PREPARATION OF SCALDED SAUSAGES 'BUTIFARRA'

Sandra M Madera, Lisseth L Tarrá, María J Ramos

Kelia P Vega, Yanelis Guerra.

SUMMARY

The blanched or poached cured meats known commercially are due to

general mixtures of meat, fat, ice, filler raw materials, additives and
other ingredients that characterize a certain product. A large part of the
scalded products are made from fine paste and granulation, these products of
thin pasta is subjected to the cutting operation, it is at this moment that
apply the concept of emulsion, considering that meat emulsion as such does not
It exists, but the fat-water emulsion is part of the total mixture and in large
part of the quality of the product will depend on the stability of the 'Emulsion'.
the objective of this work is to apply the fundamental principles of science and
food technology for the preparation of blanched sausages, in this
case for butifarra.

PALABRAS CLAVES:Embutidos escaldados, butifarra, emulsión.

ABSTRACT

Scalded or poached sausages known commercially are usually mixtures of meat,

fat, Ice, filling Raw materials, additives and other ingredients that characterize a
product. Much of the blanched are made from fine paste and granulation, these
products are subject to fine paste operation cuteado, it is at this point that the applies the
concept of emulsion, whereas meat emulsion as such does not exist, but the fat-
water emulsion, is part of the total mixture and largely depends on product quality
stability of the "emulsion". The aim of this paper is to apply fundamental principles
of science and technology for the preparation of food scalded sausages, in this
case for sausage.
Keywords: scalded sausages, sausage, emulsion sausage.

INTRODUCTION

Cold cuts are prepared from minced or whole meat, subjected to various
processed and introduced into casings. They can be raw or scalded.
escaldados son picados más finos y sometidos a la acción del agua entre70 y 80
grades and subsequently smoked or not (sausages, butifarra). The nutritional value
the first ones, in general, is greater than that of the second ones, although they can

vary the fat content in all of them.

These meat derivatives have become a very important part of food

Colombians, for this reason it is of vital importance for engineers.
agroindustrial the acquisition of all those knowledge to around these
products, such as elaboration, in order to take into account the
type of raw material used in this, as well as the cutting times,
cooking temperatures among other very important variables that are presented
in this process.

Factors that affect the formation and stability of emulsions

Temperature: The operating temperature can generally be increased.

due to the force of friction between the material and the equipment, it can cause the
instability of the emulsion during the blanching, mainly due to the
denaturation of proteins, decrease in viscosity and melting of
fat particles. The recommended limit temperature is 15 ºC, meanwhile
the operation could approach this limit if the speed is
slow the range is below 12 º C, to maintain these levels of
It is recommended to incorporate ice into the process at the beginning, halfway through.
and in the end.

Size reduction level: An excess in cutting time implies a

exaggerated decrease in the size of the fat globule particle so if the
globe is less than 10 m the surface area increases as the diameter increases
an appreciable amount of protein will be necessary to coat the globules
fats.

A high proportion of connective tissue: Connective tissue is composed of

mainly collagen, this protein in the skin covers the fat globule
and partially emulsifies it, but in blanching, due to its nature, it gels.
discovering the fat globule which would remain un-emulsified causing
texture defects.

Quantity and nature of added fats: By their nature, meats

Used from cattle and pigs have different contents of matter.
fat, the formulations require a certain percentage of fatty matter, the
the most suitable fat is firm pork fat, that is, the dorsal fat or in its
defect a pre-emulsified fat.

High operating temperatures in scalding: It is also inconvenient

subject the blanched products to short-time thermal treatments that
they involve high temperatures as they contribute to the phenomenon of 'breaking of
the emulsion.” A fundamental aspect that must be taken into account in the
the preparation of fine pasta is the evolution of viscosity, since the
an increase in viscosity implies an increase in temperature, this is one of
the reasons why an order of incorporation should be followed
ingredients into the cutter as follows:

Meats + fresh spices + salt

Ice.
Polyphosphate.
Condiments.
Ice.
Fat.
 Ice + Flour.

THE SCALDED
Esta operación al igual que la de cuteado es fundamental para obtener un
excellent quality product. Scalding is a gradual thermal treatment that
allows the formation of a coagulated protein network enabling the obtaining of a
product with an elastic texture but also soft and juicy. To achieve this
the objective of this step is to eliminate the microbial flora present in the mass, this operation

it can be carried out using a liquid heating medium (hot water)

around 74º C), and a heating medium based on saturated steam.
Traditionally, an empirical criterion has been used regarding time
operation, and the diameter of the
sausage, in this way it is established that the scalding time corresponds to
minute/millimeter in diameter.

For the case of the application of blanching or the preparation of sausages,

they must take into account the following aspects:
Having a temperature above that of the corresponding scalding
heating medium, it is part of it.
The product enters the heating medium at a temperature well below
the one in the middle.

the temperature of the heating medium decreases.

An increase in temperature of both the medium and the product begins.
until reaching a constant temperature.

The following conditions for heat transmission are presented.

From the heating medium to the surface of the product.
From the surface of the product to the center.

It is a stable process with respect to the heating medium, with respect to the product.
it is an unstable process since the temperature varies from an initial condition Ti
up to a final temperature close to 70 °C. For this reason in the above
knowing certain properties of the heating medium, the properties of the
products. All these factors are related through the Biot number.
Bi = hd / K.

EQUIPMENT, UTENSILS AND RAW MATERIAL

Lean beef.
Pork back fat
Frost ice.
Condiment for butifarra.
Comino.
Pepper.
Nutmeg.
Garlic.
Liquid smoke.
Realized.
Phosphate.
Onion.
Synthetic fiber casing. Gauge 120.
Industrial thread.
Mill.
Cutter.
Sausage stuffer.
Casserole
Smoker oven or drying chamber.
Cold room.
Razor.
Thermometer.
Scale.
 METHODOLOGY

The received meat was weighed and control analyses were performed on it.
quality (pH, Nessler test, Benzidine, and organoleptic analysis).
Weigh the raw materials according to the weights of the formulation (See
table 1)
Adapt the raw materials.
Cut up.
Presalado.
Milling.
Cutteado.
Cured meat.
Scalded.

TABLE 1. FORMULATION OF BURIFARRA

BUTIFARA WEIGHT (g)

Beef 3770
Fat 464
Starch 232
Ice 1160
Butifarra condiment 58
Cumin 23,2
Pepper 17.4
Nutmeg 5.8
Garlic 17.4
Bulb onion 23.2
Phosphate 17.4
Liquid smoke 8.7
Realizer 2.9
 RESULTS AND ANALYSIS

Quality tests

Ammonia Test (Nessler)

After taking 20 grams of sample and macerating it completely with water

distilled at a 1:10 ratio and to obtain a liquid extract from that filtrate, the procedure was carried out

take approximately 2 ml and add 2 or 3 drops of Nessler's reagent,

the sample was shaken and left to rest for 2 minutes, the absence of the
reddish-brown tone characteristic of the presence of ammonia, and therefore
synonym of decomposition.

Benzidine Test

A sample of meat (ham, beef, and pork) was taken and marinated with water.
destilada en un relación 1:10, se procedio a tomar 2ml del filtrado de cada muestra
and 3 drops of the Benzidine reagent were added, each test tube was shaken, and
I let it rest for 2 minutes, finally the absence of the formation was observed.
of the reddish ring characteristic of meat in a state of decomposition.

Determination of pH

A homogeneous meat mixture was prepared in a blender using as

distilled water solvent in a 1:1 ratio, following the handling instructions
del equipo se tomo la medida correcta de pH para cada una de las muestras
studied, falling within the standard value range (5.5-6.5).

Cost evaluation

Product: blood sausage

Cost
Description Unit Quantity Total cost
per unit/Kg
Beef Kg 3.77 10000 37700
fat Kg 0.464 5500 2552
 starch Kg 0.232 14500 3364
Ice Kg 1.16 900 1044
Unipac condition Kg 0.058 15000 870
cumin Kg 0.0232 29500 684.4
pepper Kg 0.0174 21000 365.4
nutmeg Kg 0.0058 47000 272.6
garlic Kg 0.0174 9000 156.6
Head kg 0.0232 3320 77.024
Phosphate Kg 0.0174 10500 182.7
liquid smoke Kg 0.0087 7200 62.64
Realer Kg 0.0029 5000 14.5
Total weight Kg 5.8 Total: $ 47346

Final weight of the product: 5.348 kg

(Final weight/Initial weight) x100: (5.348/5.8)*100

Performance: 92.2%

% loss: ((Initial weight - final weight) / initial weight) x 100

% decline: ((5.8-5.348)/5.8)x 100
%merma:7.8 %

Costo/Kg: Costo total/peso producto

Costo/kg: 47346$/5,348
Costo/kg: $8853

After evaluating the nutritional composition of each of the ingredients, and seeing the
percentage contribution of each nutrient in the final product, the following table was obtained for the

composition of the final product.

EVALUATION
composition
% PROT.total 12.410
% PROT.n/c 0.110
% FAT 22.046
 HUMIDITY 66.647
STARCH 4.338
% SAL 0.795
PHOSPHATES 0.406
ASCORBATES 0.027

From the above, the indices are obtained to see whether the final product meets or does not meet the requirements.
requirements of NTC1325.

Indices:
HUM / PROT 5.4
GRA / PRO 1.8
SALT / HUM 1.2
PROT/WATER 0.2
PROT/FAT 0.5628825

According to the technical standard, the minimum protein % is 10%, maximum fat 40%, maximum moisture.
90%, starch 8% max., non-meat protein 6% max.

Theoretical Values

HUM/PR 4.5
GRA/PR 2
SAL/HUM 3.5
PROT/WATER 0.5

As we can see, the final product meets the requirements set forth by NTC 1325.
 QUESTIONNAIRE

1. How viscosity affects the preparation of meat emulsions.

The dispersibility (solubility) of an emulsion is determined by the phase

if the continuous phase is water-soluble, the emulsion can be diluted with
water, if the continuous phase is oil-soluble, the emulsion can be dissolved in oil.
The ease with which an emulsion can be dissolved can be increased if one
reduce the viscosity of the emulsion.

The viscosity of an emulsion when there is excess continuous phase is

virtually the viscosity of that phase. As the proportion of the phase increases
internal increases the viscosity of the emulsion to a point where the emulsion
stop being liquid. When the volume of the internal phase exceeds that of the
external, the particles of the emulsion cluster and the apparent viscosity is
partially structural viscosity.

The viscosity of an emulsion can be adjusted in the following way:

a) To reduce viscosity:

1st. The proportion of the continuous phase is increased,

2nd. The viscosity of the continuous phase is reduced, 3rd. In suspensions, it is

They add surface activity agents to enhance lubrication.

b) To increase the viscosity:

1st. Thickeners such as soap gels, gums, and alumina gel are added to the
continuous phase, 2nd. The proportion of the internal phase is increased, 3rd. The
particle size of the emulsion or reduces the agglomeration of the particles
existing, 4th. Air in a finely divided state is incorporated as a third phase. A
the most important difficulty encountered in these formulations is that in
the storage conditions variables affect the structure of the gel and with
frequency forges the product and turns it semi-solid so that it cannot
flow.
High operating temperatures in scalding: It is also inconvenient.
subject the blanched products to short time thermal treatments that
they imply high temperatures as they contribute to the phenomenon of 'breaking of
the emulsion”. A fundamental aspect that must be taken into account in the
the preparation of fine pastes is the evolution of viscosity, given that the
an increase in viscosity implies an increase in temperature, this is one of
the reasons why a sequence of incorporation should be followed
ingredients to the cutter as follows:

Meat + fresh spices + salt

Ice.
Polyphosphate.
Condiments.
Ice.
Fat.
Ice + Flour.

2. What is the importance of adding salt and Polyphosphate in the preparation?

of meat emulsions.

The salt, which allows the swelling of meat protein and partially causes
la solubilizaciòn de la misma, mejora la capacidad de retención de agua por el
swelling of the meat particles. The effect of salts is an example
typical of the influence of the electric charge of proteins on the capacity of
water retention of meat. At pH values above the isoelectric point,
low concentration sodium chloride significantly increases the ability of
water retention, while at high concentration values the opposite happens
on the contrary. Honikel, (1988) states that Cl- ions, above the point
isoelectric weaken the bonds between the groups of opposite sign of the
protein chains and they interact with positively charged groups.
This brings an increase in the negative electric charge of the molecules that
they repel each other, causing the protein structure to relax and increase the
CRA. At pH values below the isoelectric point, Cl- ions neutralize.
the positive charges of the proteins so that, when the repulsion decreases between
they, a contraction of the protein structure occurs that causes a loss
from the CRA.

This is the reason why salt can be used to dehydrate meat,

as is the case with dry products, semi-dry matured (of moisture
intermediate) or in emulsified products to improve C.R.A. and facilitate the process
de emulsification through the solubilization of proteins.

Phosphates significantly influence the functional properties of

meat proteins, including the ability to gel. Such salts exert their
action through the dissociation of actomyosin into its components, actin and
myosin, and increasing the concentration of usable myosin improves the
gelation capacity and in general all functional properties.

Phosphates, for their part, significantly increase the C.R.A of meat. This
The effect has been based on various factors, including the variation of pH.
ionic strength, the chelating capacity and its interaction with proteins.
In addition, phosphates can behave differently if they are found
only in the flesh or in the presence of sodium chloride. It is currently accepted that
The effect of phosphates is based, more than anything, on their interaction with the
myofibrillar proteins.

The addition of monophosphates and polyphosphates to meat with low pH values,

produce a change in the isoelectric point of myofibrillar proteins, similar to
observed when NaCl is incorporated, which means that phosphates reduce
the CRA of the meat in an acidic pH range below the isoelectric point.
This phenomenon seems to indicate that, as in the case of NaCl, phosphate anions
they interact with the myofibrillar protein on the same sides as the filaments of
myosin binds with actin. According to this reasoning, it is
possible that the increase in CRA produced by the phosphates incorporated into the
muscle, in the rigor and post-rigor phase, whether due to the dissociation of the complex
actomyosin that leads to a relaxation of the protein matrix.

3. What is the difference between coagulation and coalescence in emulsions? Which

its importance in the stability of emulsions.

For an emulsion, the larger the surface area of the dispersion,

the smaller the particles are, the greater the surface free energy will be
Gibbs, por lo tanto, las emulsiones liofílicas son termodinámicamente estables,
whereas lyophobic emulsions are thermodynamically unstable.

Instability means that particles begin to join together forming

larger particles called aggregates. We can define a stable system
like the one where the small particles in the emulsion are evenly distributed
distributed in the continuous medium and thus remain as time passes.
There are two different processes by which particles are added in
the emulsion: flocculation or coagulation and coalescence.

Flocculation or Coagulation: Process by which two particles join together

to form larger particles. In this process, the identity of
the original particles. In this case, there is no reduction in the total surface area,
only some active sites are made impossible.

Coalescence: Process by which two or more particles merge to

to form a larger particle. In this case, the total surface area is
reduced and the identity of the original particles is lost.

In an emulsion, a series of phenomena can occur that modify it or

they even destroy it, such as: The displacement of the microglobules of the phase
discontinuous, either towards the surface or towards the bottom, depending on its density; the

flocculation by particle agglomeration; coalescence by joining or fusing of

particles that increase in size and decrease in number, and change of
emulsion or phase inversion by changing from oil in water type to water in oil type
oil, or vice versa

4. In order to reduce production costs, what will be the maximum load?

of sausage or another product in the pot?

5. What is the maximum production capacity for sausage and mortadella?

in a time of 8 h / day.

6. What are the main defects of scalded sausages?

general, and how it can be prevented.

Insufficient color stability and inadequate reddening, due to refrigerating with

excessive slowness.
Poor color stability and rapid decomposition due to temperatures
too high deposit rates in refrigerated warehouses, refrigerated showcases and
self-service shelves.
Desiccation of the exterior of the sausages, with the formation of wrinkles and a
dry bark, due to the prevalence of low relative humidity.
Surface pringiness of the pieces, due to excessive humidity prevailing
relativa ambiental; se acompaña de verdeado y agrisado u otras alteraciones
of color, as well as flavor modifications based on the regions
peripherals.
Color alteration due to excessive action of light and oxygen
Bursting of the casing intestines, when the sausages are hung in
areas with air currents or exposed to intense movements of it.
Bursting of the wrappers, when the parts are not properly cooled before
to enter the refrigerated ships.
 Pringosidad of vacuum-packed sausages, when the
dew point and packaging hygiene.
Poor color preservation due to the use of sheets that are highly permeable to oxygen.
Poor color preservation due to inadequate hygiene and cleaning of the
cutting machines.
Intense contamination of cutting surfaces, when the slices are
tomaron con la mano

7. What is the purpose of drying the sausage before blanching?

The drying process is carried out in order to achieve a firm consistency in the final product,
without separating the packaging from the product; it also provides a red color
characteristic, eliminates microbial load and reduces blanching time.

During the drying process, water is removed, which causes shrinkage in

the scalded products. This leaves a margin during heating due to
above 100ºC for thermal expansion. Depending on the degree of drying,
formulation and heat treatment, a certain proportion of water is taken
again during sterilization, storage and subsequent heating.

8. Was the cutting time sufficient? Did it go over?

Regarding the cutting time, it was sufficient as the type was achieved.
emulsion necessary for the preparation of butifarra, achieving the desired texture
and other properties of these products.

9. Was the mixing time sufficient? It was too long.

 CONCLUSION

After experimentally applying the acquired knowledge for the

Preparation of butifarra, the following can be concluded:

All the stages applied in the production of this product require

a lot of attention to obtain a product in excellent condition, that's how it is
like scalding applied in an appropriate way (67–72ºC for 30 min)
It provides the product with greater permanence in the market.
The quality of the product will depend a lot on the hygienic conditions.
sanitary conditions in which the raw materials to be used are located
process, that is why it is necessary to have strict control regarding
to the raw materials provided by the pilot plants.
Los análisis físicos–químico y microbiológicos determinan en gran parte la
quality of the final product, which is why it cannot be guaranteed at 100%
that the product meets all the characteristics established by the standard
NTC 1325.
Nitrates and nitrites are those thatthey help the healing process of the
meats improve the preservation power, the aroma, the color, the flavor and the
consistency. They also help achieve a higher weight performance,
because they have a water-retaining capacity. But the most important thing is that
nitrate protects meats from 'Botulism', one of the worst forms of
poisoning that man knows
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