Lab 2 Energy and Sausage.pdf

Food Engineering Lab 1: Energy and Sausage Making January 25, 2010
The food industry uses a tremendous amount of energy in processing and
transportation, and generates a large amount of waste. With rising costs of energy
sources and technologies for mediating pollutants, the food industries are paying
greater attention to finding cheaper energy sources, switching to renewable low‐
cost alternatives, and improving process efficiencies.
In this lab, we will take a look at a few of the energy costs of sausage manufacturing.
From the Food and Agriculture Organization of the United Nations handbook on
Small Scale Sausage Production:
“There are some common requirements determining the layout of a sausage plant.
Doubtlessly, the basic requirement is that the raw materials should enter at one end
of the building and the sausage products, either chilled or unchilled, leave at the
opposite end. The arrangement should be that the meat and products move in one
direction without any risk of contamination. The operators are placed along the
tables and machines and they move the raw materials and sausages in the necessary
direction.
Normally, a sausage plant begins with a receiving and chilling section. When the
meats reach the plant by truck, provision has to be made for an off loading ramp.
There should be a direct and unobstructed entrance from the receiving area to the
chillroom and main processing room. The operation of receipt, weighing and storage
of meats should be carried out in a refrigerated room adjacent to the main
workroom. Where output permits, nonmeat raw materials (casings, spices,
packaging materials etc.) should be dealt with separately in order to ensure a good
hygienic standard.
Effort should be made to provide refrigeration in the cutting and trimming room.
The deboning and trimming operations should be performed on special tables in a
clean and controlled atmosphere. The deboning of hot carcasses should have
priority.
All grinding, chopping, stuffing, linking and other processing operations have to be
organized in a separate room. The type and extent of equipment required for
comminuting meat and stuffing sausages depend upon the variety and volume of the
operations. For operations of any magnitude, equipment such as an ice crusher or ice
generator, knife grinder, frozen meat slicer etc. is advisable.
The meat, after being trimmed, graded, chopped and mixed with nonmeat
ingredients, is conveyed from the cutter to the stuffer for filling into casings and then
the sausages, hung on smoke rods, are carried from the meat chopping and mixing
area to the smoking and cooking facilities. Any sausage manufacturing line
terminates in the smokehouse and cooker, where the necessary trucks, cages and
other accessories are available. The size of the smokehouse and boiler will depend
upon the factory throughput. Adequate provisions should be made even in the
smallest plant for weighing, grading, storing and distribution of final products.”

Food Engineering Lab 1: Energy and Sausage Making January 25, 2010
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Food Engineering Lab 1: Energy and Sausage Making January 25, 2010
We will be making a Bratwurst sausage from pork and spices. The formula:
The general process is :
Pork 70% lean 20 lbs
Black pepper 5.66 g
Sage 3.96 g
Ginger 2.83 g
White pepper 2.26 g
Corriander 0.79 g
Nutmeg 0.79 g
Ground celery seed 0.68 g
Carroway 0.68 g
Cardamon 0.68 g
Savory summer 0.28 g

Food Engineering Lab 1: Energy and Sausage Making January 25, 2010
In addition to making sausage, we will be measuring energy use in the processing
rooms and unit operations. Our three major tools will be:
1. Power meters: for processes that rely on motors or other electrical input
(mixers, choppers, conveyors, packaging machines) we will assess power use
from measurement of the current (I) and voltage (V) delivered over the time
of the operation. The equipment is plugged into a board from which we
record both. The total power is given by
Power = I V t
This is only strictly true for DC circuits. Measuring AC power is much more
complicated. As the current and voltage oscillate, and may even be out of
phase, one needs to calculate the root‐mean‐square (RMS) voltage and
current. The real power is given by P = (Power factor)(Apparent power).
We’ll disregard the roll of power factor for our estimate of power.
2. Steam flow meters: a common means of measuring flow is the variable‐area
meter, in which a tube with variable area contains a float that moves upward.
Fluid causes the float to rise. As it moves up, more area is exposed around
the float, and fluid can move around the float. At some point, a dynamic
equilibrium is reached between the upward pressure difference and
buoyancy, countered by the downward force of gravity on the float. The
height of the flow measures the flow rate.

Food Engineering Lab 1: Energy and Sausage Making January 25, 2010
We will also get an estimate of power consumption in the cold room. The power
requirements of the lights will be estimated by counting the number of lights and
multiplying by the bulb wattage.
TO DO:
The sausage production will be demonstrated in the lab. Meters will be provided to
determine electric and steam consumption. The class will be divided into groups,
with each group assigned a task.
Group 1: Cut and trim meat. Measure electrical consumption of devices with
motors.
Group 2: Measure out dry ingredients. Package representative samples. Count
lights in processing room and determine bulb wattage.
Group 3: Operate bowl chopper and stuffer. Measure steam use.
Group 4: Cook meat by steam. Determine going costs for steam and electricity.
REPORT:
1. Make a table of the energy use for the following parts of the process: (1)
cooling room, (2) bowl chopper, (3) stuffer, (4) steam cooker, (5) packaging
machine, (6) electrical lights, and any other sources of energy use we
determined. Also estimate the total costs for each operation.
2. Determine the ingredient total costs per pound of the product.
3. Estimate the total costs per pound of product
4. Make a pie chart of the relative contributions of ingredients and each of the
energy costs to the product costs.
Questions:
1. What was the most energy intensive part of the process?
2. Were there any parts of the process where we might have saved on energy
use? If so, which parts?