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MEAT PROCESSING TRAINING MANUAL Motivational Centre for Africa’s Transformation Plot 22A, Suite 1, Off Chishango
MEAT PROCESSING
TRAINING MANUAL
Motivational Centre for Africa’s Transformation
Plot 22A, Suite 1, Off Chishango Road,
Villa Elizabetha,
Box 32834, Lusaka-Zambia
Tel: +260 211 221875/221878
Cell: 0977 848320/ 0963201397
Email: gilbert@mocat.zm
Website: www.gilbertbanda.net.
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Table of Contents

INTRODUCTION PROCESSING OF MEAT PRODUCTS

2

EQUIPMENT FOR MEAT PROCESSING

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STANDARD PRACTICES

11

PRINCIPLES OF MEAT PROCESSING TECHNOLOGY

11

MAKING SAUSAGE

12

HOW TO MAKE BOEREWORS SAUSAGES

15

HOW TO MAKE

FRENCH POLONY- BOWL CUTTER METHOD

17

HOW TO MAKE VIENNA’S BOWL CUTTER METHOD

19

CURED AND SMOKED MEATS

21

INTRODUCTION PROCESSING OF MEAT PRODUCTS

The fall in profits as a result of increased feed prices has resulted in Livestock farmers being interested in slaughtering and marketing their own animals. As a result, Abattoirs on farms are also becoming more common as farmers try to increase their profits and profitability. However to process meat, one does not have to have an abattoir on the farm as you will learn in this training course. Approved meat from a butchery can be brought in for processing from outside Meat is a very versatile food substance with a wide variety of processed product possibilities. So far the consumption patterns favors processors as most Zambians like to eat processed products like pork sausage, beef sausage or Chicken sausages. Value addition is an important concept and approach in today’s business environment where innovation in farming and agri food processing are important to remain competitive and to optimize returns from an enterprise.

Principles of Meat Processing Technology

from an enterprise. Principles of Meat Processing Technology Meat processing technology comprises the steps and

Meat processing technology comprises the steps and procedures in the manufacture of processed meat products. Processed meat products, which include various different types and local/regional variations, are food of animal origin, which contribute valuable animal proteins to human diets. Animal tissues,

in the first place muscle meat and fat, are the main ingredients, besides occasionally used other tissues such as internal organs, skins and blood or ingredients of plant origin. All processed meat products have been in one way or another physically and/or chemically treated. These treatments go beyond the simple cutting of meat into meat cuts or meat pieces with subsequent cooking for meat dishes in order to make the meat palatable. Meat processing involves a wide range of physical and chemical treatment methods, normally combining a variety of methods. Meat processing technologies include:

Cutting/chopping/comminuting (size reduction) Mixing/tumbling Salting/curing Utilization of spices/non-meat additives Stuffing/filling into casings or other containers Fermentation and drying Heat treatment Smoking

Meat Processing Equipment

In modern meat processing, most of the processing steps can be mechanized. In fact, modern meat processing would not be possible without the utilization of specialized equipment. Such equipment is available for small-scale, medium- sized or large-scale operations. The major items of meat processing equipment needed to fabricate the most commonly known meat products are listed and briefly described hereunder.

The following machines are the basic machines for meat processing

1. BOW CUTTER

-

2. MINCER/GRINDER

3. BUTCHER BOY

-

-

4. SAUSAGE FILLER -HYDRAULIC

5. STEAM COOKER

6. WRAPPING MACHINE

-

-

7. VACCUM SEALING MACHINE

8. DISPLAY CHILLER

9. FRIDGE

10. SCALES

Meat grinder (Mincer)

Meat grinder (Mincer) 4
5

A meat grinder is a machine used to force meat or meat trimmings by means of

a feeding worm (auger) under pressure through a horizontally mounted cylinder

(barrel). At the end of the barrel there is a cutting system consisting of star- shaped knives rotating with the feeding worm and stationary perforated discs (grinding plates). The perforations of the grinding plates normally range from 1 to 13mm. The meat is compressed by the rotating feeding auger, pushed through the cutting system and extrudes through the holes in the grinding plates after being cut by the revolving star knives. Simple equipment has only one star knife and grinder plate, but normally a series of plates and rotary knives is used. The

degree of mincing is determined by the size of the holes in the last grinding plate. If frozen meat and meat rich in connective tissue is to be minced to small particles, it should be minced first through a coarse disc followed by a second

operation to the desired size

Hole diameters can vary from 13 to 5 mm.

The smallest type of meat grinder is the manual grinder) designed as a simple stuffing grinder, i.e. meat material is manually stuffed into the feeder. For all these small machines the Enterprise cutting system is used with one star knife and one grinder plate. These machines are very common everywhere in food processing but their throughput and production capacity is limited due to the small size and manual operation. The intermediate size meat grinder, also

designed as a stuffing grinder, has orifice diameters up to 98 mm. It is driven by a built-in single-phase electrical motor (250 V) and available as both a table and floor model. The meat is put onto the tray and continuously fed by hand into a vertical cylindrical hole leading to the feed auger. The meat or fat is forced by

its own weight into the barrel with the rotating feed auger. This type of meat

grinder is the most suitable for commercial small-scale operations. Some brands

use the Enterprise cutting system, others the Unger system

Large industrial meat grinders are driven by a three-phase electrical motor (400 V) and equipped with the Unger cutting system. The orifice cylinder diameter of this type of grinder ranges from 114 - 400 mm. Industrial grinders are either designed as stuffing grinders with either tray or hopper or as an automatic mixing grinder. The automatic mixing grinder has a big hopper and the meat falls automatically onto the mixing blades and the feeding worm (auger). The mixing blades and feeding worm can be operated independently with mixing blades rotating in both directions but the feeding worm only towards the cutting set. Most of the industrial meat grinders are also equipped with a device for separating tendons, bone particles and cartilage

Bowl cutter, single-phase motor(20 Litre)

Bowl cutter, single-phase motor(20 Litre) The bowl cutter is the commonly used meat chopping equipment designed

The bowl cutter is the commonly used meat chopping equipment designed to produce small or very small (“finely comminuted”) lean meat and fat particles. Bowl cutters consist of a horizontally revolving bowl and a set of curved knives rotating vertically on a horizontal axle at high speeds of up to 5,000 rpm. Many types and sizes exist with bowl volumes ranging from 10 to 2000 litres. The most useful size for small- to medium-size processing is 20 to 60 litres. In bigger models bowl and knife speed can be regulated by changing gears. Bowl cutters are equipped with a strong cover. This lid protects against accidents and its design plays a crucial role in the efficiency of the chopping process by routing the mixture flow. Number, shape, arrangement, and speed of knives are the main factors determining the performance of the cutter). Bowl cutters should be equipped with a thermometer displaying the temperature of the meat mixture in the bowl during chopping.

Bowl Cutter- Industrial

Bowl Cutter- Industrial 8
Manual Sausage filler 9

Manual Sausage filler

Wrapper Hydraulic sausage filler 10
Wrapper Hydraulic sausage filler 10

Wrapper

Hydraulic sausage filler

MEAT PROCESSING STANDARD PRACTICES

Meat processing technologies include on the one hand purely technical processes such as Cutting, chopping, comminuting Mixing, tumbling Stuffing/filling of semi-fabricated meat mixes into casings, synthetic films, cans etc

. Heat treatment On the other hand, chemical or biochemical processes, which often go together with the technical processes, are also part of meat processing technology such as Salting and curing Utilization of spices and additives Smoking Fermentation and drying These processes are described hereunder Frozen meat cutter with rotating round knives for cutting out pieces/chips from frozen meat blocks

PRINCIPLES OF MEAT PROCESSING TECHNOLOGY

1. Cutting (reducing meat particle size) There are five methods of mechanical meat cutting for which specialized machinery is used: Mincing (grinding) of lean and fatty animal tissues. Larger pieces of soft edible animal tissues can be reduced in size by passing them through meat grinders. Some specially designed grinders can also cut frozen meat, others are equipped with devices to separate “hard” tissues such as tendons and bone particles from the “soft” tissues (minced muscle meat particles)

2. Chopping animal tissues in bowl cutter (discontinuous process) Bowl cutters are used to chop and mix fresh or frozen lean meat, fat (and/or edible offal, if required) together with water (often used in form of ice), functional ingredients (salt, curing agents, additives) and extenders (fillers and/or binders) .Chopping animal tissues in emulsifying machines (continuous process) The animal tissues to be emulsified must be pre-mixed with all other raw materials, functional ingredients and seasonings and pre-cut using grinders or bowl cutters. Thereafter they are passed through emulsifiers (also called colloid mills) in order to achieve the desired build-up of a very finely chopped or emulsified meat mix Chopping of meat mixture in bowl cutter; lid opened after finalizing chopping, cutter knives visible: Mincing of raw meat material for processed meat products in meat grinders

3. Frozen meat cutting Boneless frozen meat blocks can be cut in slices, cubes or flakes by frozen meat cutters or flakers. The frozen meat particles can be directly chopped in bowl cutters without previous thawing thus avoiding drip

losses, bacterial growth and discoloration which would happen during thawing

4. For small operations the manual cutting of frozen meat using cleavers or axes is also possible. Cutting of fatty tissues Back fat is cut in cubes of 2-4 cm on specialized machines to facilitate the subsequent chopping in cutters/emulsifiers. In small-scale operations this process can be done manually.

5. Salting / curing Salting Salt (sodium chloride NaCl) adds to the taste of the final product. The content of salt in sausages, hams, corned beef and similar products is normally 1.5-3%. Solely common salt is used if the cooked products shall have a greyish or greyish-brown colour as for example steaks, meat balls or “white” sausages For production of a red colour in meat products

MAKING SAUSAGES

Sausage making is a very old form of food preservation- it is believed that sausages have been made for as long as animals have been slaughtered for food. Although some sausages were eaten fresh, some types were spiced to help prolong their shelf life for few days or dried and preserved for later use.

Today, the making of sausages differs from country to country and from region to region. This difference may be due to the type and coarseness of the meat, the proportion of fat to lean meat and the addition of spices and seasonings. Even the casings used tend to differ and may be pork, beef, mutton or cellulose.

The making of Hungarian sausages has become an art form. This coarse, bind textured sausage is flavored with spices such as coriander, binder, cooked salami and garlic powder we have provided one variation which can serve as the starting point for the development of your own personal Hungarian recipe.

Preparing to make Hungarian Sausage (cooked sausage)

When you are preparing to make your Hungarian sausages, the meat has to be ready (Boneless: Pork, Speck, and Beef).

As you are preparing your meat, debone your beef, pork (which means to separate steak from bones).

your beef, pork (which means to separate steak from bones). Then remove connective tissue and cut

Then remove connective tissue and cut the meat in small pieces.

Clean your equipment with clean running water

Mince the beef/pork/speck using 3mm mincing plate.

Add the spice, ice water and the minced meat and mix well in a bowl cutter. Add all the other remaining ingredients and chop until you get the desired smooth texture or paste.

Stuff the emulsion into 28-32mm sausage casing then twist the casing to form sausages 10cm in length.

To smoke the sausages, hang them in the smoker and smoke at a medium temperature for 20-30 minutes. Lower the sausages so that they are closer to the heat, add more saw dust and smoke with increased heat for a further 30-40 minutes until brick colour. Cook at 75- 80*C (use a Butchers temperature probe) for 20 minutes, then cool down with ice water. Hang up to dry, and then refrigerate or put in cold room

RECIPE FOR HUNGARIAN Sausage

Inputs

Pork (boneless)

10kg

Beef (boneless)

5kg

Cooked Russian

1kg

Water/ice

4lts

Binder

100g

Garlic

50g

Starch

250g when it has more fats

Casing

½ Hunk

We put the weighed meat into the mincer and mince

We put the minced meat into the bowl cutter and run the machine and put spice while it is running until it turns into paste form

We take the meat paste into the filler and fill it into the casings

Note that the casing must be washed in water before using them because they have salt as they are preserved in salt. Too much salt can damage the product

Russian or sunset yellow is added to the casing to make the sausage look golden brown.

We hung the sausages in the smoker for 40 minutes then we apply the saw dust on the fire for the sausages to be smoked in the smoker

From the smoker the sausages are taken in the cooker for cooking for 40 minutes at 80 degrees temperature

Finally the product is hung for 30 minutes to cool and ready for packaging

HOW TO MAKE BOEREWORS SAUSAGES- UNCOOKED SAUSAGE Traditional Boerewors -Ingredients Binder Casing Crystal salt

HOW

TO MAKE BOEREWORS SAUSAGES- UNCOOKED SAUSAGE

HOW TO MAKE BOEREWORS SAUSAGES- UNCOOKED SAUSAGE Traditional Boerewors -Ingredients Binder Casing Crystal salt

Traditional Boerewors -Ingredients

Binder

Casing

Crystal

salt

Beef

Boneless

Pork

Boneless

Equipment preparation

1. Ensure that equipment is clean.

2. Ensure mincer knives and plates are sharp. Run fat through

mincing.

mincer prior to

3. Place a nozzle correlating with the diameter of the casing onto the filler.

Preparation

1. Rinse and soak casings.

2. Pre cool all meat to 0 degrees Celsius.

3. Chill water to 2 degrees Celsius.

Method

1. Weigh off suggested meat and mince through a 13mm plate of the mincer/ grinder.

2. Add the crown unit/ batch pack to the chilled water, mix thoroughly and allow standing for 15-20 minutes.

3.

4. Mix well and mince through

Combine

minced meat with crown unit pack or batch/water

mixture.

2=4.5mm for boerewors, braaiwors and wors or

3mm plate for sausage products.

5. Put the meat mixture

into the filler and charge the nozzle with washed casing.

Fill slowly.

6. Allow the completed boerewors

refrigerated room.

to

mixture for 12 hours by hanging in a

The above production method is also applicable in the manufacture of wors,

braaiwoers and all kinds of sausage products.

Troubleshooting in fresh products

It sometimes happens

that fresh

products such as boerewors, woers etc. take on

an unpleasant dark color soon after manufacture. To prevent this occurring to your products, insure that you adhere to the following tips

1. Keep to the recommended recipe as the levels of preservatives have been accurately determined for the final product by our Research and Development Laboratory.

2. Always thoroughly rinse buckets and containers used to decant tap water, as they may be contamination with nitrate dust.

3. Always ensure equipment used for the manufacture of fresh products is located well from the cured/processed products line. This is because curing salts contain

nitrate which easily dusts. This I will settle on equipment and products causing

contamination. For this reason it is always a good idea to rinse equipment before

using.

4. Saltpeter will cause a curing reaction in the fresh product causing it to darken,

looking old and stale. This process will reverse on

product a raw cured appearance. Fix fresh may be used to neutralize the effects

of nitrate contamination. Ascorbic

will preserve product, preventing bacterial growth resulting in color

deterioration.

cooking, giving the cooked

acid can be used to enhance color. Crystal

5. Meat quality is the most important factor in manufacture of fresh products. The

use of old/off meat will accelerate the deterioration by bacterial growth.

of color and product

6. Always rehydrate/dissolve the unit/batch pack in some of the iced water

to

ensure an even distribution in the ingredients.

of spices, salt and most importantly, the preservation

7. Blunt or unpaired knives, blades and plates will cause-

a. Breakdown of the muscle

protein, allowing bacteria to multiply rapidly and

cause spoilage and discoloration of products.

b. Heat generation due to the friction, which may result in a pale grey product.

HOW TO MAKE

FRENCH POLONY- BOWL CUTTER METHOD

Preparation

HOW TO MAKE FRENCH POLONY- BOWL CUTTER METHOD Preparation 1. Pre mince lean beef and lean

1. Pre mince lean beef and lean pork through and chill to 0 degrees Celsius.

2. Pre mince spec through 3mm plate and chill to 0 degrees

Method

Celsius.

1. Place minced lean beef and lean pork in a bowl cutter; add curing salts and cutter for a few revolutions.

2.

Add half of the ice and cut to the fine emulsion on high speed until good binding is achieved (max 6 degrees Celsius).

3. Add

remaining

ice, spec and the rest of crown unit/batch pack and cutter

until a temperature of 12 degrees Celsius is reached.

4. Dissolve 5grams of butcher’s red into 50ml boiling hot water. Mix well and add ice to mixture.

5. Remove emulsion from bowl

cutter and place

meat

mixture into the filler. Fill

6.

into crown French polong casings.

Cook

degrees Celsius.

at

75 - 80 degrees

Celsius

7. Cool in cold water.

to an internal core temperature of 68

Troubleshooting in Emulsion Products

Consistency

too hard

This can have a number of causes. Firstly percentage lean and /or connective tissue protain could be too high. This means the excessive rind material may have been used. It can be remedied by using the correct sausage formation. The second cause could

be that too little ice water

formulation. If one is manufacturing under a vacuum, the

at too high a level. To rectify this, reduce the vacuum time and intensify. If too much

soy protain or starch was used, the consistency will also be too hard and your problem will be solved.

was used. To

remedy. Increase the ice water quantity in

vaccum should be drawn

the formulation

Consistency too soft

In this case, it means not enough connective tissue protain is going into emulsion. Increase the percentage lean and the ratio of the tendon rice meat. Sausage emulsion

that is excessively processed

Keep the required process temperatures in mind

cutter must also be checked for mechanical defects such as blunt cutting edges on

the bowl cutter knives.

in a bowl cutter destructs the connective tissue structure.

throughout

the process. The bowl

Another reedy to the problem could be to increase the percentage of soya or starch used in the formulation.

Fat caps and jelly pockets

This happens because of borderline or unstable emulsion which air to be incorporated

during the cutting or filling process. These air pockets are then filled with gelatin if the

emulsion has borderline stability. If too much collagen protain and insufficient

myosin protain are use, fat caps and jelly pockets form too. High fat and high collagen

ratios have similar consequences.

salt

Fat rendering, fat pockets and greasing out

The breakdown of emulsion could be caused by:

Too much collagen protein used.

Too much frozen meat used.

Overcooking the product.

Too much frozen fat used.

Too much product rework.

Emulsion chopped for too long, so that not enough soluble protain is available to coat and solubilize the fat globules.

Emulsion at elevated temperatures.

Emulsion held too long under pressure before filling.

Emulsion overworked during transfer pumps and pipes.

Product being under filled.

Product not properly filled.

If frozen meat is held at 4 to 2 degrees Celsius,

the

resulting formation of large ice

crystals will rupture cell structure and denature the protain. Thus the binding and emulsion stability will be reduced.

HOW TO MAKE VIENNA’S BOWL CUTTER METHOD

1.

Preparation

1.

Pre mince lean beef and lean pork through 3mm plate and chill to 0 degrees Celsius.

2.

Pre mince spec through 3mm plate and chill to 0 degrees Celsius.

Method

1. Pre minced lean beef and pork in a bowl cutter, add curing salts and cutter for a few revolutions.

2. Add half of the ice and cut to fine emulsion on high speed until good binding is achieved (max 6 degrees Celsius).

3. Add remaining ice, spec and rest of the crown unit pack/batch pack and cutter until temperature emulsion from degrees Celsius is reached.

4.

Remove emulsion from bowl cutter and place meat into desires casing.

mixture into the filler. Fill

5. Dry

at 55 degrees Celsius, hot

color is achieved.

smoke at 65 degrees Celsius until desired smoke

6. Cook at 75 degrees Celsius to an internal core temperature of 68 degrees Celsius.

BOEREWORS

SAUSAGE

Traditional Boerewors

Binder

Casing

Crystal

salt

Beef

Boneless

Pork

Boneless

TIPS

ON

BUTCHERY

SET UP

1. Know the beef cut and pork cuts

2. Price or value the Beef/Pork cuts accordingly

3. Do not run out of stock

4. Fill your shop with varieties

5. Display every product you have. It cannot

6. Offload your old stock before you start the new stock. That is first come first go.

7. Keep your shop clean and neat.

8. Know the best way on how to price your processed products.

9. Advertise your products. Spread to customers well and convince them to go out

be

sold

if not displayed.

atleast with

CURED AND SMOKED MEATS

Until the last century, curing was used for preservation, but is now used primarily for the development of flavor and color.

There are two basic methods of curing, namely, dry curing and wet curing. In dry curing, the cure is rubbed into the meat by hand while in the later method the meat is soaked in a mixture of water and curing agents. Although dry curing is faster, it results in high mass loss and is now considered old-fashioned. Commercially prepared curing period considerably- the meat is ready for cooking or smoking six to seven hours after injecting the curing mixture into the meat by means of a perforated needle or two to five days after immersion.

Apart from the preserving effect smoking has on meat, it also gives it a unique flavor and rich brown color. Whether done on a commercial or a home scale, the technique of smoking involves hanging the meat or placing it on racks in a chamber designed to contain the smoke. Depending on the thickness of the meat and the type of meat being smoked, the smoking period may vary from as short as a few minutes to several hours or even days.

as short as a few minutes to several hours or even days. CURING INGREDIENTS The basic

CURING INGREDIENTS

The basic ingredients of a home cure are salt, pepper,sugar, bicarbonate of soda, spices and for wet curing, water.

Salt is the active preservation agent and gives cured meat its specific taste. Clean, coarse salt (doing salt) is best for home curing although fine salt is generally used in commercial mixtures.

Sugar counteracts the toughening effect of salt and adds to the flavor. Although yellow or brown sugar is tastier than white, it should never be moist as this causes the curing mixture to foam and the meat to spoil.

Spices help to improve the flavor of the meat and are usually added according to personal taste. Combinations of some or all of the following seasonings are commonly used: Pepper, bag leaves, whole coriander, garlic, ground ginger and mustard powder.

Water should always be pre-boiled. This helps to dissolve the curing ingredients more easily and also serves to sterilize the current to prevent spoilage.

also serves to sterilize the current to prevent spoilage. The smoking chamber or SMOKER A smoking

The smoking chamber or SMOKER

A smoking chamber can be built of brick with a concrete floor and tight-fitting door. The size of the chamber may vary but a convenient guide 1,5 X 1,5 X 2

meters for ventilation the roof should have a chimney and at the base of the chamber there should be an opening of about 25mmX600mm. Make provision for hanging the meat by building steel bars into the walls. Those can be placed at two different heights about 500mm apart.

can be placed at two different heights about 500mm apart. The Sawdust Sawdust from pine is

The Sawdust

Sawdust from pine is usually used for smoking purposes. Mealie stalks, vine stalks and sunflower hay make adequate substitutes. You can use also wet fruit leaves like guava, mango lemon to smoke

stalks and sunflower hay make adequate substitutes. You can use also wet fruit leaves like guava,

Smoking Times

Smoking times are difficult to predict since other factors such as the outside temperature, wind, the type of smoking apparatus used and so on influence these times. As you gain more experience in smoking your products you will be able to judge more accurately when the product is ready, but good guideline is to use the recommended quality of sawdust (2kg) and allow it to burn out completely; sausages and biltong on the other hand often have to be removed before the sawdust burns out as they are ready sooner than large cuts of meat.

burns out as they are ready sooner than large cuts of meat. Smoking Chickens Inputs for

Smoking Chickens

Inputs for smoking 10 Chickens

Chickens

10

Salt

250g

Garlic powder

30g

Quick Cure

70g

Dark brown Sugar

70g

Cold water

15lts

Step by step process

1. Select chickens should not be more than 2kg! On average should be 1.5 kgs per chicken.

2. Put the 15 liter water in a bucket.

3. Mix the ingredients that you selected and weighed and put them in the bucket and stirs until they dissolve completely. Then put the chickens in the solution made and soak them for 12-24 hours to ensure the solution soaks in the meat

4. Then after the 12=24 hours soaking hung the chickens in the smoker! Depending on the type of smoker, let them hung for 40 minutes to drip and dry them, after that then you apply the saw dust on the fire until you get the brown golden color

5. For smoking, we recommend that you use Pine wood sawdust

6. The smoking period should be 2 hours minimum for the chicken to be ready. But we have had people who smoke for 2- 18 hours

2. Making Garlic Polony

Inputs

Pork boneless

10kg

Beef boneless

5kg

Ice water

4lts

Binder

100g

Garlic powder

50g

French spice

1kg

Butcher’s red

5g

Casing

3mts

We take the meats into the mincer for mincing

After mincing ,the mince is taken into the bowl cutter

This is where we mix the spices and ice water. we run the bowl cutter until the mixture in the bowl cutter turns into paste form

From here we take the paste into the sausage filler and fill into the casings

After filling the paste in the casing, we take the product to be cooked for two hours and the temperature should be 80 degrees Celsius

There after the product is done and put it in cold water for 20 minutes to cool off

Note the casing should be cut into 30cm size

3. Boerewors Sausages

Inputs

Beef (boneless)

10kgs

Pork (boneless)

5kgs

Salt

150g

Coriander

150g

Nutmeg

15g

Black paper

30g

Cloves

15g

Crystal

10g

Casings

¼ hunk

We take the weighed meats and mix them the meat with spices in a dish

The mixture we put into the mincer and mince it once

Then we put the mixture into a filler and fill it in the casings

We put our sausages on trays for wrapping using a wrapping machine

We put stickers and put the product into a cold room or fridge

4. Hungarian Sausages

Inputs

Pork (boneless)

10kg

Beef (boneless)

5kg

Cooked Russian

1kg

Water/ice

4lts

Binder

100g

Garlic

50g

Starch

250g when it has more fats

Casing

½ Hunk

We put the weighed meat into the mincer and mince

We put the minced meat into the bowl cutter and run the machine and put spice while it is running until it turns into paste form

We take the meat paste into the filler and fill it into the casings

Note that the casing must be washed in water before using them because they have salt as they are preserved in salt. Too much salt can damage the product

Russian or sunset yellow is added to the casing to make the sausage look golden brown.

We hung the sausages in the smoker for 40 minutes then we apply the saw dust on the fire for the sausages to be smoked in the smoker

From the smoker the sausages are taken in the cooker for cooking for 40 minutes at 80 degrees temperature

Finally the product is hung for 30 minutes to cool and ready for packaging

5. Chicken Hungarian

Inputs

Spice cooked Russian

1kg

Chicken fillets

8kg

Chicken skins

4.5kg

Garlic powder

50g

Chicken fat

2.5kg

Binder

100g

Starch

200g

Casing

½ hunks

Ice water

4 lts

The same formula of the other Hungarian

We put the weighed meat into the mincer and mince

We put the minced meat into the bowl cutter and run the machine and put spice while it is running until it turns into paste form

We take the meat paste into the filler and fill it into the casings

Note that the casing must be washed in water before using them because they have salt as they are preserved in salt. Too much salt can damage the product

Russian or sunset yellow is added to the casing to make the sausage look golden brown.

We hung the sausages in the smoker for 40 minutes then we apply the saw dust on the fire for the sausages to be smoked in the smoker

From the smoker the sausages are taken in the cooker for cooking for 40 minutes at 80 degrees temperature

Finally the product is hung for 30 minutes to cool and ready for packaging

6. Smoking of Fish

Inputs

To start with 7.5kgs of fish

Garlic

30 grams

Quick cure

50 grams

Dark brown sugar 70grms

Salt

60 grams

Cold water

10lts

1. Put the above ingredients in bucket of water and stir until they are dissolved completely and put the fish in the solution for 2 hours.

2. After two hours put the fish in the smoker for smoking

3. Put saw dust on fire until the fish turns brown

4. The smoking period is 1 hour 30 minutes and the fish is done for packaging and ready for sale or eating.