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FLAVORED SAUSAGES: Their Ups and Downs. HOST Bill McDowell Editorial Director, Meatingplace MODERATOR Lisa Keefe Editor, Meatingplace.

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Presentation on theme: "FLAVORED SAUSAGES: Their Ups and Downs. HOST Bill McDowell Editorial Director, Meatingplace MODERATOR Lisa Keefe Editor, Meatingplace."— Presentation transcript:

1 FLAVORED SAUSAGES: Their Ups and Downs

2 HOST Bill McDowell Editorial Director, Meatingplace MODERATOR Lisa Keefe Editor, Meatingplace

3 A BALANCED APPROACH Roger W. Mandigo Animal Science Department University of Nebraska-Lincoln- Lincoln

4

5 Poll Questions 1.You made a great artisan fresh Bratwurst sausage with fresh jalapenos, fresh basil, fresh leak and pine nuts, however, the inclusions all fell out after you cooked and sliced the sausage. What failed? A. Too many different inclusions. B. The Jalapenos should have been either vinegar or oil packed. C. Insufficient amount of emulsifier to coat all surface areas. D. More salt would have protected the inclusions.

6 Poll Questions 2. Why do fresh vegetables shrink and fail to remain eye appealing and held in place in the sausage? A. They loose the shape, and shrink because moisture cooks out of the vegetables. B. Plant materials have fresh enzymes that must be heat denatured or blanched. C. Mixing longer before stuffing will correct the problem. D. Flash frozen inclusion will not have this problem

7 Poll Questions 3.Jalapeno peppers are available in four forms : fresh, dehydrated, packed in vinegar and packed in oil. Name the problem associated with all of these forms? A. The seeds in the peppers cause the problem. B. Jalapeno peppers contain compounds that will not stick to muscle proteins. C. Replace the Jalapeno peppers with soluble seasonings. D. All have surface conditions that reduce the ability of the emulsifier to bind the inclusion to the meat in the system.

8 Poll Questions 4. Your cracked/ground spices wont stick to the outside of your "Old World" dry sausage, Why? A. The spices were not cracked to the correct size. B. Insufficient emulsifier or protein on the surface to cause the spices to stick. C. Failed to heat the surface enough to cause the spices to stick. D. Spices won't stick to the surfaces.

9 Todays Assignment Inclusions for Unique/Designer Sausages Added Food Ingredient Objects Fresh fruits, vegetables, hard cooked eggs, fruit, nuts, vegetables, unique meat ingredients, pasta, other foods INCLUSIONS Salted, vinegar based, alcohol based and dehydrated inclusions Added Flavor Profile Ground, powdered, oil or water based flavors Added Surface Ingredients Fresh or Dried ground, powdered particulates Oil or water based liquids

10 INCLUSIONS Fresh Fruits & Vegetables – Hot Water blanched to inactivate enzymes Dehydrated – Re-hydrated in water and drained/dried Packed in Oil – Hot water washed/dried to remove oil from surfaces Packed in Vinegar – Hot water washed/dried to remove acid from surfaces Packed In Salt – Hot water washed/dried to remove excess salt

11 INCLUSION APPLICATIONS Formulation - Added Ingredients – Concerns with enzymes, salt, oil, acids – Contribute to Flavor Profile – Usually fine chopped or ground fresh or dried – Concerns with enzymes, salt, oil, acids – Water vs. Oil soluble flavors Added Surface Ingredients – Extra protein emulsifier needed on surface for binding

12 Basic Sausages -Meat Proteins Beef, Pork, Lamb, Chicken, Turkey Farm Raised Fish - Salmon, Trout, Catfish Exotic/Novel Species Bison, Red Deer, Elk, Ostrich, Emu, Llama Any specie with available contractile muscle proteins MUSCLE FOODS !

13 What is Meat ? Sarcoplasmic Proteins (water soluble) Myofibrillar Proteins (salt soluble) – Actin, Myosin, Actomyosin Stromal Proteins (connective tissue) – Collagen – Elastin and Reticulin Water Fat

14 What is the EMULSIFIER? Water containing: Salt Salt soluble proteins Actin, Myosin, Actomyosin Solubilized Protein Solution Binder or the "glue" for the meat system No change in amount of protein Borrow the protein – function as glue

15 Key Factors with Emulsifier! Need about a 4.5% salt addition Too High a Concentration for finished product taste! Most products are about 2% or less salt in the finished product. But only temporarily About half of the meat & all the salts for few minutes Then, add balance of water, meat and other ingredients Finish processing, stuff and heat process

16 Key Factors with Emulsifier! Temporary high dry salt level > % instead finished products of ~2.0% All the formula salt, add to 40 – 50% of the lean meat, and mechanical action Then Water added after initial protein solubilization, and Before rest of meat and non-meat ingredients Final mix contains all the ingredients !

17 Meat Emulsion

18 Key Factors with Particle Size! All surface area of all particles must be covered with the emulsifier (glue or binder)! MEAT: Muscle, Fat, Connective Tissue, Added Water INCLUSIONS: Any Added Other Ingredients Smaller particles have greater surface area than larger particles!

19 Equal Volume vs. Surface Area ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo ooooooooooooooooooooooooooooooooooooo o 1 Basketball 6 Softballs 36 Golf Balls 100 Marbles 1000 Peppercorns 0

20 Fat, Gel & Inclusions Fats must be completely coated/covered with soluble myofibrillar protein = EMULSIFIER Gels from high collagenous materials must also be completely coated/covered with soluble myofibrillar protein = EMULSIFIER Inclusions [olives, cheese, peppers, fruit, nuts & other materials] must also be completely coated/covered with soluble myofibrillar protein = EMULSIFIER

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23 Poll Question Results 1.You made a great artisan fresh Bratwurst sausage with fresh jalapenos, fresh basil, fresh leak and pine nuts, however, the inclusions all fell out after you cooked and sliced the sausage. What failed? C. Insufficient amount of emulsifier to coat all surface areas. 2. Why do fresh vegetables shrink and fail to remain eye appealing and held in place in the sausage? A. They loose the shape, and shrink because moisture cooks out of the vegetables. B. Plant materials have fresh enzymes that must be heat denatured or blanched.

24 Poll Question Results 3. Jalapeno peppers are available in four forms : fresh, dehydrated, packed in vinegar and packed in oil. Name the problem associated with all of these forms? D. All have surface conditions that reduce the ability of the emulsifier to bind the inclusion to the meat in the system. 4. Your cracked/ground spices wont stick to the outside of your "Old World" dry sausage, Why? B. Insufficient emulsifier or protein on the surface to cause the spices to stick.

25 Risco USA For more information visit us at For all your sausage production needs !

26 IN PRODUCTION David Samuels Owner Esposito Sausage New York, NY

27 Started as a traditional pork store in 1933 Store-made sausage sales started to eclipse rest of store sales Family divided business up into Retail Pork Store and Wholesale Sausage company Traditional Sausage recipes (Sweet Italian, Hot Italian) have stayed the exact same ever since Same Ingredients Still Fabricating our own CT-Butts and Pork Trim Specialty Sausages have been key to growing our business since the late 90s About Espositos

28 FUN FACT It is projected that 910,000 sausages were served at Miller Park – Home to the Milwaukee Brewers, the MOST in all of MLB Coming in a very distant 2 nd was our local team – The Mets. At Citi Field they served 376,650 sausages. – If only we had that account!

29 POLL QUESTIONS: Growth of Specialty Sausages Poll Question #1: Have you or your company started to make any specialty sausages as part of your product offerings? Poll Question #2: Have you seen an increase in requests/demands for these specialty sausages since you started to offer them?

30 New Sausages as a Balancing Act Traditional products / recipes are needed to maintain your existing and more traditional customer base Newer Funky-er products / recipes are needed to attract the next generation of customers Questions to consider: – Is this product going to just replace existing volume – Is this product going to introduce our brand to new customers – Is this product really a fit for our brand

31 The devil is in the details Lets talk about our first foray into Specialty Sausages – Protein Switch to Chicken from Pork – Same Recipes – Same Casing – NEW PROBLEMS Shorter Shelf Life Less salt in Chicken More Water in the Chicken End Result – YUCK!

32 Finding a new niche Identify a problem – Traditional pork breakfast sausage sales are slowing at High End Restaurants and Hotels Identify a cause – These high end customers dont want your average pork sausage or even any pork on their plate at all Identify a need – Most CHICKEN Sausages are stuffed into PORK casings Craft a solution – What if we created a alternative breakfast sausage with no Pork Test the market – Sample, Sample, Sample – Adjust recipe – Repeat

33 Lessons Learned Make one change at a time – Adjusting for salt?, dont change pepper at the same time – Changing Apple variety?, dont touch the meat block too

34 Lessons Learned Time heals causes all wounds – New ingredients can cause interesting effects Onions can turn GREEN Peppers can turn BLACK Apples become mushy, mushy, mushy,

35 Lessons Learned Pop Goes The Weasel – Make sure your specialty items fit your casing size – Match the size of your new items to your grind size if your adding them post grind

36 Opportunities The world is your oyster (oyster sausage……maybe, why not?) – Jalapeño's vs. Salsa Why not go for a higher margin Mexican mix? – Hog Casing vs. Sheep Casing The market trend this year favors developing with HC over SC There are no rules, just good taste – Dont lock yourself into something just because its always been – Use these specialty sausages to create new opportunities for you – Being limited in supply can create a increase its demand

37 POLL QUESTION RESULTS: Growth of Specialty Sausages Poll Question #1: Have you or your company started to make any specialty sausages as part of your product offerings? Poll Question #2: Have you seen an increase in requests/demands for these specialty sausages since you started to offer them?

38 Grow with the growth Our gross margin is up 8% overall because of specialty sausages Our volume on specialty sausages has shown over 100% growth each year Our #1 specialty item is Chicken Apple – which now has its own family of product with 4 varieties within the product group.

39 QUESTIONS & ANSWERS

40 FOR MORE INFORMATION Roger Mandigo: David Samuels: Sarah Miller (Risco): Lisa Keefe: Bill McDowell: Webinar recording and PowerPoint presentation will be ed to you within 48 hours. For more information:


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