25lb batch of Signature Smoked Kielbasa - Ready for smoke tomorrow
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Jamieson22 We stuff the whole casing then cut to size (a couple of inches longer than what you want) then squeeze a small amount out of each end. We let them lay out overnight before smoking and do not tie the ends. I made a template using PVC that I capped and then cut in half with my bandsaw and mounted the halves (using stainless carriage bolts) to boards longer than the pipe and use for cutting board (pipe cut at 18", when done ring is 16"). Comes apart for cleaning.
Sounds like we are doing it in similar way but I waste some casing and you get a few extra snack patties to cook up. Guessing yours is faster way though.
Could probably even build it simply out of PVC - would just need some upright supports depending how long your span is (and how small a diameter PVC you use). Would allow you to easily break it down to hang on wall in garage vs storing a PVC cube.
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cdavis Amazing what a difficult time I had finding two equal-sized/height items that can hold 25lbs and will fit on my kitchen counter. I ordered a pair of cheap saw horses though they won’ t be here till tomorrow.
Jamieson22 saw horses sound like a good idea
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About 50 years ago, I remember watching actual sausage makers cutting beef rounds to predetermined lengths for rings and then tying one end with string. Then they would stuff them. After stuffing, someone else on the line would tie the loose end of the string to the open end of the stuffed casing.
At that point, the finished ring was ready to hang on a smoke stick and load on trucks to go in the smoke house.Some years later, they got away from strings and tying. The precut, stuffed ring casings were clipped with a pneumatic clipper. Then they were hung on sticks for smoking. This method could probably be duplicated with a couple of hog rings instead of a pneumatic clip fairly easily for a small scale home operation.
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Just finished my 1 hour dry at 120F with vents fully open. Sausages reading 90F IT.
Turned up to 130F, closed vents down to 1/2 open, added water pan with hot water, and 2/3 bowl of damp hickory sawdust. Since I don’t have a wicking towel and couldn’t drape towel on 2nd lowest grate (sausage hanging below it slightly) I just put two terrycloth towels over the side of the water pan onto the drip tray. Hoping it gives me a similar evaporative effect.
Any input on temp schedule from here? Was planning:
- 130F for an hour
- then 145F for an hour
- then 160F for an hour (close dampers 100%)
- finally 175F till 155F IT?
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Sounds like we are doing it in similar way but I waste some casing and you get a few extra snack patties to cook up. Guessing yours is faster way though.
Could probably even build it simply out of PVC - would just need some upright supports depending how long your span is (and how small a diameter PVC you use). Would allow you to easily break it down to hang on wall in garage vs storing a PVC cube.
Jamieson22 We have done about 500 lbs of venison sausage at a time this way, stuffed, cut and laid out in about 3 hours. Had lot of help, hunting group annual get together.
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Just finished my 1 hour dry at 120F with vents fully open. Sausages reading 90F IT.
Turned up to 130F, closed vents down to 1/2 open, added water pan with hot water, and 2/3 bowl of damp hickory sawdust. Since I don’t have a wicking towel and couldn’t drape towel on 2nd lowest grate (sausage hanging below it slightly) I just put two terrycloth towels over the side of the water pan onto the drip tray. Hoping it gives me a similar evaporative effect.
Any input on temp schedule from here? Was planning:
- 130F for an hour
- then 145F for an hour
- then 160F for an hour (close dampers 100%)
- finally 175F till 155F IT?
Jamieson22 schedule looks good. Awesome looking smoker. Maybe 1 of these days I’ll have 1. Sausage looks great
. Congrats on all. -
Well at a bit over 7 hours I noted it had been stalled at 149F for some time. Opened smoker for first time and my water pan was empty and my wicking towel scorched to the tin foil lining the drip-tray. So refilled with boiling water and wet the towel but IT had dropped down to 143F and was taking some time to recover. So at 7h45m and 146F IT I moved the batch inside to finish sous vide.
I can already tell I didn’t get that beautiful smoke coloring evenly on the entire batch (even more apparent in water). Also not sure why I can’t seem to finish a batch to 155-160F IT in smoker. Am I just not giving it enough time?
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Stocked up a bit when butts were on sale for $1.49/lb which is cheapest I’ve seen in some time. Made 25lb of Jalapeno Cheddar Brats earlier this week and today did 25lb batch of Signature Smoked Kielbasa with the rest of it.
Just upgraded my LEM #8 to a LEM #22 so got to use it for the first time. Made my batch seem small with how fast it tore through it. Used a 10mm plate and then reground maybe 1/3 of it back through the 10mm plate. Stuffed into 42-45mm hog casings. Shooting for a chunkier texture.
Any advice on smoking them tomorrow? Plan to hang and dry at room temp with a fan for an hour or so before starting. Then figured 120F for 1 hours, 135F for 1.5 hours with smoke (and water pan), 155F for an hour, 165F for an hour, then 175F till done? Am using my PK100 but pretty new to smoking sausage.
Also, I turned them all into rings by basically stuffing till 17" (can see my green tape on counter to measure) then extending some extra casing before starting the next one. Then cut to separate them. give a few twists, then tie both ends of casings together to form ring. Is the an easier way?
Also a bonus pic as I bought three 2-packs of butts to cover my two batches. Deboned and cut into chunks last night to prep for today and one weighted in at 11lb7oz after deboning. So I had an entire butt left-over. Fired up my smoker and did an overnight cook on it for pulled pork.
Jamieson22 Looking very good. That will fill up the freezer for sure. There’s many meals in those rings.
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Well at a bit over 7 hours I noted it had been stalled at 149F for some time. Opened smoker for first time and my water pan was empty and my wicking towel scorched to the tin foil lining the drip-tray. So refilled with boiling water and wet the towel but IT had dropped down to 143F and was taking some time to recover. So at 7h45m and 146F IT I moved the batch inside to finish sous vide.
I can already tell I didn’t get that beautiful smoke coloring evenly on the entire batch (even more apparent in water). Also not sure why I can’t seem to finish a batch to 155-160F IT in smoker. Am I just not giving it enough time?
Jamieson22 Totally looks like it had enough smoke. The sous vide did the trick. Now, just enjoy.
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Jamieson22 Totally looks like it had enough smoke. The sous vide did the trick. Now, just enjoy.
zbigjeff Thanks.
End result is far from what I am after - so could def use some advice. The majority came out looking like they were simply steamed not smoked as casing has very little color. Even those that got what I am after have sections that look grey/steamed.
I used maybe 2/3 - 3/4 of a sawdust pan (wet) and kept it in till it was fully burned out. Do I just need to plan far longer than I am expecting a batch to take? I pulled these after 7h 45m and IT was close to 150F. Only finished in sous vide as it was getting late.
I am sure they will be delicious once grilled, just not sure where I am going wrong on proper color/smoke adhesion. They were hung/dried with fan for a couple hours before the drying phase in smoker.
Kinda sad looking smoked kielbasa:
Nicely color part was probably top rack closest to door or back wall. Inner sausages all seem grey. Nothing was touching and had plenty of space between.
Other side of sausage above:
Here is what sous vide water looks like after 25lb batch:
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zbigjeff Thanks.
End result is far from what I am after - so could def use some advice. The majority came out looking like they were simply steamed not smoked as casing has very little color. Even those that got what I am after have sections that look grey/steamed.
I used maybe 2/3 - 3/4 of a sawdust pan (wet) and kept it in till it was fully burned out. Do I just need to plan far longer than I am expecting a batch to take? I pulled these after 7h 45m and IT was close to 150F. Only finished in sous vide as it was getting late.
I am sure they will be delicious once grilled, just not sure where I am going wrong on proper color/smoke adhesion. They were hung/dried with fan for a couple hours before the drying phase in smoker.
Kinda sad looking smoked kielbasa:
Nicely color part was probably top rack closest to door or back wall. Inner sausages all seem grey. Nothing was touching and had plenty of space between.
Other side of sausage above:
Here is what sous vide water looks like after 25lb batch:
Jamieson22 I can only say there is a good reason to SV bag. Do what you will, that is a lot of cleanup… That is what my big soup pot looked liked when i poached 20lbs. Sorry. If you used cure#1 it may not have been evenly mixed. I always dissolve my spices in the added water for even distribution. A little paprika can help with a visual to check for an even mix… Just what i do. Cheers
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zbigjeff Thanks.
End result is far from what I am after - so could def use some advice. The majority came out looking like they were simply steamed not smoked as casing has very little color. Even those that got what I am after have sections that look grey/steamed.
I used maybe 2/3 - 3/4 of a sawdust pan (wet) and kept it in till it was fully burned out. Do I just need to plan far longer than I am expecting a batch to take? I pulled these after 7h 45m and IT was close to 150F. Only finished in sous vide as it was getting late.
I am sure they will be delicious once grilled, just not sure where I am going wrong on proper color/smoke adhesion. They were hung/dried with fan for a couple hours before the drying phase in smoker.
Kinda sad looking smoked kielbasa:
Nicely color part was probably top rack closest to door or back wall. Inner sausages all seem grey. Nothing was touching and had plenty of space between.
Other side of sausage above:
Here is what sous vide water looks like after 25lb batch:
Jamieson22 my initial thoughts would be that there may have been an air circulation issue because of an over crowded smoker. But neither looks to be an issue by your photos. Your cook schedule looks good. I don’t ever recalling my water tray going empty during a smoke or cooking session. I have used water in my MB, BGE and stick offset smoker. My guess, maybe to much moisture inside during the cook. The heated smoke is moving along the outside and steam through the middle. Just a WAG, Wild A_s Guess. Any folks that use that type of smoker have an opinion?
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Jamieson22 my initial thoughts would be that there may have been an air circulation issue because of an over crowded smoker. But neither looks to be an issue by your photos. Your cook schedule looks good. I don’t ever recalling my water tray going empty during a smoke or cooking session. I have used water in my MB, BGE and stick offset smoker. My guess, maybe to much moisture inside during the cook. The heated smoke is moving along the outside and steam through the middle. Just a WAG, Wild A_s Guess. Any folks that use that type of smoker have an opinion?
YooperDog Might be on to something I have never had water pan dry up when smoking.
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zbigjeff Thanks.
End result is far from what I am after - so could def use some advice. The majority came out looking like they were simply steamed not smoked as casing has very little color. Even those that got what I am after have sections that look grey/steamed.
I used maybe 2/3 - 3/4 of a sawdust pan (wet) and kept it in till it was fully burned out. Do I just need to plan far longer than I am expecting a batch to take? I pulled these after 7h 45m and IT was close to 150F. Only finished in sous vide as it was getting late.
I am sure they will be delicious once grilled, just not sure where I am going wrong on proper color/smoke adhesion. They were hung/dried with fan for a couple hours before the drying phase in smoker.
Kinda sad looking smoked kielbasa:
Nicely color part was probably top rack closest to door or back wall. Inner sausages all seem grey. Nothing was touching and had plenty of space between.
Other side of sausage above:
Here is what sous vide water looks like after 25lb batch:
Jamieson22 Let us know if the lighter ones have the smoke flavor.
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Jamieson22 I can only say there is a good reason to SV bag. Do what you will, that is a lot of cleanup… That is what my big soup pot looked liked when i poached 20lbs. Sorry. If you used cure#1 it may not have been evenly mixed. I always dissolve my spices in the added water for even distribution. A little paprika can help with a visual to check for an even mix… Just what i do. Cheers
JoeB You are spot on with placing the items in bags. Makes it very, very, bad for the sous vide cleanup for sure.
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Stocked up a bit when butts were on sale for $1.49/lb which is cheapest I’ve seen in some time. Made 25lb of Jalapeno Cheddar Brats earlier this week and today did 25lb batch of Signature Smoked Kielbasa with the rest of it.
Just upgraded my LEM #8 to a LEM #22 so got to use it for the first time. Made my batch seem small with how fast it tore through it. Used a 10mm plate and then reground maybe 1/3 of it back through the 10mm plate. Stuffed into 42-45mm hog casings. Shooting for a chunkier texture.
Any advice on smoking them tomorrow? Plan to hang and dry at room temp with a fan for an hour or so before starting. Then figured 120F for 1 hours, 135F for 1.5 hours with smoke (and water pan), 155F for an hour, 165F for an hour, then 175F till done? Am using my PK100 but pretty new to smoking sausage.
Also, I turned them all into rings by basically stuffing till 17" (can see my green tape on counter to measure) then extending some extra casing before starting the next one. Then cut to separate them. give a few twists, then tie both ends of casings together to form ring. Is the an easier way?
Also a bonus pic as I bought three 2-packs of butts to cover my two batches. Deboned and cut into chunks last night to prep for today and one weighted in at 11lb7oz after deboning. So I had an entire butt left-over. Fired up my smoker and did an overnight cook on it for pulled pork.
Jamieson22 do me a favor and next time try this smoke schedule
110* for 1 hour vents all open (drying phase)
125* for 2 hours (with smoke) close dampers to half on bottom 1/8th open on top
140* for 1 hour (with smoke)
155* for 2 hours (no smoke)
170* until IT reaches your desired finished temp. 157*-160*
Ice bath immediately -
Jamieson22 my initial thoughts would be that there may have been an air circulation issue because of an over crowded smoker. But neither looks to be an issue by your photos. Your cook schedule looks good. I don’t ever recalling my water tray going empty during a smoke or cooking session. I have used water in my MB, BGE and stick offset smoker. My guess, maybe to much moisture inside during the cook. The heated smoke is moving along the outside and steam through the middle. Just a WAG, Wild A_s Guess. Any folks that use that type of smoker have an opinion?
YooperDog said:
My guess, maybe to much moisture inside during the cook. The heated smoke is moving along the outside and steam through the middle.
Seems like a reasonable WAG. My first cook had issues as well as they wouldn’t not break past 140F and some weighed in it could be case hardening and I should use a water pan. The towel draped out of it was to mimic the “Advanced Thermal Processing” video to increase humidity. Shame to think this time I had TOO much humidity. LOL I did start it with boiling water from my electric kettle - 1.75L of it + whatever the dishtowel held.
bocephus said:
Let us know if the lighter ones have the smoke flavor.
Will check one in a bit when I vac seal. I’ll also grill up one of the “grey” ones and post pics.
JoeB said:
I can only say there is a good reason to SV bag. Do what you will, that is a lot of cleanup… Sorry. If you used cure#1 it may not have been evenly mixed.
Actually clean up was a snap. Just dumped cooler, wiped inside with some clorox wipes and then a quick rinse out with water. Took maybe 2 min. Also not sure how I’d bag up 25lb of sausage for sous vide + would take quite some time to do.
I also mix the sure cure into a bit of water in a bowl and whisk till melted. Then I add more ice water and the seasoning mix and whisk till well combined. I pour all that into my meat block and then mix till I get protein extraction. So I THINK it would not be from bad cure spread.
twilliams said:
do me a favor and next time try this smoke schedule
110* for 1 hour vents all open (drying phase)
125* for 2 hours (with smoke) close dampers to half on bottom 1/8th open on top
140* for 1 hour (with smoke)
155* for 2 hours (no smoke)
170* until IT reaches your desired finished temp. 157*-160*
Ice bath immediatelyMuch appreciated! Will definitely try this next time. Will also try to get going even earlier so time is less a factor.
How long do you hang/dry before you start smoking? I think I had these hanging on counter with a fan for a couple hours which helped quite a lot. I store them all in a covered meat lug in fridge so they definitely come out of fridge reasonably wet.
I also wet the saw dust pretty well. Basically adding water and mixing till I see some standing water on bottom. Then I drain out the excess as much as possible. For your 3 hours above with smoke, do you refill the pan at all? Also at end with no smoke, do you open and pull the pan or just assume it has burned out?
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YooperDog said:
My guess, maybe to much moisture inside during the cook. The heated smoke is moving along the outside and steam through the middle.
Seems like a reasonable WAG. My first cook had issues as well as they wouldn’t not break past 140F and some weighed in it could be case hardening and I should use a water pan. The towel draped out of it was to mimic the “Advanced Thermal Processing” video to increase humidity. Shame to think this time I had TOO much humidity. LOL I did start it with boiling water from my electric kettle - 1.75L of it + whatever the dishtowel held.
bocephus said:
Let us know if the lighter ones have the smoke flavor.
Will check one in a bit when I vac seal. I’ll also grill up one of the “grey” ones and post pics.
JoeB said:
I can only say there is a good reason to SV bag. Do what you will, that is a lot of cleanup… Sorry. If you used cure#1 it may not have been evenly mixed.
Actually clean up was a snap. Just dumped cooler, wiped inside with some clorox wipes and then a quick rinse out with water. Took maybe 2 min. Also not sure how I’d bag up 25lb of sausage for sous vide + would take quite some time to do.
I also mix the sure cure into a bit of water in a bowl and whisk till melted. Then I add more ice water and the seasoning mix and whisk till well combined. I pour all that into my meat block and then mix till I get protein extraction. So I THINK it would not be from bad cure spread.
twilliams said:
do me a favor and next time try this smoke schedule
110* for 1 hour vents all open (drying phase)
125* for 2 hours (with smoke) close dampers to half on bottom 1/8th open on top
140* for 1 hour (with smoke)
155* for 2 hours (no smoke)
170* until IT reaches your desired finished temp. 157*-160*
Ice bath immediatelyMuch appreciated! Will definitely try this next time. Will also try to get going even earlier so time is less a factor.
How long do you hang/dry before you start smoking? I think I had these hanging on counter with a fan for a couple hours which helped quite a lot. I store them all in a covered meat lug in fridge so they definitely come out of fridge reasonably wet.
I also wet the saw dust pretty well. Basically adding water and mixing till I see some standing water on bottom. Then I drain out the excess as much as possible. For your 3 hours above with smoke, do you refill the pan at all? Also at end with no smoke, do you open and pull the pan or just assume it has burned out?
Jamieson22 I do not pre dry by hanging at room temperature. I go straight from fridge to smoker. However I also have a bigger unit with two burners, but I would be curious to try it half and half if able to, to see if there is a difference. All your really wanting to do is evaporate the outside so the smoke will adhere to the casing and start penetrating the meat. I have a fan in my smoker so that helps accelerate the drying process.
My opinion is your getting the sawdust too wet, I get them damp and that’s it. I add some water and grab a handful of dust from the bottom of the pan and smoosh or squeeze in my hand and turn the pan at the same time to get it all absorbed evenly if that makes sense. If it feels a bit dry I add a little more but not saturated. Dig out a small dish in the center of your dust to help the burning start a tad bit faster. Leave about a half inch of dust in the middle to start the embers.
The key is to not open the door unless absolutely have to, with that being said I have a big square opening for my dust pan to fit through the door where you don’t have that option. I also have a 10” pan so one pan is enough for the 3 hours of smoke schedule. I’m thinking you probably got a 7” with your unit? I don’t like a lot of smoke so I only do a half pan, if you fill yours I think it would be plenty.
With not opening the door I also don’t put in a water pan for humidity, I probably should try it one of these times just to see what I’m missing.
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So learned my Vac Master 350 does NOT like sealing sausage rings. Had to cut them into links to seal and ended up with 3 bags of short cuts consisting the round part of each ring.
Here is my lamest looking smoked sausage before and after cooking. Once grilled it looks really nice (did on my gasser so no extra smoke added). Also an interior shot of a cold piece. Really happy with the 10mm rind “rustic” kielbasa - just what I was after.
bocephus said:
Let us know if the lighter ones have the smoke flavor.
Everything had a very prominent smoke to it.
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So learned my Vac Master 350 does NOT like sealing sausage rings. Had to cut them into links to seal and ended up with 3 bags of short cuts consisting the round part of each ring.
Here is my lamest looking smoked sausage before and after cooking. Once grilled it looks really nice (did on my gasser so no extra smoke added). Also an interior shot of a cold piece. Really happy with the 10mm rind “rustic” kielbasa - just what I was after.
bocephus said:
Let us know if the lighter ones have the smoke flavor.
Everything had a very prominent smoke to it.
Jamieson22 color and particle definition looks good. Did you get a good bloom after letting them sit after smoking? Sounds like you got good smoke flavor. Maybe some rings never got dry enough for smoke to adhere.
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