Fire-Roasted Turkey Meatloaf

We all know and love the classic meatloaf, generally made with beef—perhaps with some ground pork and veal—and accompanied by rich gravy. However, as with many comfort foods, the dark side of this delicious concoction is high levels of calories and fat, and often sodium. Our challenge was to create a turkey meatloaf that delivers a healthy alternative—particularly low in sodium, fat and saturated fat—without sacrificing the moist, rich, delicious flavors and textures we associate with traditional beef-based meatloaf.

For the gold standard, we started with ground white and dark turkey, enhancing it with a flavorful and colorful array of complementary nourishing elements, such as red and green pepper, red onion and some simple seasonings. Using a traditional combination of binders such as eggs and breadcrumbs, the overall recipe delivered great texture, good yield and great flavor—but not at the indulgence level of a similar meatloaf made with beef.

The conversion to a plant-ready formula required alternative ingredients. To reformulate, we had to overcome challenges associated with beef’s fat content, which adds to the succulence and mouthfeel of the meatloaf. Also, we sought to replace the egg to remove a common allergen, so we needed to compensate for its binding properties. Finally, the product was to be precooked and frozen, so freeze/thaw stability was a necessity; plus it needed to reheat without any “warmed-over” flavors.

The first task was replicating a beef-like mouthfeel and moisture content in a lower-fat turkey meatloaf. Ground beef, which is naturally higher in fat and saturated fat than turkey, is available in a multitude of fat contents, from 30% to extra lean at 99% fat-free. Usually, for meatloaf, meat in the 7% to 10% fat range is used to yield a moist product.

Turkey is also available in a variety of fat contents. Turkey breast, at 99% lean, is obviously the healthier choice, but doesn’t yield the same mouthfeel and texture as a mixture of white and dark, at 7% fat. To reach our targeted nutritional outcomes, we used 99% fat-free turkey breast in our manufacturable formula. However, we added products to compensate for the lack of fat, particularly a small amount of vegetable oil and water, bound with xanthan gum so they weren’t lost (purged) during the cooking process, and prune concentrate. This latter addition can replicate the mouthfeel of fat while also helping prevent the “warmed over” flavor commonly associated with meats that have been cooked, cooled and reheated. Iota-carrageenan, which creates a soft gel, replaced the eggs and is easy to use in a manufacturing facility. Xanthan and iota-carrageenan also helped maintain the freeze/thaw stability of the product.

Next we addressed the issue of the sodium. First, we took out the salt completely, and substituted ingredients that contain sodium at a much lower level than sodium chloride. We also emphasized ingredients that naturally provide umami (high glutamate content), which adds a savory flavor that emphasizes the heartiness of a dish while compensating for lower sodium. In addition to the already-existing Parmesan cheese, these included Worcestershire sauce powder, beef flavor concentrate, yeast extract and the prune concentrate. Not only did these help to lower the sodium content without a noticeable impact on cravability (and in fact, making it more cravable), but they also helped address the missing “meaty” flavor commonly associated with umami-rich beef. The fire-roasted flavor also contains glutamates, boosts the flavor impact from the roasted vegetables, and adds a flavor that we associate with beef roasting in the oven.

The end product turned out to be a moist, robust and flavorful meatloaf reminiscent of the ones Mom made us at home, with lower levels of fat and sodium.

Recipe:
Ingredients

1.25 lbs. skinless turkey breast, cubed
¼ lb. dark turkey meat, skin on, cubed
2 tablespoons unsalted butter, melted
¼ cup red bell pepper, quartered
¼ cup green bell pepper, quartered
¼ cup red onion, quartered
1 tablespoon vegetable oil
2 tablespoons sweet, white dessert wine (like Sauternes)
2 eggs
½ teaspoon salt
½ teaspoon black pepper, ground
1 teaspoon dried parsley
1 tablespoon Parmesan cheese, grated
½ cup plain breadcrumbs
¼ teaspoon ground sage

Procedure: Grind turkey with medium to fine plate on the meat grinder and place into a stainless-steel mixing bowl. Coat quartered vegetables with melted butter and roast over a mesquite grill with lid on or broil in oven. Let cool, then dice and add to the meat. Mix together remaining ingredients. Add to the ground turkey and vegetables and combine in mixer with paddle attachment on low until thoroughly blended. Form into a meatloaf on jelly roll pan and bake at 350°F until it reaches an internal temperature of 165°F, about 35 minutes. Serving suggestion: Serve with tomato relish, mashed potatoes, green beans and carrots.

Formula:

Procedure: Add ground turkey, prune concentrate, red and green bell pepper, and red onion to a ribbon blender or V-Mac and blend thoroughly on low for 2 minutes. Combine remaining ingredients to create a slurry. Add to the ground turkey mixture and blend on low until thoroughly incorporated. Extrude on a medium to small plate ¼-in. grind, to form 20-oz. meatloaves, onto a conveyor oven rack set to bake at 350°F until the meatloaves reach an internal temperature of 165°F. Cool immediately in a blast chiller to 38ºF, vacuum-package in ovenable bag, label accordingly, and place on freezer belt. End user: Thaw under refrigeration overnight. Bake at 300ºF for 40 minutes. Remove from bag, slice and serve with tomato relish, mashed potatoes, green beans and carrots.