Degree Program Engineer of Food Technology Student name LY THI HE Student ID DTN1654190008 Thesis Title Survey of process and technology for smoked sausage production at Vinh Anh Food T
INTRODUCTION
Rationale
In modern life, consumer demand for meat products has been steadily increasing, making meat and processed meat products some of the most popular items in the food industry Advances in technology have led to the development of innovative meat products, such as sausages, which are experiencing rapid growth in industrial-scale production Over the years, various types of sausages have been created, each reflecting regional characteristics, climate influences, and unique spice ingredients.
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Survey of process and technology for smoked sausage production at Vinh Anh Food Technology Joint Stock Company "
Report set out objectives as follows:
- Research the process of smoked sausage processing on an industrial scale from raw materials to packaging and finished products;
- Participate in the process of smoked sausage production, observe, evaluate and comment on the production process of sausages;
- Research on factors affecting the smoked sausage production process in Vinh Anh factory
- Investigate the procedure of smoked sausage producing in Vinh Anh Food Technology Joint Stock Company ;
- Comprehend and describe all steps in the smoked sausage producing and analyze factors that affect the quality of products during these processes;
- To study all equipments in the smoked sausage producing;
- To investigate the factory's food safety and hygiene system
Month Time Content of Work
Investigate the procedure of smoked sausage producing in Vinh Anh Food Technology Joint Stock Company
Comprehend and describe all steps in the smoked sausage producing and analyze factors that affect the quality of products during these processes
To study all equipments in the smoked sausage producing
To investigate the factory's food safety and hygiene system
31/08/2020 Collect the data and write the report
The survey was carried out in Vinh Anh Food Technology Joint Stock Company from March 01, 2020 to June 30, 2020.
Detailed schedule
Month Time Content of Work
Investigate the procedure of smoked sausage producing in Vinh Anh Food Technology Joint Stock Company
Comprehend and describe all steps in the smoked sausage producing and analyze factors that affect the quality of products during these processes
To study all equipments in the smoked sausage producing
To investigate the factory's food safety and hygiene system
31/08/2020 Collect the data and write the report
Timeline
The survey was carried out in Vinh Anh Food Technology Joint Stock Company from March 01, 2020 to June 30, 2020.
LITERATURE REVIEW
General information about Vinh Anh Food Technology Joint Stock Company 3 1 Introduction of company
Company name: Vinh Anh Food Technology Joint Stock Company (Vinh Anh FTJSC)
Type of activity: Joint Stock Company
Address: Ha Binh Phuong Industrial Cluster, Van Binh Commune, Thuong Tin District, Ha Noi City
Legal representative: Dao Quang Vinh
Vinh Anh Food Technology Joint Stock Company is a leading enterprise specializing in the processing and slaughtering of cattle and poultry, adhering to strict food safety and hygiene standards Equipped with modern livestock, poultry processing lines, professional cold storage, and automatic wastewater treatment systems, the company ensures product quality and environmental sustainability Vinh Anh's diverse range of products, including sausages, pork pies, and packaged fresh meats, are supplied to supermarkets, restaurants, schools, factories, and industrial zones across northern Vietnam The company continually innovates by developing new pork and chicken products to offer customers a wider selection of high-quality, safe food options.
Currently Vinh Anh FTJSC is applying the ISO 22000: 2005, GMP and HACCP for measuring and managing quality of products [19]
2.1.2 History and development of the company
Vinh Anh FTJSC was established on October 12, 2007, operating under the business license No 050070248, issued by the Department of Planning and
Investment of Hanoi City The working area of the company is about 17,000 m 2 and located in Ha Binh Phuong industrial cluster, Thuong Tin District, Hanoi City
The forerunner of Vinh Anh FTJSC was Vinh Anh slaughterhouse in Trung Van Commune, Tu Liem, Hanoi since 1990
In 2007, recognizing evolving societal trends and consumer demands, Vinh Anh founded Vinh Anh Food Technology Joint Stock Company Initially, the company operated with a single workspace and a basic slaughterhouse equipment system, laying the foundation for future growth in the food technology industry.
In 2008, Vinh Anh FTJSC leased 17,000 m² in Ha Binh Phuong Industrial Cluster, Thuong Tin District, Hanoi, to develop an investment project focused on cattle and poultry slaughtering, as well as food processing.
Between 2009 and 2012, with support from the Hanoi People's Committee, Vinh Anh's departments and branches successfully constructed a modern industrial slaughter line, a specialized cold storage system, and an automatic wastewater treatment system, with a total investment of nearly 100 billion VND, significantly enhancing their operational capacity.
Since 2013, Vinh Anh FTJSC has expanded beyond slaughter activities to focus on researching and developing new food products, including pork and chicken sausages The company has also invested in advanced cold storage facilities and established a state-of-the-art chicken slaughter plant to produce high-quality products for consumers.
The factory consists of three main areas for producing They are a factory for pig slaughtering that is closed, synchronous and modern, with a capacity of 600-
The facility processes up to 1,000 pigs per shift, featuring dedicated areas for cutting, filtering, packaging, and processing pork products such as sausages and pork pies, with a production capacity of 30 tons per shift Equipped with modern technology, the factory utilizes advanced machinery imported from France and China to ensure high-quality food processing standards Additionally, the company is currently constructing a state-of-the-art chicken slaughter plant, equipped with modern lines imported from the Netherlands, to expand its meat processing capabilities.
2.1.3 Map of the Vinh Anh FTJSC's management apparatus
Figure 2.1 The organizational map of Vinh Anh FTJSC
2.1.4 Duties and roles of departments
The general director is responsible for overseeing the daily operations of a company, organization, or corporate divisions, ensuring smooth management and functionality Additionally, they are accountable for achieving the company's annual profit targets This role is equivalent to the CEO (Chief Executive Officer), serving as the executive head responsible for overall strategic leadership and decision-making within the organization.
The production manager at Vinh Anh FTJSC plays a vital role in assisting the director in the production field and can act on behalf of the executive director when authorized Both the production director and executive director are ultimately responsible for the company's production and business results before the state and labor collective Currently, the production manager oversees slaughter processing and sausage products, with the company preparing to implement a new chicken slaughter process imported from the Netherlands In this role, he designs and plans the procedures for this new process while managing six departments, including the human resources department.
R&D Department production department, financial-accounting department, technical department and
The human resources department is responsible for labor management, workforce coordination, developing personnel policies, handling labor contracts, conducting skills training, monitoring employee performance, and managing payroll and employee needs to support company operations The production department oversees the company's manufacturing processes, ensuring technical standards, managing import/export activities, driving product innovation, conducting quality assessments, and ensuring timely product delivery that meets quality standards The finance and accounting department manages the company's financial activities, including expenses related to salaries, bonuses, machinery purchases, and materials, while maintaining accurate records of all financial transactions and complying with company regulations.
The technical department is responsible for repairing, operating, maintaining, and planning the company's equipment and machinery to ensure optimal performance They provide instructions for the proper use of equipment across factory units and continuously monitor and verify the validity of measuring instruments to ensure accurate and reliable operations.
The QA department's mission is to ensure food hygiene and safety by establishing and enforcing regulations, monitoring product quality during manufacturing, purchasing, and storage, and participating in research for new product development It evaluates raw materials, finished products, and brand performance in collaboration with government agencies, issuing quality certificates before warehousing The department regularly analyzes, evaluates, and reports on product quality to company leadership and quality control agencies The QA team comprises the QC department and R&D department, working together to maintain high standards and ensure compliance with safety regulations.
The QC department oversees the entire quality assurance process, from inspecting raw materials to final products before stock release, ensuring compliance with quality standards Concurrently, the R&D department focuses on researching and designing innovative products that meet evolving consumer demands, driving continuous product improvement and innovation.
The business director is responsible for overseeing customer engagement, sales, and service operations in alignment with company strategies Their key activities include developing marketing strategies, managing advertising campaigns, driving sales initiatives, coordinating agency distribution, and enhancing customer service Additionally, the business director plays a vital role in expanding into new markets and launching innovative products to ensure business growth and competitiveness.
2.1.5 Some products of the Vinh Anh Food Technology FTJSC
Pig’s legs Pork Pork chops
Pork Pork fat Pig heart
Figure 2.2 Fresh products of Vinh Anh FTJSC ( Source: www.vaf.com.vn )
Figure 2.3 Processed products of Vinh Anh FTJSC (Source: www.vaf.com.vn )
Overview of sausage products
Sausages are globally popular, with consumption patterns that vary across nations They are produced by processing fresh, ground meats through specific methods to achieve desirable organoleptic properties As one of the oldest forms of meat processing, modern sausage technology has deep historical roots, reflecting a rich culinary tradition.
The origins of sausage production date back to ancient times, with its exact beginnings remaining unknown Historical records confirm that sausages were already produced and consumed by early civilizations thousands of years ago The Romans were renowned for creating various delicious sausage types, which were enjoyed during annual festivals and religious sacrifices Conversely, the lower social classes in Roman society often ate sausages made from tripe and other by-products Additionally, the early Christian Church in Rome prohibited the consumption of sausages for many years, highlighting the complex cultural attitudes toward this food.
Sausage production has a history spanning over two thousand years and remains a thriving industry today While some fundamental processes have remained unchanged since ancient times, the industry continuously adopts new technological advancements and scientific innovations to enhance processing methods This ongoing development ensures that sausage manufacturing evolves with modern trends and standards, maintaining its relevance in the global market.
Sausages are versatile, comminuted meat products typically made from red meat, poultry, or a combination of both, combined with salt, binders, and seasonings Due to their numerous varieties, sausages are challenging to define with a single description but are often categorized by their form, size, or meat content They are usually stuffed into casings and may undergo curing, smoking, or cooking processes to enhance flavor and preservation.
The FAO (1985) definition about sausages that sausages are products in which fresh comminuted meats are modified by various processing methods to yield desirable organoleptic and keeping properties [2]
Sausages, as defined by Barnaby Sutton (2016), are a mixture of ground or chopped meats combined with spices and other ingredients, typically shaped in casings of various sizes They are among the oldest forms of meat processing, with their origins deeply rooted in history Modern sausage technology continues to evolve, building on this rich historical tradition.
Sausages are classified worldwide based on their processing and manufacturing methods The five main categories include fresh sausage, cooked sausage, uncooked sausage, semi-dry and dry sausage, and specialty meats These classifications help consumers understand the production techniques and unique characteristics of each type Proper categorization also enhances SEO by targeting relevant keywords related to sausage types and processing methods.
Figure 2.4 Fresh sausage: Bratwurst (Source internet: mvmdeliveries.com)
Fresh sausages are made from uncooked, fresh meats that are not dried, cured, smoked, fermented, or cooked They require refrigeration to maintain freshness and safety until ready to eat Consumers must heat fresh sausages before serving to ensure they are properly cooked and safe to consume.
Figure 2.5 Semi-dry and dry sausage
(Source internet: meatandsausage.com & amazon.com)
Fermented sausages are crafted from cured or uncured meats that undergo fermentation and often include smoking, without undergoing heat processing These sausages are characterized by a distinctive tangy flavor resulting from lactic acid produced during fermentation The meat is stuffed into casings and allowed to ferment, a process where bacteria metabolize sugars to produce acids and other compounds, contributing to their unique taste and texture Fermented sausages are categorized into semi-dry and dry varieties, offering different levels of moisture and flavor profiles.
Figure 2.6 Cooked sausages: Frankfurter sausages
(Source internet: incarlopsa.es/frankfurter-sausages)
Cooked sausages are ready-to-serve products, basically made from previously cooked fresh or exceptionally cured raw materials, subjected to final cooking after stuffing without additional smoking [4]
Specialty sausages are a diverse category of meat products that do not adhere to a specific processing method, encompassing cured, uncured, smoked, and non-smoked meats These sausages are uniquely seasoned and often shaped into loaves, making them distinct from other sausage types.
The trends of sausage production in Vietnam and in the world
2.3.1 The trends of sausage production in Vietnam
Vietnam boasts over 50 sausage manufacturing companies, with Vissan being the pioneering Vietnamese enterprise in sausage production Vissan currently holds the leading position in sterilized sausages, supplying approximately 40% of the country's annual output The company's consistent growth rate of 15-20% annually has allowed Vissan sausages to capture more than 65% of the Vietnamese sausage market, contributing over half of Vissan's total revenue Similarly, Nipponham has established itself as a major brand in Vietnam, experiencing steady profit growth of 15-20% per year Duc Viet has pioneered cooperation in manufacturing German-technology sausages using Vietnamese materials, and its sausage products have increasingly become popular among Vietnamese consumers, securing a strong market presence.
Vietnam's sausage market features popular brands like Vissan, Duc Viet, CP, Le Gourmet, Mavin, Dabaco, AFF, Ba Huan, and S-food, alongside numerous small and medium-sized companies Among these, Vinh Anh Food Sausage stands out as a notable local brand, primarily distributed through major supermarkets such as BigC Hanoi, Metro Hanoi, Hai Phong, Unimart, Coopmart, and Fivimart The brand operates food processing plants and industrial kitchens in northern Vietnam, ensuring widespread availability and quality standards.
In Vietnam, sausages are categorized into two main types based on taste and processing methods Sterilized sausages, popular in the southern regions, are vacuum-sealed with PVDC film, sterilized at high temperatures, and have a long shelf life when stored at room temperature Conversely, in northern Vietnam, where the colder climate favors different food preservation, fresh sausages are more commonly consumed These are pasteurized at lower temperatures and have a shorter storage time, reflecting regional preferences and environmental conditions.
Figure 2.7: Sausage market share by application in 2014
In Vietnam, the prices of primary sausage ingredients such as pork and beef consistently exceed the regional average by 5,000 to 10,000 VND per kilogram, according to the Ministry of Industry and Trade As a result, utilizing shrimp as an alternative meat ingredient offers a significant cost advantage for sausage production.
Figure 2.8: Sausage market share by taste in 2014
(Source internet: Euromonitor.com 2017) 2.3.2 The trends of sausage production in global
The sausage industry has experienced increased consumption in recent years, prompting a need for more efficient resource utilization to boost productivity, reduce costs, ensure reliable operations, and shorten lead times Implementing advanced production and management strategies is now more achievable through the use of programming tools and automation solutions.
Cocktail sausages hold the largest market share globally, fueling international demand In the United States, hot dogs and sausages are especially popular at major league ballparks, significantly contributing to the growth of the US hot dog and sausage market Additionally, the rising consumer preference for hygienic, low-fat, and low-calorie foods presents new opportunities for hot dog and sausage products in France, highlighting their expanding market potential.
The Asia Pacific region leads the hot dogs and sausages industry in both sales and volume, with China emerging as a key market Hot dogs and sausages are especially popular among China's younger generation, particularly those in their 20s and early 30s, fueling market growth Additionally, the rise in busy lifestyles over the years has further supported the increasing demand for convenient food options like hot dogs and sausages in China.
Japan is one of the largest markets for hot dogs and sausages in the Asia-Pacific region, driven by the significant proportion of the population in their late 20s to mid-30s who frequently consume these foods This demographic, primarily working professionals with busy lifestyles, has contributed to the steady growth of the Japanese hot dog and sausage market over the years Additionally, Brazil is recognized as Latin America's fastest-growing market for these products, with a forecasted high demand for hot dogs and sausages in the coming years.
Leading global brands with the highest market share in the hot dogs and sausages industry include major companies such as ConAgra Foods, Inc., Tyson Foods Inc., JBS Argentina, Nestlé S.A., Hormel Foods Corporation, and Sara Lee Food & Beverage Notable regional players in the Asia Pacific market include Shineway Group, Venky’s, and Goodman Fielder Ltd These companies dominate the market through extensive product portfolios and strong regional presence, establishing themselves as key players worldwide.
2.3.3 Advances in technology of sausage production
Almost all development areas undergo certain changes, but the values remain the same With the advent of civilisation and technological evolution, sausage production have been improved
- The species of animal used for sausage production traditionally were pork, beef and veal Recently, species of animal being used include turkey (poultry), venison, shrimp and fish [4];
- The shape of the product: Sausages have traditionally been symmetrically formed but today they come in various shapes, sizes and shapes to meet the consumer's appeal;
Innovative sausage casings include natural animal gut and advanced synthetic options like smooth polyethylene, which allows for printing and attractive presentation Cellulose casings with antimicrobial systems are specifically designed to reduce the risk of Listeria monocytogenes contamination on hot dogs and cooked sausages Co-extruded casings made from collagen and alginate facilitate continuous production processes, enhancing efficiency Additionally, liquid-based casings utilizing alginate provide insulation and are applied by dipping, ensuring a natural taste and texture from one end of the sausage to the other.
The sausage industry has undergone significant advancements in product quality, including improved integrity, particle definition, texture, and yield These innovations are driven by the evolution of vacuumization in pumps, inline grinding technologies, and automated systems such as hanging devices, mold loading, batching, and computer-controlled product flow, enhancing efficiency and consistency in production.
Materials for sausage production
The main sources of raw materials include: Pork, lard, pigskin, chicken breast meat, chicken skin and ground chicken The raw materials usually used in frozen forms [19]
Pork is a nutrient-rich source of high-quality protein and essential minerals like iron, copper, magnesium, phosphorus, and sodium, supporting overall health It also supplies vital vitamins, including vitamin A and other important nutrients that contribute to maintaining optimal body functions.
D, Vitamin B1 (thiamin), vitamin B2 (riboflavin), vitamin B3 (niacin), etc, and in the meat contains full of non-replaceable amino acids Meat plays a key role in determining the quality of sausage products [10] a Classification of meat
- According to percentage of lean meat
+ Lean pork: High percentage of lean meat ≥ 80%
+ Pork half lean - half fat: Percentage of lean around 50% to 80%
+ Fat pork: Percentage of lean ≤ 50% [15]
+ Meat has a fresh color, dry surface, does not leak, the pH of meat has a value of 5.6 - 6.2
+ PSE meat (Pale - soft-excudative): Meat is pale, soft, the surface has a leak, pH ≤ 5.2
+ DFD meat (dark-firm-dry): Meat is dark and the surface is hard, pH ≥ 6.4 [15] b The texture of pork
Depending on the role, function and food value of meat, we can divide the meat into muscle tissue, bone tissue, adipose tissue, connective tissue and blood tissue [29]
Table 2.1: Composition of tissues in pork
(Source: Technology for processing and preserving meat 2013)
Muscle tissue makes up the majority of meat's structure, consisting of bundled muscle fibers primarily composed of myosin and actin, and its main function is to facilitate elastic movements Chemically, muscle tissue contains 72-75% water, 18-21% protein, with the remaining components including lipids, vitamins, and minerals Connective tissue, which is widely distributed throughout meat, plays a crucial role in linking muscle fibers and bundles together, providing structural integrity and cohesion to the meat.
Adipose tissue consists of fat cells connected in a porous mesh structure, with its quantity influenced by species, gender, and feeding conditions.
Bone tissue is a specialized connective tissue that plays a crucial role in the body's structure and function It consists of organic substances that absorb mineral salts, providing strength and durability Typically, bone tissue contains approximately 20% to 25% water and 75% to 85% dry matter, with proteins making up about 30% and inorganic compounds around 45% These components work together to ensure the resilience and metabolic functions of bones.
+ Cartilage tissue is made up of basic substances, including cell components, protein fibers and elastin [18]
Blood tissue consists of approximately 40% to 60% blood secretion upon cutting, with the remaining blood residing in capillaries, organs, and skin It is composed of 16.4% to 18.5% protein, 79% to 82% water, along with non-protein organic matter and minerals accounting for 0.8% to 1% Understanding the chemical composition of blood is essential for analyzing meat quality and nutritional value.
- Nutrition contents in 100g of pork
Table 2.2: Nutrition facts in 100g of pork
(Source: Technology for processing and preserving meat 2013)
Pork half lean - half fat 16.5 60.9 21.5 0.3 1.1 268
Table 2.3: The amino acid composition of pork
(Source: Technology for processing and preserving meat 2013)
STT Amino acids In protein content (%)
- Content of minerals in pork meat (mg/100g of meat)
Table 2.4: Minerals found in meat (mg/100g of meat)
(Source: Technology for processing and preserving meat 2013)
Pork Ca Mg Fe K Na P
Pork half lean - half fat 13.2 41 2.3 442 149 170
Fat 2.5 42 2.5 442 128 180 d Spoiled forms of meat
Proper meat storage is essential to prevent spoilage caused by improper conditions that promote the growth of harmful enzymes and microorganisms Spoiled meat exhibits symptoms such as increased viscosity, rotting, sour fermentation, color changes, and mold formation Ensuring correct storage conditions helps preserve meat freshness and safety.
Viscous formation on the surface of chilled meat typically occurs in storage environments with relative humidity above 90%, marking the initial stage of meat deterioration This phenomenon manifests as a viscous mucus layer on the meat surface and is primarily caused by bacteria such as Micrococcus albus, M liquefaciens, M aureus, M candidus, Streptococcus liquefaciens, as well as E coli, Bacteroides alcaligenes, Bacillus mycoides, Bacillus mesentericus, Pseudomonas, Leuconostoc, Lactobacillus, and certain yeast strains.
The rotting of meat produces an unpleasant odor due to the activity of microorganisms that produce protease enzymes, which break down the meat's proteins Common responsible microorganisms include aerobic bacteria such as Proteus vulgaris, Bacillus subtilis, Bacillus mesentericus, and Bacillus megatherium, as well as anaerobic bacteria like Clostridium perfringens, Clostridium putrificum, and Clostridium sporogenes These bacteria play a key role in the decomposition process, leading to the characteristic foul smell associated with spoiled meat.
Moldy meat is caused by mold growth resulting from the breakdown of proteins and lipids in the meat, leading to a musty odor, sticky texture, and discoloration Common molds associated with spoiled meat include Mucor, Penicillium, and Aspergillus, which thrive on decaying organic matter Proper storage and handling are essential to prevent mold growth and ensure meat safety.
Discoloration of meat occurs due to the growth of aerobic microorganisms on its surface, causing the meat to change color from red to shades of gray, brown, or green The most common microorganisms responsible for this change include various aerobic bacteria that thrive on the meat's surface, indicating spoilage and reduced freshness Proper storage and handling are essential to prevent microbial growth and maintain meat quality.
Bacterium prodigiosum or Serratia marcerans: Red stain;
Chromobacterium: Light gray, dark brown;
Animal fat is stored in adipose tissue and organs, primarily composed of porous connective tissue with numerous fat cells The proportion of fat tissue in an animal's body varies from 1% to 48% Its main components include triglycerides, phosphatides, cholesterol, esters, pigments, vitamins, and enzymes Fatty acids in triglycerides consist of both saturated and unsaturated types, such as palmitic, stearic, oleic, linoleic, and arachidonic acids While triglycerides are insoluble in water, they can form emulsions with water when acted upon by emulsifiers, facilitating their integration into aqueous environments.
Table 2.5: Chemical compositions in lard
(Source: Technology for processing and preserving meat 2013)
Function of fat in sausage producing
+ Pork fat is a source of fat;
+ Grease works to increase the adhesion, fat, gloss and increase the sensory value of the product;
+ Fat will help to take advantage of raw materials, reduce costs and increase economic efficiency [15]
Chicken breast meat, which is the white meat from the ribs to the chicken breast, is a lean protein source that is high in meat content and low in fat It is particularly rich in vitamin B6 and contains no carbohydrates, making it an excellent choice for those seeking healthy, nutrient-dense foods.
Table 2.6: Chemical composition in 100g of chicken breast meat
(Source: Technology for processing and preserving meat 2013)
Several amino acid components in 100g chicken breast are decribed in table 2.7
Table 2.7: Several amino acid components in 100g chicken breast
(Source: Technology for processing and preserving meat 2013)
- Function of chicken breast meat is to create nutritional value for the product and help to take advantage of raw materials, reduce costs and increase economic efficiency
2.4.1.4 Pig skin and chicken skin
- Characteristics of pig and chicken skin used in sausage production
Pigskin, commonly used as back skin, offers an ideal balance of durability and flexibility Its moderate hardness, resulting from sourcing older pigs, ensures strong adhesion in products, while its softness, derived from younger pigs, maintains the desired plush feel This combination makes pigskin an excellent material for creating products that are both durable and comfortable, enhancing overall quality and customer satisfaction.
+ The skin for making sausages must be clean
- The role of the skin is to increase the ability to stick, create toughness for sausages, and as fillers help reduce production costs and increase economic efficiency [17]
Flake ice consists of thin, dry ice flakes approximately 2 mm thick and 12-16 mm long It is produced using a flake ice machine that operates on the principle of a vertical drum with a rotary knife Cold water, maintained between 5-10ºC, is pumped onto a separating tray and evenly sprayed onto the drum surface As the drum rotates at -9ºC, part of the water freezes into ice on its surface and is then sliced off by the rotating knife, while the unfrozen water is cooled, flows into a trough, and recirculates for continuous production.
OBJECTIVE, CONTENTS AND METHODS OF RESEARCH 23 3.1 Object and scope of the study
Object of the study
The object of the study is the process and technology of smoked sausage production at Vinh Anh Food Technology Joint Stock Company.
Scope of the study
Sausage production workshop of Vinh Anh Food Technology Joint Stock Company from the materials, processing, and packaging department.
Location and time
Vinh Anh Food Technology Joint Stock Company, address: Ha Binh Phuong Industrial Cluster, Van Binh Commune, Thuong Tin District, Ha Noi City
Research contents
- Investigate the procedure of smoked sausage producing in Vinh Anh Food Technology Joint Stock Company;
- Comprehend and describe all steps in the smoked sausage producing and analyze factors that affect the quality of products during these processes;
- To study all equipments in the smoked sausage producing;
- To investigate the factory's food safety and hygiene system.
Reasearch methodology
- Collection of documents and information available at the company from the managers
- Interviewing the production staff in the company
- Refer to related documents from different sources such as the Internet, textbooks, books, etc
- Observe the whole process, from importing raw materials into storage until manufacturing finished products;
- Participate directly in the production process;
- Find out and observe technical parameters, operating principles of equipment and machines used
Survey data is collected from actual production on lines, company references and in books, newspapers and the media.
RESEARCH RESULTS
Results of surveying the production process of smoked sausage in Vinh Anh
Anh Food Technology Joint Stock Company
4.1.1 Smoked sausage production diagram tº: 6 to 10ºC tº: 16 to 18ºC tº: 16 to 18ºC tº: 16 to 18ºC tº: 16 to 18ºC tº: Environment tº: 16 to 18ºC tº: 0 to 4ºC tº: 0 to 4ºC
Figure 4.1: Diagram of sausage production process
Labels and bags Cold storage
4.1.2 Describe the stages of smoked sausage production
Meat ingredients such as pork, chicken, ground chicken, and pork fat are essential raw materials in processing, all of which are typically stored in frozen form at temperatures ranging from -25ºC to -18ºC Before production, these frozen meats must be properly defrosted to ensure safety and optimal quality Proper defrosting is a crucial step to achieve the best texture and flavor in the final product, adhering to food safety standards.
The defrosting process is essential for preparing meat for sausage production, as it raises the temperature to the optimal level for further processing During freezing, the meat becomes a solid, hard mass, making grinding difficult Proper defrosting ensures the meat is soft enough for efficient blending and consistency in sausage production.
The factory utilizes a natural defrosting method, maintaining a room temperature of 12ºC to 16ºC for 15 to 18 hours to ensure optimal thawing After this process, raw materials are transported to the preparation area for cutting, with ingredients reaching a temperature of 0ºC to 4ºC, preserving their fresh natural color and quality.
Table 4.1: The mixing ratio of 100 kg material in one batch
Salt, sugar, polyphosphate, nitrit 2.4 Pepper powder, color, monosodium glutamate 4.4
Meat is supplied by a pig slaughter plant of Vinh Anh Food company according to the TCVN 7046 - 2002 standard with the following criteria
Table 4.2: Meat quality assessment standards TCVN 7046 - 2002
Fresh meat boasts high elasticity, ensuring a succulent texture without any watery residue It features a clean surface that is not pale and is free from tendons, broken bones, feathers, bruising, hematomas, or bleeding This quality guarantees superior freshness and optimal quality for culinary uses.
Color Not allowed to be dark red, dark brown, gray and blue Meat and fat are not contaminated by yellow pigments
No rancid smell of metamorphic meat, no oxidized grease greasing oil No antibiotic smell or treatment agent No strange taste like sour, acrid and salty
Hygiene Tight, clean packaging Meat and fat without sticky objects such as soil, sand and feathers Frozen Frozen meat must have a center temperature ≤ -18ºC pH Fresh meat: 5.6 ÷ 6.0
NH3 content Fresh meat: ≤ 20mg /100g
Meat, such as pork and chicken, plays a vital role in recipes by providing high-quality protein essential for muscle development, as it contains all eight non-substituted amino acids Vinh Anh Food Company supplies pork and chicken for sausage production, with each batch incorporating 20 kg of pork and 36 kg of chicken Additionally, ground chicken imported from Korea is used at a dosage of 8 kg per batch to enhance the product.
When producing sausages, it’s essential to select the appropriate type of fat based on the meat’s pH level; high-pH meat requires less-degraded fat, while low-pH meat is suitable for trans fat The fat used must be clean, free of bones, feathers, and impurities to ensure product quality Vinh Anh FTJSC supplies quality fat for sausage production, with a standard usage of 9 kg of fat per batch Additionally, the skin is an important component that should be carefully prepared to maintain product standards.
To ensure optimal quality, the skin must be properly prepared by shaving, cleaning from fat, avoiding bruising, and ensuring it’s not too hard or dry The company uses pigskin from back leather, supplied by Vinh Anh FTJSC, which is incorporated into recipes to enhance product adhesion without compromising fineness Chicken skin, sourced from chicken necks after removing nuts and impurities and imported from Germany, is added to increase adhesion and toughness in sausage production Using 2 kg of skin per batch—both pigskin and chicken skin—helps optimize raw material utilization, reduce costs, and improve economic efficiency.
5 kg/batch for chicken skin d Flake ice
- Role of flake ice in sausage production
Maintaining a low temperature below 12ºC during the pureeing process is essential to prevent overheating of the emulsion system The grinding process generates friction, which raises the mixture's temperature, potentially promoting microbial growth; therefore, controlling temperature is crucial for ensuring product safety and quality.
+ Flake ice is a solvent dissolving additives and spices;
+ Flake ice affects the ability to create emulsions, participate in creating the structure and state of the product;
+ It increases the moisture and weight of the product, reduces product costs; + Flake ice is also used to preserve foods when importing goods and during processing
Table 4.3: Drinking water standards TCVN 5501-1991
The taste is determined by the senses at 20ºC and 60ºC Undetectable The content of insoluble sediment < 10mg/l
The content of soluble sediment < 500mg/l pH 6 - 8.5
Total aerobic bacteria Not have
Total coliforms (bacteria/100ml) < 200 bacteria/1ml Total stool coliform (bacteria/100ml) Not have
Total C perfringens (bacteria/100ml) Not have
The dosage of flake ice used in sausage manufacture is 6 kg/batch e Soy protein
Requirements of soy protein in sausage processing in table 4.4
Table 4.4: Requirements of soy protein in sausage processing
Total number of fungal cells < 100 colonies/g
Soy protein is used in sausage production to enhance the product's structure, such as gels and emulsions, by effectively holding water and binding with fats and proteins It should be directly incorporated into the emulsification process for optimal results Additionally, soy protein helps balance animal and vegetable proteins, thereby increasing the nutritional value of the sausage The typical dosage of soy protein in sausage manufacturing is 1.5 kg per batch.
Tapioca starch is the primary starch used in sausage production, playing a vital role in providing polysaccharides that contribute to the product's structure and texture The interaction between starch and proteins through hydrogen bonding imparts characteristic elasticity to the sausage gel For optimal quality, the starch should be of high purity, smooth, and fine in consistency Typically, the starch dosage in sausage manufacturing is 3 kg per batch, ensuring consistency and desired texture.
- Spices are used in the form of a powder and spices purchased from Neo Foodtech Co Ltd
Salt (NaCl) enhances the flavor of meat by providing a salty taste while improving its texture and overall quality It acts as a mild preservative, preventing the growth of pathogenic bacteria, reducing oxidation, and inhibiting aerobic microorganisms, thereby extending product shelf life Additionally, salt promotes better adhesion of actin and myosin proteins in meat through osmotic pressure and increased water retention, which helps reduce moisture loss during cooking.
Table 4.5: Salt standards in sausage processing TCVN 9639:2013
Taste 5% salt solution has a pure salt taste, no strange taste
External form Dry, clean, white
NaCl content in% of dry mass > 97%
The content of insoluble matter in water is expressed as a percentage by weight of the dry substance
Monosodium glutamate enhances the sensory appeal of sausages by providing a savory, meat-like sweetness when dissolved with salt Its optimal use is up to 10 grams per kilogram of raw material, ensuring improved flavor without overpowering the product.
Table 4.6: Standard of monosodium glutamate TCVN 1459: 1996
Status Fine powder, no lumps, easily soluble in water, the number of black spots in 10cm 2 < 2
Odor Fragrant and sour, no fishy, no other strange smell
Taste Sweet characteristic of MSG
Sugar plays a key role in sausage processing by imparting a sweet flavor and balancing the saltiness of the product It works in combination with salt to increase osmotic pressure, which inhibits bacterial activity during storage Additionally, sugar binds to water through hydrogen bonding, converting free water into associated water, thereby reducing water activity and effectively preventing microbial growth.
Table 4.7: Standards of sugar TCVN 6959: 2001
Shape The crystal form, uniform, dry, no lumps
Taste Sweet taste, no strange taste
When diluted in distilled water, a clear solution is obtained
Pepper powder is used in sausage processing to create a pungent, aromatic flavor that enhances the sensory properties of the product
Table 4.8: Standard of pepper powder
Status Loose, smooth, dry, impregnated, particle size less than 0.2mm
Taste Spicy naturally, typical taste
Extractive non-volatile matter (% mass dry matter) ≥ 6%
Evaporated essential oil (ml /100g dry mass) ≥ 1
Piperine content (% of dry weight) ≥ 4%
Acid insoluble ash (dry mass) < 1.2% h Additives
- Additives are used in the form of a powder and it purchased from Neo Foodtech Co Ltd
Survey results of some equipments in the production of smoked sausages of
The purpose of this machine is to cut the meat that has a big size to small size as required, preparing for the grinding process
Figure 4.2: Meat freezing machine (Diecer): Magurit
- Composition of meat freezing machine
The meat freezing machine is composed of essential components such as sharp knives, a powerful motor that drives the shaft via a chain drive system, and an efficient pneumatic control system including cylinders, filters, pressure reducers, and electric sensors Trolleys are used to transport the meat after cutting, ensuring smooth handling throughout the process The knives are designed to cut meat into small, uniform sizes, thanks to the sharpness of the blades and the torque provided by the motor, optimizing efficiency and precision in meat processing.
-Principle of operation of meat freezing machine
The meat block is inserted into the machine, where it is automatically cut as it slides down the cutting area until fully processed The cutting is performed by knife nets attached to the drum, ensuring precise and uniform slices After cutting, the meat drops into a collection cart at the bottom of the machine This process guarantees that the meat is uniformly sized according to the specified requirements, optimizing efficiency and product consistency.
- Operating process of meat freezing machine
The meat freezing machine plays a crucial role in sausage production by cutting meat, skin, and fat into small pieces suitable for grinding It operates in batches—simply load the meat, press start, and the machine automatically guides the meat down to the knives, ensuring efficient processing After each batch, the processed meat falls into a plastic bin below, streamlining the workflow Once processing is complete, the machine should be turned off and thoroughly cleaned to maintain hygiene and optimal performance.
The purpose of meat grinder is to reduce the size of frozen meat to facilitate the puree process
Figure 4.3: Meat grinder (mincer): Mado Ultra
The feeding unit features a material feeder combined with a screw-type meat compression and conveying system designed with tapering steps for efficient operation It offers two rotating modes for the screws, labeled as Mode 1 and Mode 2, situated above the safety-covered trough Key working components include a screw-type compression chamber, a chamber wall with spiral grooves matching the screw blades, a four-sided cutter, and a mesh screen equipped with a sieve of either 8 mm or 3 mm in diameter The system operates at two distinct screw rotation speeds to optimize performance and ensure precise meat processing.
The machine features a controller with four buttons that allow users to select between slow and fast rotation speeds for two screws, as well as a button to stop the machine It is powered by a belt-driven three-phase electric motor, ensuring reliable and efficient operation.
-Principle of operation of meat grinder
This meat processing machine begins by cutting meat into small cubes, which are then loaded into a hopper and transported via a screw conveyor The screw conveyor can be powered by either a manual crank or an electric motor, ensuring versatile operation The machine features a press head and a food mixing component to enhance processing efficiency At the end of the screw conveyor, a knife positioned in front of a fixed plate slices the minced meat, with the fineness determined by the size of the holes in the blender.
- Operating procedure of meat grinder
To operate the machine, mount the screw, cutter, and wire mesh as specified, then supply materials into the cavity Press the operation button to initiate automatic grinding until the ingredients are processed, and manually stop the machine by pressing the shutdown button Finally, turn off the power, remove the screws, cutters, and sieve, and thoroughly clean all components for maintenance.
Purpose of bowl cutter is to mix all the main ingredients after roughing with appropriate spices and additives to create a uniform emulsion
The pan features a convex center and a concave rim, with a circular-shaped cross-section in the indentation During use, the pan rotates around its central axis, allowing for efficient mixing and mincing of ingredients placed within the concave area It offers two rotation speed modes—slow and fast—enhancing versatility in food preparation This design ensures smooth and controlled processing of ingredients during cooking or grinding.
The cutting knife features six identical blades arranged alternately around a rotating axis, ensuring efficient blending During operation, the blades spin around the axis with a circular diameter that aligns with the concave part of the pan, minimizing the distance between the blade tips and the pan’s bottom for even mixing The tool offers four adjustable rotation speeds (levels 1 to 4), providing versatile control for various blending tasks.
The lid securely covers half of the rotating pan, equipped with gears that align with the wall of the pan to effectively scoop and guide ingredients into the mixing area When the knife is not in motion, the lid ensures the ingredients remain contained, while the gear system promotes even chopping and thorough mixing for optimal culinary results.
The control unit features multiple buttons, each designed to perform specific functions such as adjusting and closing the lid, as well as regulating the rotation speed of the knife and pan These controls enable seamless operation and precise management of the entire system, ensuring optimal performance.
- Principle of operation of bowl cutter
Raw materials, additives, and additives put in the mixing process in a certain order The operator will control the pan and knife at a suitable speed by adjusting the button
The emulsion process consists of three key phases Initially, ingredients are prepared and placed into the pan, with the machine operating slowly at around 0ºC, progressing to 4ºC before moving to the next stage In the second phase, the machine speeds up, and spices, additives, and flake ice are added while closely monitoring the temperature, progressing when it reaches 8ºC The final phase involves increasing the machine to maximum speed to finely grind the mixture to particle sizes of 0.2-0.5mm, forming an emulsion system with melted water from flake ice The process concludes when the emulsion becomes homogeneous, ensuring the temperature does not exceed 12ºC before stopping the machine and removing the product.
The primary purpose of a stuffer is to efficiently fill sausage casings with the prepared emulsion after mixing This process ensures that the sausage material is properly packed into the casing, allowing for consistent shaping and portioning Using a stuffer streamlines the production process, helping achieve uniform sausage sizes and maintaining quality throughout manufacturing Proper stuffing is essential for producing high-quality sausages that meet desired specifications and standards.
Hopper: Inside the hopper has a system of twisted wings to prevent clogging and the swing system moves along the wall;
The compressor system efficiently pushes materials into the sausage casing, seamlessly connected to the bottom of the funnel for smooth operation The hopper's continuous material flow is maintained by a suction pump that prevents the material from being drawn into the compressor compartment The compression chamber's outlet is directly connected to the casing tube, ensuring consistent and efficient sausage filling.
Tubing system of casings, cups, forks have the appropriate size for stuffing sausages;
The control unit and PLC system manage key operational parameters such as vacuum levels, drive motor rotation speed in the compression chamber, and the twisting mechanism between sausages to ensure optimal performance The system is configured to meet specific operational requirements Additionally, a dedicated lever allows operators to quickly stop the machine for cover changes or in case of errors, enhancing safety and operational efficiency.
- Principle of operation of stuffer
Survey results on occupational safety and sanitation system of Vinh Anh FTJSC
Our company prioritizes safety by utilizing comprehensive labor protection equipment and adhering to strict fire prevention standards All machinery and equipment are operated according to established safety principles, including protective barriers for high-speed transmission devices and the installation of protective relays Workers are responsible for managing and maintaining the machinery specific to their work stage, ensuring proper operation and safety Regular maintenance checks are conducted, and employees promptly notify the technical department of any issues to ensure swift resolution Additionally, the company is equipped with fully installed and regularly tested emergency exits and fire extinguishers to guarantee swift response in case of emergencies.
Maintaining hygiene for officers and employees is essential; upon entering the workshop, all staff must wear hats, masks, gloves, rubber boots, and protective gear Additionally, personnel should avoid wearing jewelry such as watches and rings to ensure a clean and safe working environment.
Workers undergo health checks every six months to monitor their well-being Those diagnosed with infectious diseases are only permitted to re-enter the workshop or production area after they've fully recovered Regular health screenings ensure a safe and healthy work environment for all employees.
Before entering the production area, workers don clean workwear and wash their hands using an automatic water tap, followed by rinsing with water and disinfecting with a 700 ppm alcohol spray They then dry their hands using an automatic drying system Additionally, workers step through water tanks containing a 200 ppm chlorine solution for foot sanitation, ensuring thorough hygiene protocols are maintained before entering the production environment.
During production, strict hygiene protocols are maintained to ensure safety and cleanliness Workers are required to wear protective clothing outside the production area, use gloves when handling raw materials and products, and keep their protective gear free from contamination Additionally, smoking, eating, or spitting within the production area are strictly prohibited to maintain a hygienic environment.
After leaving the production area, workers must thoroughly wash their hands and clean their personal tools to maintain hygiene Protective gear should be properly hung at designated locations to ensure safety and organization When using the toilet, protective equipment is not required, but upon returning to the production area, strict adherence to cleaning procedures is essential These practices promote a safe, clean, and compliant production environment.
The processing factory is equipped with a dedicated cleaning area for tools to ensure hygiene and safety All raw materials and finished products are stored in designated baskets, barrels, or bins, which are systematically organized on stainless steel or plastic pallets to prevent contamination The floors and walls are kept consistently clean and dry, maintaining a hygienic environment Each room features separate trash cans for organic and production waste, supporting proper waste management Routine cleaning of the entire factory is performed once a week to uphold cleanliness standards and ensure a sanitary processing environment.
Regular cleaning of tools, machinery, and equipment is essential to maintain hygiene in processing facilities Semi-finished product bins and baskets should be washed with a pressurized water spray to remove residual meat samples, then scrubbed with soap and a brush, rinsed with clean water, and finally sanitized with hot water at 90°C Hand tools such as knives, scissors, cutting boards, and work tables must be cleaned thoroughly after each use using the same procedure to prevent contamination Sausage processing machines require cleaning with soap and high-pressure water hoses to wash all machine parts, contact surfaces, and equipment slots to ensure hygiene and operational efficiency.
Maintaining proper sanitation in the warehouse is essential, ensuring that the environment is always clean and dry to prevent contamination Trolleys, bins, and transportation carts are systematically organized in designated areas for easy access and efficiency Additionally, separate storage facilities are used for raw and cooked produce to uphold food safety standards and prevent cross-contamination.