What I am reading seems to be improper prep and I would like offer a few tips.

We specialize in Wild Game and Sticks are probably the most popular item we make for folks. We Chamber Vac Seal 100% of our sticks but they are dried properly in the smokehouse and when they come out of the smokehouse they get rolled into the cooler overnight prior to packaging the next day.

I have never understood why folks Ice Bath sticks (?). When you consider the time spent DRYING them why would you ever introduce moisture back in??

An Ice Bath is not necessary to stop cooking. 156 degree sticks will cool to 41 degrees in 1 hour 20 minutes in a 38 degree cooler which is well within the USDA required HACCP requirements.

I am guessing that another mistake being made is not allowing their sticks enough time to reach room temperature before packaging.

Make sure the sticks are allowed enough time to warm up to room temperature. As they warm up condensation will form on the outside. MAKE SURE the condensation that forms on the outside has sufficient time to dry BEFORE putting them in bags and sealing.

If packaged to soon the moisture will be trapped and form ice crystals in the freezer and then turn back into water upon thawing which is what I believe folks are experiencing.

With Proper prep prior to sealing/freezing sticks should come out of the freezer the same as they went in. Keep in mind that as they thaw and warm up they will once again form condensation that will need to be dried. Taking them out of the bag and onto paper towel as they thaw will help the drying.

Hope this helps…

RJ Adventures
Make sure to use Mahogany casings. They are intended for the smokehouse and hanging. Ours go into the smokehouse 6’ long (3’/side) and never had a split yet.

RJ Adventures
Yup hydraulic stuffer and commercial (electric) smokehouse.

Hydraulic is definitely not for the hobbyist but I started out the same as everyone else (Horn Stuffer, Manual 5 # vertical, 12#, 30# manual, 30# electric, and then finally a 50# Hydraulic Talsa Stuffer.

I have a friend that uses ONLY sheep casings but he is making it for his friends and family and that is how they like it. I have had his sticks many time and they are fantastic.

Another thought:
I have another friend that only has a gas smoker and he is ALWAYS struggling with his drying. Gas smokers add moisture and hinder the drying process. It can be done but requires more time and attention than an electric smokehouse. He is planning on getting a second (electric) smoker for sausage making and keeping his gas for smoking big meats (Pulled Pork, Brisket, Ribs, and also Polish) which is ideal when trying to keep meat moist.

Both casing options are great but it comes down to personal preference. In all my years I have not had anyone request natural casings. Maybe they are unaware that there is an option just never had anyone ask is all.

Everything we have is computerized and our smokehouse sends all data to a PC complete with graphs so it is very easy to track and see exactly what is happening down to 1/10 of a degree.

We pull sticks (21mm Mahogany) at 156.0 and being they are so small they do stop cooking almost immediately (normally climbs to only 156.4-156.6). Within 5 minutes they are already in the mid 140’s.

Summer Sausage and Polish is another thing. Those DO require an Ice Bath to stop cooking. We pull 2.5" SS at 154.0 degrees and immediately into an Ice Bath. SS continues to climb and reaches 156 (every once in a while 157) depending on how big of a load we are unloading and how long it takes to get into the ice bath.

Not trying to tell folks what to do or how to do it, I am only offering my experience to anyone that may want to try another variation or method.

twilliams
That is awesome!

I realize that I am on a different level but I (most likely like everyone else here) also started with a 3# horn stuffer in the kitchen.

I also started with meat lugs and realized right away that they cooled differently like you said so I invested in some jerky racks for cooling which lets air flow for more even cooling. https://www.waltonsinc.com/3-tier-jerky-racks