Sausages

Emulsion sausages

This is the largest group.
An emulsion refers to a mixture of two unlike compounds ( eg oil and water ) held together in a
colloidal suspension.
In essence a meat emulsion is fat surrounded by protein in water matrix.
What happens when an emulsion does not form well –
a) Fatting out
b)Fat caps
Types of dry and semi-dry sausages common to U.S.

Type	Process	Meat product	Process features
Germanic	Smoked/cooked	Beef/pork Summer sausage Thuringer Cervelat	18-48 hr @90 - 110 F (5-9 days without cultures)Cook to 137 F Cervelat ( 50% final moisture )
Italian	Dried	Pork/beef Genoa salami Hard salami Pepperoni (San- Francisco-style )	18-48 hrs. green room 30-60 days. Dry room Decrease R.H. overtime Pepperoni 35 -40% final moisture) Mold on surface
Lebanon	Smoked (Not cooked)	Beef Lebanon bologna	10 days salt@ 10 F Use KNO3 cure cold Smoke at 110 F 4-8 days (50+%final moisture )

Moisture : Protein ratios for dry sausages

Product	Moisture - Protein (range)
Bologna, Lebanon Capicola, Italian semidry 1.3 to 1 Cervelat, Dry 1.9 to 1 Cervelat, Soft 2.6 to 1 Pepperoni, Dry 1.6 to 1 Salami, Dry 1.9 to 1 Salami, Soft 2.0 - 3.7 to 1 Summer sausage/ Thuringer 2.0 - 3.7 to 1 Jerky 0.75 to 1	2.0 - 3.7 to 1 1.3 to 1 1.9 to 1 2.6 to 1 1.6 to 1 1.9 to 1 2.0 - 3.7 to 1 2.0 - 3.7 to 1 0.75 to 1

All above products maximum pH acceptable 5.0

Process and product features for dry and semi - dry sausages ( phase I )

Process step Product Control

Process step	Product Control
Raw material	Well trimmed; sinews and glands removed . No Off-condition by- product meats, caps removed from hearts as they provide color.
Chop/ mix	28 to 34 F ; meat temperature. Plates/ knives should be sharp and in top condition, definite Particle size, don't over- mix; use pre- mix cocept. Keep cold and vacuum mix; no pumps or screw Augers.

Use level and function of certain ingredients used in dry and semi- dry sausage (Phase II )

Ingredient

Use level

Function

Liquid smoke

Cereals/milk/proteins

GDL 16 oz/cwt. (glucono delta lactone)

Ascorbate/ erythrobate

1 to 3 oz /cwt. in raw product

3.5 % in finished product

16 oz/cwt.

.875 oz/ cwt. or less

Flavor ; odor

Cost; flavor; buffering Capacity.

Accelerates cured Color development

Accelerates cured Color development

Starter culture requirements for use in dry and semi - dry sausage (Phase III)

Salt - tolerant and fast growth in 6% brine.
Ability to grow well in presence of 80 - 100 ppm nitrite.
Optimum growth at 90 F ; range = 80 to 110 F in USA
Homofermentative ( produce only lactic acid)
Must not be proteolytic or lipolytic.
Must not produce off - flavors as by - products of fermentation.
Must not be harmful to health and should be inactivated around 135 to 140 F 8.May or may not survive
freeze drying and subsequent reconstitution.

Use level and function of certain ingredients used in dry and semi-dry sausage (Phase III)

Ingredient	Use level	Function
Salt Sugar Natural spice Paprika Garlic	2.75 to 3.50% 0.75 to 20% 0.3 to 1.0 % 0.5 to 1.0 % 0.25 to 0.50 oz/ cwt.	Flavor; bind; anti-trichinae; bacteriostat. Fermenting substrate; (dextrose corn Counters harshness of syrup solids ) salt Flavor; color; appearance Color Flavor (depends on source) (Not as oil)

Use level and function of certain ingredients in dry and semi-dry sausage

Ingredient

Use level

Function

Nitrite

Nitrate

Potassium
sorbate

Antioxidant

0.125 to 0.25 oz NaNO2/cwt. 0.31 oz KNO2/cwt.

2.75 oz NaNO3/cwt.3.3 oz KNO3/cwt.

2.5 % in solution.

.003% BHA, .006%BHA, BHT, Propyl gallate

Anti-botulinal; cured color Flavor development.

Residual source of nitrite During long-term storage

Dip casings Retards mold growth on sorbate Before or after stuffing Product surface

Retard oxidative rancidity combined.

Process and product control features for semi-dry sausage

Process step

Product control

1.Stuff

2.Green room

As cold as possible, prevent smearing; handtmann for small diameter product, vemag for large diameter product.

Period shortened if starter culture is used. Rapid drop in initial pH. 80-110 F is best at 90 F product temp. Relative humidity of 85 - 90%

Process and product features for dry and semi- dry sausage

Process step

Product control

1.Cook/smoke

2.Dry room (ripening)

15-20 air changes/min. for cook and smoke

Good air flow; decreasing relative humidity , 15-25 Changes/hr. ; cooked -137 F ; non-cooked -110-115 F Or lower.