How Salami can be made in two days
Award for new Rohwurstsystem
High recognition for the "Ferma Quick Rohwurstsystem" Van Hees GmbH in Walluf: It won the International FoodTec Award in Silver. The award ceremony will take place on 27. March 2012 at Anuga FoodTec, the international trade fair for food and drink technology in Cologne.
Two weeks had been the least that a salami needed for their maturation. It now goes well in two days: The Van Hees GmbH has the appropriate patent for a manufacturing process and a combination of ingredients logged bearing the name "Ferma Quick Rohwurstsystem".
When the system was presented at a seminar industry for the first time, it could hardly believe the experienced Rohwurstexperten. Not only the extremely short preparation time was hitherto unthinkable, but also the fact that the salami is enclosed by a sterile intestines. It all depends closely.
Raw sausage is traditionally made of raw meat, which is matured for several weeks and dried it. The long maturation period and the weight loss is a high cost factor, which clearly falls into the weight, especially in staple goods of basic quality. The technologists of VAN HEES have developed a method in which the raw sausage can be produced not only faster but also more than ten percent cheaper than similar goods. They have found ways to make the drying before bottling in sterile intestine, and they have developed for the formulation special quality additives and spices called Primal Ferma Quick.
The development of "Ferma Quick Rohwurstsystems" preceded many months of research and testing. The technologists were doing a perfect guide: the so-called hurdle concept, which was developed years ago by Professor Lothar Leistner in the 70's and dealing with the microbiological and chemical factors influencing the stability and durability of a product. They examined, among other things, how to reduce the aw value so far with Van Hees additives that it prevents spoilage. And they analyzed the additional hurdle blocks as pH, preservative, storage or bacterial flora.
The result was another serving of raw sausage, an unusual way of drying and a new formulation:
The first component of the new system: The raw sausage is packaged in sterile intestine, because there penetrates moisture from the inside out, because there is no surface coverings, the goods moldy or not turn gray. An advantage is also the price, because a fibrous casing costs tenfold.
The second component: Since the salami in sterile intestine can not dry, a way had to be found to anticipate the drying already. Therefore, freeze-dried meat is used, which corresponds to a drying of about nine percent. In addition, the product of three percent includes many relatively dry substances such as mustard flour - the more dry substances, the less moisture in the product. And the less moisture, the more stable it is.
The third component concerns the formulation. At the beginning of the production of normal salami, the fat content is only 24 to 25 percent. Due to the loss of water and the associated increasing concentration of protein and fat, this fat content in the end product rises to around 34 to 35 percent. With the new raw sausage system, this fat content is anticipated by the formulation; the fat components are dosed so high that the analytical values of the end product are given right from the start. When the raw sausage mass goes into the casing, it already has the analysis values of a product that has matured for 14 days. The aw value is 0,94, which corresponds to the value of staple goods of medium quality.
Modified was also the cutter method: So in the first phase, the muscle cells are disrupted and exposed the protein. The protein can then cross-link the amino acids, so that the desired resistance is achieved. Unusually, it is also to let the lean meat phase running relatively finely in the first phase of production. This is done in order for the structure and strength to provide a surface for the transglutaminase, one of the components.
“With this new raw sausage system, we don't want to dilute or destroy any salami culture,” emphasizes Rolf Häussler, Head of Van Hees Product Development. "Instead, we want to develop additional options for raw sausage production with technological solutions." The advantages for the raw sausage manufacturer are indeed manifold: The production is faster and cheaper, the casing costs are lower, there are no surface coverings, the raw sausage can be produced without a maturing chamber, man saves equipment and investments, there is no loss of storage or weight, there is no "cone formation" in the case of pizza, the readiness for delivery is shortened considerably, there are no ripening errors. And above all, the Primal systems guarantee safe production.
The first response from manufacturers in Germany was very positive. One senses here new production facilities for export goods in order to compete with low-cost producers abroad can. A main target group sees Van Hees simultaneously in Eastern European countries that do not have the necessary maturity options. Even pizza manufacturers have already shown interest. Finally, it is possible that especially in the discount sector may lead to a new level of salami in addition to traditional products.
Source: Walluf [Van Hees]
