point, the lean trim may be treated with a pH enhancement process that forms ammonium hydroxide in the finished product. Ammonium hydroxide is a natural constituent of meat, GRAS (Generally Regarded As Safe) approved by the FDA, and used in other foods such as baked goods, cheeses, gelatins, and puddings. Process validation studies conducted by Iowa State University and National Food Laboratory, Inc. each demonstrated the value of BPI’s pH enhancement processes in eliminating E.coli O157:H7 and significantly reducing other pathogens such as Salmonella and Listeria monocytogenes. The pH enhanced product is marketed as BPI^® Boneless Lean Beef Trimmings. BPI^® Boneless Lean Beef Trimmings are approved for unrestricted use in ground beef and hamburger with no labeling restrictions other than beef.

After pH enhancement, the lean beef is transferred to a 14'x12' Roller Press Freezer™ and contact frozen to the drum in just 90 seconds. This rapid-freezing technique minimizes dehydration and locks in freshness. As the product comes off the Roller Press Freezer™, it is cut into small squares, passed through an in-process metal detector and packaged in 60-pound blocks. The time elapsed between product entering the process to the finished package is approximately seven to nine minutes. This rapid freeze/stress process also significantly improves the microbiological characteristics of BPI's finished products.