Professor Doctor Fahim Professor Doctor Fahim ShaltoutShaltout

Professor of Meat HygieneProfessor of Meat Hygiene

Food Control DepartmentFood Control Department

Faculty of Veterinary MedicineFaculty of Veterinary Medicine

Benha University, Egypt.Benha University, Egypt.

Email: Email: fahimshaltout@hotmail.comfahimshaltout@hotmail.com

Meat Meat TechnologyTechnology

Salting and Salting and curingcuring

Salting : means using of Salting : means using of dry salt.dry salt.

Curing : using of salt Curing : using of salt solutionsolution

Ingredients of salt Ingredients of salt mixturemixture

Salt : is the basic for all curing mixturesSalt : is the basic for all curing mixtures

Salt act by dehydration and altering of Salt act by dehydration and altering of osmotic pressure, so it inhibit osmotic pressure, so it inhibit bacterial growthbacterial growth

Only food – grade salt must be usedOnly food – grade salt must be used

Reducing of salt in meat products in view Reducing of salt in meat products in view of its relationship to hypertension in of its relationship to hypertension in about 20% of the populationabout 20% of the population

Sodium chloride : potassium Sodium chloride : potassium chloridechloride

11 : : 11

High levels of potassium High levels of potassium chloride have chloride have unacceptable bitter tasteunacceptable bitter taste

SugarSugar

For flavor For flavor Sugar soften the productSugar soften the product Counteract saltiness effect of Counteract saltiness effect of

salt and hardening effect of salt and hardening effect of salt petresalt petre

Nitrate and nitrite Nitrate and nitrite ( saltpeter)( saltpeter)

Stabilize the colour of cured Stabilize the colour of cured meatmeat

Characteristic flavorCharacteristic flavor Inhibit growth of food Inhibit growth of food

poisoning bacteria (poisoning bacteria (Cl. Cl. botulinumbotulinum))

Retard development of Retard development of rancidityrancidity

PhosphatesPhosphates To increase the water-binding capacityTo increase the water-binding capacity Improve the water retentionImprove the water retention Cause unfold of muscle protein Cause unfold of muscle protein Phosphate also chelate trace metal ions Phosphate also chelate trace metal ions Phosphate retard development of Phosphate retard development of

rancidity in meat productsrancidity in meat products Because of the corrosive action of Because of the corrosive action of

phosphates the equipments must be phosphates the equipments must be made of stainless steel or plastic.made of stainless steel or plastic.

Potassium sorbatePotassium sorbate

Antimicrobial agentAntimicrobial agent Used as preservative Used as preservative Inhibit mold growthInhibit mold growth Potent inhibitor of Potent inhibitor of Cl. Cl.

botulinumbotulinum when used in when used in combination with nitritecombination with nitrite

Monosodium glutamateMonosodium glutamate

To enhance flavorTo enhance flavor

Hydrolyzed vegetable Hydrolyzed vegetable protein (HVP)protein (HVP)

Improve flavor efficiency .Improve flavor efficiency . Increased protein contentIncreased protein content

SmokingSmoking

SmokingSmoking

Purposes of smoking:Purposes of smoking: 1- development of flavor1- development of flavor 2- preservation2- preservation 3- creation of new product3- creation of new product 4- development of colour4- development of colour 5- protection from oxidation 5- protection from oxidation

( antioxidant)( antioxidant)

One of the most important properties of One of the most important properties of smoke is its effect on bacterial smoke is its effect on bacterial population population

This is due to bactericidal and This is due to bactericidal and bacteriostatic effect bacteriostatic effect

These properties are attributed to certain These properties are attributed to certain components in smoke in the smoke such components in smoke in the smoke such as phenols and acids.as phenols and acids.

Removable of moisture from the surface Removable of moisture from the surface of meat during smoking also retard and of meat during smoking also retard and reduce bacterial growth.reduce bacterial growth.

Composition of smokeComposition of smoke

Phenols :Phenols : Phenols plays three fold role in Phenols plays three fold role in

the smoking of meat and other the smoking of meat and other food :-food :-

1- They act as antioxidants1- They act as antioxidants

2-They contribute to the color and 2-They contribute to the color and flavor of smoked products.flavor of smoked products.

3-They have bacteriostatic effect 3-They have bacteriostatic effect that contribute preservation.that contribute preservation.

Colour developmentColour development

Is caused by the interaction of Is caused by the interaction of carbonyl in the vapor phase of carbonyl in the vapor phase of the smoke with the amino group the smoke with the amino group on the surface of the foodon the surface of the food

The characteristic flavor of The characteristic flavor of smoked meatsmoked meat

Is primarily due to the phenolic Is primarily due to the phenolic compounds in the vapor phase compounds in the vapor phase

The bacteriostatic action of The bacteriostatic action of smoking meatsmoking meat

Is due to the combined effects of Is due to the combined effects of heating , drying and the chemical heating , drying and the chemical components in the smoke components in the smoke

AlcoholsAlcohols

The most common and simplest The most common and simplest of alcohols is methanol or wood of alcohols is methanol or wood alcoholalcohol

The role of alcohol in wood The role of alcohol in wood smoke :-smoke :-

1- carrier for other volatile 1- carrier for other volatile componentscomponents

2- Minor bactericidal effect 2- Minor bactericidal effect

Organic acidsOrganic acids As formic acid , acetic , propionic , As formic acid , acetic , propionic ,

butyric ……butyric …… Organic acids have little or no direct Organic acids have little or no direct

influence on the flavor of smoked influence on the flavor of smoked productsproducts

Organic acids have minor Organic acids have minor preservative action preservative action

Coagulation of the surface protein Coagulation of the surface protein is enhanced by heat but acids also is enhanced by heat but acids also seem to be essential for good skin seem to be essential for good skin formation formation

CarbonylsCarbonyls

Important to smoke colour Important to smoke colour , flavor and aroma, flavor and aroma

HydrocarbonsHydrocarbons

Carcinogenic Carcinogenic

GasesGases

Co2 and Co are readily absorbed Co2 and Co are readily absorbed on the surface of meaton the surface of meat

Nature of smokeNature of smoke

Although smoke at the point of Although smoke at the point of generation exists in gaseous generation exists in gaseous state it rapidly partions into state it rapidly partions into vapor and particle state .vapor and particle state .

Vapor phaseVapor phase

Contains the more volatile Contains the more volatile components and largely components and largely responsible for the characteristic responsible for the characteristic flavor and aroma of smoke .flavor and aroma of smoke .

Particle phaseParticle phase

Removal of particle phase by Removal of particle phase by precipitation also greatly precipitation also greatly reduces the contents of tars reduces the contents of tars and polycyclic hydrocarbons and polycyclic hydrocarbons all of which are undesirable all of which are undesirable in smokein smoke

Liquid smokeLiquid smoke

AdvantageAdvantage

1-doesnot require the installation of smoke 1-doesnot require the installation of smoke generation.generation.

2-composition of liquid smoke is more 2-composition of liquid smoke is more constant.constant.

3-liqid smoke can be prepared with the 3-liqid smoke can be prepared with the particle phase can be removed and the particle phase can be removed and the possible problems from carcinogens can possible problems from carcinogens can be avoided.be avoided.

4- Liqid smoke application creates little 4- Liqid smoke application creates little atmospheric pollutionatmospheric pollution..

5-liquid smoke application is 5-liquid smoke application is faster than convential smoking.faster than convential smoking.

Liquid smoke Liquid smoke preparationpreparation

Liquid smoke is prepared by pyrolysis of Liquid smoke is prepared by pyrolysis of hardwood sawdust .hardwood sawdust .

The smoke captured in water by drawing The smoke captured in water by drawing counter current to water through an counter current to water through an absorption tower .absorption tower .

The smoke is recycled until the desired The smoke is recycled until the desired concentration is reached.concentration is reached.

The solution is then aged to allow time The solution is then aged to allow time for polymerization and tar precipitation .for polymerization and tar precipitation .

It is then filtered through a cellulose It is then filtered through a cellulose pulp filter which filter any dissolved any pulp filter which filter any dissolved any dissolved hydrocarbons that are present dissolved hydrocarbons that are present in the liquid smokein the liquid smoke

The final product is composed primarly The final product is composed primarly of vapor phase and contains mainly of vapor phase and contains mainly phenols, organic acids . Alcohols and phenols, organic acids . Alcohols and carbonyl compoundscarbonyl compounds

They donot cntain polycyclic They donot cntain polycyclic hydrocarbones espically benz (a ) hydrocarbones espically benz (a ) pyrene.pyrene.

All carcinogenic substances in the smoke All carcinogenic substances in the smoke are removed during production of liquid are removed during production of liquid smokesmoke

Application of liquid Application of liquid smokesmoke

There are a number of ways of adding There are a number of ways of adding liquid smoke to food products:-liquid smoke to food products:-

1-adding it directly to the meat emulsion1-adding it directly to the meat emulsion

2-dipping the product directly into the 2-dipping the product directly into the smoke solution .smoke solution .

3-spraying the smoke solution over the 3-spraying the smoke solution over the product product

4-atomizing the liquid smoke into a dens 4-atomizing the liquid smoke into a dens fog and injecting it into the smoke housefog and injecting it into the smoke house

5-vaporizing the liquid smoke by 5-vaporizing the liquid smoke by putting it on a hot surface.putting it on a hot surface.

The latter three methods are commonly The latter three methods are commonly used for smoking meats with the spray used for smoking meats with the spray method most frequently being utilized method most frequently being utilized for continuous meat processingfor continuous meat processing

Liquid smoke preparations are usually Liquid smoke preparations are usually diluted before applying to meat.diluted before applying to meat.

Commercially prepared liquid smoke Commercially prepared liquid smoke solutions are diluted with water or solutions are diluted with water or frequently with vinegar or citric acid.frequently with vinegar or citric acid.

20-30 parts liquid smoke 20-30 parts liquid smoke

+ 5 parts citric acid or vinegar ( to + 5 parts citric acid or vinegar ( to enhance skin formation on skinless enhance skin formation on skinless frankfurter and other small sausage frankfurter and other small sausage products)products)

+ 65-75 parts water+ 65-75 parts water

Raw materialsRaw materials

Raw materialsRaw materials

For sausage and canned meat For sausage and canned meat

For manufacturing of For manufacturing of sausage and canned meatsausage and canned meat

Lean skeletal beef and pork are the Lean skeletal beef and pork are the most desirable raw meat materials.most desirable raw meat materials.

Veal and mutton are less used in Veal and mutton are less used in much smaller quantities.much smaller quantities.

If used in excessive quantities If used in excessive quantities mutton imparts an undesirable flavor mutton imparts an undesirable flavor to the finished product .to the finished product .

Federal meat inspection Federal meat inspection regulationsregulations

Classified animal tissues used for Classified animal tissues used for preparation of comminuted meat products preparation of comminuted meat products either:-either:-

1- Meat : tissues must must be of skeletal 1- Meat : tissues must must be of skeletal origin and for purpose of labeling need only origin and for purpose of labeling need only be referred to as beef , pork , veal or be referred to as beef , pork , veal or mutton.mutton.

2- Meat by products :2- Meat by products : non skeletal or smooth muscle tissue such as lips, pork tissue such as lips, pork stomach and cardiac muscle and must be stomach and cardiac muscle and must be listed separately in the ingredient statement listed separately in the ingredient statement printed on the package printed on the package

In the trade sausage In the trade sausage ingredients are classified asingredients are classified as

: : 1- binder meat are further subdivided into 1- binder meat are further subdivided into

high , medium and low categories high , medium and low categories depending on their ability to bind water depending on their ability to bind water and emulsifying fat .and emulsifying fat .

Meat with high binding properties are lean Meat with high binding properties are lean skeletal tissues such as whole carcase bull skeletal tissues such as whole carcase bull and cow meat, beef and pork cheek meatand cow meat, beef and pork cheek meat

Veal are medium value as binder.Veal are medium value as binder. Low binding meat contain alarge Low binding meat contain alarge

proportion of fat , smooth muscle or proportion of fat , smooth muscle or cardiac muscle tissue .cardiac muscle tissue .

2- filler meat : meats with very poor 2- filler meat : meats with very poor binding properties . Their use in binding properties . Their use in comminuted meat products should comminuted meat products should be limited if overall quality of be limited if overall quality of sausage or canned meat products is sausage or canned meat products is to be maintained to be maintained

Moisture protein ratio Moisture protein ratio

Of various tissues are important in Of various tissues are important in preparing sausage formulapreparing sausage formula

Fat contentFat content

Of meat used for comminuted meat Of meat used for comminuted meat products is influenced primarily by products is influenced primarily by carcase grade and particular cut or carcase grade and particular cut or type of trimmings from the carcase.type of trimmings from the carcase.

BeefBeef

The following cuts of boneless The following cuts of boneless processing beefprocessing beef

Whole carcase bull meatWhole carcase bull meat Whole carcase cow meatWhole carcase cow meat Boneless beef (90 % lean ) Boneless beef (90 % lean )

PorkPork

1- boned primal cuts from heavy 1- boned primal cuts from heavy hogshogs

2- trimmings obtained during 2- trimmings obtained during preparation of primal cuts for curingpreparation of primal cuts for curing

VealVeal

Either Either

1- whole carcass 1- whole carcass

2- veal trimmings2- veal trimmings

MuttonMutton

Usually in form of whole carcase meat is Usually in form of whole carcase meat is usued in processed meat products usued in processed meat products

Mutton is usually dark in colour and Mutton is usually dark in colour and contributes desirable pigment to contributes desirable pigment to comminuted sausage or canned meat comminuted sausage or canned meat formulation .formulation .

Mutton has good binding properties but Mutton has good binding properties but because of pronounced flavor its usage is because of pronounced flavor its usage is usually restricted to 20% or less of total usually restricted to 20% or less of total meat block.meat block.

Variety meatsVariety meats

Variety meats are used in many Variety meats are used in many comminuted processed meat comminuted processed meat products are tongue , liver , heart , products are tongue , liver , heart , tripe and pork stomach .tripe and pork stomach .

Mechanically deboned Mechanically deboned meatmeat

It is most commonly used in sausage . It is most commonly used in sausage . The level used should be carefully The level used should be carefully controlled however as too much can controlled however as too much can cause structural and flavor problems .cause structural and flavor problems .

In sausage the best levels appear to In sausage the best levels appear to be from 5 to 10 %with amounts above be from 5 to 10 %with amounts above 20 % having adverse effects .20 % having adverse effects .

It can be originated from any of the It can be originated from any of the species including beef , pork , lambs species including beef , pork , lambs and poultryand poultry

Meat inspection regulations Meat inspection regulations requiring labelling to indicate that requiring labelling to indicate that the products contain mechanically the products contain mechanically deboned meat deboned meat

Poultry meat Poultry meat

Use of poultry meat for producing Use of poultry meat for producing processed meat has become processed meat has become increasing important in recent years increasing important in recent years with both chicken and turkey meat with both chicken and turkey meat being widely used .being widely used .

Bone – in or boneless chicken and Bone – in or boneless chicken and turkey breast and thighs .turkey breast and thighs .

Partially defatted tissuePartially defatted tissue

Partially defatted beef and pork tissues Partially defatted beef and pork tissues are subjected to low temperature are subjected to low temperature rendering to remove fat without rendering to remove fat without denaturation of the protein .denaturation of the protein .

Two types of partially defatted tissues Two types of partially defatted tissues

1- chopped tissues can be used in meat 1- chopped tissues can be used in meat sausage in unrestricted amounts sausage in unrestricted amounts

2- fatty tissues : limited to 15%2- fatty tissues : limited to 15%

Storage of raw materialsStorage of raw materials The life of any raw material is related The life of any raw material is related

to :to : 1- sanitation : all raw materials should be 1- sanitation : all raw materials should be

handled under the most sanitary handled under the most sanitary conditions possible.conditions possible.

2- refrigeration : meats should be chilled 2- refrigeration : meats should be chilled as rapidly as possible to approximately as rapidly as possible to approximately 30 F and maintained at this temperature 30 F and maintained at this temperature until used .if trimmings are not be used until used .if trimmings are not be used within 5 days they should be frozen within 5 days they should be frozen immediately and held at 0 F or below.immediately and held at 0 F or below.

Undesirable conditionsUndesirable conditions

1- PSE (pale soft exudative pork)1- PSE (pale soft exudative pork)

Pale soft watery porkPale soft watery pork

2- DFD ( dark firm and dry pork )2- DFD ( dark firm and dry pork )

3- PSS ( porcine stress syndrome )3- PSS ( porcine stress syndrome )

44 - -Two ToningTwo Toning

Is associated with muscular tissues of Is associated with muscular tissues of swine .swine .

It refers to light and dark colour in the It refers to light and dark colour in the same surface or muscle . It is undesirable same surface or muscle . It is undesirable condition .condition .

Both pale and dark colours are associated Both pale and dark colours are associated with pH and the content of myoglobin.with pH and the content of myoglobin.

High pH meats are dark in colour and have High pH meats are dark in colour and have good water binding and emulisifying good water binding and emulisifying properties .properties .

Low pH meats are pale in colour and Low pH meats are pale in colour and have poor water – binding and have poor water – binding and emulsifying properties. emulsifying properties.

Its effect is primarily from visual or Its effect is primarily from visual or aesthetic view point.aesthetic view point.

5- Dark Cutting Beef5- Dark Cutting Beef

Dark cutters Have dark appearing Dark cutters Have dark appearing lean muscle that failed to brighten lean muscle that failed to brighten on exposure to the oxygen in air .on exposure to the oxygen in air .

This condition occures in about 1-5% This condition occures in about 1-5% of all steer and heifer carcassesof all steer and heifer carcasses

6-10% of all cows6-10% of all cows 11-15% of young bulls 11-15% of young bulls

This condition characterized by This condition characterized by

A-having low glycogen reservoir A-having low glycogen reservoir

B – high pH 5.8 or above B – high pH 5.8 or above

C – low oxidation reduction potential .C – low oxidation reduction potential .

D – it is more susceptible to spoilage D – it is more susceptible to spoilage and microbial growth.and microbial growth.

6- Sex odour 6- Sex odour Sex odour refers to the objectionable Sex odour refers to the objectionable

odour which emanates pork when heated odour which emanates pork when heated This odour refers to as boar odourThis odour refers to as boar odour Meat with pronounced sexual odour must Meat with pronounced sexual odour must

be condemned and can not be used for be condemned and can not be used for food production food production

Raw materials suspected of having sex Raw materials suspected of having sex odour can be checked by heating a small odour can be checked by heating a small sample and sniffing the odour emanating sample and sniffing the odour emanating during cookingduring cooking

7- Mutton flavor 7- Mutton flavor

Although mutton usually contributes Although mutton usually contributes highly desirable lean to processed meat highly desirable lean to processed meat formulations use should be limited to no formulations use should be limited to no more than approximately 20-25%of total more than approximately 20-25%of total meat block to avoid significant meat block to avoid significant contribution to product flavor.contribution to product flavor.

Mutton flesh tend to be dark red .Mutton flesh tend to be dark red . Cause of mutton flavor is not known Cause of mutton flavor is not known

definitely definitely

But is related to the age of the sheep.But is related to the age of the sheep.

SausageSausage

ClassificationClassification

1- according to degree of chopping 1- according to degree of chopping A-coarsely ground A-coarsely ground B- emulsion or finely choppedB- emulsion or finely chopped 2-according to amount of cooking 2-according to amount of cooking A-uncookedA-uncooked B-cookedB-cooked 3-amount of smoking 3-amount of smoking A-unsmokedA-unsmoked B-smokedB-smoked

4-amount of water added4-amount of water added A- no water added B- water A- no water added B- water

addedadded 55- amount of curing - amount of curing A-uncured B-curedA-uncured B-cured 6-amount of fermentation6-amount of fermentation A-unfermented B-fermentedA-unfermented B-fermented

7-amount of moisture in final 7-amount of moisture in final productproduct

A-fresh unsmoked or smokedA-fresh unsmoked or smoked B-smoked fresh and curedB-smoked fresh and cured C-cooked fresh and cured smoked C-cooked fresh and cured smoked

and unsmokedand unsmoked D-cured: smoked and unsmokedD-cured: smoked and unsmoked E- meat loaves and speciality items E- meat loaves and speciality items F-dried : smidry and dryF-dried : smidry and dry

Classifying using USDA Classifying using USDA meat inspection system meat inspection system

1-fresh sausage : made of fresh uncured 1-fresh sausage : made of fresh uncured meat . Generally cuts of fresh pork and meat . Generally cuts of fresh pork and sometimes beef . Their taste texture , sometimes beef . Their taste texture , tenderness and colour are directly related tenderness and colour are directly related to the ratio of fat to lean .to the ratio of fat to lean .

A-fresh pork sausage : made from fresh or A-fresh pork sausage : made from fresh or frozen pork.frozen pork.

B- fresh beef sausage : made from beefB- fresh beef sausage : made from beefC- break fast sausage : may be made from C- break fast sausage : may be made from

fresh or frozen pork and / or beef and meat fresh or frozen pork and / or beef and meat by productsby products

2- uncooked smoked sausage : these 2- uncooked smoked sausage : these products have all the characteristics products have all the characteristics of fresh sausage except they are of fresh sausage except they are smoked to give the product a smoked to give the product a different flavor and colour and they different flavor and colour and they must be cooked before eating .must be cooked before eating .

3- cooked sausage : frankfurter prepared from 3- cooked sausage : frankfurter prepared from one or more kinds of raw skeletal meat and / one or more kinds of raw skeletal meat and / or poultry meat.or poultry meat.

They should not contain more than 35%fat and They should not contain more than 35%fat and no more than 10% added water. May be no more than 10% added water. May be either smoked or unsmoked. Poultry meat not either smoked or unsmoked. Poultry meat not more than 15%.more than 15%.

Liver sausage : made from fresh and or frozen Liver sausage : made from fresh and or frozen pork and / or beef and pork livers and / or veal pork and / or beef and pork livers and / or veal livers .livers .

Liver not less than 30%of the fresh weight.Liver not less than 30%of the fresh weight.

4-dry and semidry sausage : these 4-dry and semidry sausage : these products are produced by fermentation.products are produced by fermentation.

After mixing the meat ingredients with After mixing the meat ingredients with the spices , cure and cultures the meat the spices , cure and cultures the meat is held in a curing cooler until the is held in a curing cooler until the desired acidity achieved .desired acidity achieved .

Then the meat is stuffed into casings Then the meat is stuffed into casings and air dried under carefully controlled and air dried under carefully controlled drying conditions.drying conditions.

A-semidry sausage : they are A-semidry sausage : they are generally have yield of 70-80 % of generally have yield of 70-80 % of original weight.original weight.

B- dry sausage : have a yield 60-70 B- dry sausage : have a yield 60-70 % of original weight , are drier % of original weight , are drier firmer and higher in price than firmer and higher in price than semidry sausagesemidry sausage

5-Luncheon meat , loaves5-Luncheon meat , loaves

Cured cooked products is made from Cured cooked products is made from comminuted meat and may contain comminuted meat and may contain mechanically de boned meat . Water mechanically de boned meat . Water or ice may be added up to 3 % of or ice may be added up to 3 % of total ingredients.total ingredients.

Steps in processing of Steps in processing of sausagesausage

1- grinding : meat chunks of variable 1- grinding : meat chunks of variable size and shape and with variable fat size and shape and with variable fat contents are ground to uniform cylinders contents are ground to uniform cylinders of fat and lean.of fat and lean.

2- mixing : cylinders of fat and lean 2- mixing : cylinders of fat and lean obtained by grinding are tumbled in a obtained by grinding are tumbled in a mixer to give a uniform distribution of mixer to give a uniform distribution of fat and lean particles, and with addition fat and lean particles, and with addition of required ingredients to obtain the of required ingredients to obtain the desired texture and uniformity of desired texture and uniformity of composition .composition .

3- chopping : a chopper is often used 3- chopping : a chopper is often used as a means of batching the sausage as a means of batching the sausage mix. The mixed patch being mix. The mixed patch being transferred to an emulsifier for transferred to an emulsifier for acquiring the desired texture.acquiring the desired texture.

4- emulsifying : it has the principles of 4- emulsifying : it has the principles of grinding and chopping . Emulsifiers grinding and chopping . Emulsifiers handle large volumes of meat rapidly handle large volumes of meat rapidly to produce desired textureto produce desired texture

5- stuffing : the sausage emulsion ( mix , 5- stuffing : the sausage emulsion ( mix , sausage dough or batter) it is sausage dough or batter) it is transferred to stuffers for extruding into transferred to stuffers for extruding into casings . At this point the size and casings . At this point the size and shape of the product is determined .shape of the product is determined .

6- linking and tying : after the emulsion 6- linking and tying : after the emulsion is stuffed into casings , the encased is stuffed into casings , the encased mass is tied with thread or fastened mass is tied with thread or fastened with metal clips or mechanical device.with metal clips or mechanical device.

7- smoking and cooking : encased sausage at the 7- smoking and cooking : encased sausage at the time of introduction into the smoke house usually time of introduction into the smoke house usually has an internal temperature of 60-70 F . During has an internal temperature of 60-70 F . During cooking this temperature rises to 155-160 F .cooking this temperature rises to 155-160 F .

The important factors relating to the smoke house The important factors relating to the smoke house performance are as follows :performance are as follows :

A- dimensions A- dimensions B- time cycle B- time cycle C- temperature range C- temperature range D- thermal requirements D- thermal requirements E- relative humidity E- relative humidity F- air flowF- air flowG- smoke density. G- smoke density.

8- chilling : after smoking and cooking 8- chilling : after smoking and cooking the product is showered with cold the product is showered with cold waterand chilled by refrigeration.waterand chilled by refrigeration.

9- peeling and packaging : after 9- peeling and packaging : after proper chilling the product usually to proper chilling the product usually to an internal temperature of 35-40 F. an internal temperature of 35-40 F. the cellulosic casings on frankfurters the cellulosic casings on frankfurters are removed . This known as peeling are removed . This known as peeling operation and packaged.operation and packaged.

CasingsCasings Casing are used to make most sausage as well as Casing are used to make most sausage as well as

some other processed meat:some other processed meat: They determine sausage sizes and shapes They determine sausage sizes and shapes Casing must be sufficiently strong to contain the Casing must be sufficiently strong to contain the

meat mass but have shrinkage and stretch meat mass but have shrinkage and stretch characteristics that allow contraction and expansion characteristics that allow contraction and expansion of the meat mass during processing and storage.of the meat mass during processing and storage.

Must be able to withstand the forces produced Must be able to withstand the forces produced during stuffing and the forces of linkage or closure.during stuffing and the forces of linkage or closure.

Years ago sausage production was limited by the Years ago sausage production was limited by the amount of of avilable animal intestine . Since the amount of of avilable animal intestine . Since the advent of cellulosic casings , sausage production is advent of cellulosic casings , sausage production is limited only by the available meat supply.limited only by the available meat supply.

Casings for the meat industry are made of two basic Casings for the meat industry are made of two basic materials cellulose and collagenmaterials cellulose and collagen

1- Animal casings 1- Animal casings The gastrointestinal tract is used for casings The gastrointestinal tract is used for casings Bladders are used for special types of sausage.Bladders are used for special types of sausage. The structures are washed , scraped and treated The structures are washed , scraped and treated

with chemicals to remove soluble components.with chemicals to remove soluble components. The vaious anatomical structures such as The vaious anatomical structures such as

oesiphagus , stomach, small and large intestine . oesiphagus , stomach, small and large intestine . Appendix , and rectum are all separated , Appendix , and rectum are all separated , cleaned , salted and graded as to size , and cleaned , salted and graded as to size , and conditions , and packaged in sutable containers conditions , and packaged in sutable containers for shipment and storage.for shipment and storage.

Products in animal casings cost moreProducts in animal casings cost more Animal casings are usually edible so Animal casings are usually edible so

that consumers generally eats the that consumers generally eats the casing along with the product.casing along with the product.

However the animal casings are less However the animal casings are less uniform in size , tends to be more uniform in size , tends to be more fragile and require more care in fragile and require more care in stuffing.stuffing.

High quality products are put in animal High quality products are put in animal casings because of their higher unit costcasings because of their higher unit cost

2- Regenerated collagen 2- Regenerated collagen casings casings

Have many of the physical properties of animal Have many of the physical properties of animal casings and the uniformity and the cleanliness of casings and the uniformity and the cleanliness of cellulosic casingscellulosic casings

Are prepared from a suitable collagen source Are prepared from a suitable collagen source Are generally more uniform in size and strength Are generally more uniform in size and strength

than natural animal casing and are used for the than natural animal casing and are used for the same products.same products.

Their cost is higher than cellulosic casings so Their cost is higher than cellulosic casings so that products stuffed into collagen casings tend that products stuffed into collagen casings tend to be higher priced than those in cellulosic to be higher priced than those in cellulosic casingscasings

Since collagen casings are manufactured they Since collagen casings are manufactured they can be made in a wide variety of sizes.can be made in a wide variety of sizes.

3- cellulosic casings 3- cellulosic casings

Include those made from cotton bags and Include those made from cotton bags and those derived from processed cotton linters.those derived from processed cotton linters.

Advantages Advantages

1- their uniformity1- their uniformity

2- cleanliness2- cleanliness

3- ease of handling 3- ease of handling

4- they can be printed or pigmented to give 4- they can be printed or pigmented to give attractive appearance for retail displays.attractive appearance for retail displays.

5-are avilable in many sizes and types5-are avilable in many sizes and types

Additives Additives

The processing , handling , and The processing , handling , and storage of sausage for today's storage of sausage for today's markets has required the use of markets has required the use of additives to meet the demands of additives to meet the demands of modern consumers modern consumers

Some of the common additives are Some of the common additives are water or ice , curing salts and water or ice , curing salts and chemical stabilizers such as chemical stabilizers such as antioxidantsantioxidants

1- ice or water1- ice or water Added to the meat mass provide considerable Added to the meat mass provide considerable

functional qualitiesfunctional qualities The ice or water chills the meat during The ice or water chills the meat during

chopping or mixing operations which permits chopping or mixing operations which permits longer and more efficient churning of the longer and more efficient churning of the meat mass without mechanical overheatingmeat mass without mechanical overheating

Adding water aids in dissolving sodium Adding water aids in dissolving sodium chloride and curing salts to give better chloride and curing salts to give better distribution in the massdistribution in the mass

Texture and tenderness of the finished Texture and tenderness of the finished sausage markedly affected by the added sausage markedly affected by the added water content water content

2- salts 2- salts

Salts for sausage must be of food –Salts for sausage must be of food –grade quality grade quality

Sodium chloride salt serves three Sodium chloride salt serves three functions in sausage functions in sausage

1- dissolve in water to form brine which 1- dissolve in water to form brine which acts to retard microbial growth .acts to retard microbial growth .

2- it aids in solubilizing the myosin type 2- it aids in solubilizing the myosin type protein of comminuted muscle for protein of comminuted muscle for emulsifying the fat in emulsion sausage emulsifying the fat in emulsion sausage

3- it contributes to basic taste3- it contributes to basic taste

Binders and extendersBinders and extenders They are added to meat formulations for They are added to meat formulations for

one or more of the following reasons one or more of the following reasons 1- to reduce the formulation costs.1- to reduce the formulation costs.2- to improve cooking yield.2- to improve cooking yield.3- to improve slicing characteristics3- to improve slicing characteristics4- to improve flavor.4- to improve flavor.5- to increase the protein content 5- to increase the protein content 6- to improve emulsion stability.6- to improve emulsion stability.7- to improve fat binding 7- to improve fat binding 8- to increase water binding8- to increase water binding

Cereals , starch, vegetables , Cereals , starch, vegetables , flour ,soy flour , soy protein flour ,soy flour , soy protein concentrate ,, non fat dry milk and concentrate ,, non fat dry milk and calcium –reduced non fat dry calcium –reduced non fat dry milkare permitted in finished milkare permitted in finished sausage products .sausage products .

Non meat ingredients not more than Non meat ingredients not more than 3-5 %.3-5 %.

Soy protein not more than 2 % Soy protein not more than 2 %

Milk protein – dried Milk protein – dried extendersextenders

As non fat dry milk (NFDM)As non fat dry milk (NFDM) Calcium- reduced non fat dry milkCalcium- reduced non fat dry milk Dried wheyDried whey Whey protein concentrate Whey protein concentrate Butter milk solids Butter milk solids CasinateCasinate Are good food ingredients and are widely Are good food ingredients and are widely

used as protein extenders in processed used as protein extenders in processed meat.meat.

Sodium and potassium casinate are widely Sodium and potassium casinate are widely usedused

Skim milkSkim milk

Yeast protein – dried Yeast protein – dried extendersextenders

1- dried yeast1- dried yeast 2- yeast extract2- yeast extract

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