Influence of filling conditions on product quality and machine parameters in fermented coarse meat emulsions produced by high shear grinding and vacuum filling

• Salamis with similar properties were prepared in a high shear grinder-filler.
• Energy consumption could be reduced using higher number of knife blades.
• Raw material temperature affected energy consumption but not product quality.

The influence of process conditions (knife geometry, volume flow rate, and bulk mass temperature) on structure, physicochemical properties, and sensory performance of fermented coarse meat emulsions (aka salami) was evaluated. Salamis (65% lean pork meat, 35% pork belly) were prepared by passing mixtures through knife-plate assemblies with varying knife blade numbers (6–10). Casings were filled and fermented (22/25 days: 24–14 °C; 94–74% RH). Bulk mass temperature prior to processing was varied between −3 and +2 °C. Coarse meat emulsions produced with 8- and 10-arm knives yielded products with similar texture attributes and sensory performance. Energy consumption was reduced by 25% (eight blades) and 20% (10 blades) relative to six blades per knife. An increase of volume flow rate from 46 to 97 L/min had no negative effects on product appearance. Regardless of bulk mass temperature similar high quality products could be prepared. Swirling and delays during fermentation were not observed. Warmer raw material decreased energy consumption by 40%.