Sounds to me like you did everything right other than your protein extraction.
Beef vs. Pork does not matter and neither will the fat ratios. Spice selection makes no difference either, some spices may need more mixing than others to get the right extraction.

Just for argument sake and as an example:
Not that you should but you could add 4-6 cups of water and with enough mixing and protein extraction make that mix so stiff that you would struggle to crank it out. On the flip side you could use no water at all, spice the meat, hand mix for a minute or less which would give you virtually no protein extraction and that mix would crank out with virtually no effort.

Next time you get things dirty do an experiment to help get a feel for protein extraction:
Getting the right protein extraction is not something you can get with a clock it is a feel, I know by the sound the meat makes during mixing when it is done mixing and ready for the stuffer but that comes from many years (and pounds)of experience, you can get the same thing by feel so pay close attention to how it looks and feels in your hands when mixing/stuffing.

Pull a pound or two out at the start of mixing as soon as the spice is mixed in, stuff, link, and set aside. Half way through your anticipated mixing time do the same thing. And then finally at the end finish stuffing the rest. Pay close attention to how the meat looks, feels, stuffs, and links for all 3 versions.

Next time you have friends/family over grill some up making sure to keep all 3 version separate. Cut them up on separate plates and have your guests try all 3 and pick which they prefer. It’s going to come down to how you and your family like them but getting thoughts and opinions from as many people as possible is part of the learning.

Yup!
They do allow lower temps with longer hold times so if someone was so inclined they could. It’s all about “LOG” I cannot tell you exactly what it is but getting to a 7 log is considered a 10,000,000 (10 million) times reduction of bacteria.

We bring all of our smoked products up to 156 for a minimum of 1 minute for peace of mind in the odd instance that our thermometers may be off even though they are checked and re-calibrated weekly if off.

For example to get to a LOG 7 the hold times are:
130 IT= 121 Minutes
140 IT = 12 Minutes
145 IT = 4 Minutes
150 IT = 72 Seconds
152 IT = 46 Seconds
154 IT = 29 Seconds
155 IT = 15 Seconds (temp USDA recommends)
158 IT = Instant (0 seconds)

I would never do it but it could be done safely according to the USDA. The whole process is aimed at killing bacteria that could cause a food born illness.

USDA has lowered ground meat IT requirements a few years back from 156 to 155 with a minimum hold time of 15 seconds at 155. If you bring your IT up to 158 the hold time is instant meaning 0 seconds.

When cooling the ‘critical’ temps are 140 to 70 within 2 hours and then from 70-41 within an additional 4 hours (6 hour total from 140-41) with 41 being done with the cooking/cooling process.

These temperature requirements are to control food born illness.
Hope this info helps…

Chef said in Processing laws???:

KARLHEIDOLPH I’m likely to get a lot of pushback on this, but is it your intentions to make this for friends? And am I understanding that they just want to cover your cost?

I see no need to jump through all those hoops to make a few pounds of sausage for friends. If you were selling to restaurants and retailers, then yes all the advice applies.

No one is going to come after the hobbyist for making a few pounds for friends. Enjoy making it and giving a blessing to your friends. If they bless you in return with funding to cover your cost, all the better - everyone wins.

This all really depends on the scope of what you intend.

I agree.
If just making it for friends and family from time to time and not technically “selling” I don’t see any reason why you would ever get a visit from a compliance officer.

BUT!
As stated by someone earlier being the cause somebody get sick from a product you made is definitely not a path you want to go down so regardless which way you decide to go MAKE SURE that you follow ALL of the guidelines set forth by the USDA!

The guidelines are there to keep everybody safe and healthy so every home processor even those that are only making it for themselves should know what they are and follow them.

You can definitely do it but you are “supposed” to be licensed and legal in order to sell.
I am in Minnesota but assume that most if not all states are close to, if not the same.

If your going to go ‘legal’ you will have to make a commitment that doesn’t give you too many options to turn back.

If your looking at being legal you have to have your facility inspected and approved followed by getting a license. Once licensed you will need to start keeping records and have annual inspections to review all your records as well as the facility. Don’t forget that equipment, appliances, and all utensils will have to be NSF rated. The initial inspection is to make sure that you have everything.

Some of the requirements in Minnesota are:
Walls and floor need to be smooth and washable (floors need to be tile or commercial 5 mil epoxy coated applied by a licensed installer) a 3 basin sink with approved soap and sanitizer (sinks have to be labeled wash, rinse, sanitize), hand wash sink (labeled), hot water, aprons, gloves, hair nets, mop sink, cooler and freezer, your suppliers (both meat and spices) must issue a “letter of guarantee” that is posted along with your license, it’s also not legal to transport your own meat (it must be delivered in a refrigerated truck), and on and on and on…

This is just the tip of the iceberg for what is involved and obviously VERY expensive. You should definitely check with your local inspectors and see what is required in your state and make your decision based on what they say.

Mcjagger said in Venison Hot Dog Issue:

The Brat Barn …very interesting, using mustard flour as a binder…how much would one use per lb/kg and does it impart an overwhelming mustard flavor or just hang out in the back of the flavor profile.

Sorry, I did not realize I missed this post until now.

We use 2C of Mustard Flour in a 25# batch of Weiners.

Does add a touch of flavor which is one of the reasons we use it. It is very subtle though, if you did not tell someone it was in there they would most likely not be able to tell.

I agree with NOT pre grinding. Grinding partially frozen meat just prior to needing it is always going to give you a better product.

We get deliveries once a week and always get at least a few cases of butts not knowing what is coming up in the following week. When we get a day or two from the next delivery and still have butts left we debone, cut into baseball size chunks that fit our grinders and then vacuum seal 12.5# into 14"x16" bags making sure to date each bag. If we ever get into a situation that we run out of the prior weeks butts we simply pull the oldest bag from the freezer and into the cooler overnight.

Works great for us always having some pork on hand just in case.

RJ Adventures said in Hard Willie's Snack Stick Seasoning.:

Definitely still ok, when I seal my stuff I don’t draw a full vacuum to prevent this and haven’t ever had an issue… seasonings won’t go bad per say even after their 2 year shelf life usually just lose potency so after that time could see a flavor difference

If you do have an old spice lying around that you suspect has lost it’s punch simply cut back on the meat a tad and you will never know the difference.

Not uncommon.
When this happens to us we put it in a bowl and use a fork to break it up into smaller chunks. Measure out your water that you plan on using in your meat block and add however much of it is needed to dissolve what chunks are left. Letting it sit for an hour or two also really helps.

Once dissolved add it to the meat, then put the balance of the water in the bowl to essentially wash out any remaining spice and add it to the meat block as well.

GREAT to hear!

Not that my way is the right way but I am happy with my results as are our customers so it must be close (LOL).

I can still remember struggling and not being happy with my results from grinding to packaging and everything in between. Not to mention all of the trial and error and ruined product over the years. Not sure if MEATGISTICS was even a thing back then but can only imagine how much quicker I could have got to where I am today and wouldn’t mind helping anyone just getting started or struggling like I have in the past.

I get a kick out of those that have a “TRADE SECRET” and won’t share with anyone but lets face it, what we are doing is not rocket science and anyone can do it. Boils down to how involved you want to get and how much to invest in equipment. I tell any customer that wants to know the how and why so they can go home and do it themselves. In fact, I even supply them with the spices, casings, meat, etc… if they wish all way down to the process we use.

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

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.

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.

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…