FERMENTED SAUSAGE

Raw Material:

The meat
The fat
Salt with nitrite or nitrate

What we can offer:

Starter cultures
Quality additives
Red colouring aids
Emulsions and meat protein additives
Spices
Aromas
Taste enhancers
Casings
Other products (inlays, visible spices…)

Raw Material:

 

The meat
The fat
Salt with nitrite or nitrate

What we can offer:

Starter cultures
Quality additives
Red colouring aids
Emulsions and meat protein additives
Spices
Aromas
Taste enhancers
Casings
Other products (inlays, visible spices…)

Fermented sausage manufacturing technology
Fermented sausage manufacturing technology

1. Sorting of the materials (fat material free of rind: back fat / pork belly, lean meat: well-dehided)

2. Raw material should have a pH value between 5,5 and 5,8, assemble batches and store in a well cooled place until use

3. Freeze bacon ( -18°C) ; freeze 10% to 30% of the meat ( -10°C to -18°C) ; cool the remaining part well

4. Mix frozen meat + spices and additives + ripening cults and cut to pea size ; then add frozen bacon Shortly before the end of cutting add the salt and cut it into bindings

5. Filling and maturing

1. Sorting of the materials (fat material free of rind: back fat / pork belly, lean meat: well-dehided)

2. Raw material should have a pH value between 5,5 and 5,8, assemble batches and store in a well cooled place until use

3. Cool meat and fat material to approx. +0°C to +3°C and then pre-cool to approx. 2mm

4. Finely chop the pre-ground material in the cutter with spices and ripening cultures, then add salt and cut the Teewurst up to max. +20°C (do not cut coarse Teewurst, just mix)

5. Filling and maturing

1. Sorting of the materials (fat material free of rind: back fat / pork belly, lean meat: well-dehided)

2. Raw material should have a Ph-value between 5.5 and 5.8 ! Assemble batches and store in a cool place until use

3. Chill meat and fat material to approx. +0°C to +3°C

4. Mix the material with all additives and also the salt and either grind or cut and bring to the desired grain size (max. +8°C temperature)

5. Filling and maturing

Maturing programme for air conditioning systems at calibre 60-70

BESSAVIT® maturing process on nitrite salting basis

Time (hours)

Temp. (°C)

rF(%)

Smoke

Air movement

8-10

36

0,5-1

24

24

0,5-1

72

0,5-1

96

96

ca. 22

22-24

20

22-24

20

20

18

18

18

18

16

92

90

88

86

83

80

78

+

+

+

slow

slow

slow

slow

slow

slow

slow

slow

slow

slow

slow

The last step is maintained until the desired degree of drying (particularly important when manufacturing with SALREIF®). Sausages manufactured with SALREIF® have to be matured for a minimum of 4 weeks! After that, the finished salami can be stored at 12 – 15°C and ca. 75 – 78 % humidity. It is vital to monitor the goods despite this stipulation. It is vital to ensure that the temperature is not reduced before a pH value of at least < 5.1 has been achieved. In addition to that, the basic rule for setting the air humidity (aw x 100 – 5= rel. humidity in %) should not be deviated from too much as, this way, the desired drying degree can be achieved without having to accept the mistake of a dry skin (rule of thumb for fibrous casings: the tips of the sausage casing must not appear to have fully dried out).

SALREIF® maturing process on Salpeter basis

Time (hours)

Temp. (°C)

rF(%)

Smoke

Air movement

8-10

3

36

0,5-1

36

0,5-1

48

48

0,5-1

96

96

ca. 20

20

20

20

20

20

18

18

18

18

16

16

0

75

92

90

88

86

84

82

78

+

+

+

slow

slow

slow

slow

slow

slow

slow

slow

slow

slow

slow

slow

Possible mistakes in the manufacture

Problems and causes

This is where we present you with possible dangers and mistakes in the manufacturing process and how you can prevent them.

Choice of raw materials

• DFD meat or meat with a bad hygiene status (e.g. due to a too slow or late cooling process) used: Too high a bacteria count; this causes wrong maturing (rancid taste down to the formation of mould); lack of red colouring and poor colour stability; insufficient firmness due to wrong pH value course.
• Too fresh meat with too high pH values (> 5.9) used (the meant should be 2-3 days old): Lack of red colouring and poor colour stability; insufficient firmness due to wrong pH value course.
• PSE meat, meat from too young animals, wet meat used with too high aw values: Lack of colour due to low myoglobin content, tough dry exterior due to too fast loss of water on the exterior, wrong maturing with major taste deviations at too slow acidification and high aw value.
• Fat cooled down too slowly: Changes occur caused by oxidation, which later on lead to the fermented sausage become rancid too quickly.
• Fat is not fresh: Fast rancidity of the fermented sausage, major taste deviations, pungent, insufficient colour stability due to oxidative influences of the fat.
• Fat too soft: Insufficient consistency, faster rancidity due to many unsaturated fatty acids, unclear slicing pattern.
• Fat too firm in spreadable fermented sausage and fermented sausages: Bad distribution and unpleasant bite in coarse types, poor spreadability.

Sorting and material preparation

• Meat badly de-sinewed, parts of rind also included: Ragged slicing, unpleasant to chew.
• Meat left lying in the meat juice during the removal of water process or not sufficiently refrigerated, Thaw point not heeded in preparation (meat sweats, water intake up to 1.5%, increase in the raw value): Too high bacteria count causing wrong maturing (biting taste down to formation of mould); lack of red colouring and poor colour stability.

Preparation and combination of the ingredients

• Starter cultures not premixed with the spice preparation or added too late: Poor distribution of the starter cultures and thus lack of consistency, uneven red colouring and retention of colour (partly also formation of specks); insufficient effect of the starter cultures with negative impact on all steps of maturing due to undesirable decay or colour-destroying bacteria.
• No longer fully effective or no starter cultures used (e.g. stored wrongly): insufficient effect of the starter cultures with negative impact on all steps of maturing due to undesirable decay or colour-destroying bacteria.
• Maturing aids wrongly dosed or wrongly compiled (better to use ready-made preparations such as BESSAVIT® or FIXREIF®), starter cultures and sugar ingredients not attuned (please note MOGUNTIA recommendation); too little salt added: Hyperacidity and major taste deviations with too much sugar or incorrect starter cultures; colour and maturity
problems with too little sugar or the wrong starter cultures (sausage does not bind properly and obtains a strange or possible even mouldy taste), blotchiness or red colour problems with an overdosage or underdosage of ascorbate. With spreadable fermented sausages, in principle, the same mistakes occur, however, due to the hyperacidity, these sausages also coagulate.
• Too much sugar used when processing Salpeter (KNO3) or processed with GDL, wrong starter cultures (too strong acidifiers) used: When the acidifying process is too fast, it is not possible to decompose the KNO3, thus causing major colour problems, very bad red colouring and retention of colour, in some cases blotchiness of the core. Better to use all-inclusive products such as SALREIF®.

Grinding technique

• Too much heating up in the cutter or in the grinder; due to blunt or too many blades in the cutter, cutter overfilled, fat not frozen hard, too much fresh or not enough frozen meat used, grinder knife of the grinder not immaculate, blunt grinder auger: Ragged pale cutting pattern, fine sinews visible, faster rancidity, lacking firmness for cutting, poorer drying, thus causing shorter shelf life.
• Fermented sausage meat is too cold when it leaves the cutter due to the use of too much or too deeply frozen meat (no fresh meat added); salt added too late: No blinding in the cutter (sausage meat does not begin to clot), thus causing a porous structure in the finished
fermented sausage, in some cases even cracks.

Grinding technique spreadable fermented sausages

• Too warm cutter end temperature caused by blunt knife or grinder plate or too warm raw material: Fat exudation and resulting blotchiness, bits of connective tissue in the cutting pattern, insufficient red colouring and ragged slicing pattern (especially with coarse Mettwurst (pate-type meat sausage).

Filling

• Nozzle too narrow, too long or coarse on the inside, raw sausage meat too warm (> 4°C): Sausage meat sticks to the casing, unpleasant appearance, poor drying out of the fermented meat, which can lead to the maturing mistakes such as the core turning green and mouldy (both caused by undesired or peroxide- forming bacteria).
• Not filled air-free or a ball has not been formed (before filling), filled too loosely: green or grey speckles, porous places in the sausage.
• Fermented sausage meat containing GDL left to stand too long before filling: The already bound sausage meat can break, the sausage will become crumbly.
• Casings have not been stretched out properly or are not hygienically immaculate (pre-rinsing the casings with a 5% FRISCHIN® solution improves the hygiene): Blotchiness on the exterior or edge turns grey.
• Fermented sausages filled too full or clotted spreadable fermented sausages: Mistake by so-called ressing” the sausage.

Maturing

• Too low air humidity, too strong air movement, measuring devices not in proper working order (e.g. the fabric hose of the psychrometers of the facility has not been serviced): Formation of a more or less thick dry edge. Due to the lacking as value reduction, this can lead to major colour mistakes (green, grey) and lack of cutability; the formation of hollows and cracks, wrinkles and dents (the outer layer can no longer shrink with them); one-sided dry edge caused be wrong air supply. With spreadable products, this can lead to the casing peeling away.
• Too high air humidity, adaption time not observed (thaw point exceeded): Prolongation of maturity time; wrong maturity (core decay, major colour mistakes – green, grey – and lack of cutability), mould on the exterior down to decomposition of the casing, nitrite is washed out by “sweating” at the beginning of the maturing process This results in the exterior turning grey.

Fermented sausages: lexicon of ingredients

GdL (Glucono-delta-Lacton)

GDL is a type of carbohydrate, which relatively quickly turns into an acid when combined with water and not too low temperatures. This then leads to the desired reduction in the pH value. Products containing GDL are predominantly used in difficult maturing conditions or to achieve a particularly fast ability to sell. GDL should never be used together with Salpeter.

Quality additives and sugars

Quality additives and sugars are of key significance for the manufacture of fermented sausages. The lactic acids that are imperative for the maturing of fermented sausages are formed from the substances. These result in a reduction in the pH value. This is necessary for the shelf life and for the firmness. It is important that the sugars and quality additives are selected in such a way that the right acid and the right amount of acid is formed (the right interplay with the starter cultures).

Starter cultures

In order to obtain microbiologically safe and ever constant products, starter cultures should definitely be used.
The advantages of the starter cultures:
• Increase in product safety in all areas
• Improved gelation by way of secured acidification and thus faster firmness and longer shelf life
• Improvement in the red colouring and colour retention with nitrate and nitrite processing
• They cater for a typical aroma

Our startercultures:

• AromaSTART®                • BESSASTART®
• FixSTART®                      • MildSTART® FB-CA4
• MildSTART® Rubin          • MouldSTART® PN1
• PökelSTART®                  • PökelSTART® aromatic
• PökelSTART® CB-CA2    • PrestoSTART®
• PrestoSTART® aromatic
• PrestoSTART® FF-CS2
• ProtectSTART®
• RedSTART®
• RedSTART® aromatic

Starter cultures production and know how in-house

100 04

The MOGUNTIA FOOD GROUP has more than 20 years experience in the development, production and sale of starter cultures. Every step in the production process of our starter cultures lies in our own hands and therefore is subject to the highest quality standards.

Everything from one house: our spices, additives and maturing compounds are perfectly adapted to our starter cultures. This is something quite special on the market that only very few other companies can guarantee. Our technological facilities allow a high degree of flexibility in the fermentation of small and large production units. In addition, a variety of packaging types and quantities can be perfectly adapted to your batch size. All products are tested during the production process according to a variety of quality assurance methods in our own laboratory in Switzerland as well as by the independent institute Arotop food & environment GmbH. In collaboration with the independent institute Arotop food & environment GmbH and a number of Swizz universities we are working on various research projects.

Redding and colour of fermented sausages

The consumer expects the fermented sausages to have a red curing colour.
Conventionally, a red curing colour is formed by the curing process with the decomposition product nitrogen oxide from the nitrite curing salt. To accelerate the curing process, the antioxidant ascorbic acid and its derivatives are used. These products are called reddening aids. At MOGUNTIA we know of two classes of reddening aids.

FARBFEST®
products are based on ascorbic acid and accelerate nitrate removal. Some of them are also combined with citric acid and other auxiliary agents to improve their effectiveness.

FARBFEST Rubin®
products on the other hand contain the salt of ascorbic acid and have a moderate rate of nitrite degradation. This is especially important in the pre-curing of meat to prevent deflagration of the nitrogen oxide.

RUBINAL®
For the extra color of reddened sausages. This gives the sausage the attractiveness and color stability it deserves. Even in strong light, the sausage retains its beautiful red color.

Emulsions and protein substitutes

Emulsions, or more specifically, preemulsions, are used to put processing materials and foodstuffs into a state that makes production possible. As a result, it is also possible to prepare vegetable fat and protein substances, and also those in non-conventional
animal form (for example flare fat and kidney fat), in such a way that they correspond to processability similar to that of a common bacon material. The same applies to animal and vegetable proteins.

SAFTEX®
represents the group of functional saccharides. From monosaccharides (dextrose) to polysaccharides (fiber and fibers). Depending on the application, these products can be used for the pre-emulsion, as synarase blocker, to give structure, for fiber enrichment or to increase the water binding capacity.

Fatbinder
This, in contrast, offers the perfect basis for all types of pre-emulsions, in particular meat, chicken skin and fat emulsions and for the production of fat and meat substitutes.

Flavour enhancers for an even better taste
Flavour enhancers for an even better taste

Flavour enhancers are the feng shui of meat processing. They create the harmony of taste withoutappearing dominant themselves.
Flavour enhancers
• give a full and rounded taste
• create a harmonic taste profile
• make you use less salt
• shape the taste profile (by complementing with smoke (SMOOX®), garlic and other flavours)
• conceal foreign influences, for example in the processing of MDM meat or emulsions.

GLUTESSA®
Combines all flavour enhancers based on monosodium glutamate. For a perfect taste.

AROSTAR®
Flavour enhancer without glutamate. For best taste with highest naturalness.

Casings

Fermented sausage fibrous casing

With the fibrous casings by the MOGUNTIA FOOD GROUP, you cater for a Mediterranean fermented sausage optic for home-made salami.
The casing is ideal for all types of air-dried fermented sausages or lightly smoked salami products.
• Attractive look
• Easy to use
• No cross-product mould cultures needed
• No mould substitute needed
• Casing does not crumble when sliced
• With all the properties of BESSAVIT®Net

Dip coats

Besides the optical improvement, dip coats have more advantages for fermented sausage applications and smoked ham:
• Increase in the variety of products
• By varying the refinement of the surface, any number of end products can be made available
• Upgrading the product and optimising the grammage
• Customer-specific solutions
• Bacteria barrier, no loss in the drying process in the course of the best before date

Spices and compounds

Balanced spice mixtures for all needs of traditional and modern fermented sausage production with the perfect combination of sugar.
The spices are a perfect match for the MOGUNTIA starter cultures.

BESSAVIT®
The classic way of making fermented sausage. By using nitrite curing salt, the work is done effectively and quickly – and in a natural maturing process.

FF 110
For the extra fast maturing of fermented sausages in combination PrestoSTART® aromatic Starter Cultures. Under natural maturing conditions, the specially contained
sugar combination is metabolised by the lactic acid bacteria.

FIXREIF®
The fast way of raw sausage production and for all Impatient. Acidification does not come alone here about the microorganisms but above all through the GDL. So it works under nearly all conditions.

FIXREIF® GdL free
The modern way of maturing fermented sausage. Instead of the GDL, in this case, special starter cultures and a balanced combination of sugar does the work. This way, it works just as fast as with GDL but in a natural way under the right climatic conditions.

SALREIF®
The traditional method of making fermented sausages. My maturing with Salpeter, the unmistakeable taste of long matured salami is achieved. The greater effort in time is rewarded by a really special product.

Bacteria reduction by way of infrared

As a modern, family-run company and one of the leading spice factories in Europe, we not only bear responsibility for food safety, the focus for us is equally on quality.
With our new degermination plant on the basis of infrared technology, we are able to treat products by way of short-wave infrared light in such a way that their microbiological load is significantly reduced. In contrast to other degermination processes, the product is not damaged optically or in terms of the senses.

IRD-Technology: Gentle heat treatment thanks to infrared

Heat into the core. Thanks to short-wave infrared rays, the heat is directed straight into the core of the product.
From the inside out. Due to the active principle of infrared light, that product to be treated is heated from the inside out and exposed to heat from the outside as well. This ensures a homogenous distribution of heat.
• Release of humidity. The heat flow drives the humidity from the inside out. After the humidity has left the product it is removed directly by the air circulation in the machine.

IRD-Technology: Always on the move

Turning. The turning of the drum caters for a constant movement of the material.
Even. the spirals and mixing elements attuned to the product cater for a permanent and optimal stirring of the material. It does not stick and is heated evenly. A formation of clusters is prevented.
Gentle. The product is stirred and transported gently, continuously and at low speed. Swirling is prevented. Even sensitive, fragile and sugary products are treated gently.

The advantages of IRD technology infrared rotary drum

Besides food safety, the focus is on the quality of the raw materials. With IRD technology, we manage both.

• Product protection. Maximum protection of the sensorics, optics and ingredients of the product such as essential oils and other easily transient aroma components.
• No steam required. No condensation, which could impact the sensory properties, is formed.
• Stabilisation and intensification of the colour values.
• The method can both dry and accumulate residual humidity in a targeted way.
• Reduction in bacteria and harmful substances.

• Natural process. No use of additives in the degermination process.
• The continuous stirring caters for a homogenous drying process and prevents the formation of clusters.
• Infrared does not dissipate any ionising radiation. The infrared bacteria reduction process thus does not represent processing with ionising radiation, meaning that no corresponding labelling is necessary.
• The process is classified as permitted under food safety laws and is thus not subjected to any special regulations.