A fresh look at the familiar can reveal surprises that change conventional thinking and even spark new products.

Just ask Chris Calkins, a University of Nebraska Institute of Agriculture and Natural Resources meat scientist who studied undervalued portions of the beef carcass. Results provide comprehensive information about the muscles of the beef chuck and round. This research is helping change industry thinking and providing the science behind the new flat iron steak and some other new beef products in the works.

NU meat scientists and University of Florida colleagues painstakingly characterized more than 5,500 muscles in the beef chuck and round in the largest study of its kind. They were looking for untapped potential in cuts usually used for ground beef or roasts. They found plenty.

"These muscles have been there for a long time. We identified their potential and called the industry's attention to muscles that are undervalued," Calkins said. "Industry is taking this information and making it work in the marketplace."

The flat iron steak is perhaps the best known outcome of this muscle profiling research and much broader National Cattlemen's Beef Association efforts to introduce new beef products. Collaboration with NCBA and the meat industry is key to translating research findings into new products, he said.

"Some people knew this muscle was tender but lots of people either forgot it, ignored it or dismissed it," Calkins said of the flat iron steak. "It kept showing up tender in our tests so we've refocused industry attention on its potential."

The flat iron comes from the top shoulder of the chuck. This muscle's looks can deceive even a trained meat-cutter's eye. A seam of connective tissue runs down the middle of it, making it appear tough.

"It's easy to look at this and perceive that this meat isn't tender, but you'd be wrong," he said. "If you remove the connective tissue, the rest of the muscle is exceptionally tender – one of the three most tender cuts."

Removing the connective tissue involves literally going against the grain – cutting the muscle lengthwise, contrary to meat cutters' training.

"It's like filleting a catfish," Calkins explained. After removing the connective tissue, the muscle looks like two fish fillets.

Some people are initially skeptical about the new steak but a taste test usually convinces them. Consumers say the flat iron is tender, flavorful and similar to a strip or loin steak.

"The first time I went to a processor and pointed out that muscle, he looked at me like I was crazy," Calkins recalled. After tasting it, he became a believer. "He just didn't realize the sensory properties of that muscle."

Recent workshops hosted by the Nebraska Beef Council and IANR meat scientists to teach meat processors to properly cut flat iron steak and increase awareness of other promising undervalued beef cuts drew crowds, Calkins said.

"I didn't imagine it would take off like this."

Consumers, beef producers and meat processors all will benefit from the flat iron steak and other value cuts NCBA and industry are developing, he said.

"This is a good deal for consumers. It won't replace the top end steaks but it's a wonderful alternative for someone who wants to pay a little less."

Industry is developing other new products from promising undervalued muscles, Calkins said, and his research continues. He's assessing the flavor of value cuts and profiling muscles in older beef and dairy cows.

"We're again evaluating whether there are ways to increase carcass value and better serve consumer needs."

The Cattlemen's Beef Board funded the muscle profiling research through NCBA.

– Vicki Miller

Muscle profiling research identified untapped potential in several muscles in the beef chuck and round. Findings are helping industry better use these muscles. Above: Flat iron steak is among the promising new products. It comes from the top shoulder of the chuck, which traditionally is used for roasts or ground beef. Research revealed its exceptional tenderness.

IANR Meat Scientist Chris Calkins, who headed the research, demonstrates how to cut the top shoulder muscle to remove connective tissue that runs through the middle of the muscle.

Once connective tissue is removed, the result is two tender fillets ready to be grilled as flat iron steaks.