Sausage - Meat Emultion Product 2018年11月6日

History of sausagen name Frankfurters – Frankfurt, Germany Wiener – Vienna, Austria Genoa salami – Genoa, Italy Bologna – Bologna, Italy Braunschweiger – Braunschweig, Germany Libanon Bologna – Libanon country 2018年11月6日

Meat Emulsions Definitions In a meat emulsion, fine fat droplets are dispersed in an aqueous medium containing soluble proteins, other soluble muscle constituents, segments of muscle fibers and connective tissue fibers. In a stable emulsion, each fat droplet is coated with a thin layer of soluble protein which has been released into the aqueous medium from the muscle fibers. 2018年11月6日

Key goal: Fat and Moisture Stabilization Soluble proteins act as emulsifiers to stabilize fat and moisture. When fat is not stabilized, fat separation occurs. Formulation and processing impact stabilization. 2018年11月6日

Sausage type Fresh sausages Cooked and smoked sausages Uncooked, smoked sausages Dry or fermented sausages Fermented sausages Semi-dry sausages Mold-ripened sausages 2018年11月6日

Fresh Sausage Fresh sausage is made from coarse or finely ground meat. It is mixed with seasonings and can be stuffed into casings, wrapped as a bulk package, or pressed into patty form. This type must be refrigerated and thoroughly cooked before eating. 2018年11月6日

Fresh Sausage Fresh sausage is typically prepared from one or more kinds of meats, but not from meat by-products (heart, kidney, or liver, for example). It may contain water (not exceeding 3 percent of the total ingredients in the product) and binders and extenders (for example, wheat flour and non-fat dry milk). Examples include fresh pork breakfast sausage, Italian sausage, bulk pork sausage, and most bratwurst. 2018年11月6日

Cooked and Smoked Sausages Cooked and smoked sausages are made from meats that are ground, seasoned, stuffed into casings, and fully cooked (to a min. internal temperature of 155oF) and smoked during processing. Cooked sausages, like frankfurters or bologna, are made from fresh or frozen meats that are cured during processing, fully cooked and/or smoked, then packaged as ready-to eat products. 2018年11月6日

Cooked and Smoked Sausages Cooked sausages are perishable and will last approximately seven to 14 days under refrigerated conditions. These sausages must be refrigerated all the time, up until time of consumption. Since most processors prefer to vacuum package these sausages, consumers should pay attention for storage-life and re-heating conditions. 2018年11月6日

Cooked and Smoked Sausages Cooked and smoked sausages develop some additional flavors through the addition of nitrates and during the cooking and smoking processes. Examples of cooked and smoked sausages are wieners, bologna, Berliner, cotto-salami, frankfurters, and red hots. 2018年11月6日

Uncooked, Smoked Sausages Uncooked , smoked sausages are manufactured from ground meat, seasoned, stuffed in casings, and smoked. These sausages are smoked for flavor development; they MUST be fully cooked before eating. Uncooked, smoked sausages must be stored under refrigerated conditions or can be frozen for longer storage. 2018年11月6日

Uncooked, Smoked Sausages Uncooked, smoked sausages are NOT ready to eat. “Uncooked”, “Ready-to-cook”, “Cook-before-eating”, “Cook and serve,” or “Needs to be fully-cooked” should be stated in the label. The product should display cooking directions that are sufficient for the intended user to prepare it properly. 2018年11月6日

Dry or Fermented Sausages Dry or fermented sausages are prepared using ground meats, which are seasoned, cured, stuffed in casings, fermented, often smoked, and carefully air-dried. Dry and fermented sausages develop a characteristic tangy flavor due to fermentation and the production of lactic acid. 2018年11月6日

Dry or Fermented Sausages The lactic acid is produced by microbial fermentation of the sugars, and the addition of salt often provides a distinctive and enticing aroma, flavor, and a characteristic “bite.” Sausages are dried for varying lengths of time during processing and smoking, depending on the sausage type. 2018年11月6日

Dry or Fermented Sausages Fermentation and drying are the oldest way of preserving meat and meat products. The drying is accomplished by adding salt to meat to prevent spoilage. They are also referred to as “summer sausages” and eaten cold. Some examples are summer sausage, Italian salami, German salami, Lebanon bologna, Genoa salami, thuringer, cervelat, and pepperoni. 2018年11月6日

Fermented Sausages Fermented sausages are prepared from chopped or ground meat products that, as a result of microbial fermentation of a sugar, reach to a pH range of 4.6–5.3 (pH of 4.6–5.0 is more typical) and have undergone a drying or aging process to remove 15–25 percent of the moisture. These products are typically cured, but not necessarily cooked or smoked. 2018年11月6日

Fermented Sausages Dry- and semi-dry sausages are considered shelf stable due to low water activity (aw), and may be sold and consumed without further cooking or heat treatment. Sausage products must have an aw below 0.85 and a pH under 5.3 to be shelf stable. Examples are pepperoni and salami(s). 2018年11月6日

Semi-Dry Sausages Semi-dry sausages differ greatly from dry sausages due to their pronounced tangy flavor. These products are generally stuffed in medium- to large-diameter natural casings, and the length of fermentation, drying, and/or smoking depends on their type. The final pH of semi-dry sausages varies from 4.7 to 5.4, but their moisture content is typically 35 percent or higher. 2018年11月6日

Semi-Dry Sausages Semi-dry sausages may be smoked and slightly cooked in the smokehouse and after smoking, or these sausages may be air dried for a relatively short time. Compared with dry sausages, semi-dry products have higher water activity (aw) values (greater than 0.90 up to 0.91). The main difference with semi-dry fermented sausages is the long ripening and drying process. 2018年11月6日

Mold-Ripened Sausages Mold-ripened sausages are raw, fermented products usually with a longer ripening and drying time. Mold-ripened sausages can be classified as very similar to fermented sausages. Mold growth requires time and a supporting environment with adequate temperature and relative humidity. 2018年11月6日

Mold-Ripened Sausages The starter culture can be the mold present either as native flora or added as an artificial inoculum. Mold growth and changes in ripening conditions are the basic differences between sausages with and without mold. 2018年11月6日

Sausage Ingreedients Encapsulated acids Antioxidants Meat Variety Meats Game Meats Salt Sugar Spices Nitrates and Nitrites Encapsulated acids Antioxidants Binders and Extenders Water Casing 2018年11月6日

Meat Sausage making is a great way to use less tender, low-value cuts and trim pieces. Good sausage begins with good meat. Beef, veal, pork, lamb, mutton, and poultry are all suitable for use in sausage. 2018年11月6日

Variety Meats Variety Meats or fancy meats may also be used in sausage manufacture. It provides the sausage maker with an opportunity to use various types of meat by-products, also known as “variety meats,” such as hearts, tongues, livers, tripe, blood or blood plasma, brains, lungs, udders (nonlactating), spleens, suet and cod and brisket fat, pork stomachs, gelatinous skins, pork back-fat and caulfat, ears, snouts, ox lips, etc. 2018年11月6日

Game Meats Game meats may be substituted in sausage recipes to create a unique and original flavor. It is very important that the meat is handled properly after the animal is killed and to retain the wholesomeness and condition of the meat. 2018年11月6日

Game Meats It is good practice that any evidence of spoilage (discoloration, off-odors, stickiness, slime, etc.) should be carefully trimmed from the carcass and discarded. The animal should be bled and dressed as soon as possible after killing and the meat MUST be kept cold (below 40oF) at all times. 2018年11月6日

Salt Salt is an essential ingredient for flavor and functionality in sausage. It aids in the water binding and emulsifying capacity of meat proteins. Salt can provide for enhancing flavor, preserving the sausage from microbial spoilage, and extracting the soluble meat proteins.. 2018年11月6日

Salt The extracted meat protein forms a film and coagulates during heating and binds the meat particles together providing a firmer texture for sausage. Most sausages contain 2–3 percent salt. Salt levels can be adjusted to your taste. 2018年11月6日

Sugar Sugar is used for flavor development and to counteract the slight, bitter taste of salt. A variety of sugar sources can be used to provide sweetness and flavor to sausage. These include sucrose (table sugar), brown sugar, dextrose, and corn and maple syrup. Sugar is also used as a substrate for microbial fermentation to reduce the pH of the dry and fermented sausage. 2018年11月6日

Sugar The lactic acid produced due to fermentation reduces the pH of the meat and gives sausage a characteristic tangy flavor. 2018年11月6日

Spices Spices are found many forms: fresh, dried, whole, crushed, pureed, as paste, and as an extract. The commercial meat processing plants use spice extracts in place of natural spices. Seasonings and spices used for sausage making should be fresh. 2018年11月6日

Spices Most consumers prefer the taste of freshly made food that often comes from spices. For the best results, store seasonings and spices at 55ºF. The characteristic flavor of a sausage comes from the spices, herbs, and flavorings that are used, so buy the best quality seasoning that you can get. 2018年11月6日

Nitrates and Nitrites The use of nitrite to preserve and cure meats evolved centuries ago. It is one of the oldest forms of food preservation. It has great benefit for the production of sausage with improved food safety with extended shelf life and excellent storage stability. 2018年11月6日

Nitrates and Nitrites Many of today’s cured sausage products enjoyed by consumers contain sodium nitrite. Curing imparts unique colors, texture, and flavors that cannot be recreated by any other ingredient. These curing ingredients are required to achieve the characteristic flavor, color, and stability of cured meat. 2018年11月6日

Nitrates and Nitrites Nitrate and nitrite are converted to nitric oxide by microorganisms and combine with the meat pigment (myoglobin) to give the characteristic pink cured-meat color. Nitrite provides protection against the growth of botulism-producing microorganisms, acts to retard rancidity, and stabilizes the flavor of cured meat. 2018年11月6日

Starter Culture Starter culture is an inoculum of bacteria that produce lactic acid from sugar. Sausage processors can use a starter culture for making a batter for summer sausage, snack sticks, etc., prior to filling and stuffing. the stuffed sausages must be held at temperatures favorable for bacteria growth (80–100oF) for 10 to 15 hours minimum to allow the starter culture bacteria to grow and ferment the sugar to lactic acid. 2018年11月6日

Starter Culture A noticeable aroma is usually present during this fermentation period indicating that fermentation is indeed occurring. 2018年11月6日

Antioxidants Antioxidants are approved for use in fresh sausages to retard oxidative rancidity and protect flavor, including butylated hydroxytoluene (BHT), butylated hydroxyanisole (BHA), propyl gallate, tertiary butylhydroquinone (TBHQ), and tocopherols. 2018年11月6日

Antioxidants These compounds are added to spice mixtures based on the actual percentage of fat in the fresh product formulations (typically 0.01 percent separately, 0.02 percent in combination) or on the total meat block weight for dry sausage formulations (typically 0.003 percent). 2018年11月6日

Binders and Extenders Sausages may contain other ingredients such as binders and/or extenders to retain natural juices and reduce the cost of the formulation. These ingredients help may improve the binding characteristics, flavor, cook yield, slicing characteristics, and reduce the cost of the sausage formulation (i.e., extenders). 2018年11月6日

Binders and Extenders The most commonly used ingredients of this type are nonfat dry milk, cereal flours, and soy protein products. The use of soy, wheat, egg, or milk products in your formulation, had to be stated on the label. 2018年11月6日

Water Water is added to most sausage formulations to rehydrate the nonfat dry milk and to replace the expected moisture loss during smoking and cooking. Approximately 10 percent added water typically is used in moist types of cooked sausage 2018年11月6日

Water A small amount of water (usually less than 3 percent) is added to fresh sausage to aid in stuffing, mixing, and processing. No water is added to sausages that will be dried, such as summer sausage or pepperoni. 2018年11月6日

Casings Casings sausages may be formed into loaves and oven baked. Most sausages are either wrapped or packaged in bulk chub packs or stuffed into casings. Two types of sausage casings are natural and synthetic. 2018年11月6日

Casings Natural casings are obtained from the digestive tract of animals. These casings are made from sheep (3/4-inch in diameter), hog (1-3/8 inches) and cattle (1-3/8 inches) intestines. These usually come in lengths of several feet packed in salt in one pound cups or in bulk by the yard. 2018年11月6日

Casing Edible synthetic casings made from collagen are also available, in approximately the same sizes as the natural casings. Collagen casings are derived from animal protein, often extracted from beef hides, and manufactured into an edible casing (collagen is also the main protein present in natural casings). 2018年11月6日

Casing Collagen casings are used on some breakfast links, bratwurst (especially pre-cooked bratwurst), and other types of linked sausages. Collagen casings provide straight sausage links (no curve). 2018年11月6日

Casing Synthetic casings come in a variety of forms. “Skinless” hot dogs are manufactured in cellulose casings (made from inedible plant and tree fibers), which allow smoke to penetrate and moisture to escape during cooking. Large synthetic casings, which are used for slicing products such as summer sausage or bologna, are not edible. 2018年11月6日

Nitrate and nitrite Stabilize the colour of cured meat Characteristic flavor Inhibit growth of food poisoning bacteria (Cl. botulinum) Retard development of rancidity 2018年11月6日

Phosphates To increase the water-binding capacity Improve the water retention Cause unfold of muscle protein Phosphate also chelate trace metal ions Phosphate retard development of rancidity in meat products Because of the corrosive action of phosphates the equipments must be made of stainless steel or plastic. 2018年11月6日

Potassium sorbate Antimicrobial agent Used as preservative Inhibit mold growth Potent inhibitor of Cl. botulinum when used in combination with nitrite 2018年11月6日

Smoking Development of flavor Preservation Creation of new product Development of colour Protection from oxidation (antioxidant) 2018年11月6日

Composition of smoke Phenols Carbonyl Alcohols Organic acids Hydrocarbon Gases 2018年11月6日

Nature of smoke Although smoke at the point of generation exists in gaseous state it rapidly partions into vapor and particle state. Vapor phase contains the more volatile components and largely responsible for the characteristic flavor and aroma of smoke. Particle phase by precipitation also greatly reduces the contents of tars and polycyclic hydrocarbons all of which are undesirable in smoke. 2018年11月6日

Liquid smoke Doesnot require the installation of smoke generation. Composition of liquid smoke is more constant. Liqid smoke can be prepared with the particle phase can be removed and the possible problems from carcinogens can be avoided. Liqid smoke application creates little atmospheric pollution. Liquid smoke application is faster than convential smoking. 2018年11月6日

Liquid smoke preparation Liquid smoke is prepared by pyrolysis of hardwood sawdust . The smoke captured in water by drawing counter current to water through an absorption tower. The smoke is recycled until the desired concentration is reached. The solution is then aged to allow time for polymerization and tar precipitation . It is then filtered through a cellulose pulp filter which filter any dissolved any dissolved hydrocarbons that are present in the liquid smoke. 2018年11月6日

They donot cntain polycyclic hydrocarbones espically benz (a) pyrene. The final product is composed primarly of vapor phase and contains mainly phenols, organic acids, alcohols and carbonyl compounds They donot cntain polycyclic hydrocarbones espically benz (a) pyrene. All carcinogenic substances in the smoke are removed during production of liquid smoke. 2018年11月6日

Application of liquid smoke Adding it directly to the meat emulsion. Dipping the product directly into the smoke solution. Spraying the smoke solution over the product. Atomizing the liquid smoke into a dens fog and injecting it into the smoke house. 2018年11月6日

Application of liquid smoke Vaporizing the liquid smoke by putting it on a hot surface. The latter three methods are commonly used for smoking meats with the spray method most frequently being utilized for continuous meat processing. Liquid smoke preparations are usually diluted before applying to meat. 2018年11月6日

Application of liquid smoke Commercially prepared liquid smoke solutions are diluted with water or frequently with vinegar or citric acid. 20-30 parts liquid smoke + 5 parts citric acid or vinegar ( to enhance skin formation on skinless frankfurter and other small sausage products) + 65-75 parts water 2018年11月6日

Raw materials Lean skeletal beef and pork are the most desirable raw meat materials. Veal and mutton are less used in much smaller quantities. If used in excessive quantities mutton imparts an undesirable flavor to the finished product. 2018年11月6日

Raw materials Meat: tissues must must be of skeletal origin and for purpose of labeling need only be referred to as beef , pork , veal or mutton. Meat by products: non skeletal or smooth muscle tissue such as lips, pork stomach and cardiac muscle and must be listed separately in the ingredient statement printed on the package 2018年11月6日

Raw materials Binder meat are further subdivided into high , medium and low categories depending on their ability to bind water and emulsifying fat . Meat with high binding properties are lean skeletal tissues such as whole carcase bull and cow meat, beef and pork cheek meat Veal are medium value as binder. Low binding meat contain alarge proportion of fat, smooth muscle or cardiac muscle tissue . 2018年11月6日

Raw materials Filler meat: meats with very poor binding properties . Their use in comminuted meat products should be limited if overall quality of sausage or canned meat products is to be maintained. 2018年11月6日

Mechanically deboned meat It is most commonly used in sausage . The level used should be carefully controlled however as too much can cause structural and flavor problems. In sausage the best levels appear to be from 5 to 10 %with amounts above 20 % having adverse effects. It can be originated from any of the species including beef, pork, lambs and poultry. 2018年11月6日

Milk protein non fat dry milk (NFDM) Calcium- reduced non fat dry milk Dried whey Whey protein concentrate Butter milk solids Casinate Are good food ingredients and are widely used as protein extenders in processed meat. Sodium and potassium casinate are widely used Skim milk 2018年11月6日

Binders and extenders to reduce the formulation costs. to improve cooking yield. to improve slicing characteristics to improve flavor. to increase the protein content to improve emulsion stability. to improve fat binding to increase water binding 2018年11月6日

Binders and extenders Cereals, starch, vegetables, flour, soy flour, soy protein concentrate, non fat dry milk and calcium – reduced non fat dry milkare permitted in finished sausage products. Non meat ingredients not more than 3-5%. Soy protein not more than 2%. 2018年11月6日

Salts Dissolve in water to form brine which acts to retard microbial growth. It aids in solubilizing the myosin type protein of comminuted muscle for emulsifying the fat in emulsion sausage. It contributes to basic taste. 2018年11月6日

Ice or water Added to the meat mass provide considerable functional qualities. The ice or water chills the meat during chopping or mixing operations which permits longer and more efficient churning of the meat mass without mechanical overheating. Adding water aids in dissolving sodium chloride and curing salts to give better distribution in the mass. Texture and tenderness of the finished sausage markedly affected by the added water content. 2018年11月6日

Additives The processing , handling , and storage of sausage for today's markets has required the use of additives to meet the demands of modern consumers. Some of the common additives are water or ice , curing salts and chemical stabilizers such as antioxidants. 2018年11月6日

Animal casings The gastrointestinal tract is used for casings Bladders are used for special types of sausage. The structures are washed , scraped and treated with chemicals to remove soluble components. The vaious anatomical structures such as oesiphagus , stomach, small and large intestine . Appendix , and rectum are all separated , cleaned , salted and graded as to size , and conditions , and packaged in sutable containers for shipment and storage. 2018年11月6日

Animal casings Products in animal casings cost more Animal casings are usually edible so that consumers generally eats the casing along with the product. However the animal casings are less uniform in size , tends to be more fragile and require more care in stuffing. High quality products are put in animal casings because of their higher unit cost 2018年11月6日

Regenerated collagen casings Have many of the physical properties of animal casings and the uniformity and the cleanliness of cellulosic casings Are prepared from a suitable collagen source Are generally more uniform in size and strength than natural animal casing and are used for the same products. 2018年11月6日

Regenerated collagen casings Their cost is higher than cellulosic casings so that products stuffed into collagen casings tend to be higher priced than those in cellulosic casings. Since collagen casings are manufactured they can be made in a wide variety of sizes. 2018年11月6日

Cellulosic casings Uniformity Cleanliness Ease of handling They can be printed or pigmented to give attractive appearance for retail displays. Avilable in many sizes and types 2018年11月6日

Steps in processing of sausage 1- grinding: meat chunks of variable size and shape and with variable fat contents are ground to uniform cylinders of fat and lean. 2- mixing: cylinders of fat and lean obtained by grinding are tumbled in a mixer to give a uniform distribution of fat and lean particles, and with addition of required ingredients to obtain the desired texture and uniformity of composition. 2018年11月6日

Steps in processing of sausage 3- chopping: a chopper is often used as a means of batching the sausage mix. The mixed patch being transferred to an emulsifier for acquiring the desired texture. 4- emulsifying: it has the principles of grinding and chopping. Emulsifiers handle large volumes of meat rapidly to produce desired texture 2018年11月6日

Steps in processing of sausage 5- stuffing: the sausage emulsion (mix , sausage dough or batter) it is transferred to stuffers for extruding into casings. At this point the size and shape of the product is determined. 6- linking and tying: after the emulsion is stuffed into casings, the encased mass is tied with thread or fastened with metal clips or mechanical device. 2018年11月6日

Steps in processing of sausage 7- smoking and cooking: encased sausage at the time of introduction into the smoke house usually has an internal temperature of 60-70oF. During cooking this temperature rises to 155-160oF . 2018年11月6日