APPLICATION

Coextrusion of a fresh preparation with a vegetable casing

A coextruded sausage with a vegetable casing has the aspect of a regular sausage. The skin is a fully edible veggie alternative. The process requires attention throughout the forming, coating and drying operations.

Updated Aug 08, 2021 - 10 min Read

BASE

Core products

The core is made of a meat, fish, cheese, or vegetable-based compounds.

RECIPE

Ingredients

The coating is prepared with:

  • Water
  • A hydrocolloid such as alginate
  • A calcium salt

Optionally, the coating film can be mixed or further coated with:

  • A spice coating
  • A smoke flavour
  • Inclusions

PROCESS

How does it work?

The coating occurs with the forming of a film and its setting by a reaction with calcium salt which polymerizes it.
The thickness and firmness of the alginate film results from the respective hydrocolloid and salt proportion in water.
It is a continuous operation. Speed is adjusted to balance firmness and softness for cutting and closing the edges. The coating sequences run as follows:

1.

Forming of the core material into a mostly round, sausage-like, cohesive rope

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2.

Simultaneous coextrusion with a fluid alginate-based film

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3.

Combination or immersion into a solution of calcium salt

4.

Draining of the coated rope optionally

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5.

Cutting into portion, partial drying

PROCESS

Coating system

The operation occurs in a former for sausage which has been adapted with a coextrusion head or device to apply a film all around the core shape.
After coating, the product can be kept as such. It is usally partially dried to reduce the coating thickness and give it a crispy texture.

PROCESS

Coating system

Machine design. Courtesy of Albert Handtmann GmbH

PRODUCT EVALUATION

How do you measure your success?

Key quality features

The product is fresh and with versatile definition

Core

No excessive bumps, cylindrical shape

Casing

No cracks and leaks

Staibility

Solidity of the casing

Key quality parameters

Multiple factors to play with

Core product

Specific taste, texture and rheology

Casing

Alginate quality, use of inclusions

Operation

Residence time, constant calcium concentration of the reaction bath