Basic Sausage Making Process

Sausage making can be broken down into 4 main steps:

• Grinding the meat
• Adding of spices and flavorings
• Stuffing the casings
• Storing

One thing we advocate is that you must keep your meat as cold as possible throughout the sausage making process. Before and after each step of the process refrigerate the meat and keep it as stiff as possible without actually freezing it. When grinding the meat, if you use warm or soft meat, it tends to be mashed through the grinding plates, turn mushy and lose all of the juice in the meat. You will also notice that once meat has been ground there is far more surface area for bacteria to develop, which is another good reason to keep it cold.

Grinding The Meat

Make sure that you cut your meat to fit the size of your grinder ‘funnel’. Then refrigerate the cubed meat. Get the grinder and dishes for the ground meat setup on your work surface. Take the meat out of the refrigerator and grind, working as quickly as possible. Cover the ground meat and return to the refrigerator or freezer, to chill down again.

Stuffing and Grinding

Adding Of Spices And Flavorings

We use two different methods of adding spices to the sausage:

Spice It Up First

Adding the spices to the cubed meat before grinding. This way when you grind the meat the spices are evenly distributed throughout the meat. If using this method we like to add the spices to the cubed meat the night before your grind. This allows more of the flavors to work their way into the meat.

Grind First Spice Later

Adding the spices to the ground meat. You must be careful when using this method that you mix the spices thoroughly into the ground meat. The trick is not to compact the meat together too tightly when you do this. Again, keeping the ground meat very cold prior to adding the spices makes a big difference.

Put the meat back into the refrigerator once you have finished adding the spices.

Spice later and Spice it up before you grind

Stuffing The Casings

Follow the instructions for Preparing Casings for Stuffing depending on which casings you are using.

After flushing the casings we like to keep them in a bowl of warm water next to the sausage stuffer. The warm water keeps the casing lubricated when you feed it onto the stuffing horn. Select the stuffing horn that is best suited to the thickness of the casing you are using. Find the end of a casing and slip this over the end of the stuffing horn. Push the casing over the stuffing horn towards the sausage stuffer, so that it forms an accordion-like pleat. Keep the casing wet throughout this process or it will not slide back on the stuffing horn very easily.

Leave some of the casing hanging over the horn. Start stuffing the sausage meat into the casing. You will need to regulate the flow of sausage into the casing, which will determine how tightly packed the sausage is. If you try and pack the sausage too tightly the casing will burst. If the casing does burst, tie it off at that point and start again. To regulate the flow of sausage hold the casing on the stuffing horn with your thumb and forefinger. Increasing or decreasing finger pressure on the casing will determine how tightly and consistently the sausage is packed.

As the sausage comes out of the stuffing horn, you can tie the ends at regular intervals or make links by twisting the sausage. Sausage like Boerewors is made in one continuous piece, which is coiled for storage.

Spice later and Spice it up before you grind

Click image for CLOSER LOOK

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Storing

After stuffing the sausage into the casings, we like to hang the sausage.

This allows the casings to dry properly as well as gives the flavors in the sausage time to develop. We turn the central air conditioning up full until the house gets really cold. Cover a broom handle with aluminum foil and straddle between two chairs. Hang the fresh sausage over the broom handle until the casings are dry. Make sure that the sausage stays cool, or bacteria will develop. If the sausage has a lot of liquid it will drip from the casings as they dry, so you may want to put something down on the floor to catch the drippings.

When freezing sausage, you should place the sausage in zip-up type plastic bags. Use a straw to suck out as much of the air as possible. Seal the bag and freeze the sausage quickly to lock in the flavor. We use a vacuum sealer for this purpose which works very well, and makes for an attractive presentation if you are dishing out sausage to your friends as gifts.

Beef

Beef, the meat of an adult (over 1 year) bovine, wasn't always as popular as it is today. America has had cattle since the mid-1500s, but most immigrants preferred either pork or chicken. Shortages of those two meats during the Civil War, however, suddenly made beef attractive and very much in demand.

Today's beef comes from cows (females that have borne at least one calf), steers (males castrated when very young), heifers (females that have never borne a calf) and bulls under 2 years old. Baby beef is the lean, tender but not too flavorful meat of a 7- to 10-month-old calf.

Grading

Meat packers can request and pay for their meat to be graded by the U.S. Department of Agriculture (USDA). The grading is based on three factors: conformation (the proportion of meat to bone), finish (proportion of fat to lean) and overall quality

Beginning with the best quality, the eight USDA grades for beef are Prime, Choice, Select, Standard, Commercial, Utility, Cutter and Canner. The meat's grade is stamped within a purple shield (a harmless vegetable dye is used for the ink) at regular intervals on the outside of each carcass. USDA Prime and the last three grades are rarely seen in retail outlets. Of all beef carcasses offered for quality grading in the U.S., 2% are graded U.S. Prime, 44% U.S. Choice, 27% U.S. Select. The remainder, about 27%, are not quality graded, and may be referred to in the industry as "No Roll" carcasses.

Young beef with the most marbling is given the Prime or highest quality grade. Prime is usually sold to restaurants, but may be available in some specialty markets. Choice is the most widely available grade in the retail market. Select has the least amount of marbling, but may not be as tender, juicy or flavorful as Prime or Choice. The lower-quality grades are generally only used for sausages and in cured and canned meats. Ideally, beef is at its best — both in flavor and texture — at 18 to 24 months. The meat at that age is an even rosy-red color. If the animal is over 2 1/2 years old it is usually classified as "well-matured beef" and, though more full-flavored, the meat begins to toughen and darken to a purplish red. Slow, moist-heat cooking, however, will make it perfectly delicious.

Storage

To store fresh beef:  If the meat will be cooked within 6 hours of purchase, it may be left in its plastic-wrapped package. Otherwise, remove the packaging and either store unwrapped in the refrigerator's meat compartment or wrap loosely with waxed paper and keep in the coldest part of the refrigerator for up to 2 days for ground beef, 3 days for other cuts. The object is to let the air circulate and keep the meat's surface somewhat dry, thereby inhibiting rapid bacterial growth. Cooked meat should be wrapped airtight and stored in the refrigerator. Ground beef can be frozen, wrapped airtight, for up to 3 months, solid cuts up to 6 months.

Aging

Aging is a natural process that improves primarily the tenderness, but also the flavor of beef, especially in cuts from the rib and loin (rib, ribeye, Porterhouse, T-Bone, top loin, sirloin and tenderloin steaks).

Aging allows the natural enzymes in beef to tenderize the meat by breaking down specific proteins (connective tissue) in muscle fibers; most of the tenderization occurs within the first 7 to 10 days of the aging process. The increase in tenderness after 7 to 10 days is relatively small compared to the increase during the first 7 to 10 days.

Two Types Of Aging Are Practiced Commercially: Dry And Wet Aging.

Dry Aging

- Dry aging is the process of placing an entire carcass or wholesale cut (without covering or packaging) in a refrigerated room (320 to 340F) under humidity controlled conditions for up to 28 days. Too much humidity allows excessive microbial growth; too little causes excessive shrinkage. If the temperature gets too high, microbial growth increases significantly. During properly controlled dry aging, beef usually loses moisture. The dry aging process also adds flavor to beef, often described as "brown-roasted beefy flavor." Today most dry aging is done by upscale steakhouses and specialty beef purveyors.

Wet aging

- Wet aging refers to the aging of beef in vacuum bags under refrigerated conditions of 320 to 340F. Humidity control is not necessary for wet aging as the beef is tightly sealed in the packaging. Because most beef is vacuum packaged at the site of carcass cutting, wet aging is the predominant method of aging used today. By the time the vacuum-packaged beef reaches the retail store, at least 7 to 10 days (the time needed for much of the tenderization to occur) have usually elapsed. However, additional tenderization will occur with longer aging. (Ideally rib and loin cuts should have a minimum of 14 days for aging; tender-loins a minimum of 7 days; sirloins a minimum of 21 days and preferably 28 days; and chucks and rounds a minimum of 7 days.)

Cuts

The first step in breaking the carcass is to separate it into primal cuts that can be handled more easily. The primal cuts correspond fairly closely to the units that a retail butcher might order from a wholesaler or abattoir. The primal cuts of beef are shown below. The separation of the forequarter and the hindquarter leaves only the last rib on the hindquarter.

Primal Cut	Retail Cuts	Retail Cuts
Chuck	Chuck Eye Roast Arm Pot Roast Cross Rib Pot Roast Blade Roast 7-Bone Pot Roast Flanken Style Ribs	Short Ribs Under Blade Pot Roast Mock Tender Boneless Shoulder Pot Roast Boneless Top Blade Steak
Rib	Rib Roast Large End Rib Roast Small End Rib Eye Roast	Back Ribs Rib Eye Steak Rib Steak Small End
Short Loin	Boneless Top Loin Steak Porterhouse Steak T-Bone Steak	Tenderloin Roast Tenderloin Steak New York Strip Steak
Sirloin	Sirloin Steak, Round Bone Sirloin Steak, Flat Bone	Top Sirloin Steak
Rump	Rump Steaks
Round	Round Steak Top Round Roast Boneless Rump Roast Tip Roast, Cap Off	Tip Steak Eye Round Roast Bottom Round Roast Top Round Steak
Flank	Flank Steak	Flank Steak Rolls
Short Plate	Skirt Steak
Brisket	Corned Brisket, Point Half Brisket, Flat Half	Brisket, Whole
Fore Shank	Shank Cross Cut

What Spice to use for BBQ

Spices are the basis for flavoring your barbecue. They are many and are everywhere in the world. In days of old they were a sign of wealth. They were traded, and the quest for them has spawned new nations and caused wars. Once you learn how to work with spices, you can make your own spice mixtures, to season your barbecue, and even serve at the table instead of or in addition to, salt and pepper.

Spice	Properties	Images
Arrowroot	An edible starch known as Arrowroot Powder. Used mainly as a thickening agent.
Basil	Also called sweet basil. With an aroma that is like mint and tea. Basil is available in leaf form. It is used as a seasoning for pizza, spaghetti sauce, sausage, soup, tomato juice, dressings, salads, and any dish where oregano would be used
Bay Leaves	They have a woody, astringent flavor with a pleasant, slightly minty aroma. Bay leaves should always be removed before food is served. Works well in soups, with meat and poultry dishes, pasta sauces, fish and is also used to flavor some desserts.
Black Pepper	Black pepper has a sharp, penetrating aroma and a characteristic woody, piney flavor. It is hot and biting to the taste.
Broiled Steak Seasoning	A unique blend of seasonings including black pepper, onion, garlic, paprika and celery seed. Especially good flavor with beef as well as pork and lamb.
Caraway (Seed)	With a tangy flavor similar to dill. It is used as a seasoning in potatoes, cabbage, carrots, sausages, rich meats, in breads and pastries. Caraway is available as the whole seed.
Cayenne (Red ) Pepper	A seasoning ground from small, red chili peppers. It has been used as a spice in the dishes of many countries and is also used as a table condiment. It's heat and spiciness varies.
Celery Seed (Salt)	Celery seed tastes like celery and is aromatic with a slight bitterness which enhances other flavors. Celery seed is available whole, ground, or mixed with salt. Celery salt is a blend of ground celery seed and fine salt. It is used primarily as a flavoring in salads (especially potato), sauces, pickling, soup, tomato juice, and meat. It is also an integral part of the flavoring of traditionally prepared crabs and other seafood.
Chervil	An essential spice in French cuisine, it used like parsley and provides an herbal taste with the slight flavor of anise. Chervil is used much like parsley, but is more delicate. It is most commonly used on fish, egg dishes, salads and as a glaze on vegetables such as carrots.
Chili Powder	Made from dried chilies, usually blended with garlic, onion, cumin, oregano, chili peppers, allspice, garlic, and salt. Color and spiciness varies. It has an earthy, slightly sweet, and sometimes hot flavor. This spice blend usually dominates food rather than enhancing it. Mexican and other Latin American dishes depend on chili powder for their characteristic flavor
Chinese 5 Spice Powder	A blend of star anise, fagara (Szechwan pepper), cassia (cinnamon), fennel and clove. It is heavily used in Chinese and Vietnamese cuisine.
Cilantro	Cilantro has a bold flavor often described as a mixture of sage, parsley, and citrus. In Mexican dishes and salsas, cilantro is the "indescribable" flavor note that sets them apart. Cilantro adds pungent flavor to many Latin American and Asian dishes such as stews, soup, steamed fish, curries, vegetables, , salads, relishes and tomato based sauces, and noodle dishes. It is often called "Chinese parsley."
Cinnamon	Cinnamon has a characteristic woody, musty, earthy, and sweet flavor. It is warming to taste. It is available whole, as cinnamon sticks, and ground. Used in spiced vegetable dishes, also in sweet dishes such as baking, pies, compotes, and also with meats, stews, vegetables and curries.
Cloves	The flavor of cloves is strong, fruity, and sweet almost hot. Cloves are available both whole and ground. Used for flavoring ham, pork, pickled fruit, onions, gravy, and syrup, spice cake, pumpkin pie, fruitcake, gingerbread, chili sauce, ketchup, and in combination with many other spices.
Coriander	Coriander has a sweet, slightly lemony flavor. (Coriander leaves are called cilantro.) Coriander is available as whole seed and ground and is a principal ingredient in curry powder. Middle Eastern, Indian, Russian, North African, and Mexican recipes include coriander for its distinctive flavor. Coriander seed is a pleasant addition to potato salad, rice's, bean, vegetable dishes, hot dogs, apple pie, poached fish, or bean, pea, and lentil soup.
Creole Spice	A blend of garlic, onion, cayenne, black pepper, thyme, oregano, paprika.
Cuban Spice	A blend of cumin, chili powder, cinnamon
Cumin	Cumin has a penetrating musty, earthy flavor with some green, grassy nuances. Cumin is available as whole seed and ground. It is a principal ingredient in both chili powder and curry powder. Middle Eastern, Mexican Indian, and North African recipes often include cumin. Also used in curries, stews, and chili./td>
Curry Powder	Not a single spice but a blend of many spices. Usually contains turmeric, ginger, black pepper, coriander, cumin, chilies and fenugreek and can also contain cinnamon and clove. Flavors vary according to the use or the creator of the blend. All curry blends have a rich, warm, earthy, and pungent flavor with a great many overtones. The characteristic golden color comes from turmeric. Curry powder is available in mild or hot blends. Curry powder is usually intended to be the dominant flavor but it also may be used in small amounts simply to enhance the flavor of foods such as corn bread, stuffed eggs, soup, and sour cream dips.
Dill	Dill is an annual of the parsley family and is related to anise, caraway, coriander, cumin, and fennel. The seeds are light brown in color, strongly aromatic, and warming to the taste. Dill weed has a subtle, anise like, sweet flavor. Dill is available as the whole seed and as chopped leaves, called dill weed. Dill weed is used in salads, sauces, egg dishes, and especially in seafood dishes. Dill seed is used primarily to flavor pickles and in bread, potato, and vegetable dishes. It works well with a variety of culinary dishes such as omelets, soups, stuffed grape leaves, potato salad, cucumber, veal, breads, cabbage, meat stews and rice. It is also widely used with herring, salmon and other seafood dishes.
English Pickling Spice	A blend of mustard seed, coriander, allspice, red chilies, bay leaves, ginger.
Fenugreek	Has a bitter, maple-like flavor. It is primarily used in Indian cuisine and is also used with curry, as a pickling spice and as imitation maple.
Fil'e Gumbo	A blend of dried ground sassafras leaves and thyme. It is used as a thickener in and with soups, gumbo, meat, fish, stew and poultry.
Four-Pepper Mix	A blend of black pepper, white pepper, rose pepper and green peppercorns, coarsely crushed.
Garlic (Powder, Salt)	It has a strong, pungent green flavor and is one of the most popular seasonings used today. Garlic can be conveniently purchased as fresh bulbs, dehydrated powder, minced flakes, and blends with salt. It adds flavor to almost any dish. Garlic is especially popular in Italian cuisine and throughout the Mediterranean region and Asia. Sprinkle to taste on hamburgers, lamb, chuck roast, steak, chicken, Italian green beans, zucchini, tomatoes and green salads. Use with sour cream or cream cheese for dips. Sprinkle on stuffed eggs. Use it sparingly to begin with and add small amounts until it suits your taste.
Ginger	The flavor of ginger is pungent, lemon/citrus, warm, and sweet. Ginger is available ground, whole (gingerroot), and crystallized. Used to add zest to many dishes such as gingersnaps, gingerbread, in Asian dishes and in sweets such as cakes, cookies, puddings, pumpkin pie and sweet breads.
Herbs De Province	A Mediterranean blend containing oregano, savory, rosemary, thyme and marjoram, use to flavor stews, chicken, kabobs and tomato dishes and pizza.
Italian Seasoning	A blend of marjoram, thyme, rosemary, savory, sage, oregano and basil. Add to dip, herb breads, any tomato dish, good in marinades and rubs.
Jamaican Jerk	Ground chilies, accented heavily with thyme and allspice. Used as a spicy flavoring to meats and vegetables.
Juniper Berries	Aromatic and spicy with the slight flavor of pine. It is mostly used a spice for meats in marinades, on roasts and in sausage mixes.
Kosher Salt	A course ground salt, with no chemicals added. Used in brines, rubs, and marinades. Also used to coat the rim of the glass for Margaritas!
Marjoram	Marjoram has a distinctly aromatic green and pleasant woody flavor, with a slightly bitter undertone. Available in both leaf and ground forms, marjoram should be used sparingly at first. It complements the flavor of chicken and turkey stuffing, vegetable and bean soup, as well as tomato sauces. Marjoram also enhances the flavor of many meat dishes.
Mexican Hot Chili Powder	A blend of spices and chili pepper, is a U.S. invention. Similar blends were used by the Aztecs. It is usually used to dominate the flavor of a food but can be used as a background flavor. Use in Mexican dishes such as chili, tacos and enchiladas. Add to quacamole, dips and salad dressings.
Mexican Spice	A blend of cinnamon, cloves, black pepper, coriander seeds, aniseed, cumin, chili powder.
Moroccan Spice	A blend of saffron, cumin, ginger, paprika, cinnamon.
Mustard (Seed, Ground)	Mustard has a clean, fresh aroma and a pungent, biting flavor. Ground mustard enhances meat, fish, poultry, sauces, salad dressings, cheese, and egg dishes. It must be moistened for about ten minutes to develop its sharp, hot, tangy flavor. The whole seed is used in pickling, boiled with beets, cabbage, or sauerkraut, and as a garnish for salads.
North African Spice	A blend of cumin and cinnamon.
Nutmeg & Mace	Nutmeg has a strong cinnamon, nutty flavor used to flavor sweets, fruit dishes, sauces and vegetables. Nutmeg is available both whole and ground. Mace is sold primarily in the ground form. Nutmeg and mace are most commonly used in flavoring sweet foods such as puddings, cakes, and cookies. They are also used in meat products such as sausage. Mace is the lacy covering of the Nutmeg which is the seed of the fruit.
Onion (Flakes, Powder, Salt)	Onions are an important flavoring in almost every country in the world. When combined with other ingredients, onion flavor is rarely overwhelming or assertive. Onions, pungent when raw and sweet in flavor when cooked, are an extremely versatile flavoring and can be used to accent nearly any kind of dish.
Oregano	Similar in flavor to marjoram, it is not as sweet and is slightly more pungent and bitter. Use oregano in your favorite ethnic dishes as well as in fresh garden salads, egg dishes, quick breads, rubs, and sauces.
Paprika	The brilliant red powder is the "garnish spice" contributing color and sweet pepper flavor. Hungarian paprika is characterized by a hotter taste, achieved in recent times by adding hot, red capsicum pepper to ground paprika. Sold in ground form. Used as a garnish for light-colored food such as fish, potatoes, eggs, and cheese dishes. A popular addition to many rubs, marinades and sauces. It is the principal seasoning in Hungarian goulash and often is used in French dressing. To retain its red color, paprika should be kept in the refrigerator.
Parsley	Parsley has a slightly mild green taste. Parsley is available fresh or as dried flakes. It adds both flavor and visual appeal to salads, soup, pasta, butters, shellfish, meat, poultry, sauces, potatoes, omelets and soft cheeses.
Poultry Seasoning	A mixture of ground thyme, sage, marjoram, rosemary, black pepper, and nutmeg. Poultry seasoning was created mainly to season stuffing but it also adds an unusual flavor to all poultry, pork, or veal dishes.
Rosemary	Rosemary has a distinctive fresh, sweet, piney aroma and flavor. Rosemary is available in leaf form. Use with lamb, pork, potatoes, carrots, stews, sauces, marinades, fish, poultry, bread, on grilled or skewered meat and in roasted potato dishes.
Sage	Comes in whole, rubbed (crushed) and ground form. The herb is distinctively aromatic and fragrant with slightly medicinal, piney, and bitter flavors. It is used to flavor pork, pork sausage, poultry stuffing, veal, stuffing, and tomato sauces.
Savory	Available in ground form and gives a piquant flavor to many dishes. It has a strong, slightly peppery flavor and is used to flavor legumes, meat, fish (especially trout), sausage, stuffing, tomato sauces, bean soup, meat loaf, hamburgers, eggs, or poultry.
Southwestern	A sweet/spicy blend of cinnamon, cumin, cloves, cayenne.
Szechwan Peppers	Not a true pepper but a dried berry of a prickly ash tree. It has a woody aroma with a spicy, tingly taste. It is an essential ingredient in Chinese 5 Spice.
Tarragon	It is rich and sweet with a faint anise-like flavor. It is an excellent seasoning for sauces, dressings, and with meat, poultry and fish.
Thyme	It has a pungent and sweetly herbal fragrant. It can be used to improve the flavor of most dishes, especially slow cooked dishes.
Turbinado Sugar	Also known as "Sugar in the Raw". Used in many rubs and sauces because it can take higher temperatures without carmelizing.
White Pepper	A blend of whole and broken spices, herbs and seeds. In it you find cinnamon, allspice, mustard seed, coriander, bay leaves, ginger, chilies, black pepper, mace and cardamom. Used by some as a rub.