Sausage is everything
High performance, precise processes, absolute weight accuracy and reliable machine technology – these are the central requirements for a sausage production line. Vemag Maschinenbau offers the corresponding solutions for processes ranging from filling to depositing – the company sees itself as a one-stop shop.
Producers of linked sausage products currently face new challenges. In a highly competitive field, they must differentiate themselves from others by promoting their product range and product ideas. Everything revolves around a company’s own sausage products and their characteristics as opposed to the competition’s. At one time, product adaptations were sufficient to provide more variation. Today, however, completely new ideas are needed for the many types of products available on the market. Trend and snack products as well as changed eating habits are expanding the target group of end consumers. Manufacturers want to retain their customers over the long run and extend and expand their range of retail products.
To master such tasks, production technology must provide maximum flexibility and all necessary expansion options. Sausage lines from Vemag meet this requirement and can be converted into all-rounders through simple adjustment and re-tooling.
With a flexible and modular range of machines and attachments, users can expand their product portfolio at any time, from wieners to modern raw sausage snacks, or to sausages in alginate casings. Vemag is a single-source provider of the optimal technical equipment required for filling, mincing, separating, casing mounting and changing, as well as for portioning and linking, separating, depositing or hanging.
Filling plays an important role in sausage production. Parameters such as geometry, component size and function influence essential product features – from the hopper to the outlet. Vemag solutions are precisely adapted to the properties of the desired product. Weight-accurate products and a measurable reduction of product leftovers save the user valuable resources and costs.
Continuous product intake, constant vacuum performance and gentle product transport ensure the perfect feed to all high-quality downstream attachments and automated line modules. Vacuum fillers transport raw materials with great care, over the shortest possible distance and with a short dwell time. This prevents air inclusions and smearing, minimizes residual material and guarantees hygiene.
The company has designed its fillers to cover both the SME and the industrial sectors. While the Robby and DP series are constructed for SMEs, the HPE and DPE fillers target industrial producers. Depending on how much power and output an application requires, any machine in this series can be used as a filler. Because raw sausage applications must process cold, solid masses, machines such as the Vemag HP20E and the HP30E, which combine power and output, are required.
A highly efficient extension of the filling machine is the filler-grinder technology for direct grinding and separating during the filling process. Combining these two technologies has many advantages that significantly improve the quality, appearance and mouthfeel of the end-product, not only of raw sausage, but also of fresh bratwurst.
The unique selling point of this innovative solution is the inline flow of the product through the knives and perforated discs of the grinder attachment, as direct product flow prevents dead spaces and transport losses.
Because meat is reduced to its final grain size during the filling and grinding process, sensitive raw sausages are handled very gently, right until the casing procedure. The meat particle structure is exceptionally regular; the system guarantees clear cutting with clean separation of lean and greasy particles and no smearing. This also supports the even ripening process and prevents dry edges, which of course guarantees the perfect presentation of a quality raw sausage.
The Separation grinder982 can be combined with the HP20E and HP30E for the filling-grinding process. This filling-grinding technology can be supplemented by a separator, which removes undesirable particles such as cartilage or bone splinters before the emulsion is filled into the sausage casing, resulting in a flawless end product.
For reliable and consistent separation, Vemag offers a new type of blade set for particularly economical and effective separation of solid particles and undesirable components. An independent scientific study demonstrated that the Separation grinder982 in combination with the Separator813 achieves considerably improved separation results due to its newly developed separating blade. This device reduces undesired throwaway of red meat by up to 60 percent, giving the operator certainty that only cartilage, gristle and sinew are reliably sorted out.
Simple, fast casing changes reduce downtime and contribute to increased productivity. When loading and changing casings, the Vemag gripper fully controls and stabilizes casing handling, optimally positioning the casing on the linking horn. This prevents incorrect loading or kinking. In addition, an integrated casing pusher supports the linking function and ensures even and gentle advance of the linking horn, ensuring precisely linked sausages. The company’s length portioners (LPG) meet all requirements in this respect:
- The LPG208 servo with twin head and optional casing slider is the specialist for linking natural, collagen or artificial casings and ensures absolute length and weight accuracy.
- The LPG209 features a fully automated casing magazine and twin head with two identical linking horns. It rapidly changes collagen, cellulose and polyamide casing sticks.
- The LPG218 is predestined for hot dog production. It automatically processes artificial, polyamide and collagen casings and convinces with superb length and weight accuracy and an above-average production speed of up to 2,200 portions per minute, depending on the portion length.
For its FSL211 Flexible Sausage Line, Vemag offers an attachment for smaller batches and SMEs. The flexible device provides length-accurate portioning and linking of sausages in natural, collagen and cellulose casings. Its small footprint enables connections to any vacuum filler in a company, even in confined spaces.
The TM203 cutting machine is reliability in person. It perfectly synchronizes the belt systems that extend the linking point, and thanks to sensor technology, always cuts precisely in the middle. Thus divided, the sausage portions are easily guided to automated downstream solutions, always under full control of the operator.
Divided fresh sausages are automatically grouped and placed in trays by the LinkLoader LL335 and sent to the subsequent process. Because there are neither manual intervention nor product jams, products have no pressure marks that can be caused by manual handling. Automation also ensures a high standard of hygiene.
If sausages are not meant to be separated but subsequently thermally treated or matured, the AH212 hanging machine is used. It automatically hangs sausage chains and allows easy removal with the smoke stick. The controller is placed directly over the filling machine.
Vemag’s CC215 attachment is a flexible solution for producing sausages in alginate casings. Alginate enables the production of “pure” products, such as halal or poultry sausages. Sheep or hog casings are no longer required. It also enables the production of purely vegetarian sausages, which can open new markets.
The SmartLink4.0 software solution is an operating and product-data acquisition system for Vemag production lines that precisely evaluates production data. It bundles all internal machine parameters and documents production. The operator can see at a glance which process step is currently running. The current line performance, weight statistics, production status and pressure curve, for example at the filler grinder, as well as other relevant information can be read out, compared and evaluated. The SmartLink4.0 identifies weak points or deviations as well as optimization potential. As a result, resources and production equipment can be more efficiently employed and ultimately, production costs reduced.