Precision in Emulsified Sausage Production: Ensuring Firmness with High Water Content

by Eben van Tonder, 9 Feb 2025

Introduction

The quality of emulsified sausages depends on precise temperature control and ingredient balance. When increasing water content to 30%, maintaining the same firmness and texture as a traditional Krainerwurst with only 10% water requires careful formulation and strict thermal management.

Temperature Control for Emulsification and Firmness

To ensure a strong gel structure and prevent fat separation or excessive softness, temperature must be strictly regulated throughout the process.

Maximum Temperature Limits:

During emulsification (bowl cutting or mixing): ≤12°C (54°F)
Before stuffing into casings: ≤14°C (57°F)
Gradual temperature increases during smoking and cooking to avoid fat-out.

Why These Limits Matter:

Above 12°C (54°F): Myosin extraction weakens, reducing binding ability, and fat dispersion becomes unstable, leading to poor emulsification.
Above 14°C (57°F) before stuffing: Risk of fat separation during smoking and cooking. Gel network weakens, resulting in a softer texture.
Excessive temperature before cooking: Water and protein interactions become unstable, causing the sausage to lose firmness and feel mushy after heating.

-> Clarifying Temperature Thresholds Before Cooking & Their Impact on Sausage Firmness

The last point of Excessive temperature before cooking needs clarification. The excessive temperature before cooking refers to two critical stages:

During emulsification (in the cutter or mixer):
- If the mix exceeds 12°C (54°F), myosin extraction weakens, leading to poor binding.
- Above 14°C (57°F) before stuffing, the gel network begins breaking down.
- Fat destabilisation can occur beyond 18°C (64°F), leading to poor emulsification.
During drying/smoking (before steam cooking):
- If the surface of the sausage exceeds 55–60°C (131–140°F) too soon, proteins set unevenly, leading to a dry exterior and soft, unstable interior.
- Fat can begin melting out at 50–55°C (122–131°F), especially if drying is too aggressive.

-> Why We Dry & Smoke Before Steam Cooking

Drying (50–55°C / 122–131°F):
- Removes surface moisture to help form an initial protein coating (pellicle), which locks in fat and moisture during subsequent cooking.
- Prevents excess condensation during smoking, ensuring better smoke adhesion.
Smoking (65–70°C / 149–158°F):
- Allows for controlled temperature rise before full coagulation of proteins.
- Reinforces structural integrity before steam cooking.
Steam Cooking (75–80°C / 167–176°F):
- Finalizes protein coagulation while preventing excessive moisture loss.
- Maintains a uniform internal temperature, avoiding fat-out or texture degradation.

To prevent these issues listed under “Why These Limits Matter“:

Pre-chill all raw materials: Meat, fat, and water should be at 0–2°C (32–36°F) before mixing.
Grind frozen fat: Use semi-frozen back fat to keep the mix cold.
Use ice water: Replace regular water with crushed ice during emulsification.
Monitor temperature at every step using an infrared or probe thermometer.

Step-by-Step Thermal Processing Guide for Emulsified Krainerwurst with 30% Water & 20% Beef Skins

1. Pre-Chilling Raw Materials

Meat Temperature: 0–2°C (32–36°F)
Fat Temperature: -5 to 0°C (23–32°F) (semi-frozen)
Water/Ice Temperature: ≤0°C (32°F)
Beef Skin Emulsion Temperature: 1–3°C (34–37°F)

2. Grinding (Cold Grind for Best Emulsification)

Lean Meat: Grind through 3–5 mm plate (semi-frozen).
Beef Skin Emulsion: Keep cold and mix separately.
Fat: Grind separately through 6–8 mm plate (semi-frozen).

3. Mixing Step 1 – Protein Extraction

Add ground lean meat, salt, phosphate, and half of the ice water.
Mix in a high-speed cutter or paddle mixer for 2–3 minutes.
Target Temperature: ≤6°C (43°F)
The mix should become sticky and tacky. If not, continue mixing.

4. Mixing Step 2 – Adding Functional Ingredients

Add soy isolate, TVP, tapioca starch, and kappa carrageenan.
Slowly add another quarter of the ice water (keep mix cold).
Continue mixing until homogeneous.
Target Temperature: ≤9°C (48°F)

5. Mixing Step 3 – Fat & Emulsion Integration

Add ground fat and beef skin emulsion.
Gradually add the last quarter of ice water.
Final Mixing Time: 3–5 minutes until smooth.
Target Temperature: ≤12°C (54°F)

If the mix exceeds 12°C (54°F), stop and chill to 0–2°C before proceeding.

6. Stuffing (Must be Cold)

Use 26–29 mm natural or artificial casings.
Stuffing Temperature: ≤14°C (57°F)
Stuff tightly to prevent air pockets.

If mix is above 14°C (57°F), refrigerate before stuffing.

7. Thermal Processing: Drying, Smoking & Cooking

Step	Temperature (°C)	Duration
Drying	50–55°C (122–131°F)	30–40 min
Smoking	65–70°C (149–158°F)	1–2 hours
Cooking	75–80°C (167–176°F)	Until core 72°C (161.6°F)
Showering	Cold water shower	5–10 min

Final Core Temperature: 72°C (161.6°F)
After Cooking: Shower with cold water (5°C) until core is 30–35°C (86–95°F).

Cooling prevents excessive moisture loss and retains firmness.

8. Blooming & Final Firmness Test

Hang sausages at room temp (~20°C) for 30 minutes.
Check firmness by cutting a sample.
Store at 0–4°C before distribution.

Conclusion

To maintain the firmness of Krainerwurst while increasing water and beef skin content, precise temperature control and functional ingredient adjustments are necessary. Keeping emulsification below 12°C (54°F), stuffing at ≤14°C (57°F), and following a gradual heat increase during thermal processing are essential steps. Proper chilling, grinding, and mixing ensure protein extraction and water-binding are optimised. By adhering to these guidelines, manufacturers can produce high-quality emulsified sausages that match the texture and firmness of traditional formulations.