Defect rate in sausages and sausages
Lack of consistency
Cut without garter
Cracks, air pockets
Lack and poor color conservation
Core discoloration
Colorless surface
Dry surface
Dry and dark surface
Dry, grayish surface
Wrinkled loose casing
Stains on the product
Burst gut
Excessive acidity
Rancidity
Putrefaction
Unwanted flavors
Inadequate seasoning
Lack of Aroma
Aroma and flavor changes
Lack of Consistency
Feedstock
- very high initial pH;
- Use of meat from sick and/or fatigued animals;
- Meat without rest in cooling chambers;
- Fat without consistency;
- High initial contamination due to lack of hygiene during the slaughter operation (proteolytic germs and other unwanted microorganisms);
- Poorly refrigerated meat;
- Formulation with excess fat (especially in sausages with finely ground meat).
Tripe
1. Poorly washed (casing impermeable to water vapor);
2. Poorly degreased, without exchange of moisture with the environment.
Additives
1. Little salt;
2. Few carbohydrates (carbohydrates), especially when the initial pH is very high;
3. Cultivation employment (starters) without multiplication capacity;
4. Too long resting of the dough and high temperature;
Manufacturing
1. Very high temperature in the Grinder or Mixer;
2. Low build-in pressure;
3. Release of fat during embedding.
Process
1. Very high relative humidity (poorly dehydrated).
2. Low relative humidity (formation of a very dry surface, leaving the interior very moist and soft);
3. High temperature with dough having initial contamination favors the development of undesirable microorganisms;
4. Very high relative humidity in the chamber where the product remains before packaging.
Packaging
1. Product packaged without proper rest and/or complete cooling when it was processed. (dehydration no longer occurs and for this reason there is a lack of consistency in the cut).
Cut without Alloy
Feedstock
1. Meat with very high humidity (excess water);
2. Poor hygiene;
3. High initial contamination contributing to very rapid acidification in the first days of storage at a temperature of 0 – 5ºC. (cooling);
4. Improperly refrigerated meats.
Additives
1. Very long rest before embedding, especially when using GDL;
2. Excessive addition of sugar normally accompanied by high dough temperatures (very rapid drop in pH);
3. Excessive addition of GDL and/or carbohydrates.
Process
1. Very low build-in pressure;
2. Loose inlay;
3. Air in the dough;
4. Very low relative humidity;
5. Excessive ventilation (dry surface) causing the formation of cracks and air inside the piece;
6. Very high process temperature accompanied by large addition of carbohydrates or use of contaminated raw material;
7. Gas formation by heterofermentative microorganisms as a consequence of a very dry (impermeable) surface.
Cracks, air pockets
Feedstock
1. Use of highly contaminated raw material. formation of cracks between the dried coating (casing) and the sausage core.
Tripe
1. Poorly degreased, formation of a dry surface on the side with the formation of cracks between the dried coating (casing) and the sausage core.
Additives
1. High concentration of carbohydrates that act as nutrients for heterofermentative microorganisms with the consequent formation of gas in the final product.
Process
1. Very low build-in pressure;
2. Loose inlay;
3. Air in the dough;
4. Air in the mass originating from defects in the piston sealing rings of vertical baggers;
5. Very low relative humidity;
6. Excessive ventilation (formation of a dry surface) resulting in the formation of cracks and air inside the piece;
7. Very high process temperature accompanied by large addition of carbohydrates or use of highly contaminated raw material;
8. Gas formation by heterofermentative microorganisms, as a consequence of a very dry (impermeable) surface.
Lack and poor color conservation
Feedstock
1. Little lean meat in the formulation;
2. Use of meat with a low myoglobin content (very young animals);
3. Meat contaminated either by unhygienic procurement or treatment;
4. Use of rancid bacon (formation of peroxides capable of altering the color of the final product);
5. Poorly cooled raw material;
6. Using very soft bacon.
Tripe
1. Tripe with remnants of intestinal mucosis;
2. Casing with excess water inside, forming a film of water between the dough and the product;
3. Unremoved casing decolorizer, which changes the color of the final product;
4. The permeability of the casing has been altered due to it being poorly washed.
Additives
1. Insufficient quantities of curing salts;
2. Use of GDL, salt and curing salts in inadequate proportions, resulting in a lack of reaction between the curing salts and myoglobin as a result of a very rapid drop in pH;
3. High concentration of sugars together with curing salts not suitable for the elaboration process and high storage or maturation temperatures;
4. Cultivations (starters) not suitable for the process, inactive due to being poorly stored (dead starters);
5. Excessive addition of color fixatives or other reducing substances that alter the redox potential;
6. Deficient dosage of antioxidants;
7. Very high dosage of curing salts that alter the taste (metallic) and color of the final product.
Process
1. High dough temperatures during preparation;
2. Very low temperatures (very slow reaction);
3. Very intense lighting, especially when using lamps with a lot of ultraviolet emission;
4. High preparation temperatures combined with high sugar contents, resulting in a very rapid drop in pH, all of this worsens if cures that are not appropriate for this process were used;
5. Storage chambers with very low temperatures with consequent color changes, this problem becomes worse if the lighting is very intense;
6. Equipment and utensils in poor hygiene conditions (dirty), which causes intense contamination of surfaces with germs that change the color;
7. Packaging the product too quickly without giving the necessary time for all curing reactions to be completed;
8. Poor hygiene of the workplace and operators (hands, caps, boots, etc.);
9. Very humid workplace.
Core discoloration
Feedstock
1. Use of bacon without texture (soft) which forms a film of fat on the surface of the meat, preventing dehydration and/or masking the color of the cured meats.
2. Use of highly contaminated meat (slaughter, conservation, etc. in unhygienic conditions).
3. Meat stored for a long time.
Tripe
1. Water vapor permeability of the casing was not observed, with the formation of a dry surface film (shell) resulting in the core becoming pale;
2. Poorly washed or poorly hydrated casing (altered permeability).
Additives
1. Very low dosage of salt, with no inhibition of the growth of undesirable microorganisms;
2. Too high or low dosages of curing salts.
Process
1. High temperatures during dough preparation and/or filling (partially melted fat);
2. Very low relative humidity, which forms a very dry surface (shell) with the formation of a pale core;
3. Very low preparation and/or storage temperatures (incomplete curing reaction).
Colorless surface
Feedstock
1. Use of bacon without texture (soft).
Process
1. Dough temperature too high during preparation;
2. Cutter with poorly sharpened knives (heating the dough);
3. Baptism or jowls with high temperature;
4. Very low filling pressure or very thin funnel, consequently the fats are located between the casing and the cured meats, masking the color of the cured meats (whitish).
Dry Surface
Feedstock
1. Low fat formulation.
Tripe
1. Poorly degreased (crust formation on one side only);
2. High permeability to water vapor, not considered in the process.
Process
1. Initial greenhouse temperature too high;
2. Very low relative humidity;
3. Very intense ventilation;
4. Temperature in disagreement with the permeability of the casing to water vapor;
5. Built-in left exposed to air currents, sometimes with the formation of a dry unilateral surface;
6. Very hot smoking;
7. Very rapid smoking coinciding with high relative humidity and the formation of a dark and dry smoked surface.
Storage
1. Very low relative humidity;
2. Excessive ventilation;
3. Air currents with the formation of a dry surface on one side.
Dry and dark surface
Process
1. Very high smoking temperature;
2. Very high relative humidity in the smokehouse;
3. Smoked product without the dough having had the necessary rest, coinciding with excessively high relative humidity and curing without developing.
Dry, grayish surface
Feedstock
1. Use of rancid bacon;
2. Due to the influence of oxygen in the air on the surface of the product, it turns grayish in color.
Tripe
1. Casing with intestinal mucosis residues;
2. Excess water inside the casing, forming a layer of water between the dough and the casing;
3. Casings stored for a long time, high surface contamination by microorganisms that change the color.
Process
1. Very high humidity acting for a long time, forming a superficial viscous film as a consequence of very high environmental contamination, resulting in a superficial color change;
2. Storage in chambers with very low temperatures;
3. Influence of oxygen in the air;
4. Very intense lighting with a high amount of ultraviolet during storage of the dough or embedded product;
5. Formation of superficial mold, which causes changes in surface color due to very high relative humidity and unhygienic conditions with high environmental contamination.
Packaging
1. Defective packaging (failed welding, stapled, etc.) which causes internal contamination by microorganisms, changing the color of the product due to the development of microorganisms that consume air;
2. Packaging in the most hygienic conditions;
3. Very high ambient humidity (running point).
Loose and/or wrinkled casing
Feedstock
1. Formulation with very low fat content, resulting in very rapid dehydration with the formation of wrinkles.
Tripe
1. Insufficiently washed (poor elasticity);
2. The casing does not retract after the process.
Process
1. Very low ambient humidity with very dry surface formation;
2. The intestine does not retract evenly;
3. Pieces hung too close together, which creates wet and dry areas;
4. Covering the product with protective films (waterproofing) or similar coatings applied to the damp or cold product.
Stains on the product
Feedstock
1. Use of bacon and/or jowls without texture (soft);
2. After the process (smoking or oven) release of fat;
3. Excessive smoke stains;
4. Use of rancid bacon or jowls.
Tripe
1. Salt exhumation when poorly washed casings are used (salt stains);
2. Casings stored for a long time;
3. Formation of mold under the surface of the casing that causes colored or black spots;
4. Poorly washed casings.
Process
1. Presence of rust in the dough (as a result of working with old equipment in poor condition) which, in the presence of fasteners, forms black spots;
2. Very high relative humidity with the consequent formation of mold;
3. Wet smoking at very high temperatures;
4. Brown smoke stains accompanied by the release of fat or condensation of water vapor;
5. Very high storage temperature;
6. Influence of light especially when working with rancid bacon/jowls.
Packaging
- Poor packaging (welding, clamp, string) with leaks penetrating contaminated air with the consequent growth of mold and yeast, resulting in black, green or white spots.
Burst gut
Feedstock
1. Use of raw materials excessively contaminated mainly by gas-forming germs.
Tips
1. Use of cellulosic casings contaminated with mold and yeast;
2. Casings stored for a long time (contaminated);
3. Excessively washed casing.
Additives
1. Excessive addition of carbohydrates accompanied by undesirable microorganisms (gas formers).
Process
1. Very high process temperatures accompanied by high dosages of carbohydrates and poor hygiene;
2. Very high relative humidity;
3. Formation of mold on the surface, especially when using cellulose casing;
4. Poor hygiene accompanied by high environmental contamination, which favors the formation of surface mold and yeast and causes the cellulosic packaging to break when it is used.
Excessive acidity
Feedstock
1. Use of raw material highly contaminated by heterofermentative, spore-forming germs, acidifiers, etc.
Additives
1. Excessive use of carbohydrates or high amounts of GDL.
Process
1. Contaminated equipment (machines and utensils);
2. High contamination by microorganisms that produce fundamentally heterofermentative acids;
3. Very high temperatures when the dough rests;
4. Very low relative humidity with consequent superficial drying of the sausage, which facilitates the development of undesirable microorganisms with an intense production of acidic flavor;
5. Very high process temperatures.
Packaging
1. Unhygienic packaging (hands, equipment, slicers, etc.). Packaging of very fresh products (very high water activity).
Rancidity
Feedstock
1. Use of rancid bacon and/or jowls;
2. Bacon stored for a long time (old) including frozen;
3. Bacon without texture (high proportion of unsaturated fatty acids that tend to go rancid very easily).
Tripe
1. Using casings that have been stored for a long time, especially if there is fat attached (poorly processed).
Additives
1. Use of high amounts of GDL together with high dosages of carbohydrates.
Process
1. Presence of metallic particles in the mass (rust, improper functioning of equipment, etc.);
2. Excess air in the dough, high process temperatures;
3. Very intense lighting (high concentration of ultraviolet radiation);
4. Formation of mold and yeast on surfaces as a result of very high relative humidity for a long time;
5. Unhygienic production, high environmental contamination.
Packaging
- Poor packaging, very permeable films, defective welding, lack of hygiene (hands, cap, equipment, etc.).
Putrefaction
Feedstock
1. Meats with high initial pH;
2. Meat stored in inadequate conditions for long periods.
Tripe
1. Use of casing stored for a long time;
2. Use of poorly washed natural casing.
Additives
1. Very low carbohydrate dosage, essentially coinciding with a high pH of the meat;
2. Very low salt levels and putrefactive germs are not inhibited.
Process
1. Unhygienic production;
2. Very high temperatures generally accompanied by very low dosages of carbohydrates;
3. Very high relative humidity during the process;
4. Very low environmental humidity consequently forms a very dry and impermeable surface, proliferating putrefactive germs inside the product.
Packaging
1. Defective packaging (welding, micro-holes, etc.);
2. Unhygienic packaging;
3. Very fresh product (high water activity).
Unwanted flavors
Feedstock
1. High initial load of microorganisms.
Tripe
1. Casings stored for a long time (old).
Additives
1. Use of very old and/or contaminated seasoning.
Process
1. Unhygienic production;
2. Very high relative humidity and, as a consequence, the formation of yeast and mold on the surface of the product;
3. Very low relative humidity with the formation of a very dry surface with the formation of cracks where undesirable germs develop.
Inadequate seasoning
Feedstock
1. Very high fat content in the formulation;
2. Fats with a high level of rancidity.
Additives
1. Inadequate composition of seasonings, poorly balanced, not respecting the participation of each of the seasonings used;
2. Failure to observe the relationship between lean and fatty meats;
3. Use of inappropriate preservatives;
4. Inadequate or inappropriate additives.
Lack of aroma
Additives
1. High dosages of carbohydrates or GDL;
2. Excessive seasoning that masks the aroma of the sausage.
Process
1. Very high process temperatures, which makes the process develop very quickly, damaging the final aroma.
Aroma and flavor changes
Feedstock
1. Feeding animals with inappropriate products, such as fish meal (fishy odor and taste).
Tripe
1. Poorly washed natural casings;
2. Use of casings that have been stored for a long time (old).
Additives
1. Use of garlic and onions that have begun to germinate or are beginning to putrefaction;
2. Condiments stored for a long time and/or contaminated (old).
Process
1. Use of green wood or wood unsuitable for smoking (remains of varnish, mold, paint, etc.);
2. Finished product or raw materials stored with other foods with strong odors such as cheese, fish, etc.;
3. Finished product stored together with aromatic organic solvents.
Packaging
1. Unhygienic packaging (hands, equipment, utensils, etc.);
2. Defects in packaging such as faulty welds, micro-holes, which favor the growth of undesirable microorganisms that alter the color, aroma and flavor of the final product;
3. Product with high water activity.
Source: Brazilian Technical Response Service – SBRT
http://www.sbrt.ibict.br/dossie-tecnico/downloadsDT/MTQy
English 
Português do Brasil
Because pure salami keeps loosening its casing
Good afternoon. Because excess curing or antioxidants could alter the color of the meat. What could harm the process?
Thanks
Good afternoon Eduardo, to make salami or other quick-curing sausages, it requires a cooking oven, can I use a home electric oven for this cooking? Because I saw that it needs controlled humidity, what is the solution to make this recipe at home? I thank the attention. Ricardo
Hi Ricardo, for many products you can use the electric oven, yes, to maintain humidity you can add a pan with water. Evaporation during the process ensures a level of humidity. Some products are steamed, in which case it is not possible to do so in a regular electric oven. Only with a solution adapted to the stove, a combined oven or a professional oven for a refrigerator. Hugs!
What can the industry do when it finds any of these defects in sausages?
What is GDL, what is the minimum and maximum relative air humidity for handling the dough and the maximum and minimum temperature. Thanks.
GDL is Glucone Delta Lactone, it provides a slow, gradual and continuous decrease in the pH value until reaching balance and its final acidic flavor is much lighter than that of other acids.
Handling the mass of which product? Sausages and salami can be handled hotter, sausages need to be handled at a temperature preferably below 12ºC, as the fat in the emulsion is very susceptible to melting.