Method for producing sausage products in heat chamber
By employing heat-resistant plastic boxes with perforated sides and bottoms for sausage products, the heat treatment process achieves a substantial increase in productivity and efficiency, addressing the limitations of existing methods.
Patent Information
- Authority / Receiving Office
- RU · RU
- Patent Type
- Patents
- Current Assignee / Owner
- AKTSIONERNOE OBSHCHESTVO SERGIEVO POSADSKII MIASOKOMBINAT
- Filing Date
- 2025-08-18
- Publication Date
- 2026-06-29
Smart Images
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Abstract
Description
[0001] The invention relates to methods for producing sausage products and meat delicacies, in particular, to methods for industrial heat treatment of formed sausage products and delicacies [A23L13 / 50, A23L13 / 70].
[0002] A METHOD FOR PROCESSING RAPIDLY FERMENTED DRIED MEAT WITH REDUCED SODIUM CONTENT is known from the prior art [CN119605966A, published 03 / 14 / 2025], which includes marinating the meat, drying the marinated meat in the open air, and fermenting the meat in a sealed container.
[0003] In this analogue, the use of a sealed container is necessary for the fermentation process, but the possibility of using the container for baking sausages is not indicated, nor are the significant parameters of the container used (type of material, shape, etc.) indicated.
[0004] Also known from the prior art is a METHOD OF SMOKING AND BAKING IN THE PROCESS OF PRODUCING DRIED MEAT PRODUCTS [CN115581287A, published 01 / 10 / 2023], which is characterized by the fact that the meat is first cut, the cut pieces are marinated, having previously added the necessary ingredients to the marinating container, after marinating, the marinated pieces of cut meat are moved into a clean container, in which the heat treatment process in the form of smoking is carried out.
[0005] This analog mentions the possibility of using a food container for smoking sausages, but does not specify the significant parameters of the container used (type of material, shape, etc.), the method of their arrangement in the smokehouse and how the sausages should be arranged in them in order to simultaneously smoke a larger number of sausages.
[0006] The closest in technical essence is the METHOD OF PRODUCING COOKED MEAT PRODUCTS [ES2123433A1, published 01.01.1999] including the stages of: mincing, crushing and mixing meat, fats and additives until meat dough is obtained; forming a sausage from the said meat dough in a plastic casing; heat treatment of the formed product, characterized in that after preparation of the product, packaging occurs in a flexible multilayer sheet, which can be made of plastic material.
[0007] The main technical problem with the prototype is the low productivity of the heat treatment process for industrial sausages. This is due to the fact that the prototype solution only accommodates a small volume of sausages that can be simultaneously heat treated within the heat treatment device. Furthermore, the prototype solution does not consider the placement methods or the technical means by which these methods could be implemented to increase the productivity (number of heat-treated products per unit of time) of this process.
[0008] The objective of the invention is to eliminate the shortcomings of the prototype.
[0009] The technical result is an increase in the productivity of the process of heat treatment of sausage products during their industrial baking.
[0010] The said technical result is achieved due to the fact that the method for producing sausage products in a heat chamber, characterized by the fact that it provides for the production of formed sausage products, after which, before the heat treatment process, the prepared formed sausage products are placed in plastic boxes, wherein the boxes are made of heat-resistant plastic with perforated bottom and side walls, the said boxes are placed in a universal heat chamber, arranged in rows one above the other, wherein the bottom row is placed on pallets, after which the heat treatment process is carried out by cooking the sausage products, wherein the formed sausage products are placed in a plastic box in one layer or in two layers and fixed with clamps in the form of ties made of heat-resistant plastic, which are passed through perforated holes, and each successive sausage product is placed and fixed with ties in such a way,so that it is located at a distance of at least 1 cm from adjacent sausage products, and when placing formed sausage products in a plastic box in two layers, a perforated sheet made of heat-resistant plastic at least 1 cm high is placed on top of the first lower layer of placed sausage products, which is fixed with ties to the walls of the plastic box, sausage products are placed on top of the perforated sheet in the same way as those placed on the lower layer.
[0011] In particular, the plastic boxes used are made with holes for handles in the central parts of the side walls.
[0012] In particular, the plastic boxes used are made of heat-resistant plastic with a melting point of at least 160°C.
[0013] In particular, the plastic boxes used are made with rectangular perforated holes.
[0014] In particular, the plastic boxes used are made with walls no more than 2 cm thick.
[0015] In particular, the plastic boxes used are made with partitions between perforated holes no more than 1 cm wide.
[0016] In particular, the plastic boxes used are made with perforated rectangular holes, the dimensions of the first side of the rectangle are from 2 to 6 cm, the dimensions of the second side of the rectangle are from 2 to 6 cm.
[0017] Fig. 1-2 show end views of a plastic food container.
[0018] Fig. 3-4 show side views of various types of food plastic container.
[0019] Fig. 5 shows a variant of the bottom view of a food plastic container.
[0020] Fig. 6-7 show options for placing sausages in a food-grade plastic baking container.
[0021] Fig. 8 shows an example of a food-grade plastic baking container.
[0022] The following is shown in the figure: 1 – hole; 2 – handle; 3 – sausage product; 4 – clamp; 5 – partition.
[0023] Method 3 for producing sausages is implemented using a food-grade plastic container. The food-grade plastic container has side and bottom walls. Perforated holes 1 are made in the side and bottom walls.
[0024] In the embodiment, the plastic containers are made with holes for handles 2 in the central parts of the side walls.
[0025] In the embodiment, the plastic containers are made of heat-resistant plastic with a melting point of at least 160°C.
[0026] In the embodiment, the plastic containers are made with perforated holes 1 in the shape of a quadrangle.
[0027] In the embodiment, the plastic containers are made with side and bottom walls no more than 2 cm thick.
[0028] In the embodiment, the plastic containers are made with partitions 5 between the perforated holes 1 of a width of no more than 1 cm.
[0029] In the embodiment, the plastic containers are made with perforated holes 1 of a rectangular shape, the dimensions of the first side of the rectangle being from 2 to 6 cm, the dimensions of the second side of the rectangle being from 2 to 6 cm.
[0030] Sausage production method 3 is characterized by the meat raw material initially undergoing incoming quality control, then being deboned and / or trimmed. The processed meat blocks are then transferred to production, while food additives are prepared simultaneously. During the raw material preparation stage, the chilled meat raw material is ground if necessary, after which it is minced or processed into a whole piece of meat. Formation is accomplished either by stuffing the minced meat into impermeable casings or by wrapping the product (e.g., in cellulose film).
[0031] Before the heat treatment process, the prepared raw materials in the form of formed sausage products 3 are placed in plastic containers, wherein the containers are made of heat-resistant plastic with perforated bottom and side walls, said containers are placed in a baking chamber and arranged in rows one above the other, after which the baking process of sausage products 3 is carried out.
[0032] In an embodiment, the plastic containers are placed in a baking chamber and arranged in rows on top of each other, with the bottom row located on pallets.
[0033] In the embodiment, the formed sausage products 3 are placed in plastic containers as follows: the formed sausage product 3 is placed in a plastic container and secured with fasteners 4 in the form of ties made of heat-resistant plastic, which encircle the sausage product 3 and are threaded through perforated holes 1 for fixation, each successive sausage product 3 is placed and secured with fasteners 4 (ties) in such a way that it is located at a distance of at least 1 cm from adjacent sausage products 3.
[0034] In an embodiment where the height of the food plastic container significantly exceeds the height of the sausage products 3, the formed sausage products 3 are placed in the plastic containers in the following manner: when forming the bottom layer, the formed sausage product 3 is placed in the plastic container and fixed with fasteners 4 (in the form of ties) made of heat-resistant plastic, which are passed through the perforated holes 1, each successive sausage product 3 is placed and fixed with fasteners 4 (ties) in such a way that it is located at a distance of at least 1 cm from the adjacent sausage products 3, then a perforated sheet in the form of a horizontal partition 5 made of heat-resistant plastic with a height of at least 1 cm is placed on top of the bottom layer of the placed sausage products 3, which is also fixed to the walls of the plastic container with fasteners 4 (ties), the sausage products 3 are placed on top of the perforated sheet in the same way as those placed on the bottom layer.
[0035] The claimed technical result—increasing the productivity of the heat treatment process for sausage products 3 during their industrial baking—is achieved primarily by increasing the volume of sausage products 3, which can be baked in the limited oven space due to their compact packaging. (This is in contrast, for example, to the method in which sausage products 3 are hung within the oven's interior using hooks.) The claimed technical result is also achieved by the fact that, with this arrangement of sausage products 3, the boxes can be stacked on top of each other to form rows, ensuring maximum utilization of the oven space. The use of boxes made of this material is justified by the fact that plastic is quick and easy to clean (and is also lightweight and highly durable, simplifying the process of moving containers from and to the baking zone) from baked products, allowing for quick preparation of the containers for the next loading.Perforations on all sides ensure heated air circulation around the baked sausage 3, which also speeds up the baking process and ensures proper cooking. Moreover, in various embodiments, the stated technical result can also be achieved by:
[0036] - the plastic containers used are made with holes for 2 handles in the central parts of the side walls, which increases the speed of loading and unloading the oven, thereby increasing productivity; in cases where the containers are large (when it is problematic to carry them by one person), without handles, the process of carrying the containers becomes inconvenient and time-consuming;
[0037] - the plastic containers used are made of heat-resistant plastic with a melting point of at least 160°C, which guarantees the safety of the heat treatment process in cases where high temperatures are used for baking;
[0038] - the plastic containers used are placed in the baking chamber and arranged in rows one above the other, with the bottom row placed on trays, which increases the convenience and speed of servicing the thermal chambers, thereby reducing the intervals between loading the oven (for the case, for example, when baking fatty sausages 3);
[0039] - the plastic containers used are made with perforated holes 1 of a rectangular shape, this shape allows for maximizing the contact area of convection currents from the oven (minimizing the contact points of sausages 3 with containers), which reduces cooking time and increases productivity (in the case, for example, when baking large-sized sausages 3);
[0040] - the plastic containers used are made with walls no more than 2 cm thick, this value was obtained experimentally, in particular, when baking large-sized sausage products 3, thicker walls increase the cooking time of the product due to the fact that at the point of contact between the sausage product 3 and the container, the sausage product 3 takes longer to cook, in addition, the larger size value does not in any way positively affect the heat treatment process, while it increases the size of the containers, due to which (in relation to large ovens), fewer containers can fit into the internal volume of the oven, which can reduce the productivity of the process;
[0041] - plastic containers are made with partitions between the perforated holes 1 no more than 1 cm wide - this value was obtained experimentally, in particular, thicker partitions when baking large sausage products 3 increase the cooking time of the product 3, due to the fact that the required type of crust is not formed at the point of contact between the sausage product 3 and the container (which is mandatory for some types of sausage products), which subsequently requires additional time to bring the products 3 to readiness, which can reduce the productivity of the process;
[0042] - plastic containers are made with perforated holes 1 of a rectangular shape, the dimensions of the first side of the rectangle are from 2 to 6 cm, the dimensions of the second side of the rectangle are from 2 to 6 cm; these values were obtained experimentally, in particular, when using holes 1 of a smaller size when baking sausages 3 of a large size, the cooking time of the product 3 increases due to the fact that the required type of crust is not formed at the point of contact between the sausage product 3 and the container (which is necessary for some types of sausages), due to which additional time is subsequently required to bring the products 3 to readiness, which can reduce the productivity of the process; when using holes 1 of a larger size when baking sausages 3 of a smaller size, there is a risk of the entire product (or part of it) falling (dropping out) through hole 1.
[0043] - formed sausage products 3 are placed in plastic containers as follows: formed sausage product 3 is placed in a plastic container and fixed with clamps 4 in the form of ties made of heat-resistant plastic, which encircle the sausage product 3 and are passed through perforated holes 1 for fixation, each successive sausage product 3 is placed and fixed with clamps 4 (ties) in such a way that it is located at a distance of at least 1 cm from adjacent sausage products 3 - in this case, reliable fixation of sausage products 3 is ensured with the formation of gaps that guarantee no contacts between adjacent products 3; the specified value of 1 cm was obtained experimentally, with a smaller value, the cooking time increases when baking large sausage products 3 due to the fact that heated air does not circulate between the sausage products 3 to a sufficient extent;
[0044] - in the case where there is space for placing products 3 in several rows within one container, first, a lower layer is formed in the manner specified above, then, on top of the lower layer of placed sausage products 3, a perforated sheet in the form of a horizontal partition 5 made of heat-resistant plastic with a height of at least 1 cm is placed, which is also fixed to the walls of the plastic container with clamps 4 (ties), sausage products 3 are placed on top of the perforated sheet in the same way as those placed on the lower layer - in this case, reliable fixation of sausage products 3 is ensured with the formation of gaps both in the horizontal and vertical planes, which guarantees that there is no contact between adjacent products 3 and the necessary circulation of hot air is ensured;the specified value of 1 cm was obtained experimentally; with a smaller value, the cooking time increases when baking large-sized sausage products 3 due to the fact that heated air does not circulate between the sausage products 3 to a sufficient extent.
[0045] Examples of implementation of the claimed method.
[0046] To implement the examples below, a food-grade plastic baking container was used in accordance with Fig. 8, made of heat-resistant plastic with a melting point of 160°C, with square perforated holes 1 measuring 3x3 cm; a wall thickness of 1 cm, and the thickness of the partitions between the perforated holes of 10.5 cm. Containers measuring 40x60x13.5 cm were used. Below are three examples of the technological process for the production of sausages 3 taking into account the use of the claimed method.
[0047] Example 1. Cooked sausages in natural casing (beef casing).
[0048] Upon receipt, meat raw materials undergo incoming quality control. Chilled meat with a core temperature of no less than +1.5°C and no more than +4°C, or defrosted meat with a core temperature of no less than +1.5°C and no more than +4°C, is sent for deboning and / or trimming. During deboning, the meat is removed from the bone and transferred to trimming. During trimming, sinews, coarse connective tissue, and excess fatty tissue are removed from the meat raw materials to achieve the stated lean content. Frozen blocks of trimmed meat with the stated lean content and a core temperature of no more than -18°C are transferred to production after removing the outer packaging. At the same time, food additives are prepared, which involves weighing the spices according to the recipe.
[0049] Preparation of raw materials
[0050] Chilled meat is minced using a meat grinder with a mesh diameter of 8 mm (mesh sizes from 3 to 16 mm are acceptable). Frozen meat is minced using a block cutter.
[0051] The preparation of minced meat is carried out as follows.
[0052] In the first stage, a mixture of lean raw materials (preferably beef) and 30% moisture (ice) is loaded into the cutter and chopped to a minced meat temperature of 2°C for 4-5 minutes at bowl speed 1 and blade speed 3. In the second stage, the remaining raw materials are loaded into the cutter. After chopping them, a set of spices, food additives (coloring, if present in the recipe, is diluted in water), and the remaining moisture are added in the mixing mode. Close the cutter lid and chop at maximum blade speed (3500 rpm) under a vacuum of 80-90% until the minced meat temperature reaches +12°C. Once the required minced meat temperature is reached, turn off the cutter, release the vacuum only after the blades have completely stopped, open the lid, and lower the unloading disc all the way into the bowl. Then unload the minced meat. The minced meat is filled into natural casings.
[0053] The formed loaves are placed in plastic boxes, which are arranged in rows on a plastic pallet. Settling is permitted for no more than 2 hours at a temperature no higher than 8°C.
[0054] Then the product, stored in boxes on a pallet, is sent for heat treatment. Heat treatment is carried out in universal heat chambers according to established temperature conditions. The end of the cooking process is determined when the center of the loaf reaches 72°C.
[0055] Cooling (stabilization) – showering to a temperature of 20-30°C in the center of the product and then in a cooling chamber to a temperature of 6°C in the center of the product.
[0056] Organoleptic properties: according to the regulatory documentation for this type of product. The consistency is elastic, and the smell and taste are typical for this type of product.
[0057] Example 2. Ham in an artificial impermeable casing.
[0058] Upon receipt, meat raw materials undergo incoming quality control. Chilled meat with a core temperature of no less than 1.5°C and no more than 4°C, or defrosted meat with a core temperature of no less than 1.5°C and no more than 4°C, is sent for deboning and / or trimming. During deboning, the meat is removed from the bone and transferred to trimming. During trimming, sinews, coarse connective tissue, and excess fatty tissue are removed from the meat to achieve the specified lean content. Food additives are prepared simultaneously, which involves weighing spices according to the recipe.
[0059] Preparation of raw materials
[0060] Chilled meat raw materials are ground in a grinder with a grid hole diameter according to the product’s technological map (from 5 mm to the receiving grid)
[0061] The preparation of minced meat is carried out as follows.
[0062] Pre-ground raw materials, moisture, spices, and food additives are added to the mince mixer and mixed for 40 minutes. The mince is removed and left to mature in a room at a temperature of 0 to +4°C for 12 hours. After maturation, the mince mixture is loaded into the mince mixer, starch is added, mixed for 20 minutes, removed, and transferred to the forming machine. The mince is filled into artificial impermeable casings.
[0063] The formed loaves are placed in plastic boxes, which are arranged in rows on a plastic pallet. Settling is permitted for no more than 2 hours at a temperature no higher than 8°C.
[0064] The product is then transferred to the trays for heat treatment. Heat treatment is carried out in universal heat chambers according to established heat treatment modes. The end of the cooking process is determined when the center of the loaf reaches 72°C.
[0065] Cooling (stabilization) – showering to a temperature of 20-30°C in the center of the product and then in a cooling chamber to a temperature of 6°C in the center of the product.
[0066] Organoleptic properties: according to the regulatory documentation for this type of product. The consistency is elastic, and the smell and taste are typical for this type of product.
[0067] Example 3. Cooked smoked delicacies.
[0068] Upon receipt, meat raw materials undergo incoming quality control. Chilled meat with a core temperature of no less than 1.5°C and no more than 4°C, or defrosted meat with a core temperature of no less than 1.5°C and no more than 4°C, is sent for deboning and / or trimming. During deboning, the meat is removed from the bone and transferred to trimming. During trimming, sinews, coarse connective tissue, and excess fatty tissue are removed from the meat to achieve the specified lean content. Food additives are prepared simultaneously, which involves weighing the spices according to the recipe.
[0069] Preparation of raw materials
[0070] Chilled raw meat is transferred to the deli salting shop. Water is added to the brine station to the required level, along with food additives and ice, which accounts for 20% of the total moisture. The temperature of the finished brine should not exceed +2°C. Injection is carried out at a pre-set pressure for each type of raw material and is performed in one or two passes. After injection, the raw materials are weighed in containers and then loaded into a tumbler. Tumblers are then applied. After tumblers, the raw materials are unloaded into vats / trolleys, weighed to determine tumbler losses, passe-partouted (the end time of tumbler is indicated), and transferred to maturation. Maturation takes place in a maturation chamber at a temperature no higher than +4°C for at least 6 hours and no more than 24 hours, after which the product is sent for molding.
[0071] Forming is accomplished by wrapping the product in a piece of cellulose film. The formed delicacies are placed in plastic boxes, which are arranged in rows on a plastic pallet. Settling is permitted for no more than 2 hours at a temperature no higher than 8°C.
[0072] The product is then transferred to the trays for heat treatment. Heat treatment is carried out in universal heat chambers using specific heat treatment modes. The end of the cooking process is determined when the product's center temperature reaches 72°C.
[0073] Cooling (stabilization) - without showering in the cooling chamber to a temperature of 6°C in the center of the product.
[0074] Organoleptic properties: according to the regulatory documentation for this type of product. The consistency is elastic, and the smell and taste are characteristic of this type of product.
[0075] Example of achieving the technical result.
[0076] In Example 3 of the claimed method, the products were placed individually per container (due to their large size). In Example 1, they were placed in a single layer per container. In Example 2, they were placed in two layers per container (top and bottom). Compared to the method of hanging products on hooks, the baking volume per batch increased by 45% for Example 1, by 85% for Example 2, and by 125% for Example 3. Taking into account the ability to prepare the next batch in advance and the speed of loading the baking area, the baking productivity increased from 55 to 150%, confirming the feasibility of achieving the stated technical result.
Claims
1. A method for producing sausage products in a heat chamber, characterized in that it involves obtaining formed sausage products, after which, before the heat treatment process, the prepared formed sausage products are placed in plastic boxes, wherein the boxes are made of heat-resistant plastic with perforated bottom and side walls, said boxes are placed in a universal heat chamber, arranged in rows one above the other, wherein the bottom row is placed on pallets, after which the heat treatment process is carried out by cooking the sausage products, wherein the formed sausage products are placed in a plastic box in one layer or in two layers and fixed with clamps in the form of ties made of heat-resistant plastic, which are threaded through perforated holes, wherein each successive sausage product is placed and fixed with ties in such a way that it is located at a distance of at least 1 cm from adjacent sausage products,and when placing formed sausage products in a plastic box in two layers, a perforated sheet made of heat-resistant plastic at least 1 cm high is placed on top of the first lower layer of placed sausage products, which is secured to the walls of the plastic box with ties; sausage products are placed on top of the perforated sheet in the same way as those placed on the lower layer.
2. A method for producing sausage products in a thermal chamber according to paragraph 1, characterized in that the plastic boxes used are made with openings for handles in the central parts of the side walls.
3. A method for producing sausage products in a thermal chamber according to paragraph 1, characterized in that the plastic boxes used are made of heat-resistant plastic with a melting point of at least 160°C.
4. A method for producing sausage products in a thermal chamber according to paragraph 1, characterized in that the plastic boxes used are made with perforated rectangular holes.
5. A method for producing sausage products in a thermal chamber according to paragraph 1, characterized in that the plastic boxes used have walls no more than 2 cm thick.
6. A method for producing sausage products in a thermal chamber according to paragraph 1, characterized in that the plastic boxes used are made with partitions between perforated holes no more than 1 cm wide.
7. A method for producing sausage products in a thermal chamber according to any of paragraphs 1, 4, characterized in that the plastic boxes used are made with perforated rectangular openings, the dimensions of the first side of the rectangle being from 2 to 6 cm, and the dimensions of the second side of the rectangle being from 2 to 6 cm.