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Trouble Shooting

Sausages

1. SAUSAGE SPLITTING

POSSIBLE CAUSES COMMENT AND ACTION
(a) Excess free water in the recipe Excess water will turn to steam on cooking, causing the sausage to split. Rusk will absorb twice its weight in water and should be adjusted accordingly.
A) Check water quantity in recipe
B) Ensure water is added gradually during chopping with rusk added last
(b) Too much fat in the recipe Maximum legal fat limit is 50% of the meat content.
Note how much fat is associated with lean meat. Reduce fat and increase lean meat. Newpro will help to bind fat and may be included at 2% reducing the rusk accordingly.
(c) Insufficient functional meat in
the recipe		 This may reduce the binding within the sausage leading to splitting. Try adding a proportion of belly/shoulder/flank. Newpro may also be used as an emulsifier as in 1. (b).
(d) Product may not contain
Phosphate		 Phosphate enhances the function of salt as a binder.
Seasoning containing phosphate is recommended. Contact Lucas for advice.
(e) Incorrect chopping procedure Seasoning is added at the start of chopping/mixing to ensure that the sufficient protein extraction creates a sticky brat. Water is added gradually during chopping/mixing with rusk added last.
(f) Temperature of manufacture too
high/low 		This will affect the efficiency of protein extraction and binding. Production temperature should lie between -1°C and 10°C.
(g) Blunt bowl and chopper blades,
blades set too high		 Such blades will cause inefficient emulsification resulting in poor binding. They will bruise the meat and raise the production temperature. Sharpen as necessary or reset.
(h) Inefficient filling Overfilled or underfilled sausages with air pockets are more likely to burst. Check that filler nozzle is smooth with no burrs to damage the casings.
(i) Free water trapped in sausage
after filling		 Ensure all free water and ice particles are melted and absorbed during manufacture. (See 1. (a)).
(j) Poor cooking procedure Ideally sausages should be cooked relatively slowly, e.g. shallow or deep fat fried. Rapid cooking or dry cooking of the sausage with no turning as in grill or baking may encourage splitting.
(k) Examine casings Although unlikely, remember that casings may be damaged or at fault.


2. COLOUR FADING/LACK OF SHELF LIFE

POSSIBLE CAUSES COMMENT AND ACTION
(a) Poor quality and storage of meats Poor quality meats and head meats generally have a higher bacterial count. If the storage of meats and/or sausage is poor then rancidity may occur, colour loss and poor shelf life. Storage of sausage should be dry, in a chiller at 2°C. If storage temperatures of meat or sausage is too high then bacterial problems will arise. Meat or sausage should be stored for longer periods of time in the freezer.
(b) Temperature of manufacture too high Bacterial problems may arise as in 2. (a). (See 1. (f)).
(c) Sausages have wet skins on packing This encourages bacterial growth as in 2. (a). Sausages should have a dry surface prior to packing especially those filled in natural casings.
(d) Seasoning does not contain colour/ antioxidant/preservative Colour may enhance the appearance of sausage.
Antioxidant will help prevent colour variation and rancidity. Preservatives will control bacterial growth and may extend shelf life from 3 days to 5 days.
Contact Lucas for advice or use safpreserve at 1 _ oz to 20 Lb chop. Add Safpreserve with seasoning.
(e) Seasoning contains visual herbs e.g. Sage. Visual herbs contain a number of bacteria, which may affect colour if temperature of manufacture and storage is incorrect.
(f) Nitrite contamination This may occur if curing is taking place in the same area as sausage manufacture. Sausage may appear dark when fresh and pink on cooking. Ensure all equipment used for sausage production is clean and dry. For washing equipment with suspected nitrite contamination a 2% solution or sodium ascorbate or ascorbic acid is recommended. (Handful to a bucket of cold water).


3. SAUSAGE TOO WET OR DRY

POSSIBLE CAUSES COMMENT AND ACTION
(a) Incorrect water ratio Various extenders have differing water absorbencies:
DYR Rusk - 1:2
Newpro - 1:3
Solus - 1:2-3
Bread Rusk - 1:1
Farina/Wheat Starch - 1:1 (1:4 on cooking)
Dehydrated Vegetables – as recommended by the manufacturer
(b) Temperature of manufacture too high Bacterial problems may arise as in 2. (a). (See 1. (f)).
(c) Sausages have wet skins on packing This encourages bacterial growth as in 2. (a). Sausages should have a dry surface prior to packing especially those filled in natural casings.
(d) Seasoning does not contain colour/ antioxidant/preservative Colour may enhance the appearance of sausage.
Antioxidant will help prevent colour variation and rancidity. Preservatives will control bacterial growth and may extend shelf life from 3 days to 5 days.
Contact Lucas for advice or use safpreserve at 1 _ oz to 20 Lb chop. Add Safpreserve with seasoning.
(e) Seasoning contains visual herbs e.g. Sage. Visual herbs contain a number of bacteria, which may affect colour if temperature of manufacture and storage is incorrect.
(f) Nitrite contamination This may occur if curing is taking place in the same area as sausage manufacture. Sausage may appear dark when fresh and pink on cooking. Ensure all equipment used for sausage production is clean and dry. For washing equipment with suspected nitrite contamination a 2% solution or sodium ascorbate or ascorbic acid is recommended. (Handful to a bucket of cold water).


 
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