Malabar Reference - Troubleshooting Guide

Problem

Possible Cause

Slow Fermentation

Frozen culture allowed to thaw and subsequently held too long before dispensing into meat.

Microorganisms exhaust nutrients in can reduce pH, lowering culture "activity".

Environmental temperatures/humidity (min. 80%) during fermentation inconsistent with recommended culture optimum.

Secondary growth in meat of contaminant microorganism producing end product that buffers pH drop.

Laydown procedure at cold temperature resulting in extended lag phase at beginning of fermentation cycle.

Cheese in product may contain phosphate which buffers pH drop; also has tendency to absorb moisture from surrounding meat, particular to processed cheese due to phosphate ingredient: High sugar content.

Sausage entering smokehouse colder than normal, i.e. using frozen meat.

Spice formulation adjustment that either decreases acid stimulation or inhibits culture.

Excessive salt or cure addition.

Culture contact directly with curing components.

High fat formulation, reducing moisture content.

Larger diameter product, slower heat transfer.

Rapid moisture loss in product.

Fast Fermentation

Temperature/humidity higher than normal.

Spice formulation adjustment flavouring culture, (Black Pepper)

Excessive water addition.

Product delayed prior to entering house, resulting in higher initial temperature/more time

Leaner product, i.e. more moisture.

Pork containing product.

Smaller diameter product processed at higher humidity. Keep high humidity as smaller sausages dry out faster.

Initial meat pH lower than normal.

Inconsistent Fermentation

Inadequate culture distribution, resulting in "hot" and "cold" spots in meat mixture.

Inadequate distribution of salt, cure, spices dextrose.

Laydown procedure that causes some "Batter" to dry out.

Diverse initial product temperatures.

"Laid down" product and directly processed product in same smokehouse; culture "acclimation" in laid down product resulting in faster fermentation.

Product with different spice formulations, meat components, casing diameters.

Uneven temperature/humidity in fermentation chamber.

Uneven humidity in dry room causing different drying rates.

Too low pH

Failure to monitor fermentation.

Excessive carbohydrate source.

No Fermentation

Culture not added.

Culture inactivated by direct contact with salt, cure, components, or heavily chlorinated diluent water.

Non-compliance with recommended handling temperatures after thawing.

Insufficient carbohydrate added to sausage mixture.

Excessive salt content.

Antibacterial agents added to meat mixture (i.e. preservatives, chemical boiler treatments via steam, antibiotics in meat).

"Mushy" Product

Over-working at mixer, chopper or grinder.

Excessive fat content.

Insufficient salt level or no salt added.

Spoiled raw materials.

Proteolytic microbial contaminates.

Insufficient moisture loss excessive humidity.

Excessive air speed and/or too low a humidity, "sealing" surface pores. No moisture migration from product.

Excessive smoke initially that coagulates surface proteins, retarding moisture migration.

Souring of Product, Post-processing

Insufficient heat treatment to destroy microorganisms, Post-processing residual post-processing carbohydrates in excess that permits secondary fermentation.

Excessive moisture and residual carbohydrates in non-cooked product.

Insufficient drying.

Temperature abuse post-packaging.

Microbial contaminant either growing during fermentation or post-packaging.

Use of spoiled raw meat materials.

Poor sanitation post-processing.

Chemical contaminant.

Slimy, Gassy Product

Yeast or heterolactic contamination in packaging post processing.

Excessive moisture content.

Inadequate smoke concentration at product surface (i.e. semi-dry products).

Green or Grey Colouration

Insufficient cure level or heat.

Oxidation of meat pigments via microbial contaminant, Metal contaminants.

Exposure to sunlight.

High pH.

Excessive Mould Growth

Excessive heating rate.

Excessive fermentation temperature.

Unstable meat mix, low-binding meats.

Overworked raw meat mix.

Case Hardening

Product is being dried too quickly in the initial stages of fermentation causing a ring of dry meat next to the casing. This ring does not allow the internal mass of meat to dry, as moisture cannot permeate the dry ring. The solution is to raise the humidity up to 93-95% in extreme cases or simply to 80% to correct the problem.

Extreme case hardening might necessitate cooking the product and sale as a distressed product.

Fermentation Failure

Culture solution not added.

Insufficient sugar addition

Culture solution added too soon on top of salt and/or cure.

Culture solution allowed to sit too long at room temperature.

Outdates Culture

Culture allowed to thaw too long

Culture added to wine (this happened)

Antibiotics in meat

Too long a lag time from emulsion to smokehouse or fermentation room

Product Does Not Dry

Poor fermentation

Improper drying room R.H.

Meats over worked to form an emulsion.

Questions? Contact our technical specialists
@ 1-888-456-6252, or at lab@malabarsuperspice.com.
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