The innovative Kalle's Roasted Flavor packaging allows the product to be roasted while providing a crispy appearance that mimics the look of fried foods. According to Kalle, this new casing significantly reduces production time, enhances product safety by minimizing fire risks, and helps steer clear of the negative perceptions associated with deep-frying among consumers. Furthermore, it simplifies the cleaning process and eliminates the hassle of disposing of frying fat.

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&#;The Roasted Flavor casing provides substantial advantages for sausage manufacturers: lower costs, improved product safety, and more flexible planning capabilities resulting from pre-production,&#;&#; stated Gerd Ziemes from Kalle’s business development division.

&#;Finally, utilizing Roasted Flavor casings offers a distinct edge over competitors, presenting a viable alternative to frying fat. Our development team dedicated significant effort in refining this product. They experimented with over 50 different ingredients and combinations to perfect the roasted aroma and the fresh, fried appearance of the products.&#;&#;

During the cooking process, this casing transfers both aromas and a crispy texture to the meat. When cooking is completed, the product is deemed ready and can remain encased until opened. This method also prevents the typical shrinking that occurs during frying.

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Basics of Meat Casings

Jay B. Wenther, Ph.D. American Association of Meat Processors

Introduction

Casings have played a crucial role in the manufacturing of sausages and processed meats for centuries. They are considered one of the oldest types of packaging materials for sausage. The casing determines the final shape and size of the sausage, acting as molds for processing, containers for handling and shipping, and display units for marketing. Historically, sausage production relied on the availability of animal intestines, but with advancements like collagen, fibrous, and cellulose casings, sausage production is now limited only by access to raw materials. Meat casings have transitioned from traditional methods to modern high-speed production. Generally, casings are made from two primary materials: cellulose and collagen. There are five main types of casings used: animal, regenerated collagen, cellulose, fibrous, and plastic casings.

Natural Casing

Natural casings are sourced from the gastrointestinal tracts of animals, primarily made from the submucosa, which is a collagen-rich layer of the intestines. This process removes fats and the inner mucosa. The advantages of natural casings include a traditional look, texture, and expected cooking performance. However, there are some drawbacks like decreased machinability, variable weight and length, and higher costs. Natural casings are primarily derived from cattle, hogs, and sheep.

Beef Casings

The most commonly used beef casings include beef bung caps, beef rounds, and beef middles. Depending on the type chosen, they come in various sizes as seen in the intestinal tract of cattle. Beef bung caps are utilized for larger sausages like bologna or salami, while rounds are used for ring-shaped products such as ring bologna and Polish sausage. Beef middles can be sewn to maintain size and weight uniformity, useful in crafting large diameter sausages like specialty dishes (souse or head cheese).

Hog Casings

Hog casings cater to smaller sausages (30-44 mm) and can be used for both fresh and fully cooked varieties. After cleaning, they are carefully sized to ensure uniformity for portion control. Their transparent nature allows consumers to view the meat and ingredients. Special whisker-free varieties improve visual appeal, while sewn pig bungs are designed for larger diameter products.

Sheep Casings

Sheep casings are the most delicate and small (16-28 mm) natural casings available commercially. Ideal for fresh pork sausage, they are also used for high-quality frankfurters, with color varying based on the sheep's origin.

Manufacturing of Natural Casings

The production of casings involves removing undesirable elements like fat and fluids using hot and cold water soaks. Once fully cleaned, casings are preserved in a saturated salt solution in preparation for further processes and are categorized by grade and diameter.

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Measuring the Casings

Every casing is meticulously measured, either manually or through machinery. Accurate measurements are crucial as they determine pricing. Hog and sheep casings are typically prepared in 91-meter (100 yards) hanks or bundles, whereas beef casings are sold in meter bundles or by the individual piece.

Quality of Casings

Determining the quality of natural casings involves labor-intensive procedures. Quality 'A' casings exhibit no holes or weaknesses, while quality 'B' casings are acceptable for coarse-ground sausage. Color is also a key distinguishing factor, with some appearing white and translucent, while others can be opaque.

Shipping of Casings

Casings are shipped in several forms including dry salt packed, slush or pre-flushed packed, and pre-tube packed. Each method suits specific transportation needs, with control over temperature essential for maintaining quality.

Production using Natural Casings

In final production stages, specific thermal processing techniques are applied to achieve desirable tenderness and color. Soaking hog casings prior to stuffing increases pliability and tenderness, while the right humidity levels during smoking enhance color development.

Regenerated Collagen Casings

Regenerated collagen casings mimic the properties of natural casings, made from similar collagen materials sourced from beef hides. These casings are versatile, available in various sizes, and designed for machine handling to achieve uniform diameters, enhancing profitability.

Cellulose Casings

Cellulose casings, derived from cotton products, offer high product uniformity and are often used when smoke penetration and moisture control are critical. Their specifics include small and large diameter varieties, each designed for varying usage scenarios.

Fibrous Casings

Made from strong paper-like materials infused with cellulose, fibrous casings are sturdy with good machinability. They assist effectively in the production of dry and semi-dry sausages, available in various sizes suited to market needs.

Plastic Casings

Plastic casings offer moisture impermeability for certain meat products. They are commonly used in braunschweiger, maintaining the natural moisture of the product during processing. Additionally, they enhance aesthetics via different colors and finishes like COFFI film, providing moisture retention and smoke uptake.

The USDA has provided updated regulations regarding sausage casing labeling, emphasizing transparency about ingredients sourced from various animal types.

Conclusion

Even though casings have been vital in meat processing for many years, each type holds unique properties that are important to understand for successful production. I recommend researching extensively about the casings before production. Engaging with suppliers and distributors for detailed information will be invaluable.

Reference

International Natural Sausage Casing Association (INSCA)
K Street, N.W. Suite 503
Washington, DC
: 202/639-
Fax: 202/347-

Solving sausage processing problems

A Casing Troubleshooting Guide Collagen Casings Problem: Product falling in smokehouse Possible Cause: High humidity in first cycle Solutions: Collagen must be dried in the first cycle to toughen the casings before finish cooking. Problem: Finished product wrinkling Possible Cause: 1.) Product too dry 2.) Improper cooling 3.) Under stuffing Solutions: 1.) Maintain humidity level of at least 50% in cook cycle. 2.) Upon reaching required internal temperature, product should be showered then removed to room temperature for 30 to 40 minutes and then cooled. 3.) Product should be stuffed to recommended diameter. Problem: Casing dry and breaking Possible Cause: Dehydrated casing Solutions: Collagen needs to be stored in a cool place. If casings get dry, open caddy and store in the coolers overnight. This will add moisture back into the casings. Problem: Product not coloring Possible Cause: Over drying of product before smoke is started. Solution: Casings should only be dried until tacky to the touch before smoke is started. Problem: Product streaking Possible Cause: Under drying of product before smoke is started Solution: Product not being dried properly will cause drops of water to run down product causing streaking. Problem: Casing Tough Possible Cause: Too little humidity in last cycle Solution: After casing is dried in the first cycle, product should next be smoked to desired color. High humidity of at least 50% should be used in the cooking cycle. Problem: Casing small in size Possible Cause: Dehydrated casing Solution: 1.) Check flat width against allowable flat width in the size being used. 2.) Casing may have dried, open caddy and store in cooler at least 24 hours. Fibrous Casings Problem: Casing splitting Possible Cause: 1.) Over stuffing 2.) Too dry during entire cook cycle 3.) Burns or nicks 4.) Poor quality meat Solutions: 1.) Measure stuffed circumference and make sure it matches the circumference recommended for casing. 2.) Casings should be dried until sweat is out, then smoked - If smoked and finished in higher humidity of at least 50%. 3.) Soak casings in 90 to 100 degrees F water for 20 minutes to 30 minutes. Make sure water gets inside the casing. 4.) Burns or nicks can be on the stuffing horn, clipper, stuffing table or racks in smokehouse. 5.) Meat with high loads of bacteria will gas and burst the casing during cooking. Problem: Casing separating from meat Possible Cause: 1.) Casings are not being soaked properly. 2.) Very high humidity is present during the first cycle. 3.) Clip is slipping 4.) Under stuffing. 5.) Need protein coated casing Solutions: 1.) Soak in 80 to 90 degrees F water for 20 to 30 minutes, make sure water gets inside. 2.) Very high humidity and no drying in the first cycle can cause early casing release. 3.) Check Clip tightness on casings. 4.) Stuff casing to recommended stuffing circumference. 5.) For many semi-dry products, it is recommended that a casing with an inside protein coat be used. Problem: Muddy Color Possible Cause: Humidity is too high during the entire smoke cycle Solution: Smoke should be started when the product is tacky to the touch. Product should be smoked at approximately 25 to 30 percent relative humidity, then finish product with at least 50 percent humidity. Problem: Wrinkling Possible Cause: 1.) Under stuffing 2.) Improper cooling 3.) Clip slipping Solution: 1.) Measure stuffed circumference and ensure that it matches the recommended size for the casing. 2.) The product may be cooling too fast. Shower the product and let it rest at room temperature for 30 to 60 minutes before refrigeration. 3.) Check to see if clips have moved on the casing during cooking. Problem: Casing will not peel Possible cause: 1.) Product is too dry during entire cook cycle 2.) Product is not showering or cooling properly 3.) Need easy-peel casing Solution: 1.) Dry to set casing and smoke, then finish with at least 50 percent relative humidity. 2.) Ensure a showering step is enacted. 3.) A coating can be added to the inside of the casing to enhance 'peelability'. Problem: Product does not stuff in the diameter from end to end Possible cause: Not soaked properly Solution: Soak in 80°F to 90°F water for 20 to 30 minutes, ensuring water permeates the casing. Problem: Streaking Possible Cause: Humidity is too high before and during smoking Solution: If the product is not dry and moisture is running down it, smoke will be washed away. Problem: Pear or water drop shape Possible cause: 1.) Product is not soaking adequately 2.) Under stuffing 3.) Clip is slipping 4.) Excessive weight to hang Solution: 1.) Soak in 80°F to 90°F water for 20 to 30 minutes, ensuring adequate water penetration. 2.) Stuff casing to suggested circumference. 3.) Check the tightness of clips. 4.) In larger casings, long casings may bear too much weight for stability.

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