INTRODUCTION
Rationale
In modern life, consumer demand for food, particularly meat products, has surged, making meat the most popular category in the food industry The application of advanced technologies in meat production has led to a rapid increase in industrial-scale sausage production Over the years, various types of sausages have emerged, each reflecting unique characteristics influenced by regional climates and the diverse spices used in their preparation.
The market today offers a diverse range of sausages, both domestically and internationally These sausages can be categorized based on their ingredients, including beef, shrimp, pork, and fish varieties Additionally, they can be classified by production methods, such as fresh sausage, uncooked smoked sausage, cooked smoked sausage, dry sausage, semi-dry sausage, and various cooked meat specialties.
Sausages are widely enjoyed both locally and internationally, making quality and quality control during production critical concerns In light of this, I conducted a survey focusing on these important aspects.
Survey of process and technology for smoked sausage production at Vinh Anh Food Technology Joint Stock Company "
Report set out objectives as follows:
- Research the process of smoked sausage processing on an industrial scale from raw materials to packaging and finished products;
- Participate in the process of smoked sausage production, observe, evaluate and comment on the production process of sausages;
- Research on factors affecting the smoked sausage production process in Vinh Anh factory
- Investigate the procedure of smoked sausage producing in Vinh Anh Food Technology Joint Stock Company ;
- Comprehend and describe all steps in the smoked sausage producing and analyze factors that affect the quality of products during these processes;
- To study all equipments in the smoked sausage producing;
- To investigate the factory's food safety and hygiene system
Month Time Content of Work
Investigate the procedure of smoked sausage producing in Vinh Anh Food Technology Joint Stock Company
Comprehend and describe all steps in the smoked sausage producing and analyze factors that affect the quality of products during these processes
To study all equipments in the smoked sausage producing
To investigate the factory's food safety and hygiene system
31/08/2020 Collect the data and write the report
The survey was carried out in Vinh Anh Food Technology Joint Stock Company from March 01, 2020 to June 30, 2020.
Detailed schedule
Month Time Content of Work
Investigate the procedure of smoked sausage producing in Vinh Anh Food Technology Joint Stock Company
Comprehend and describe all steps in the smoked sausage producing and analyze factors that affect the quality of products during these processes
To study all equipments in the smoked sausage producing
To investigate the factory's food safety and hygiene system
31/08/2020 Collect the data and write the report
Timeline
The survey was carried out in Vinh Anh Food Technology Joint Stock Company from March 01, 2020 to June 30, 2020.
LITERATURE REVIEW
General information about Vinh Anh Food Technology Joint Stock Company 3 1 Introduction of company
Company name: Vinh Anh Food Technology Joint Stock Company (Vinh Anh FTJSC)
Type of activity: Joint Stock Company
Address: Ha Binh Phuong Industrial Cluster, Van Binh Commune, Thuong Tin District, Ha Noi City
Legal representative: Dao Quang Vinh
Vinh Anh Food Technology Joint Stock Company is a leading enterprise in the cattle and poultry processing and slaughtering industry, adhering to stringent food safety and hygiene standards Equipped with modern livestock and food processing lines, professional cold storage systems, and automated wastewater treatment facilities, Vinh Anh ensures both food safety and environmental protection The company supplies its products to various sectors, including supermarkets, restaurants, schools, factories, and industrial zones across Northern Vietnam Vinh Anh continuously innovates and develops new offerings from pork and chicken, providing customers with a diverse range of food products such as sausages, pork pies, and packaged fresh pork meat.
Currently Vinh Anh FTJSC is applying the ISO 22000: 2005, GMP and HACCP for measuring and managing quality of products [19]
2.1.2 History and development of the company
Vinh Anh FTJSC was established on October 12, 2007, operating under the business license No 050070248, issued by the Department of Planning and
Investment of Hanoi City The working area of the company is about 17,000 m 2 and located in Ha Binh Phuong industrial cluster, Thuong Tin District, Hanoi City
The forerunner of Vinh Anh FTJSC was Vinh Anh slaughterhouse in Trung Van Commune, Tu Liem, Hanoi since 1990
In 2007, recognizing societal development trends and consumer needs, Vinh Anh founded Vinh Anh Food Technology Joint Stock Company, which initially operated from a single facility equipped with a basic slaughterhouse system.
In 2008, Vinh Anh FTJSC secured a lease for 17,000 m² within the Ha Binh Phuong Industrial Cluster in the Thuong Tin District of Hanoi City to establish a factory dedicated to the slaughtering of cattle and poultry, as well as the processing of food products.
Between 2009 and 2012, with the backing of the Hanoi People's Committee, Vinh Anh departments and branches successfully established a factory featuring a state-of-the-art industrial slaughter line, a specialized cold storage system, and an automated wastewater treatment system, with a total investment nearing 100 billion VND.
Since 2013, Vinh Anh FTJSC has not only engaged in slaughter activities but has also prioritized the research and development of innovative food products, including pork and chicken sausages Furthermore, the company has made significant investments in specialized cold storage facilities and established a chicken slaughter plant, aiming to enhance the quality of products available to consumers.
The factory consists of three main areas for producing They are a factory for pig slaughtering that is closed, synchronous and modern, with a capacity of 600-
The facility processes 1,000 pigs per shift and features dedicated areas for cutting, filtering, and packaging pork, with a capacity of 30 tons per shift It also includes a food processing factory that produces various products like sausages and pork pies, utilizing modern equipment imported from France and China Additionally, the company is constructing a state-of-the-art chicken slaughter plant, equipped with advanced machinery imported from the Netherlands.
2.1.3 Map of the Vinh Anh FTJSC's management apparatus
Figure 2.1 The organizational map of Vinh Anh FTJSC
2.1.4 Duties and roles of departments
The general director oversees the daily operations of a company or organization and is accountable for its annual profits This role is synonymous with that of a Chief Executive Officer (CEO), who serves as the executive head of the company.
The production manager plays a crucial role in assisting the director and can act on behalf of the executive director when authorized, bearing full responsibility for production and business outcomes At Vinh Anh FTJSC, the production manager oversees the slaughter processing and sausage production, while currently preparing to implement a chicken slaughter process imported from the Netherlands This involves designing and planning the new procedure, in addition to managing six departments within the company, including the human resources department.
R&D Department production department, financial-accounting department, technical department and
The Human Resources department manages labor coordination, oversees personnel allocation across company units, and handles labor contracts and employee training It also addresses worker needs, monitors performance, and manages payroll, rewards, and disciplinary actions The Production department is responsible for overseeing production processes, ensuring technical standards, managing import and export activities, conducting product research and quality assessments, and delivering products to customers while maintaining quality compliance Meanwhile, the Financial-Accounting department manages the company's finances, ensuring accurate payment of salaries, bonuses, and procurement costs, while meticulously recording all import and export data in accordance with company regulations.
The technical department is responsible for the repair, operation, maintenance, and planning of the company's equipment and machinery This includes providing instructions for equipment use within the factory and conducting regular monitoring to ensure the accuracy of measuring instruments.
The QA department is dedicated to ensuring food hygiene and safety by developing regulations and monitoring product quality across various stages, including raw material procurement and storage It actively participates in research for new products, evaluates the quality of products and brands in collaboration with state agencies, and issues quality certificates for raw materials and finished goods prior to warehousing Additionally, the department is responsible for ongoing analysis, evaluation, and reporting on product quality to company directors and quality control agencies The QA department encompasses both the QC and R&D departments.
The Quality Control (QC) department is responsible for ensuring product quality throughout the entire process, from raw materials to finished goods They verify that the production line adheres to the established quality assurance system Meanwhile, the Research and Development (R&D) department focuses on researching and designing products that align with consumer demands.
The business director is responsible for overseeing customer-related activities, sales, and service operations in alignment with the company's business strategies Key functions of the business department include developing marketing strategies, managing advertising and sales efforts, facilitating agency distribution, providing services, and exploring new markets for innovative products.
2.1.5 Some products of the Vinh Anh Food Technology FTJSC
Pig’s legs Pork Pork chops
Pork Pork fat Pig heart
Figure 2.2 Fresh products of Vinh Anh FTJSC ( Source: www.vaf.com.vn )
Figure 2.3 Processed products of Vinh Anh FTJSC (Source: www.vaf.com.vn )
Overview of sausage products
Sausages enjoy worldwide popularity, with consumption patterns differing across countries These products consist of fresh, finely chopped meats that are processed through specific methods to achieve appealing sensory qualities As one of the oldest methods of meat preservation, the technology behind modern sausage-making is deeply rooted in historical practices.
The origins of sausage production remain unclear, as it predates recorded history Historical documents indicate that ancient civilizations enjoyed sausages thousands of years ago The Romans created a variety of flavorful sausages, which were popular during annual festivals and sacrifices, while lower social classes often consumed sausages made from tripe and other by-products For many years, the early Christian Church in Rome prohibited the consumption of sausages.
Sausage production, which began over two thousand years ago, remains a thriving market today While many fundamental processes have stood the test of time, the industry continually embraces advancements in processing driven by modern scientific and technical insights.
Sausages are diverse and challenging to categorize under a single definition, but they can be described by their form, size, or meat content Typically, sausages consist of comminuted meat products made from red meat, poultry, or a combination of both, along with salt, binders, and seasonings These mixtures are often encased in a casing and can be cured, smoked, or cooked.
The FAO (1985) definition about sausages that sausages are products in which fresh comminuted meats are modified by various processing methods to yield desirable organoleptic and keeping properties [2]
Sausages, as defined by Barnaby Sutton (2016), are a blend of ground or chopped meats mixed with spices and other ingredients, typically encased in various sizes of casings This traditional method of meat processing is among the oldest, with modern sausage technology deeply rooted in its historical origins.
Sausages are classified globally based on their processing methods, which fall into five primary categories: fresh sausage, cooked sausage, uncooked sausage, semi-dry sausage, and dry sausage, along with specialty meats.
Figure 2.4 Fresh sausage: Bratwurst (Source internet: mvmdeliveries.com)
Fresh sausages are crafted from fresh meats and are not dried, cured, smoked, fermented, or cooked It is essential to keep fresh sausages refrigerated until they are ready to be consumed, as they must be cooked by the consumer before serving.
Figure 2.5 Semi-dry and dry sausage
(Source internet: meatandsausage.com & amazon.com)
Fermented sausages are unique products made from cured or uncured meats that undergo fermentation and often smoking, without heat processing They are characterized by a tangy flavor resulting from lactic acid produced during fermentation The process involves stuffing meat into casings, where bacteria metabolize sugars to generate acids and other compounds Fermented sausages are categorized into semi-dry and dry varieties.
Figure 2.6 Cooked sausages: Frankfurter sausages
(Source internet: incarlopsa.es/frankfurter-sausages)
Cooked sausages are ready-to-serve products, basically made from previously cooked fresh or exceptionally cured raw materials, subjected to final cooking after stuffing without additional smoking [4]
Specialty sausages encompass a diverse range of processed meats that do not conform to traditional classifications These unique sausages can include both cured and uncured varieties, as well as smoked and non-smoked options Typically seasoned and often shaped into loaves, specialty sausages offer a distinctive flavor profile that sets them apart from standard sausage categories.
The trends of sausage production in Vietnam and in the world
2.3.1 The trends of sausage production in Vietnam
In Vietnam, over 50 companies produce sausages, with Vissan leading the market by supplying approximately 40% of the annual output of sterilized sausages Vissan has experienced consistent growth of 15-20% per year, capturing more than 65% of the Vietnamese sausage market and contributing significantly to the company's total revenue Similarly, Nipponham has emerged as a prominent brand in Vietnam, also achieving a profit growth of 15-20% annually Additionally, Duc Viet stands out as the first cooperative to manufacture German-technology sausages using local materials, gaining popularity among consumers and establishing a strong market presence over the years.
Vietnam boasts a variety of popular sausage brands, including Vissan, Duc Viet, CP, and Mavin, alongside smaller brands like Vinh Anh Food Vinh Anh Food Sausage is primarily available in major supermarkets such as BigC Hanoi, Metro Hanoi, and Coopmart, and is supported by food processing plants and industrial kitchens in Northern Vietnam.
In Vietnam, sausages are categorized into two main types based on taste and preservation methods The first type is sterilized sausage, which is sealed in PVDC film and sterilized at high temperatures, allowing for long storage at normal temperatures; this variety is particularly popular in the Southern market In contrast, the second type is fresh sausage, which is more commonly consumed in the North due to the colder climate These fresh sausages are pasteurized at low temperatures and have a shorter shelf life compared to their sterilized counterparts.
Figure 2.7: Sausage market share by application in 2014
In Vietnam, the prices of key sausage ingredients like pork and beef exceed the regional average by 5,000 to 10,000 VND per kilogram, according to the Ministry of Industry and Trade Consequently, leveraging shrimp as an alternative ingredient for sausage production presents a significant competitive advantage.
Figure 2.8: Sausage market share by taste in 2014
(Source internet: Euromonitor.com 2017) 2.3.2 The trends of sausage production in global
In recent years, the sausage industry has experienced a surge in consumption, prompting a need for more efficient resource utilization to enhance productivity, reduce costs, ensure reliability, and shorten lead times Implementing effective production and management designs can be streamlined with the use of production programming tools.
Cocktail sausages dominate the global market, with significant consumption observed at major league ballparks in the US, as highlighted by the National Hot Dog and Sausage Council This trend is a key factor contributing to the growth of the US hot dog and sausage market Additionally, there is a rising demand for healthier options, specifically hygienic foods with reduced fat and calorie content, presenting a promising opportunity for hot dogs and sausages in France.
The Asia Pacific region dominates the hot dogs and sausages market, leading in both sales and volume In China, these products are particularly favored by the younger generation, with individuals in their 20s and early 30s driving significant market growth Additionally, the increasing prevalence of busy lifestyles among consumers further fuels the demand for hot dogs and sausages in the country.
Japan stands out as one of the largest hot dog and sausage markets in the Asia Pacific region, primarily driven by a significant portion of its population in their late 20s to mid-30s This demographic, largely consisting of busy working professionals, increasingly favors hot dogs and sausages as convenient food options, contributing to the market's growth over the years Meanwhile, Brazil emerges as Latin America's fastest-growing country, with a strong anticipated demand for hot dogs and sausages in the coming forecast period.
Leading global brands in the hot dogs and sausages market include Bar-S Foods Co., ConAgra Foods, Bob Evans Farms, Johnsonville Sausage, and Sara Lee Food & Beverage Other notable companies are Family Dollar Stores, Boklunder, Atria Plc., Animex, Campofrio Food Group, Elpozo, Sigma Alimentos, JBS Argentina, and Tyson Foods Inc Additionally, in the Asia Pacific region, major players such as Shineway Group, Venky’s, and Goodman Fielder Ltd are significant contributors to the market.
2.3.3 Advances in technology of sausage production
Almost all development areas undergo certain changes, but the values remain the same With the advent of civilisation and technological evolution, sausage production have been improved
- The species of animal used for sausage production traditionally were pork, beef and veal Recently, species of animal being used include turkey (poultry), venison, shrimp and fish [4];
- The shape of the product: Sausages have traditionally been symmetrically formed but today they come in various shapes, sizes and shapes to meet the consumer's appeal;
Casing options for sausages have evolved beyond traditional animal gut, with innovations such as smooth polyethylene casings that allow for attractive printing and presentation Additionally, cellulose casings featuring antimicrobial systems effectively mitigate the risk of Listeria monocytogenes contamination in hot dogs and cooked sausages The introduction of co-extruded casings, which utilize collagen and alginate, facilitates continuous production without interruptions Furthermore, liquid alginate-based casings provide insulation and enhance the natural taste and texture of the sausage by immersing it in a second solution.
Recent advancements in the sausage industry have significantly enhanced product integrity, particle definition, texture, and yield Innovations such as improved vacuum pumps, inline grinding technology, automatic hanging devices, automated mold loading, and batching systems, along with computer-controlled product flow, have driven these changes.
Materials for sausage production
The main sources of raw materials include: Pork, lard, pigskin, chicken breast meat, chicken skin and ground chicken The raw materials usually used in frozen forms [19]
Pork is a nutrient-rich meat, offering a significant source of protein along with essential minerals like iron, copper, magnesium, phosphorus, and sodium Additionally, it is packed with vital vitamins, including vitamin A, making it a valuable addition to a balanced diet.
D, Vitamin B1 (thiamin), vitamin B2 (riboflavin), vitamin B3 (niacin), etc, and in the meat contains full of non-replaceable amino acids Meat plays a key role in determining the quality of sausage products [10] a Classification of meat
- According to percentage of lean meat
+ Lean pork: High percentage of lean meat ≥ 80%
+ Pork half lean - half fat: Percentage of lean around 50% to 80%
+ Fat pork: Percentage of lean ≤ 50% [15]
+ Meat has a fresh color, dry surface, does not leak, the pH of meat has a value of 5.6 - 6.2
+ PSE meat (Pale - soft-excudative): Meat is pale, soft, the surface has a leak, pH ≤ 5.2
+ DFD meat (dark-firm-dry): Meat is dark and the surface is hard, pH ≥ 6.4 [15] b The texture of pork
Depending on the role, function and food value of meat, we can divide the meat into muscle tissue, bone tissue, adipose tissue, connective tissue and blood tissue [29]
Table 2.1: Composition of tissues in pork
(Source: Technology for processing and preserving meat 2013)
Muscle tissue constitutes the largest portion of meat structure, comprising numerous muscle silk fibers organized into bundles, with muscle fibers primarily made of myosin and actin This tissue's primary function is to facilitate elastic operations, and its chemical composition consists of 72% to 75% water, 18% to 21% protein, and other substances like lipids, vitamins, and minerals Additionally, connective tissue plays a crucial role in linking muscle fibers and bundles, ensuring a cohesive structure in meat.
Adipose tissue consists of interconnected fat cells arranged in a porous mesh structure The quantity of adipose tissue varies based on factors such as species, gender, and dietary conditions.
Bone tissue, a vital type of connective tissue, comprises organic substances that absorb mineral salts It typically contains 20% to 25% water and 75% to 85% dry matter, with approximately 30% being protein and 45% consisting of inorganic compounds.
+ Cartilage tissue is made up of basic substances, including cell components, protein fibers and elastin [18]
Blood tissue comprises 40% to 60% of blood that is secreted when cut, with the remaining portion found in capillaries, organs, and skin It consists of 16.4% to 18.5% protein, 79% to 82% water, non-protein organic matter, and 0.8% to 1% minerals.
- Nutrition contents in 100g of pork
Table 2.2: Nutrition facts in 100g of pork
(Source: Technology for processing and preserving meat 2013)
Pork half lean - half fat 16.5 60.9 21.5 0.3 1.1 268
The components of essential amino acids in pork are described in the table 2.3
Table 2.3: The amino acid composition of pork
(Source: Technology for processing and preserving meat 2013)
STT Amino acids In protein content (%)
- Content of minerals in pork meat (mg/100g of meat)
Table 2.4: Minerals found in meat (mg/100g of meat)
(Source: Technology for processing and preserving meat 2013)
Pork Ca Mg Fe K Na P
Pork half lean - half fat 13.2 41 2.3 442 149 170
Fat 2.5 42 2.5 442 128 180 d Spoiled forms of meat
Improper storage conditions can lead to meat spoilage, allowing harmful enzymes and microorganisms to thrive Signs of spoiled meat include a viscous texture, unpleasant odor, sour fermentation, discoloration, and the presence of mold.
Viscous formation on the surface of chilled meat occurs in environments with relative humidity exceeding 90%, marking the initial stage of meat deterioration This condition is characterized by the presence of a viscous mucus layer, which can be attributed to various bacteria, including Micrococcus albus, M liquefaciens, M aureus, M candidus, Streptococcus liquefaciens, E coli, Bact alcaligenes, Bacillus mycoides, Bacillus mesentericus, Pseudomonas, Leuconostoc, Lactobacillus, and certain yeast species.
The unpleasant odor of rotting meat is caused by microorganisms that produce protease enzymes, which break down the proteins in the meat Common aerobic bacteria involved in this process include Proteus vulgaris, Bacillus subtilis, Bacillus mesentericus, and Bacillus megatherium, while anaerobic bacteria such as Clostridium perfringens, Clostridium putrificum, and Clostridium sporogenes also play a significant role.
Moldy meat is caused by the growth of mold on the meat, resulting from the breakdown of proteins and lipids Signs of moldy meat include a musty smell, sticky texture, and discoloration The most common types of mold found on spoiled meat are Mucor, Penicillium, and Aspergillus.
Meat discoloration occurs when aerobic microorganisms grow on its surface, causing it to change from red to shades of gray, brown, or green Common microorganisms responsible for this change can affect the meat's appearance and quality.
Bacterium prodigiosum or Serratia marcerans: Red stain;
Chromobacterium: Light gray, dark brown;
Animal fat is primarily found in the adipose tissue and organs of animals, which consists of porous connective tissue rich in fat cells The fat tissue in an animal's body can comprise anywhere from 1% to 48% of its total mass Key components of this fat tissue include triglycerides, phosphatides, cholesterol, esters, pigments, vitamins, and enzymes The fatty acids within triglycerides can be either saturated or unsaturated, including types such as palmitic, stearic, oleic, linoleic, and arachidonic Although triglycerides are insoluble in water, they can emulsify with water under certain conditions when influenced by an emulsifier.
Table 2.5: Chemical compositions in lard
(Source: Technology for processing and preserving meat 2013)
Function of fat in sausage producing
+ Pork fat is a source of fat;
+ Grease works to increase the adhesion, fat, gloss and increase the sensory value of the product;
+ Fat will help to take advantage of raw materials, reduce costs and increase economic efficiency [15]
Chicken breast is a lean source of protein derived from the chicken's body, specifically the white meat located from the ribs to the breast It is low in fat and rich in vitamin B6, making it a nutritious choice for health-conscious individuals, while also being free of carbohydrates.
Table 2.6: Chemical composition in 100g of chicken breast meat
(Source: Technology for processing and preserving meat 2013)
Several amino acid components in 100g chicken breast are decribed in table 2.7
Table 2.7: Several amino acid components in 100g chicken breast
(Source: Technology for processing and preserving meat 2013)
- Function of chicken breast meat is to create nutritional value for the product and help to take advantage of raw materials, reduce costs and increase economic efficiency
2.4.1.4 Pig skin and chicken skin
- Characteristics of pig and chicken skin used in sausage production
Pigskin is commonly utilized as back skin, striking a balance between the firmness of older pigs and the softness of younger pigs This unique quality enhances product adhesion while minimally impacting the overall softness of the final product.
+ The skin for making sausages must be clean
- The role of the skin is to increase the ability to stick, create toughness for sausages, and as fillers help reduce production costs and increase economic efficiency [17]
Flake ice consists of thin, dry sheets measuring 2 mm in thickness and 12 to 16 mm in length It is produced by a flake ice machine that operates using a vertical drum and a rotary knife In this process, cold water at temperatures between 5 and 10ºC is pumped from a tank into a separating tray, where it is evenly sprayed onto the drum's surface As the water reaches -9ºC, part of it freezes into ice, which is then scraped off by the rotating knife, while the remaining water is cooled and directed into a trough for recirculation.
OBJECTIVE, CONTENTS AND METHODS OF RESEARCH 23 3.1 Object and scope of the study
Object of the study
The object of the study is the process and technology of smoked sausage production at Vinh Anh Food Technology Joint Stock Company.
Scope of the study
Sausage production workshop of Vinh Anh Food Technology Joint Stock Company from the materials, processing, and packaging department.
Location and time
Vinh Anh Food Technology Joint Stock Company, address: Ha Binh Phuong Industrial Cluster, Van Binh Commune, Thuong Tin District, Ha Noi City
Research contents
- Investigate the procedure of smoked sausage producing in Vinh Anh Food Technology Joint Stock Company;
- Comprehend and describe all steps in the smoked sausage producing and analyze factors that affect the quality of products during these processes;
- To study all equipments in the smoked sausage producing;
- To investigate the factory's food safety and hygiene system.
Reasearch methodology
- Collection of documents and information available at the company from the managers
- Interviewing the production staff in the company
- Refer to related documents from different sources such as the Internet, textbooks, books, etc
- Observe the whole process, from importing raw materials into storage until manufacturing finished products;
- Participate directly in the production process;
- Find out and observe technical parameters, operating principles of equipment and machines used
Survey data is collected from actual production on lines, company references and in books, newspapers and the media.
RESEARCH RESULTS
Results of surveying the production process of smoked sausage in Vinh Anh
Anh Food Technology Joint Stock Company
4.1.1 Smoked sausage production diagram tº: 6 to 10ºC tº: 16 to 18ºC tº: 16 to 18ºC tº: 16 to 18ºC tº: 16 to 18ºC tº: Environment tº: 16 to 18ºC tº: 0 to 4ºC tº: 0 to 4ºC
Figure 4.1: Diagram of sausage production process
Labels and bags Cold storage
4.1.2 Describe the stages of smoked sausage production
The meat ingredients used in production consist of pork, chicken, ground chicken, and pork fat, all sourced in frozen form Prior to processing, these raw materials must be defrosted, as their initial temperature ranges from -25ºC to -18ºC.
The defrosting process is essential for preparing meat for sausage production, as it raises the meat's temperature to the optimal level for further processing When meat is frozen solid, it becomes a hard mass, making it challenging to grind in a blender.
The factory employs a natural defrosting method, maintaining a room temperature of 12ºC to 16ºC for 15 to 18 hours This process ensures that the raw materials are brought to a temperature range of 0ºC to 4ºC, preserving their fresh, natural color before they are transported to the material room for cutting.
Vinh Anh FTJSC supplies frozen meat sourced from a slaughterhouse, ensuring quality for production Each day, workers retrieve the necessary frozen meat ingredients from cold storage before commencing the smoked sausage manufacturing process The specific ratios of these components vary and are detailed in Table 4.1.
Table 4.1: The mixing ratio of 100 kg material in one batch
Salt, sugar, polyphosphate, nitrit 2.4 Pepper powder, color, monosodium glutamate 4.4
Meat is supplied by a pig slaughter plant of Vinh Anh Food company according to the TCVN 7046 - 2002 standard with the following criteria
Table 4.2: Meat quality assessment standards TCVN 7046 - 2002
When selecting fresh meat, look for high elasticity and a succulent cut that is not watery The surface should be vibrant in color, free from tendons, broken bones, feathers, bruising, hematomas, and any signs of bleeding.
Color Not allowed to be dark red, dark brown, gray and blue Meat and fat are not contaminated by yellow pigments
No rancid smell of metamorphic meat, no oxidized grease greasing oil No antibiotic smell or treatment agent No strange taste like sour, acrid and salty
Hygiene Tight, clean packaging Meat and fat without sticky objects such as soil, sand and feathers Frozen Frozen meat must have a center temperature ≤ -18ºC pH Fresh meat: 5.6 ÷ 6.0
NH3 content Fresh meat: ≤ 20mg /100g
Pork and chicken are essential sources of nutrition, providing complete protein with all eight essential amino acids crucial for muscle tissue Vinh Anh Food Company supplies these meats, utilizing 20 kg of pork and 36 kg of chicken per batch in sausage production Additionally, ground chicken imported from Korea is used, with a dosage of 8 kg per batch.
When producing sausage, it is crucial to select the right type of fat based on the meat's pH level High-pH meat pairs well with less-degraded fat, while low-pH meat is suitable for trans fat Ensure that the fat is clean and free from bones, feathers, and other impurities Vinh Anh FTJSC supplies the necessary fat, with a recommended dosage of 9 kg per batch for optimal sausage production.
To ensure optimal quality in sausage production, the skin must be carefully prepared—shaven, free from fat, bruises, and not overly hard or dry The company utilizes pigskin sourced from Vinh Anh FTJSC, specifically back leather, which enhances product adhesion while minimally impacting fineness Additionally, chicken skin from the neck, imported from Germany, is incorporated to improve adhesion and toughness, allowing for better utilization of raw materials This approach not only reduces costs but also boosts economic efficiency, with a recommended usage of 2 kg of pork skin per batch in sausage production.
5 kg/batch for chicken skin d Flake ice
- Role of flake ice in sausage production
Maintaining a temperature below 12ºC during the pureeing process of the emulsion system is crucial, as the friction generated by the grinding machine can raise the mixture's temperature This temperature control helps to inhibit the growth of microorganisms, ensuring a safer and more stable product.
+ Flake ice is a solvent dissolving additives and spices;
+ Flake ice affects the ability to create emulsions, participate in creating the structure and state of the product;
+ It increases the moisture and weight of the product, reduces product costs; + Flake ice is also used to preserve foods when importing goods and during processing
Table 4.3: Drinking water standards TCVN 5501-1991
The taste is determined by the senses at 20ºC and 60ºC Undetectable The content of insoluble sediment < 10mg/l
The content of soluble sediment < 500mg/l pH 6 - 8.5
Total aerobic bacteria Not have
Total coliforms (bacteria/100ml) < 200 bacteria/1ml Total stool coliform (bacteria/100ml) Not have
Total C perfringens (bacteria/100ml) Not have
The dosage of flake ice used in sausage manufacture is 6 kg/batch e Soy protein
Requirements of soy protein in sausage processing in table 4.4
Table 4.4: Requirements of soy protein in sausage processing
Total number of fungal cells < 100 colonies/g
Soy protein is utilized in sausage production to enhance product structure, such as gels and emulsions, by effectively binding water and fat while integrating seamlessly into the emulsification process This ingredient helps achieve a balanced combination of animal and vegetable proteins, thereby boosting the nutritional value of the final product Typically, the recommended dosage of soy protein in sausage manufacturing is 1.5 kg per batch.
Tapioca starch is essential in sausage production, serving as a polysaccharide source that contributes to the product's unique characteristics Its interaction with protein, primarily through hydrogen bonding, imparts the desired elasticity to the sausage For optimal results, high-purity, smooth, and fine starch is required, with a typical dosage of 3 kg per batch.
- Spices are used in the form of a powder and spices purchased from Neo Foodtech Co Ltd
Sodium chloride (NaCl) enhances the flavor and quality of meat by providing a salty taste while also improving its structure This additive acts as a mild antiseptic, increasing the preservation of meat by preventing pathogenic bacteria, reducing oxidation, and inhibiting aerobic microorganisms Additionally, salt boosts the adhesion of actin and myosin in meat, creating osmotic pressure and enhancing water retention, which minimizes water loss during cooking.
Table 4.5: Salt standards in sausage processing TCVN 9639:2013
Taste 5% salt solution has a pure salt taste, no strange taste
External form Dry, clean, white
NaCl content in% of dry mass > 97%
The content of insoluble matter in water is expressed as a percentage by weight of the dry substance
Monosodium glutamate (MSG) plays a crucial role in sausage production by enhancing the sensory appeal of the product When dissolved in water, MSG combines with salt to produce a sweetness that mimics the natural flavor of meat The recommended maximum dosage is 10 grams per kilogram of raw material, ensuring optimal flavor enhancement.
Table 4.6: Standard of monosodium glutamate TCVN 1459: 1996
Status Fine powder, no lumps, easily soluble in water, the number of black spots in 10cm 2 < 2
Odor Fragrant and sour, no fishy, no other strange smell
Taste Sweet characteristic of MSG
Sugar plays a crucial role in sausage processing by imparting sweetness, balancing the saltiness, and enhancing the overall flavor of the meat When combined with salt, sugar increases osmotic pressure, which helps inhibit bacterial growth during storage Additionally, sugar binds with water through hydrogen bonding, transforming free water into associated water, thereby reducing water activity and further preventing the proliferation of microorganisms.
Table 4.7: Standards of sugar TCVN 6959: 2001
Shape The crystal form, uniform, dry, no lumps
Taste Sweet taste, no strange taste
When diluted in distilled water, a clear solution is obtained
Pepper powder is used in sausage processing to create a pungent, aromatic flavor that enhances the sensory properties of the product
Table 4.8: Standard of pepper powder
Status Loose, smooth, dry, impregnated, particle size less than 0.2mm
Taste Spicy naturally, typical taste
Extractive non-volatile matter (% mass dry matter) ≥ 6%
Evaporated essential oil (ml /100g dry mass) ≥ 1
Piperine content (% of dry weight) ≥ 4%
Acid insoluble ash (dry mass) < 1.2% h Additives
- Additives are used in the form of a powder and it purchased from Neo Foodtech Co Ltd
Survey results of some equipments in the production of smoked sausages of
The purpose of this machine is to cut the meat that has a big size to small size as required, preparing for the grinding process
Figure 4.2: Meat freezing machine (Diecer): Magurit
- Composition of meat freezing machine
A meat freezing machine consists of several key components, including sharp knives for cutting meat into smaller pieces, a motor that drives the shaft via a chain system, and a pneumatic control system featuring a cylinder, filter, pressure reducer, and electric sensors Additionally, trolleys are used to transport the meat after it has been cut, ensuring efficient processing The combination of the blade's sharpness and the motor's torque allows for effective meat preparation.
-Principle of operation of meat freezing machine
The meat block is fed into the machine, where it slides down to the cutting area, allowing for automatic slicing until complete Utilizing knife nets attached to the drum, the machine cuts the meat into uniform sizes, which then drop into a cart at the bottom for collection.
- Operating process of meat freezing machine
In sausage production, a meat freezing machine is essential for cutting meat, skin, and fat into small pieces suitable for grinding The machine operates in batches: once the meat is loaded and the start button is pressed, the meat is automatically guided to the knife area and collected in a plastic bin below This process continues until all the meat is processed, after which the device is turned off and cleaned.
The purpose of meat grinder is to reduce the size of frozen meat to facilitate the puree process
Figure 4.3: Meat grinder (mincer): Mado Ultra
The feeding unit features a material feeder and a screw-type compression and conveying system designed with tapering steps It operates in two rotating modes, labeled as 1 and 2, and is equipped with a safety cover above the trough Key components include a screw-type compression chamber, a chamber wall with spiral grooves that align with the screw blades, a four-sided cutter, and a mesh screen with sieve options of 8 mm or 3 mm in diameter The system also offers two rotation speeds for the screw, enhancing its functionality.
The system features a controller with four buttons that allow users to adjust the rotation speed of two screws, along with a stop button for the machine The actuator utilized is a belt-driven three-phase electric motor, ensuring efficient operation at both slow and fast speeds.
-Principle of operation of meat grinder
Meat is diced into small cubes and fed into a hopper, where it is transported by a screw conveyor powered by either a crank or an electric motor This conveyor system includes a press head and a food mixing component At the end of the conveyor, a knife is positioned in front of a fixing plate, allowing minced meat to exit the machine The texture of the minced meat is determined by the size of the holes in the blender.
- Operating procedure of meat grinder
After assembling the screw, cutter, and wire mesh, load the materials into the cavity and press the operation button The machine will automatically grind the ingredients until complete To stop the process, simply press the shutdown button, turn off the power, and then disassemble the screws, cutters, and sieve for cleaning.
Purpose of bowl cutter is to mix all the main ingredients after roughing with appropriate spices and additives to create a uniform emulsion
The pan features a convex center and a concave rim, with a circular cross-section of the indentation During operation, the pan rotates around its axis, facilitating two rotation speeds: slow and fast Ingredients are placed in the concave area of the pan, where they are minced effectively.
The cutting knife features six equally sized blades that rotate around a central axis, ensuring efficient blending As the blades spin, they maintain a minimal distance from the bottom of the pan, allowing for thorough mixing This versatile tool operates at four different rotation speeds: 1, 2, 3, and 4, catering to various blending needs.
The lid features a design that covers half of the rotating pan, ensuring that ingredients remain contained when the knife is in operation Equipped with gears, the lid positions bars close to the pan's wall, effectively scooping and guiding ingredients into the chopping area, resulting in a uniform mix.
The control unit features multiple buttons, each designed for specific functions, allowing users to manage the entire system, including lid adjustments and the rotation speed of both the knife and pan.
- Principle of operation of bowl cutter
Raw materials, additives, and additives put in the mixing process in a certain order The operator will control the pan and knife at a suitable speed by adjusting the button
The emulsion process consists of three distinct phases In phase one, the prepared ingredients are placed in a pan, and the machine operates slowly while maintaining a temperature of around 0ºC; once the temperature rises to 4ºC, the process advances Phase two involves increasing the machine's speed, adding spices, additives, and flake ice, while closely monitoring the mixture's temperature until it reaches 8ºC Finally, in phase three, the machine is set to its highest speed, finely grinding the materials to sizes between 0.2 - 0.5mm, creating an emulsion system with the melted water from the flake ice The process is complete when the emulsion system becomes homogeneous, at which point the machine should be stopped and the product removed before the temperature exceeds 12ºC.
The primary function of a stuffer is to efficiently fill sausage casings with a well-mixed emulsion of sausage ingredients, ensuring the desired shape and quantity for each sausage.
Hopper: Inside the hopper has a system of twisted wings to prevent clogging and the swing system moves along the wall;
The compressor system efficiently transfers materials into the sausage casing by connecting to the bottom of the funnel A suction pump ensures a continuous flow of material from the hopper into the compressor without drawing it down into the compressor compartment The compression chamber's outlet is directly linked to the casing tube, facilitating seamless material movement.
Tubing system of casings, cups, forks have the appropriate size for stuffing sausages;
The control unit of the PLC system manages essential settings and operational parameters, including vacuum levels and the drive motor's rotation speed within the compression chamber It also features a lever that allows for the machine to be stopped during cover changes or in the event of an error, ensuring compliance with operational requirements.
- Principle of operation of stuffer
Survey results on occupational safety and sanitation system of Vinh Anh FTJSC
The company prioritizes safety by utilizing a comprehensive range of labor protection equipment and adhering to strict fire prevention protocols All machinery and equipment operate under established principles, with high-speed equipment featuring protective barriers and relays Workers are tasked with managing and maintaining the production equipment relevant to their specific stage, ensuring that they do not operate machinery outside their designated area Regular machinery maintenance is enforced, with workers promptly notifying the technical department of any issues Additionally, the company is equipped with fully installed and tested emergency exits and fire extinguishers to enhance safety measures.
To ensure hygiene standards in the workshop, all officers and employees must wear hats, masks, gloves, and rubber boots, along with appropriate protective gear, while avoiding jewelry such as watches and rings.
Workers undergo biannual health checks to monitor their well-being Those diagnosed with infectious diseases are permitted to return to the workshop or production area only after receiving appropriate treatment.
Before entering the production area, workers don their workwear and wash their hands using an automatic water tap They then rinse with water, apply a 700 ppm alcohol spray for disinfection, and dry their hands with an automatic drying system Additionally, they wade through water tanks containing a chlorine solution at 200 ppm to ensure thorough sanitation.
Ensuring hygiene during production is critical; workers must wear protective clothing exclusively within the production area and consistently use gloves when handling raw materials and products It is essential to maintain the integrity of protective gear to prevent contamination Furthermore, there have been no instances of smoking, eating, or spitting in the production area, reinforcing a commitment to cleanliness and safety.
After leaving the production area, individuals must clean their hands and personal tools thoroughly Protective gear should be stored in designated locations, and it is important to remove all protective equipment before entering the restroom Upon returning to the production room, strict adherence to cleaning protocols is essential to ensure a safe working environment.
The processing factory maintains a dedicated cleaning area for tools, ensuring that no operations occur simultaneously All raw materials and products are organized in specialized baskets, barrels, and bins, stored on stainless steel or plastic pallets The facility's floors and walls are consistently kept clean and dry, and each room is equipped with two separate trash cans for organic and production waste Comprehensive cleaning of the entire factory is conducted once a week to uphold hygiene standards.
Effective cleaning of tools, machinery, and equipment is essential in food processing Semi-finished product bins and baskets are thoroughly cleaned using a pressurized water spray to remove residual meat samples, followed by a wash with soap and a brush After scrubbing, they are rinsed with clean water and then treated with hot water at 90°C for sanitization Similarly, tools such as knives, scissors, cutting boards, and tables must be cleaned after each use or when switching to a different product In sausage processing, machines are cleaned using soap and a high-pressure water hose to ensure all parts, equipment slots, and surfaces in contact with food materials are properly sanitized.
Maintaining cleanliness and dryness in the warehouse is essential for optimal operations Trolleys, bins, and carts are organized in their designated areas, ensuring an orderly environment Additionally, separate storage spaces are allocated for raw and cooked products to uphold hygiene standards.