INTRODUCTION
Rationale
In modern society, the demand for food products, particularly meat, is on the rise, making meat and meat products the most sought-after items in the food industry This surge in popularity has led to the implementation of advanced technologies in meat production, with sausage emerging as a notable product of these innovations Consequently, industrial-scale sausage production is experiencing rapid growth Over the years, various types of sausages have been developed, each showcasing unique characteristics influenced by regional climates and the diverse spices used in their preparation.
The market today offers a diverse range of sausages, which can be categorized based on raw materials such as beef, shrimp, pork, and fish Additionally, sausages are classified by their production methods, including 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 ".
Objectives
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.
The survey was carried out in Vinh Anh Food Technology Joint Stock
Company from March 01, 2020 to June 30, 2020.
Detailed schedule
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 stands out as a leader in the processing and slaughtering of cattle and poultry, adhering to stringent food safety and hygiene standards Equipped with modern livestock and food processing facilities, along with advanced cold storage and automated wastewater treatment systems, Vinh Anh ensures both food safety and environmental protection The company supplies its high-quality products, including sausages, pork pie, and packaged fresh pork, to supermarkets, restaurants, schools, and industrial zones across Northern Vietnam, continuously innovating to expand its product offerings.
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, initially operating with a single work area and a basic slaughterhouse equipment system.
In 2008, Vinh Anh FTJSC established an investment project by leasing 17,000 m² in the Ha Binh Phuong Industrial Cluster, located in the Thuong Tin District of Hanoi City, to construct 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 expanded beyond slaughtering by researching and developing innovative food products, including pork and chicken sausages The company has also invested in specialized cold storage facilities and constructed a chicken slaughter plant, aiming to enhance the quality of its products for consumers.
The factory features three primary production areas: a modern, closed pig slaughtering facility with a capacity of 600-1000 pigs per shift; a cutting and processing area for pork that handles 30 tons per shift; and a food processing plant that produces items like sausages and pork pies All areas are equipped with advanced machinery imported from France and China Additionally, the company is currently constructing a state-of-the-art chicken slaughter plant, featuring modern equipment sourced 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 CEO (Chief Executive Officer), who serves as the executive head of the company.
The production manager plays a crucial role in supporting the director during the production process and can represent the executive director when authorized Both the production manager and the executive director hold full accountability for the production and business outcomes At Vinh Anh FTJSC, the production manager oversees the slaughter processing and sausage product lines Currently, the company is preparing to implement a chicken slaughter process imported from the Netherlands, for which the production manager is developing a detailed plan Additionally, he is responsible for managing six key departments, including human resources, production, financial-accounting, and technical departments.
The Human Resources department plays a crucial role in managing labor coordination and establishing labor norms across the company's various departments and units This department oversees the administration of labor contracts, facilitates skills training for employees, and addresses the workforce's needs within the factory Additionally, it is responsible for recommending rewards and disciplinary actions, calculating payroll, and monitoring employee performance to ensure a productive work environment.
The production department plays a crucial role in overseeing the company's production processes, ensuring adherence to technical standards, and managing import and export activities It is also responsible for researching product innovations, assessing quality, delivering products to customers, and maintaining product management in line with quality standards.
The financial-accounting department is responsible for managing all company finances, ensuring proper allocation of funds for salaries, bonuses, machinery purchases, and materials It also prepares receipts and payments for all incurred expenses while accurately storing data on imports and exports in compliance with company regulations.
The technical department is tasked with the repair, operation, maintenance, and planning of the company's equipment and machinery, as well as overseeing repair works Additionally, it provides instructions for the proper use of equipment within the factory and monitors the accuracy of measuring instruments.
The QA department's mission is to ensure food hygiene and safety by establishing regulations, monitoring product quality in factories, and assessing raw materials during purchasing and storage It also plays a crucial role in researching new products, evaluating their quality, and collaborating with state agencies for brand assessments Additionally, the department is responsible for issuing quality certificates for raw materials and finished products prior to warehousing, as well as providing regular and ad-hoc reports 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 final output, while ensuring compliance with the quality assurance system Meanwhile, the Research and Development (R&D) department focuses on innovating 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 encompass the development of marketing strategies, advertising initiatives, sales efforts, agency distribution, and service provisions, as well as the exploration of new markets for emerging 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 ) - Processed foods
Figure 2.3 Processed products of Vinh Anh FTJSC (Source: www.vaf.com.vn )
Overview of sausage products
Sausages are a beloved food worldwide, with consumption patterns differing across cultures They are created by transforming fresh, minced meats through specialized processing techniques to enhance their flavor and texture 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, with evidence of its consumption by ancient civilizations thousands of years ago The Romans created various delicious sausage types, enjoyed during annual festivals and sacrifices, while lower 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 has a rich history spanning over two millennia and continues to thrive as a dynamic market While many fundamental processes have remained unchanged since ancient times, the industry consistently embraces innovative advancements in processing, driven by modern scientific and technical insights.
Sausages are diverse and challenging to categorize due to their variety, but they can generally be described by their form, size, or meat content Typically made from comminuted red meat or poultry, sausages include salt, binders, and seasonings, and are often encased They can also undergo curing, smoking, or cooking processes.
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].
According to Barnaby Sutton (2016), sausage is defined as a blend of ground or chopped meats mixed with spices and other ingredients, typically encased in various sizes of casings Sausages are among the oldest forms of meat processing, and contemporary sausage-making techniques are deeply influenced by historical practices.
Sausages are classified globally based on their processing methods, falling 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 typically dried, cured, smoked, or cooked To ensure safety, these sausages must be refrigerated until they are ready to be consumed, as they require heating by the consumer before serving.
Figure 2.5 Semi-dry and dry sausage
(Source internet: meatandsausage.com & amazon.com)
Fermented sausages are crafted from cured or uncured meats that undergo fermentation and often smoking, without heat processing This unique preparation results in a tangy flavor, attributed to lactic acid produced during fermentation The meat is encased and allowed to ferment, where bacteria metabolize sugars, generating acids and various byproducts These 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 processing methods, including cured, uncured, smoked, and non-smoked meats that do not conform to traditional categories These unique sausages are typically seasoned and frequently shaped into loaves, offering a distinctive culinary experience.
The trends of sausage production in Vietnam and in the world
2.3.1 The trends of sausage production in Vietnam
Vietnam boasts over 50 sausage manufacturing companies, with Vissan being the pioneer in this industry As a leader in sterilized sausage production, Vissan accounts for approximately 40% of the annual market supply, showcasing a consistent growth rate of 15%.
20 percent per year, Vissan sausages owned more than 65 percent market of sausages of Viet Nam that contribute over a half of Vissan company's total revenue
Nipponham sausage has established itself as a leading brand in the Vietnamese market, experiencing a profit growth of 15-20 percent annually Duc Viet, the first company to collaborate on trading and manufacturing German-technology sausages using Vietnamese materials, has seen its products become increasingly popular among consumers Over the years, Duc Viet's sausages have secured a strong position in the market, reflecting their status as a favorite among Vietnamese customers.
Vietnam boasts a diverse array of sausage brands, with popular names including Vissan, Duc Viet, CP, Le Gourmet, Mavin, Dabaco, AFF, Ba Huan, and S-food Among these, Vinh Anh Food stands out as a notable small to medium brand, primarily available in major supermarkets such as BigC Hanoi, Metro Hanoi, and Coopmart The brand's products are supported by food processing plants and industrial kitchens located in Northern Vietnam, contributing to its growing presence in the market.
In Vietnam, sausages are categorized into two main types based on their preparation and storage methods The first type is sterilized sausage, which is sealed in PVDC film and undergoes high-temperature sterilization, allowing for long shelf life and storage at normal temperatures; this variety is particularly popular in Southern Vietnam Conversely, fresh sausage, which is pasteurized at lower temperatures and has a shorter shelf life, is more commonly consumed in the cooler Northern region of the country.
Figure 2.7: Sausage market share by application in 2014
In Vietnam, the prices of key sausage ingredients like pork and beef consistently 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 a sausage ingredient 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 significant growth in consumption, prompting a search for more efficient resource utilization to enhance productivity, reduce costs, ensure reliable service, and minimize lead times Implementing effective production and management strategies can be streamlined with the use of production programming tools.
Cocktail sausages dominate the global market, while hot dogs and sausages enjoy significant popularity at major league ballparks in the US, as reported by the National Hot Dog and Sausage Council This trend is a key contributor to the growth of the US hot dog and sausage market Additionally, there is a growing demand for healthier options with lower fat and calorie content, presenting new opportunities 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, especially those in their 20s and early 30s, significantly contributing to market growth Additionally, the increasingly busy lifestyles of consumers in China further bolster the demand for hot dogs and sausages.
The Asia Pacific region is home to one of the largest hot dog and sausage markets, with Japan being a significant contributor to this growth A key driver of Japan's hot dog and sausage market is its demographic composition, with a majority of the population falling within the late 20s to early and mid-30s age bracket This age group, predominantly consisting of working-class individuals with busy lifestyles, has consistently driven demand for hot dogs and sausages in Japan Similarly, Brazil, Latin America's fastest-growing country, is expected to experience high demand for these products in the forecast period.
Leading global brands with significant market shares in the food industry 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 In the Asia Pacific region, key players in the hot dogs and sausages market include Shineway Group, Venky’s, and Goodman Fielder Ltd.
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;
In addition to traditional natural casings made from animal intestines, innovative alternatives such as smooth polyethylene casings are now utilized for sausages, allowing for attractive printed designs Furthermore, cellulose casings with antimicrobial properties effectively minimize the risk of Listeria monocytogenes contamination in hot dogs and other cooked sausages The introduction of co-extruded casings, which combine collagen and alginate, facilitates continuous production without interrupting the casing loading process Additionally, liquid alginate-based casings provide insulation by immersing the sausage in a second solution, resulting in a natural taste and texture.
Recent advancements in the sausage industry have significantly enhanced product integrity, particle definition, texture, and yield Key innovations include the evolution of vacuum pumps, inline grinding technology, automatic hanging devices, automated mold loading systems, and computer-controlled product flow These developments have collectively transformed manufacturing processes, leading to improved efficiency and quality in sausage production.
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 food that offers a substantial amount of protein along with essential minerals like iron, copper, magnesium, phosphorus, and sodium Additionally, it is a good source of important vitamins, including vitamin A, contributing 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 is the predominant component of meat, composed of numerous muscle silk fibers organized in bundles, along with muscle fibers consisting of myosin and actin Its primary function is to facilitate elastic movements The chemical makeup of muscle tissue includes 72% to 75% water, 18% to 21% protein, and a small percentage of other substances such as lipids, vitamins, and minerals.
Connective tissue: widely distributed connective tissue has the role of linking muscle fibers, muscle bundles together and creating a tight link for meat [15].
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 is a vital type of connective tissue, composed of 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: when cutting blood secreted about 40% - 60%, the remainder exists in capillaries, organs and skin Blood contains 16.4% - 18.5% of protein, 79%
- 82% is water, non-protein organic matter and 0.8% - 1% of minerals [15]. c The chemical composition of meat
- 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
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)
- 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 half lean - half fat
Fat d Spoiled forms of meat
Improper storage conditions can lead to meat spoilage, as they promote the growth of harmful enzymes and microorganisms Signs of spoiled meat include increased viscosity, unpleasant odors, sour fermentation, discoloration, and the presence of mold.
Viscous formation on chilled meat surfaces 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 on the meat, which is often caused by various bacteria, including Micrococcus albus, M liquefaciens, M aureus, M candidus, Streptococcus liquefaciens, E coli, Bact alcaligenes, Bac mycoides, Bac mesentericus, Pseudomonas, Leuconostoc, Lactobacillus, and certain yeast species.
The unpleasant smell of rotting meat is caused by the development of microorganisms that produce protease enzymes, which break down the proteins in the meat Common aerobic bacteria involved in this process include Proteus vulgaris and Bacillus subtilis.
Bacillus mesentericus; Bacillus megatherium Anaerobic bacteria: Clostridium perfringens; Clost putrificum; Clost sporogens [15].
Moldy meat is caused by the growth of mold due to the breakdown of proteins and lipids, resulting in a musty smell, sticky texture, and discoloration The most prevalent molds found on spoiled meat include Mucor, Penicillium, and Aspergillus.
Meat discoloration occurs when aerobic microorganisms grow on its surface, causing it to change color from red to shades of gray, brown, or green Common microorganisms responsible for this discoloration include various bacteria and fungi.
Bacterium prodigiosum or Serratia marcerans: Red stain;
Chromobacterium: Light gray, dark brown;
Animal fat is primarily found in adipose tissue and organs, which consists of porous connective tissue filled with numerous fat cells The fat content in an animal's body can vary significantly, ranging from 1% to 48% Key components of adipose tissue include triglycerides, phosphatides, cholesterol, esters, pigments, vitamins, and enzymes The fatty acids present in triglycerides encompass both saturated and unsaturated types, such as palmitic, stearic, oleic, linoleic, and arachidonic acids While triglycerides are generally insoluble in water, they can form emulsions with water when influenced by emulsifiers.
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 white meat, situated between the ribs and the breast of the chicken It is high in protein, low in fat, and rich in vitamin B6, making it a nutritious choice with no 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)
ArginineHistidineIsoleucineLeucineLysineMethioninePhenylalanineThreonineTryptophanValine
- 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, commonly utilized as back skin, strikes an ideal balance between hardness and softness, as it is sourced from pigs that are neither too old nor too young 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 flakes measuring 2 mm in thickness and 12 to 16 mm in length It is produced by a flake ice machine that operates on the principle of a vertical drum and rotary knife Cold water, maintained at temperatures between 5 to 10ºC, is pumped from a tank into a separating tray, where it is evenly sprayed onto the drum's surface As the drum's surface reaches -9ºC, part of the water freezes into ice and is subsequently removed by the rotating knife, while the remaining water is cooled and directed into a trough for recirculation.
To ensure safe ice production, the water utilized must adhere to strict hygienic standards Specialized tools for harvesting flake ice, as well as storage containers and transportation equipment, must maintain high cleanliness and hygiene levels Additionally, flake ice must comply with drinking water standards as outlined in TCVN 5501-1991.
Soy protein is a product made by extracting soy protein with a high protein content (> 90%).
Table 2.8: Chemical composition of soy protein
(Source: Vietnamese food composition table.2007)
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
Packaged 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
Cold storage tº: 0 to 4ºC
Figure 4.1: Diagram of sausage production process
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 of which are initially stored in frozen forms at temperatures ranging from -25ºC to -18ºC Prior to processing, these raw materials must be properly defrosted to ensure optimal quality and safety.
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, with a defrosting duration of 15 to 18 hours Following this process, the raw materials are moved to the material room for cutting preparation After defrosting, the ingredients achieve a temperature range of 0ºC to 4ºC, showcasing a fresh and natural color.
Vinh Anh FTJSC supplies frozen meat sourced from their slaughterhouse Each day, workers retrieve the frozen meat ingredients from cold storage prior to beginning the production of smoked sausages, adhering to the varying ratios outlined in Table 4.1.
Table 4.1: The mixing ratio of 100 kg material in one batch
Flake iceSalt, sugar, polyphosphate, nitritPepper powder, color, monosodium
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
Pork and chicken are essential sources of nutrition, providing complete protein that includes all eight essential amino acids necessary for muscle tissue development Vinh Anh Food Company supplies these meats, utilizing 20 kg of pork and 36 kg of chicken per production batch, with 8 kg of chicken specifically designated for sausage production.
When producing sausage, it is essential 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 suited for trans fat The fat must be free from impurities such as bones and feathers Vinh Anh FTJSC supplies the necessary fat, with a recommended usage of 9 kg per batch in sausage production.
For optimal sausage production, the skin must be properly prepared: shaven, free from fat, bruises, and not overly hard or dry The company utilizes high-quality pigskin sourced from Vinh Anh FTJSC, specifically the back leather, which enhances product adhesion while minimally affecting fineness Additionally, chicken skin, imported from Germany, is sourced from the neck area after removing nuts and impurities This ingredient is incorporated to improve adhesion and toughness, allowing for better utilization of raw materials, cost reduction, and increased economic efficiency The recommended dosage for skin in sausage production is 2 kg per batch for pork skin.
5 kg/batch for chicken skin. d Flake ice
- Role of flake ice in sausage production
Maintaining a temperature below 12ºC during the pureeing of the emulsion system is crucial, as the grinding process generates friction that raises the mixture's temperature By keeping the temperature low, we effectively limit 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
The content of insoluble sediment
The content of soluble sediment pH
Total stool coliform (bacteria/100ml)
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 Standard
Total number of fungal cells
Soy protein is utilized in sausage production to enhance product structure, acting as a gel and emulsion that effectively retains water and binds with fat and protein components during the emulsification process It helps achieve a balance between animal and vegetable proteins, thereby boosting the nutritional value of the sausage The recommended dosage for incorporating soy protein in sausage manufacturing is 1.5 kg per batch.
Tapioca starch is essential in sausage production, serving as a source of polysaccharides that contribute to the product's unique characteristics The interaction between starch and protein, primarily through hydrogen bonding, imparts desirable elasticity to the gel protein in sausages For optimal results, the starch used must be of high purity, smooth, and fine, with a recommended 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 of meat while improving its quality and structure This additive acts as a mild antiseptic, extending shelf life by preventing pathogenic bacteria, reducing oxidation, and inhibiting aerobic microorganisms Additionally, salt increases the adhesion of actin and myosin in meat through osmotic pressure and improved water retention, which minimizes water loss during cooking.
Table 4.5: Salt standards in sausage processing TCVN 9639:2013
NaCl content in% of dry mass
The content of insoluble matter in water is expressed as a percentage by weight of the dry substance
Monosodium glutamate (MSG) enhances the sensory appeal of sausages by combining with salt in water, resulting in a meat-like sweetness The recommended maximum dosage is 10 grams per kilogram of raw material.
Table 4.6: Standard of monosodium glutamate TCVN 1459: 1996
Sugar plays a crucial role in sausage processing by enhancing sweetness, balancing saltiness, and improving meat flavor When combined with salt, sugar increases osmotic pressure, which helps inhibit bacterial activity during storage Additionally, sugar binds with water through hydrogen bonding, transforming free water into associated water, thereby reducing water activity and further preventing the growth of microorganisms.
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 Indicators
Extractive non-volatile matter (% mass dry matter)
Evaporated essential oil (ml /100g dry mass)
Piperine content (% of dry weight)
Acid insoluble ash (dry mass) h Additives
- Additives are used in the form of a powder and it purchased from Neo Foodtech Co Ltd.
Nitrite plays a crucial role in sausage processing by stabilizing the natural pink color of meat during heating and enhancing the overall color of processed meats It effectively kills and inhibits harmful microorganisms, while also contributing to the flavor and texture of the product, thereby limiting lipid oxidation The allowable concentration of nitrite is low, capped at a maximum of 150 mg per kg of raw materials Without nitrite, the color, texture, and shelf life of the product can be negatively impacted; however, excessive nitrite levels can lead to poisoning.
Phosphate plays a crucial role in sausage processing by preventing oxidation, which helps maintain the fresh color of meat and processed products It enhances the tenderness and flexibility of meat by stretching muscle fibers, while also creating soluble proteins that improve product adhesion Additionally, phosphate increases water retention, preserves the natural flavor of meat, and inhibits bacterial growth, ensuring a high-quality end product.
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 powers the shaft via a chain drive system, and a pneumatic control system featuring a cylinder, filter, pressure reducer, and electric sensors Additionally, trolleys are utilized to transport the meat post-cutting, ensuring efficient processing and freezing.
- Principle of operation of meat freezing machine
The meat block is fed into the machine, where it automatically slides down to the cutting area Equipped with knife nets attached to the drum, the machine efficiently cuts the meat into uniform sizes before it drops into the cart below.
- 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, it automatically feeds the meat to the knife area, allowing it to fall into 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 meat compression and conveying system designed with tapering steps It operates in two screw rotation modes, ensuring safety with a cover above the trough Key components include a screw-type compression chamber, a chamber wall with spiral grooves aligned with the screw blades, a four-sided cutter, and a mesh screen available in 8 mm or 3 mm diameters Additionally, the system offers two screw rotation speeds for optimized performance.
The system features a controller with four buttons that allow users to adjust the rotation speed of two screws, as well as a stop button for the machine The actuator operates using a belt-driven three-phase electric motor, enabling both slow and fast performance.
- Principle of operation of meat grinder
Meat is diced into small cubes and fed into a hopper, which directs it into a screw conveyor powered by either a crank or an electric motor This conveyor 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 as instructed, load the materials into the cavity and press the operation button The machine will automatically grind the ingredients until completion To stop the process, press the shutdown button, turn off the power, and then carefully remove and clean the screws, cutters, and sieve.
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 cut section at the indentation It rotates around its axis, allowing for two speed settings: slow and fast Ingredients are placed in the concave area of the pan for effective mincing during operation.
The cutting knife features six equally sized blades that alternate on a rotating axis, ensuring efficient operation As the blades rotate, they maintain a minimal distance from the bottom of the pan, promoting even blending of ingredients This versatile tool offers four adjustable rotation speeds—1, 2, 3, and 4—allowing for customized blending based on your culinary needs.
The lid is designed to cover half of the rotating pan, allowing a knife to chop ingredients without them flying out Equipped with gears, the lid ensures that when placed on the pan, the bars remain close to the pan's wall, effectively scooping and guiding the ingredients for even mixing and chopping.
The control unit features multiple buttons, each designed for specific functions that allow users to manage the entire system effectively This includes the ability to open and close the lid, as well as adjust the rotation speed of both the knife and the 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 key phases In the first phase, ingredients are prepared and placed in a pan, with the machine operating slowly at approximately 0ºC Once the temperature rises to 4ºC, the process moves to phase two, where the machine speeds up, and spices, additives, and flake ice are incorporated, monitoring the mixture until it reaches 8ºC In the final phase, the machine operates at maximum speed, grinding all materials to sizes between 0.2 - 0.5mm, creating an emulsion system with the melted ice water The process concludes when the emulsion becomes homogeneous, at which point the machine is stopped, and the product is removed before the temperature exceeds 12ºC.
The purpose of a stuffer is to fill sausage casings with a well-mixed emulsion of sausage ingredients, ensuring the proper shape and quantity for each individual 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 outlet of the compression chamber is directly linked to the casing tube, facilitating a seamless filling process.
Tubing system of casings, cups, forks have the appropriate size for stuffing sausages;
The control unit of the PLC system regulates essential operation parameters, including vacuum levels and the drive motor's rotation speed in the compression chamber, ensuring optimal performance for processing sausages Additionally, it features a lever that allows for immediate machine shutdown during cover changes or in the event of an error, enhancing safety and operational efficiency.
- 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 fire prevention protocols All machinery and equipment are operated according to established safety principles, with protective barriers and relays for high-speed equipment Workers are assigned specific responsibilities for managing and maintaining production equipment during their designated stages, ensuring they do not operate machinery outside their area Regular maintenance is enforced, with workers required to report any issues to the technical department promptly Additionally, the company is equipped with fully installed and tested emergency exits and fire extinguishers to enhance workplace safety.
To maintain hygiene standards for officers and employees in the workshop, it is essential that all staff members wear appropriate protective gear, including hats, masks, gloves, and rubber boots Additionally, jewelry such as watches and rings should not be worn to ensure a safe and clean working environment.
Employees undergo biannual health check-ups to monitor their well-being Those diagnosed with infectious diseases are required to receive treatment before being permitted to return to the workshop or production area.
Before entering the production area, workers must wear appropriate workwear and thoroughly wash their hands using an automatic water tap They then rinse their hands, apply a 700 ppm alcohol spray for disinfection, and dry their hands with an automated drying system Additionally, workers wade through water tanks containing a chlorine solution at 200 ppm to ensure proper sanitation.
Ensuring hygiene during production is crucial; workers must wear protective clothing outside the production area and consistently use gloves when handling raw materials and products It is essential to prevent contamination of protective gear, and strict adherence to hygiene practices is observed, with no instances of smoking, eating, or spitting in the production area.
After exiting the production area, individuals ensure that their hands and personal tools are thoroughly cleaned Protective gear is stored in designated locations, and it is important to remove all protective equipment before entering the restroom Upon re-entering the production room, strict adherence to cleaning protocols is observed.
The processing factory maintains a dedicated cleaning area for tools, ensuring that no operations are conducted in the background Raw materials and products are stored in designated baskets, barrels, and bins, all placed on stainless steel or plastic pallets The facility prioritizes cleanliness, with floors and walls kept consistently clean and dry Each room is equipped with two separate trash cans for organic and production waste, and a comprehensive cleaning of the entire factory is conducted once a week.
To ensure proper hygiene in food processing, tools, machinery, and equipment must be meticulously cleaned Semi-finished product bins and baskets are initially sprayed with pressurized water to remove residual meat, followed by a thorough washing with soap and a brush This is succeeded by rinsing with clean water and a final rinse using 90°C hot water All tools, including knives, scissors, cutting boards, and tables, are cleaned after each use or when switching between products Additionally, sausage processing machines require cleaning with soap and a high-pressure water hose to effectively wash all parts, including those that come into contact with materials.
Maintaining proper sanitation in the warehouse is essential, ensuring that the facility remains clean and dry at all times Trolleys, bins, and carts are organized and stored in their designated areas, promoting efficiency and safety Additionally, separate storage areas are established for raw and cooked produce to prevent cross-contamination and uphold food safety standards.