05d surimi seafood products sausage

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THP 333 Diversifikasi dan Pengembangan Produk Perikanan/Kuliah Ke-3C2 Sausage 1

Lihatlah dunia apa adanya….

SAUSAGE PROCESSING INDUSTRY

oleh : Wini Trilaksani

Bambang Riyanto

DEPARTEMEN TEKNOLOGI HASIL PERIKANAN FAKULTAS PERIKANAN DAN ILMU KELAUTAN

INSTITUT PERTANIAN BOGOR

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CAPAIAN PEMBELAJARAN DAN KARAKTER YANG DIKEMBANGKAN Kognitif : Mampu menjelaskan sains dan teknologi (K)

ekstraksi, konsentrasi serta pengembangan produk pengolahan berbasis daging ikan lumat (minced fish) atau surimi

Afektif : Mampu bekerjasama dan mengembangan

konsep dan kreativitas (A) dalam pembuatan produk baru yang potensial untuk dikomersialkan dan memberi sumbangan dalam penciptaan kedaulatan pangan protein ikani.

Psikomotorik : Mampu mempraktekkan dan mengaplikasikan (P)

produk bernilai tambah hasil perairan dalam pembuatan produk baru yang potensial untuk dikomersialkan dan memberi sumbangan dalam penciptaan kedaulatan pangan protein ikani.

•  TUTORIAL DAN DISKUSI

•  COLLABORATIVE LEARNING (CBL)

•  PROJECT BASED LEARNING (PJBL) MODEL PROYEK : KOOPERATIF DAN KOLABORATIF GAGASAN KELOMPOK PENGEMBANGAN PRODUK

STRATEGI/METODE PEMBELAJARAN

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ASSESSMENT KOMPETENSI/KEMAMPUAN DIRI KOGNITIF PERFORMANCE ASSESMENT/ASESMEN KINERJA 1.  UJIAN TENGAH SEMESTER 2.  QUIS

ASSESSMENT KOMPETENSI/KEMAMPUAN DIRI AFEKTIF DISKUSI DAN PEMBUATAN RESUME (RUBRIC-DESKRIPTIF DAN HOLISTIK)

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DISKUSI DAN PEMBUATAN RESUME DISKUSI 1.  Bagaimana peran DHA dikembangkan dalam pembuatan

sosis

PENILAIAN AUTENTIK (RUBRIK DESKRIPTIF) (85%)

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LINGKARI SALAH SATU PILIHAN NILAI DIMENSI

KONTRIBUSI PADA HASIL TUGAS DAN TUGAS YANG DIBERIKAN 5 A. Sangat Berkontribusi 3 B. Berkontribusi sama dan adil 2 C. Hanya memberi kontribusi yang ada

KEPEMIMPINAN 5 A. Inisiatif dan terlihat memberikan perhatian yang besar dalam

menyelesaikan tujuan bersama 3 B. Bertanggungjawab pada tujuan dan menerima pembagian yang

adil 2 C. Kurang memberikan perhatian dan tidak sesuai dengan arah

tujuan KERJASAMA

5 A. Menghargai pendapat orang lain dan sangat berkontribusi dalam diskusi kelompok

3 B. Menghargai pendapat orang lain dan berkontribusi dalam diskusi kelompok

2 C. Tidak berkontribusi pada diskusi kelompok atau sering gagal berpartisipasi

NILAI TOTAL !

PENILAIAN UNTUK SESAMA ANGGOTA TIM (15%)

ASSESSMENT KOMPETENSI/KEMAMPUAN DIRI PSIKOMOTORIK 1.  PRAKTIKUM

2.  MODEL PROYEK : KOOPERATIF DAN KOLABORATIF GAGASAN KELOMPOK PENGEMBANGAN PRODUK

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KOMPETENSI DASAR

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1. CLASSIFICATION OF SAUSAGES 2. RAW MATERIALS 3. SAUSAGE CASINGS 4. PROCESSING TECHNOLOGY 5. KEEPING QUALITY 6. MARKET 7. NOVEL PRODUCTS

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  FRESH SAUSAGE   FERMENTED SAUSAGE   SMOKED PRECOOKED SAUSAGE   EMULSION-TYPE SAUSAGE   COOKED SAUSAGE

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1. Fresh pork sausages 2. Fresh beef sausages for grilling 3. Curry beef-mutton sausages 4. Sausage-burger (hamburger) 5. Merguez (Mergés)

FRESH SAUSAGE Fresh sausages are made from fresh meats which are, as a rule, neither cured, smoked, fermented nor cooked. Fresh sausages must be kept under refrigeration prior to eating. They are heated by the consumer himself before serving.

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Fresh pork sausages

Merguez (Mergés)

Sausage-burger (hamburger) C

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Grill Sausage

FERMENTED SAUSAGE Fermented sausages are made from cured or uncured, fermented and often smoked meats but they are not heat processed in any way; they are divided into semidry and dry sausages. 1. Summer sausages 2. Air-dried sausages 3. Pepperoni 4. Pork and beef chorizos 5. Beef salamis 6. Turkish and oriental style raw beef sausages 7. Landjaegers

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Salami

Summer sausages

Landjaegers

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Cervelat

Pepperoni

BASIC FORMULATIONS FOR SOME FERMENTED SAUSAGES

1)

1.0 g/kg monosodium glutamate may be added per 1 kg of product — addition of 1.5–5.0 g pepper is practised per 1 kg of product

SAUSAGE Beef % Pork % Pork backfat % Spices1 Large diameter (salami) German type 65–75 25–35 coriander, garlic Italian type 30 45 25 ginger, garlic Hungarian type 70 30 red pepper, nutmeg, cardamom, garlic Polish type 10–15 55–60 25–30 marjoram Small diameter salametti (28/32 mm) 30 40 30 garlic sausage 50 20 30 red pepper (hot), (24/28 mm) rosemary, garlic beef garlic sausage 80 20 fenugreek, red pepper, (24/28 mm) (beef fat) ginger, garlic

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SMOKED PRECOOKED SAUSAGE Smoked precooked sausages are mostly cured, nonfermented products; their shelf life is increased by heating due to partial reduction of their moisture content; they are usually finally cooked before consumption. 1. Smoked pork sausage 2. Precooked pork sausages 3. Smoked beef sausages 4. Precooked beef sausages 5. Smoked precooked beef sausages 6. Chinese sausages (“Lap Chong” of which the

nearest translation would be “winter stuffed intestine” or “waxed intestine”)

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Chinese sausages

Smoked beef sausages

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EMULSION-TYPE SAUSAGES Emulsion-type sausages comprise ready-to-eat products made from comminuted and well-homogenized cured meats, fatty tissue, water and seasonings, usually smoked and slightly cooked. In Europe, these sausages are known as “scalded” because they are only scalded (pasteurized) and not fully cooked. An important subgroup of larger diameter emulsion-type sausages includes products containing, in addition to previously cured meats, diced or cut into distinctive small pieces. 1. Frankfurters (wieners) 2. Bologna 3. Mortadella 4. Chicken frankfurters

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Frankfurters (wieners) Chicken frankfurters

Bologna

Mortadella

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BASIC FORMULATIONS FOR SOME EMULSION-TYPE SAUSAGES

Sausage Beef % Fat % Ice % Spices1 caraway 30 plus 30 pork fat 15 caraway (1.0), mace, sausage 10 lungs 15 beef fat

coriander, ginger, glutamate

garlic sausage 65 15 beef fat 20 coriander, rosemary, garlic (1.2 g), caraway etc.

cheese sausage 95 all-beef emulsion plus 5 low fat cheese + as for frankfurters heart sausage

80–85 all-beef emulsion 15–20 cured pork or lamb or veal hearts

as for bologna plus pistachios

red pepper sausage 50 all-beef emulsion plus 50 pork belly 3.5 red pepper, 1.0 allspice, 0.2 chili, 0.3 garlic

1 addition of 1–3 g/kg is practised in all formulations

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1.  Choice of meat. 2.  Precuring. 3.  Grinding 4.  Chopping 5.  Hot meat processing 6.  Emulsified fat batters 7.  Stuffing 8.  Linking 9.  Smoking 10.  Chilling

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PREPARATION OF EMULSIONS OF VEGETABLE OILS OR ANIMAL FATS (MELTED) FOR INCORPORATION IN EMULSION-TYPE SAUSAGES

Operation Sequence of placing ingredients into the cutter bowl

beginning of chopping 8 parts of water at 65–70°C 7 parts of water at 65–70°C

during chopping 1 part of caseinate and chopped until a homogenized mass is obtained

1 part isolate (soy) and chopped until a homogenized mass is obtained

6 parts of vegetable oils at 80°C 7 parts of animal fat at 80°C

at the end of chopping 2 percent of salt

storage 2–4°C in pans

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Operation Order of placing ingredients into the cutter bowl

beginning of chopping 7 parts of fatty tissue preheated at 65–70°C

9 parts of fatty tissue preheated at 80°C

during chopping 1 part of caseinate (of high viscosity) 5 parts of water at 80°C

7 parts of water at 90–95°C 1 part of isolate (soy)

at the end of chopping until finely homogenized 2 percent of salt

storage 0–4°C/3–4°C in pans

incorporation in sausage mix after 24 hours (after protein hydration)

PREPARATION OF EMULSIONS OF PREHEATED FATTY TISSUE FOR INCORPORATION IN EMULSION-TYPE SAUSAGES

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Operation Order of placing ingredients into the cutter bowl

beginning of chopping 5 parts of cold water 5 parts of fatty

tissue

1 part of caseinate or isolate and chopped until a homogenized mass is obtained

5 parts of water at 80°C

during chopping 5 parts of fatty tissue 1 part of isolate (soy)

until finely homogenized

at the end of chopping 2 percent of salt

storage 0–4°C/3–4 days

incorporation in sausage mix after 24 hours (after protein hydration)

PREPARATION OF EMULSIONS OF CHILLED (0–4°C) FATTY TISSUE FOR INCORPORATION IN EMULSION-TYPE SAUSAGES

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COOKED SAUSAGE Cooked sausages are ready-to-serve products, basically made from previously cooked fresh or exceptionally cured raw materials, subjected to final cooking after stuffing, with or without additional smoking. A subgroup of these sausages consists of cooked or baked specialities that are not stuffed into casings but moulded and, therefore, not always considered as sausages. 1. Liver sausages 2. Blood sausages 3. Head cheeses 4. Meat loaves

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Meat loaves

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Liver Sausage

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•  Muscle meats •  Salt (sodium chloride) •  Nitrite and nitrate •  Ascorbate and erythorbate •  Sugar •  Phosphates •  Colouring agents •  Spices •  Natural spices •  Essential oils •  Oleoresins •  Other spice properties

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S 1. NATURAL CASINGS

PIG CASINGS - Pig stomachs (or “maws”) - Small pig casings (pig rounds) - Pig caps (caecum) and pig largeintestines (middles) - Pig bungs - Pig bladders

BEEF CASINGS - Weasands (esophagus of cattle) - Beef rounds (“runners”) - Beef bungs - Beef middles - Beef bladders

SHEEP AND GOAT CASINGS SEWN CASINGS

2. ARTIFICIAL CASINGS

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ARTIFICIAL CASING

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Preparation of natural casings for stuffing

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PRODUCTION STAGES •  Raw material storage and preparation •  Curing •  Chopping and Stuffing •  Cooking •  Smoking •  Packaging and labeling •  Frozen storage/distribution

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RAW MATERIAL STORAGE

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RAW MATERIAL PREPARATION

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CURING

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SECTION AND AREA I - Cutting and trimming II - Chilling III - Meat curing IV - Chopping and stuffing V - Cooking and

Chopping and stuffing cooked sausages,

VI - Smoking VII - Equipment sanitation area. 1 - Trimming table, 2 - Curing vat, 3 - Massager, 4 - Pickle injector, 5 - Cutter, 6 - Stuffer, 7 - Cooker, 8 - Cutter, 9 - Working table, 10- Smokehouse.

SAUSAGE PROCESSING LAYOUT

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GRINDING (CHOPPING)

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CHOPPING AND STUFFING

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COOKING AND CHOPPING AND STUFFING

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SMOKING

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PACKAGING AND LABELLING

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STORAGE

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Keeping quality * Temperature * Water activity * Control of sausage spoilage and deterioration

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EXPECTED SAUSAGE SHELF LIFE AT VARIOUS TEMPERATURES

Sausages No refrigeration 10 – 15°C 0 – 4°C Freezing

fresh several hours 1 – 2 days 2 – 4 days about 5 – 7 days; if protected 1 – 3 weeks

semidry several hours 10 – 15 days not recommended

dry 1 – 5 weeks 3 – 6 weeks not recommended

smoked, precooked 10 – 15 hours 2 – 4 days (often more) 1 – 3 weeks

emulsion-type 8 – 12 hours 1 – 3 days 3 – 5 days 6 – 10 days

cooked several hours 2 – 3 days some varieties may be kept frozen for 2 – 3

weeks

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USDA CRITERIA FOR E.coli 0157:H7 in FERMENTED SAUSAGE

•  68.8 oC (135 oF) for min : assumes 1000/g in raw sausage blend (based on 5D kill for Salmonella or E. coli 0157:H7 in beef)

•  5D kill based on research data of processor

•  2D kill of E.coli 0157:H7 at level of 1/g (negative for 15 samples of 25 g = 1/125 g) in raw sausage blend)

•  Hold and test final product negative for E. coli 0157:H7 in 30

samples x 25 g (1/250 g)

•  New Technology shown to have a 5D kill

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No. Classification Example Percent of Consumption

1. Freshed, Fresh-Smoked Fresh Pork Sausage Bratwurst 15

2. Fermented Dry (Salami, Pepperoni) 6

Semi-Dry (Cervelat, Thuringer)

3. Pre Cooked, Gel-Type Braunshweiger 11

4. Cooked-smoked Emulsion Type Frankfurter, Bologna 50

5. Loaves, Luncheon Meats Olive loaf, Head cheese 18

USA MARKET 35% of the total red meat consumed in the USA can be classed as processed meat of which 70% can be classed as sausage items.

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QUALITY

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APPEARANCE

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CASING

ü  New sausage product development ü  Organic sausages ü  Vegetarian sausages ü  Low fat sausages ü  Low salt/sodium sausages ü  Exotic/gourmet recipes

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NEW SAUSAGE PRODUCT DEVELOPMENT

ORGANIC SAUSAGES

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VEGETABLES SAUSAGES

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LOW FAT SAUSAGES AND

LOW SALT/SODIUM SAUSAGES

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EXOTIC/GOURMET RECIPES

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TERIMA KASIH

05d surimi seafood products sausage

Food