1. MaterialMeat

Fat

Water/ice

Casing

2. AdditivesPhosphate

Salt

Colour stabilizer

Spice/herbs

Salt of food grade

Acids (citrate….)

3. Technology

Emulsion technology

Filling - stuffing

Pasteurising

Cooling

Storage

Meat:

Use only well chilled meat, temp < 4°C Low bacteria count impact on shelf life, & colour development Pre-grinding/mincing is recommended Not more than 20% PSE or DFD - meat from the total amount of lean meat

PSE: negative influence on water binding, pale (bright) colour

DFD: negative impact on colour development, short shelf life Free of sinews Meat should contain a certain amount of inter-muscular connective tissue

(positive impact on bite and structure)

‘Hot – carcass - meat’ shows best water binding no addition of phosphate needed ! ! ! !

No connecting bridges between actin and myosinLarge space between actin and myosin

Large amount of water can be boundSolubility of protein is high no connecting bridges

and therefore higher solubility

Beef within 3 - 4 hours, pork within one hour Preserving of ‘hot - carcass - meat’: 1. Mincing - salting Storage time max. 3 - 4 days 2. Fast freezing Defrosting not necessary usage of water instead of ice Usage of meat in slightly frozen conditions & addition of salt risk of “Tau Rigor”

Fat: Use only well chilled fat only, temp < 4°C Fresh, low bacteria count No fat containing long - chained saturated fatty acid

suet taste No rancid fat Pre - grinding is recommended

Water/Ice: Must be of good quality (food grade) Cooling during chopping Solubility of protein

Casings: Natural or artificial casings Treatment as recommended according to the type

of casing Wash natural casings well before usage Store natural casings under cold conditions with

sufficient salt Ensure adequate soaking time for artificial casings

Phosphate:

Solubility of protein immensely improvedPositive impact on water binding and texture (firmness) Pyro (di) – phosphate shows greatest impact Proper dosage is required otherwise negative impact in

taste Store in a dry area Add at the beginning of your cutting process

Curing salt:

Store in a dry area Min. 16g/kg increase of ionic concentrationimpact on protein activation water binding, texture

taste…. Nitrite: colour curing flavour inhibits bacterial

growth Add total amount of salt to lean meatactivation of protein improved

Colour stabilizer: (ascorbic acid…) Store in dry area Never add ascorbic acid directly to nitrite curing salt

chemical reaction nitrite falls out (pop)

Spice / Herbs: According to the product

Salts of food grade acids: Increase of ionic concentration improved

solubility of muscular protein

Positive impact on water binding, texture, bite…

1) MSG Mono - Sodium - Glutamate or Potassium Glutamate

Salt of glutamic acid

Enhances meaty and salty taste

Reduces bitter taste

No impact on sweet and sour taste

0.5 – 5 grams per kg of production

2) Ribotide

IMP: inosin - 5 Monophosphate

GMP: Guanosin - 5 Monophosphate

Strong synergistic effect when mixed in a ratio of 1:1

Mix is called ‘Ribotide’

40 to 50 times stronger than MSG

Mix 19kg MSG & 1kg Ribotides = same effect as 100kg of MSG

Goal: To reactivate protein as much as possible

Before starting the emulsion process, standardizing of the materials to be used is of utmost importance!!!

1. Lean Meat Method:

Start chopping the lean meat in slow gear and add phosphate blend…, Spice, temp: < 4°C

Add approx 60% of ice / water and curing salt temperature approximately 0°C

Once 4°C is reached > add remaining ice and fat Continue chopping with high rotational speed until approximately

12°C

Advantages: Optimal activation of the protein Good meat bite Point of time for adding ice can be

controlled

Disadvantage: Quite labour intensive

2. Fat Method: Start chopping the lean meat 4°C by adding phosphate, approx 60%

of ice/ water, salt and spice temperature approximately 0°C Continue chopping until you reach 4°C and add the remaining ice Temperature drops continue chopping to approximately 0°C Take cold, lean mass out of the bowl cutter Place fat only in the cutter and cut fat fine final temperature

approximately 10°C Gradually mix the cold lean mass to the fine fat and cut until 12°C is

reached

Advantages: For special types of sausages only (Weisswurst…), extremely soft bite, light colour

Disadvantage: Very labour intensive

3. All – in - method Place all materials and additives in the cutter and continue

chopping until 12°C is reached

Advantages: Little work and simple

Disadvantages: Large fat surface > soft bite

Lighter colour as lean meat method

Less protein is activated due to the presence of fat right at the beginning of the chopping process

All these methods can be done in a bowl - cutter

Advantages of a bowl cutter: Controlled process

Disadvantage of a bowl cutter: Batch production

Loss in time through loading and unloading

4°C Start chopping process in slow gear with raw materials used according to the recipe, lean meat, phosphate…

Approx. 0°C After mixing add about 60% of ice and salt

4°C

4°C

Approx. 12°C

Spices are added

Rest of the ice is added

Fat material is added

Finishing chopping after approx. 5 turns on slow gear

4°C

Approx. 0°C After mixing add about 60% of ice and salt

Spices are added

4°C

0°C to 2°CTake the ‘lean mass’ out of the cutter and place fat into cutter

Approx. 8°C Chop the well chilled fat material finely & then gradually mix the ‘lean mass’ with the ‘fat mass’

Approx.12°CFinishing chopping after approx. 5 turns on slow gear

Start chopping process in slow gear with raw materials used according to the recipe, lean meat, phosphate…

Comminute the lean meat, fat, ice, salt, additives… in one step

Approx. 12°C

Finishing chopping after approx. 5 turns on slow gear

Chopping without a vacuum:

High speed of the knives considerable amount of oxygen is incorporated into the sausage mix

Effect on:

Colour (too pale, graying, bad colour stability

Taste (off taste, rancidity is accelerated)

Consistency (soft in bite)

Chopping under vacuum:

Removal of oxygen Stronger colour Reduction of oxidative processes Reduction of the number of pores (pockets) which may turn gray

★ Note: Complete absence of air during chopping compression of the mix

volume reduction and firm bite Re-gasing with nitrogen is possible

To handle the temperature problem more effective cooling of the sausage mix

CO2 (carbon dioxide): This gas reacts with the water in the sausage mix formation

of carbonic acid pH-value drops down water binding negatively influenced

Release of bound gas bursting of the casings possible

N2 (nitrogen): This gas doesn’t react with water inert gas

When coarse meat particles (pre-salted) are mixed with the fine mass Difference in temperature is little Water separation

Filling - stuffing:

Mechanical treatment of the sausage mix always negative impact on the emulsion

Speed (pressure) not too high Application of vacuum is recommended Keep filling machine clean & sterilised

Smoking – pasteurising:

Smoking according to the product type impact on: * Colour * Flavour (taste) * Bite (formaldehyde reacts with amino acids -

hardening of the casing) * Shelf life

Pasteurising:

Min. 70°C core temperature Coagulation of protein Reduction of bacteria count impact on shelf life Stabilization of the colour Avoid long resting time of the sausage mix before

pasteurization

microorganism ferment sugar into lactic acid pH drops less water binding water separation

Pasteurizing by F- value is possible as well

Cooling:

Cold water shower or cold water bath Don’t cool down too fast (ice/water…) negative impact on

the structure of the protein Temperature range of 20 to 50°C should be passed through

fast spores germinate negative impact on shelf life

Storage:

Temperature <4°C, inhibits bacterial growth Exclude light and oxygen

Impact on shelf life, colour, taste….

Frozen meat is flaked/cut into cubes Meat + ice + water + premix is mixed thoroughly Mass is put through at: - 2 to 2°C Fine mass can be done in bowl chopper (emulsifier) Fill into casing

★ Important:

1)Personal hygiene

2)Low bacteria count of the meat

3) Temperature of mass must never be above 4°C during production, filling, packing, transport and storage