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Transcript of Pi i l fC t iPrinciples of Coextrusion - Home | Canadian Brine: Sodium-Chloride (NaCl)...
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P i i l f C t iPrinciples of Coextrusion
Stork Townsend QX systems
Stork Food SystemsStork Food Systems
By Hector Flores, Ph. D
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Sausage ClassificationsSausage Classifications
• Fresh• Fresh-Smoked• Cooked• Cooked-Smoked• Semi-Dry• Dryy• Specialty Meats
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Edible Collagen AppearsEdible Collagen Appears
• In 1960 while working to develop a stronger surgical suture material than animal gut, the Johnson & Johnson company discovered a way to makecompany discovered a way to make edible collagen casings. This collagen was harvested from the middle layer of beef skinsbeef skins
• This harvested collagen casing was stronger, more uniform and much more g ,sanitary than the traditional natural gut casings
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21st Century Technology21st Century Technology• With the approaching new
t th tcentury came the most radical development yetA f ki• A new way of making sausages appeared on the marketmarket.
• A way that is cheaper, highly automated and morehighly automated and more sanitary than ever before is…..
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is…..
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The Co-extrusion ProcessAlways innovative. Always reliable. Stork Food Systems
The Co extrusion Process
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What is Co-Extrusion (QX)What is Co-Extrusion (QX)• In modern times, casings started to be made out of:
– Cellulose
– Pre-fabricated collagenPre fabricated collagen
– Plastics
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• The success of the pre-fabricated casings prompted the development of a new sausage production method betterdevelopment of a new sausage production method, better known as:
Co-ExtrusionCo-Extrusion
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The Co-Extrusion PrincipleThe Co Extrusion Principle•• Casing Development:Casing Development:
– Casing material:Casing material:Beef and pork based collagenHybrid (collagen/Alginate)Alginate gelAlginate gel
– Brine:Sodium-Chloride (NaCl)Di-Potassium-Phosphate (K2HPO4)Calcium-Chloride (CaCl2)
C i d l t– Casing development:Crosswise fiber orientationCollagen fibers collapse
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(precipitation)Brining time: 2 – 40 seconds
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The Co-Extrusion Principle•• Casing Development:Casing Development:
p
– Chemical cross-linking:Bridge between fibresNetwork of fibresNetwork of fibresAldehydesLiquid smoke
– Result:Permanent skinPermanent skinColour, taste and flavourBite
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Co-Extrusion (QX) PrincipleCo-Extrusion (QX) PrincipleCasing gel
Meat dough
Cooling water
Brining
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Co-Extrusion (QX) PrincipleCo-Extrusion (QX) PrincipleSausage diameter
Cooling water
Casing Gel
Meat doughMeat-doughBrine
Counter-Rotating h dhead
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Co-Extrusion (QX) PrincipleSausage length
Co-Extrusion (QX) Principle
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History of Co-Extrusion• 1960 – invented in England
History of Co-Extrusion
• 1972 – First Co-extrusion system installed in England
• 1978 – Transferred to The Netherlands
• 1980 – First production systems in operation in The Netherlands
1982 Fi t f l d ti t ld t S i• 1982 – First successful production system sold to Spain
• 1985 – Japan purchased first Co-extrusion system
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• 1985 – Japan purchased first Co-extrusion system
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History of Co-Extrusion
1990 I th 90’ C t i b ld id k
History of Co-Extrusion
• 1990 – In the 90’s Co-extrusion became worldwide known.
• 1998 – Townsend Engineering Company introduces the Kontura• 1998 – Townsend Engineering Company introduces the Kontura Co-extrusion system.
• 2001 – Townsend Engineering Company acquires the Protecon Langen Company,and the Protecon Co-Extrusiontechnology from Storktechnology, from Stork.
• 2002 – The introduction of QX–systems.
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2002 The introduction of QX systems.
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History of Co-Extrusion (QX)History of Co-Extrusion (QX)• 2005 – New developments in Fresh- and Cooked-Smoked
Link SystemsLink Systems.
• 2005 – QX systems sold to Hungary, South-Africa, U.S.A.• 2006 – QX systems sold to Romania, U.S.A., U.K.
2007 QX systems sold to U S A U K
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• 2007 – QX systems sold to U.S.A., U.K.
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History of Co-ExtrusionHistory of Co-Extrusion
Austria Belgium China Denmark Great Britain France
History of Co-ExtrusionCo-Extrusion systems sold world wide
History of Co-Extrusion
Austria, Belgium, China, Denmark, Great Britain, France, Hungary, Italy, Japan, Portugal, Romania, South-Africa,
Spain, Sweden, Switzerland, Taiwan,The Netherlands, USA.
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What is Townsend QX?What is Townsend QX?• The QX Technology is based on this (Co-extrusion)
technologytechnology.
• A QX system is a fully automated system that simultaneouslyA QX system is a fully automated system that simultaneously extrudes a continuous flow of meat-batter and a thin layer of casing material.
• In stead of filling a casing, the QX process is actuallycreating the casing as the sausage is produced.creating the casing as the sausage is produced.
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Benefits of Co-Extrusion (QX)
• Commercial motivations!Commercial motivations!
• Savings motivations!• Savings motivations!
• Food safety motivations!• Food safety motivations!
Automation motivations!• Automation motivations!
V tilit
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• Versatility
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Benefits of Co-Extrusion (QX) Commercial motivations
• Appearance and sausage shape:pp g p– QX processing results in perfectly shaped sausages.
• Casing:– Bite can be influenced.
QX i dibl t f th fi l d t– QX casings are an edible part of the final product.
• Q = LV:Q = LV:– Constant weight, length, caliber.– Constant process conditions guarantee an uniform product.
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p g p
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Benefits of Co-Extrusion (QX) Commercial motivations
• Reduced Processing Times:g– Compared to conventional processes, QX typically reduces
30% to 60% of the process time.M i ti• Maximum uptime:
– The QX systems are designed for continuous operation.– They have a very little downtime.They have a very little downtime.
• Cooking characteristics:– Cooking, grilling, deep fat frying, microwave.
• Uniformity:– All QX sausages are identical and perfect for automatic
packaging
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packaging.
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Benefits of Co-Extrusion (QX) Savings motivations
• Casing Savings:g g– Less expensive gel costs than collagen or natural casing.– No twist losses.– No start-stop losses.– No breaks.
• Labor savings:– QX systems are fully automated and need one operator /– QX systems are fully automated and need one operator /
supervisor only.– Up to 80% labor reduction.
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Benefits of Co-Extrusion (QX)
• Reduced rework, waste / give away:
Savings motivations
, g y– No pre-fabricated casings.– No beginnings.– No ends.– No breaks.
I d i h l– Improved weight control.– Continuous operation.
Constant process conditions– Constant process conditions.
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Benefits of Co-Extrusion (QX) Food safety motivations
• Two Levels of Enhanced Safety!Level 1.
Elimination of peeling operations:Elimination of peeling operations:* Reduce risk of microbial contamination.
Level 2.Cook in the pack:* Eliminate microbial contamination.* Increased shelf life.* Non post lethality exposed sausage production.
(Less HACCP costs)
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(Less HACCP costs).
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Benefits of Co-Extrusion (QX)
• Cook in the pack, principle:V k d d t fi t i d i h t t
Food safety motivations
• Vacuum-packaged products are first immersed in hot water for cook-in-pack and afterwards in cold water for chilling.
• Vibrating conveyor for de-stacking the packages.• The packages are dried by air-knifes above and underneath
the packages.
• Specification:• Typical hot water temperature 176-185°F.yp p• Typical cold water temperature 35-39°F.• Process time: depending on product diameter and number
of layer
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of layer.
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Benefits of Co-Extrusion (QX)
• Cooking Principle:Food safety motivations
Heating of the vacuum packaged products to core temperatures between 149ºF - 167ºF.
• Chilling:Chilling of the vacuum packaged products to core temperaturesChilling of the vacuum packaged products to core temperatures between 39ºF - 50ºF.
• Finishing:After blowing off the residual water drops from the package,
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the product is safe and ready to be boxed, stored or transported.
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Cook - In – PackageCook - In – PackageFood safety
A Hot water spray system1 In feed conveyor A. Hot water spray systemB. Insulated coverC. Endless mesh beltD. Cold water spray system
1. In-feed conveyor2. Water-cook section3. Water-chill section4. Water blow-off section
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E. Air blow-off
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Co-Extrusion (QX) Systems
• Fresh sausage systems
• Cooked-smoked systems
• Dry sausage systemsy g y
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Fresh sausage systems
• QX Fresh-frozen/cooked sausage systems(Collagen, Hybrid, Alginate)
- Short or extended briningg
• Coexskin Nijal Fresh sausage systems(Alginate)( g )
- Short bringing
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Fresh sausage systemsQX Fresh-frozen/-cooked sausage systems
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Fresh sausage systemsQX Fresh-frozen/-cooked sausage systems
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Fresh sausage systemsCoexskin system - Extruder
Meat in center
sausage rope
Extruder Alginate gel around meat rope
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Extruder Alginate gel around meat rope
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Fresh sausage systemsCoexSkin system
Brine Bath
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Brine Bath
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QX Cooked-smoked systemsQX Cooked smoked systems
• Link system• Link system
• Ring System
• Spiral
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QX Cooked-smoked link basket systemsQX Cooked smoked link basket systems
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QX Cooked-smoked link basket systemsQX Cooked smoked link basket systems
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QX Cooked-smoked ring basket systemsQX Cooked smoked ring basket systems
QXQX –– Ring SystemRing System•Ring
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Ring
•Link
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QX Cooked-smoked ring basket systemsQX Cooked smoked ring basket systems
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QX Cooked-smoked ring basket systemsQX Cooked smoked ring basket systems
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QX Cooked-smoked ring basket systems
•• Production Savings for Production Savings for QXQX RingRing--SausageSausage
QX Cooked smoked ring basket systems
gg gg gg
• Casing Savings = 30%• Labor Savings = 50%• Labor Savings = 50%• Microbial Savings= 09%• Other Savings = %• Other Savings = %
Rework 3.5%Waste 1.5%Weight control 2.0%Smoke … %Indirect cost reduction … %
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Total = 0.19 Total = 0.19 –– 0.38 $/Lb0.38 $/Lb
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QX Cooked-smoked link spiral systemsQX Cooked smoked link spiral systems
Always innovative. Always reliable. Stork Food Systems
![Page 41: Pi i l fC t iPrinciples of Coextrusion - Home | Canadian Brine: Sodium-Chloride (NaCl) Di-Potassium-Phosphate (K 2 HPO 4) Calcium-Chloride (CaCl 2) – Ci d l tCasing development:](https://reader031.fdocuments.us/reader031/viewer/2022030419/5aa63ac17f8b9a1d728e2cb5/html5/thumbnails/41.jpg)
QX Sausages and producersQX Sausages and producers
Always innovative. Always reliable. Stork Food Systems
![Page 42: Pi i l fC t iPrinciples of Coextrusion - Home | Canadian Brine: Sodium-Chloride (NaCl) Di-Potassium-Phosphate (K 2 HPO 4) Calcium-Chloride (CaCl 2) – Ci d l tCasing development:](https://reader031.fdocuments.us/reader031/viewer/2022030419/5aa63ac17f8b9a1d728e2cb5/html5/thumbnails/42.jpg)
QX Sausages and producersg pEurope
Always innovative. Always reliable. Stork Food Systems
![Page 43: Pi i l fC t iPrinciples of Coextrusion - Home | Canadian Brine: Sodium-Chloride (NaCl) Di-Potassium-Phosphate (K 2 HPO 4) Calcium-Chloride (CaCl 2) – Ci d l tCasing development:](https://reader031.fdocuments.us/reader031/viewer/2022030419/5aa63ac17f8b9a1d728e2cb5/html5/thumbnails/43.jpg)
QX Sausages and producersg pInternational
Always innovative. Always reliable. Stork Food Systems
![Page 44: Pi i l fC t iPrinciples of Coextrusion - Home | Canadian Brine: Sodium-Chloride (NaCl) Di-Potassium-Phosphate (K 2 HPO 4) Calcium-Chloride (CaCl 2) – Ci d l tCasing development:](https://reader031.fdocuments.us/reader031/viewer/2022030419/5aa63ac17f8b9a1d728e2cb5/html5/thumbnails/44.jpg)
QUESTIONS?
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