How is salami made?

Making raw sausage/salami!

With our seasonings, finishing additives, ripening/starter cultures and dipping mixtures, raw sausage specialties with excellent taste and perfect appearance are created using the natural ripening process, abbreviated natural ripening process and rapid ripening process. There is a suitable sausage for every connoisseur, whether aromatic, spicy, national, international, hard-cut or spreadable. The Nubassa complete solutions in different flavors guarantee consistent quality and safe production.

Find out more about production and preparation.

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Salami auf Teller

What is a raw sausage?

When someone thinks of raw sausage, it is usually the typical salami. But the professionals understand much more than raw sausage. There are cut-proof and spreadable types of raw sausage. What does that mean?

What is a spreadable raw sausage?

Spreadable raw sausage varieties (Mettwurst, Teewurst, Streichmett) are raw sausages that have been reddened, matured depending on the type, but are only slightly dried and are not intended for long-term storage. The fat released from the shredded fatty tissue coats the meat particles and makes the sausages spreadable.

Production of the spreadable raw sausage mass

Depending on the degree of chopping, spreadable raw sausages are produced either with a grinder or with a cutter. Finely chopped raw sausages should have a creamy, pasty consistency. This can be promoted through various measures:

  • Depending on the quality, the fat content is between 45 and 70%. The fat forms the outer phase of a water-oil emulsion. Lean meat particles are separated by fat and therefore remain spreadable.
  • The bacon is often chopped first to release as much fat as possible. The lean meat portion is then added to the lardy fat.
  • The nitrite curing salt (2.4 - 2.7%) is only added towards the end of the cutting process (at 12 - 14°C) in order not to maintain cut resistance due to too much dissolved protein.
  • The mass is removed from the cutter at a maximum temperature of 18°C. The fat must not melt, as this would result in segregation and fat loss.

The ripening of spreadable raw sausage takes place for 1 – 3 days at a temperature of 15 – 18°C and a relative humidity of 80 – 90%. Spreadable raw sausage is stored at 15°C and approx. 75% relative humidity.

What is a cut-proof raw sausage?

Cut-resistant raw sausage varieties (Salami, Pfefferbeisser, beef jerky and Dauerwurst) are reddened, mature sausages that can be stored uncut without refrigeration. The muscle protein that comes out on the surface of the meat particles binds the meat and fatty tissue together during maturation. If the grain is coarse, fatty tissue can be seen.

Production of the cut-resistant raw sausage mass

During single-phase production in a cutter, the pre-ground and frozen lean meat is cut first.

  • Often some of the lean meat (preferably beef) is pre-ground and added chilled to improve binding.
  • The frozen bacon is added frozen and chopped until the desired degree of fineness is achieved.
  • In order to prevent protein swelling and smearing of the material, the nitrite curing salt (2.7 - 3.0%) is only added towards the end of the cutting process.
  • The final cutter temperature for cut-resistant raw sausage is generally -2 - 0°C.

Smoking of hard-cut raw sausage
Depending on the variety, raw sausages are smoked to varying degrees. Raw sausage is only smoked at low intensity in order to better control the climate during the process. In addition, due to the long maturation, there is enough time for the smoking process.

Salami auf Brett

Which types of meat are particularly suitable for raw sausage production?

The meat from older animals, such as lean (not emaciated) cows, adult sows and well-fattened, not too fat pigs, is particularly suitable for raw sausage production. The meat of older animals has a deeper color, is drier and has poorer water-binding capacity. This has a positive effect on the release of water during ripening.

Meat with a pH value of 5.4 - 5.8 is best suited for raw sausage production, as in this pH value range the muscle fibers are not so swollen and the aW value reduction is achieved more easily and quickly.

By using freeze-dried meat to produce firm raw sausage, the initial moisture can be regulated and the fermentation process can be standardized. However, no more than approx. 5% freeze-dried meat should be used, as the starter cultures require moisture to multiply. Back fat and comb bacon, as well as fat and hearty pork bellies, are suitable as fatty tissue for cut-resistant raw sausage. The fatty tissue should be frozen as fresh as possible because enzymatic and biochemical reactions (fat spoilage, becoming rancid) occur more quickly at higher temperatures. The bacon must not smear during processing; it must be hard-frozen (-12 - -20°C).

Soft, greasy dewlaps are only suitable for spreadable raw sausages.

As with all meat and sausage products, special attention must be paid to hygiene throughout the entire manufacturing process when producing raw sausages. Especially when preparing the raw material, as the raw sausage is not subjected to any heat treatment and the maturation period can sometimes be long. In addition to hygiene, the selection of raw materials is one of the most important factors for safe production.

What ripening methods are there?

Rapid ripening

Acidification is achieved via starter cultures (acid formers) and GdL (Glucono delta lactone). Sodium nitrite serves as the reddening agent.
The ripening time is 6 – 10 days at a temperature of up to 25°C.

Advantages:

  • rapid acidification through GdL and starter cultures
  • Lactobacilli predominate in the starter cultures
  • Use of higher amounts of sugar (0.5 – 0.7%)
  • Use of up to 0.8% GdL

How Glucono-delta-Lactone works:

  • GdL binds water and leads to lower weight loss
  • GdL causes a rapid reduction in pH through the formation of gluconic acid
  • rapid gel formation and cut resistance
  • Reduction of the risk of dry edges forming
  • The rapid acidification inhibits micrococcaceae
  • After long storage of more than 6 weeks, acidification and a bitter taste may occur.

Rapid maturity plan

DayChamber temp. °CRelative humidity %Air speed m/sec.Smoke
1.20 - 2294 - 960,5 
2.2092 - 940,5 
3.1990 - 920,4 
4.1988 - 900,4Smoke for 30 minutes
5.1886 - 880,3 
6.1884 - 860,2Smoke for 30 minutes 
7.1782 - 840,1Smoke for 30 minutes 

There will be a compensation phase of 6 hours at 80% relative. Humidity and at an air speed of 0.5 - 0.8 m/s. driven.
*Depending on the caliber, the maturing time can vary between 7 -10 days!
Storage takes place at 15 °C and a relative humidity of 80%

Abbreviated natural ripening

Acidification is achieved via starter cultures (acid formers). Sodium nitrite serves as the reddening agent.
The ripening time is 3 – 6 weeks at a temperature of up to 24°C.

Advantages:

  • most common ripening process
  • faster acidification than with natural maturation
  • Far better rounded in taste than quickly cured raw sausages
  • Micrococcaceae still predominate in the starter cultures
  • Use of higher amounts of sugar (0.3 – 0.5%)

Abbreviated natural ripening plan

Day

Chamber temp. °C

Relative humidity %

Air speed m/sec.Smoke
1.2094 - 960,5 
2.20940,5 
3.19920,4 
4.19900,4 
5.1888 - 900,3 
6.18880,3Smoke for 30 minutes 
7.1786 - 880,2  
8.16860,1Smoke for 30 minutes
9.1584 - 860,1Smoke for 30 minutes
There will be a compensation phase of 6 hours at 80% relative. Humidity and at an air speed of 0.5 - 0.8 m/s. driven.
Storage takes place at 15 °C and a relative humidity of 80%

Natural ripening

Acidification is achieved via starter cultures (acid formers). Potassium nitrate serves as the reddening agent.
The ripening time is 6 – 8 weeks at a temperature of 15 – 18°C.

Advantages:

  • particularly aromatic
  • Micrococcaceae are of particular importance for reddening and aromatization and predominate in the starter cultures
  • Use of little sugar (0.2 – 0.3%)

 

Natural ripening plan

DayChamber temp. °CRelative humidity %Air speed m/sec.Smoke
1.22950,5 
2.22950,5 
3.21930,4 
4.21920,4 
5.21900,3 
6. - 8.20900,3  
9. - 10.19880,3  
11.19860,3

Smoke for 30 minutes

12. - 13.18840,3 
14.18840,2

Smoke for 30 minutes

15. - 16.18820,2

Smoke for 30 minutes

17. - 18.17800,2 
There will be a compensation phase of 6 hours at 80% relative. Humidity and at an air speed of 0.5 - 0.8 m/s. driven.
Storage takes place at 15 °C and a relative humidity of 80%

Product defect in raw sausage

Flaw in appearance

Problem
Source

Wrinkling and loosening of the casing:

  • Insufficient shrinkage capacity of the casing if the casings (artificial casings or natural casings) were not sufficiently watered before filling

  • Leathery, brittle cover due to too little moisture

  • Furrow-like indentations due to one-sided or too rapid drying;

  • Loosening of the casing due to briefly excessive moisture during maturation (the sausage skin expands due to an increase in size due to the absorption of moisture)

  • Loosening the casing by depositing oily fat under the sausage skin by smearing the fatty tissue when chopping or filling the raw sausage mass

  • Bubbles under the cover due to incorrect filling

Fogging and mold:

  • Moldy due to high water activity in the edge and casing, especially at the beginning of ripening.

  • Moldy due to too high relative humidity and too little air movement.

  • Smear coating from bacteria on the surface at high temperatures and high humidity.

Salt builtup:

  • Insufficient watering when using salted natural casings

  • Adding a lot of salt if the drying process is incorrect or the sausages are completely dried out

Sweating out fat:

  • Use of soft fatty fatty tissue

  • Too high temperatures when ripening or smoking

Uneven smoke color:

  • Misting or molding before smoking

  • Sweating out the fat before smoking

  • The smoke color is too dark if the smoking is too humid, too warm or too intense

Casing damage and bursting of the sausage casing:

  • Pitting caused by cellulose-degrading mold species in cellulose and cellulose fiber casings

  • Dissolution phenomena in collagen fiber intestines caused by proteolytic microorganisms

Brown, yellow and black spotting:

  • Brown spots on finely chopped spreadable sausages due to smoking before salt adjustment

  • Deposits of smoke condensate in poorly cleaned smokehouses

  • Yellow spots when processing rancid bacon or due to storage that is too warm, too bright and too long

  • Yellow and green spots after long storage due to peroxide-forming lactobacilli

  • Black spotting caused by mold

  • Black spotting due to direct contact of ascorbic acid with cast iron (e.g. cutter bowl)

 

Color errors

ProblemSource
Inadequate reddening and poor color retention:
  • Destruction of the pickling color due to the predominance of peroxide-forming lactobacilli
  • Pale color due to excessive bacon content
  • Pale color due to unsuitable starting material (PSE)
  • Use of layered nitrite curing salt
  • Acidification occurs too quickly when using nitrate
  • Destruction of the pickling color due to the influence of light
Inconsistent cut
  • Use of dull cutter knives, wolf cutting sets or even worn wolf snails
  • Inadequate cooling of the raw material
  • The texture of the fatty tissue is too soft
Core discoloration:
  • Ripening too short at a temperature that is too low (incomplete reddening)
  • Impaired moisture release in the core due to drying errors and simultaneous proliferation of peroxide-forming lactobacilli
Edge discoloration:
  • Graying of the edges due to storage that is too cold before the reddening process is complete
  • Grey-yellow edge due to rancid bacon due to excessive storage temperature and exposure to light
  • Spotting in the edge due to the use of moist, not carefully stripped casings

 

Errors in binding and consistency

Problem

Source

Dry edge:
  • This mainly occurs when the humidity is too low and/or there is too much air movement
Void formation and porosity:
  • Filling errors or raw sausage mixture that is too loose with air pockets
  • Crack formation due to different tension ratios between edge and core when drying too quickly
Poor binding and cut resistance:
  • Insufficient acidification of the raw sausage during maturation (high pH value), e.g. due to the presence of inhibitors (antibiotics)
  • Microbial protein decomposition due to poor hygienic conditions during production
  • Smearing the fatty tissue means that the meat proteins are prevented from forming a gel by a film of fat
Soft texture:
  • High bacon content
  • Insufficient drying due to unfavorable control of the drying conditions (temperature, humidity, air movement)
  • Bacterial smear on the surface at high temperature and high humidity.
Threading (rare):
  • Formation of mucilage when corresponding microorganisms multiply, such as Leuconostoc mesenteroides (high sugar addition of 1 - 2%, high temperature) or Bacillus subtilis (poor processing hygiene)
Difficult filling of the raw sausage mixture:
  • The temperature of the filling material is too low
  • Piping nozzles that are too narrow, increased spraying pressure and smearing of the grease
  • Too long standing time before filling when using Glucono delta Lactono (GdL)

 

Smell and taste defects

ProblemSource
Excessive acidification:
  • Added high amounts of sugar
  • Excessive ripening temperatures
  • Use of excessive amounts of Glucono delta Lactono
Rancidity
  • Storage at temperatures that are too high under the influence of light
  • Storing the raw sausage or the bacon used for production for too long
  • Strong proliferation of peroxide-producing Lactobacilli
  • Processing of rancid bacon