01 Basic formula of round pork cake
Raw material
Pig hind leg meat, pig fat, konjac flour, wheat fiber, salt, white sugar, crystal sugar, monascus red, pork extract, sodium caseinate, natural spices.
Formula of round pork cake
(Based on pork, other auxiliary materials are calculated by their mass proportions): pork 100%, sugar 18%, crystal sugar 10%, sodium caseinate 0.8%, salt 2%, monascus red 0.01%, fat 12%, konjac flour 1.2%, wheat fiber 2.5% and pork extract 0.5%.
equipment
Meat grinder, mixing type sandwich pot, enema molding machine, mixer, infrared drying box, rapid moisture analyzer, metal detector, vacuum packaging machine, oven, sterilizer, blow dryer, cold storage, etc.
process flow
Acceptance of frozen pig hind leg meat → thawing → segmentation → minced meat → marinating with various auxiliary materials → molding with upper mold → drying → metal detection → smoking (curing) → cooling → vacuum packaging → sterilization → drying → finished product.
02 Key points of operation
(1) Acceptance of raw materials
The purchase of frozen pork for processing, each batch of raw materials must be quarantined before receiving. The sensory inspection items mainly include color, viscosity, elasticity and smell. For details, please refer to the relevant requirements in the Operating Rules for the Acquisition and Segmentation of Raw Meat.
(2) Thawing
Remove the frozen pork from the carton and put it into the thawing room for thawing. The temperature of the thawing room shall be as follows. In winter (temperature < 20℃), it is thawed at room temperature, and the thawing time is controlled within 16 ~ 20h. Thawing in summer (air temperature ≥0℃) under the condition of air conditioning (below 18℃), the thawing time is controlled within 12 ~ 16h, and the thawing time is adjusted or shortened if necessary.
(3) segmentation
When cutting, the broken bones, large oil tendons, membranes, etc. of the meat block are cut clean, and the meat block is cut into lkg size, which is beneficial for the meat grinder to grind the meat.
(4) ground meat
Water must be drained before the raw meat is ground (to avoid affecting the weight fluctuation of each piece of meat after drying), and the meat is ground into uniform coarse particles by using a meat grinder with an aperture of 8mm for later use.
(5) mixing and pickling
First, pour in 15kg of processed raw meat, add a small amount of corresponding ingredients evenly for many times, use a small amount of water to dissolve pigment and liquid ingredients (try to control the amount of water added, and add no more than 150g of water to each ingredient), and add evenly mixed powder when stirring, with a total stirring time of 12 ~ 15 min. After mixing, the temperature should be controlled below 15℃. After the mixed raw meat is put into a container, cover the plastic film and marinate it in a cold storage at 3-10℃ for 12-18h.
(6) upper die forming
Pouring the pickled stuffing into an enema molding machine, and quantifying 40g／/tablet (actual weight is 40-45g/tablet); Fasten the quantitative stuffing on the plate (arranged regularly), and check whether the formed patty has curled edges, overlapping pieces or unformed pieces.
(7) drying
The drying temperature is 55-60℃ and the drying time is 4-5h. After the first baking for 2 hours, the surface is dry and does not stick to the hands, and the flanging can be performed. After flanging, the position of the upper and lower parts of the frame is changed. The second drying time is 2 ~ 3h. During the drying process, the moisture content or the weight of the single piece is often detected, and it meets the requirements and is discharged from the furnace in batches for cooling. The moisture content of the dried meat pie should be within the standard range, 30-36g／/piece.
(8) metal detection
The metal detector must be tested for efficiency before each use and once every hour when working. After drying and cooling, the products are detected by metal detectors, and then loaded and weighed for identification.
(9) Smoking (curing)
Place the patties neatly on the stainless steel wire mesh, which should not overlap or be placed too closely to prevent inconsistent curing degree. Move the stainless steel wire mesh with good materials into the smoking furnace. Set the first step: the smoking temperature is 70℃ and the smoking time is 8min. Step 2: The cooking temperature is 100% and the cooking time is 8min. Step 3: Baking temperature is 120℃ and baking time is 1 5min. The surface of the cooked meat pie is oily and bright, and the color of both sides is the same. The moisture content after smoking and baking is 25% ~ 28%.
(1O) cooling
Push the dried meat pie into a sterile cooling room for cooling.
(11) vacuum packaging
Plastic in time after curing. Plastic requirements: no focus, no burnt edge and consistent color. After finishing, carry out vacuum packaging as required in time. The sealing line of vacuum sealing must be flat and free of wrinkles, pinholes and air leakage. The sealing strength should be checked frequently during the sealing process, and the unqualified products should be reworked in time.
(12) sterilization
The qualified sealed products must be sterilized in lh. During sterilization, the water temperature is raised to 60℃, and a proper amount of patties (subject to easy turning) are poured into the jacketed pot, and the water temperature is raised to 85℃ in 5 minutes, and the temperature is kept at 85 ~ 90℃ for 30 minutes. When sterilizing, it must be turned up and down every 5 minutes, and the temperature should be detected and recorded.
(13) blow dry
After sterilization, it is cooled in cooling water to below 40℃, and the unqualified products are removed, dried by a blow dryer, marked and handed over to the next working procedure after meeting the requirements.
(14) packaging
In the workshop with good hygiene, the patties are packaged into large and small packages, the batches are distinguished, and there are clear identification cards. The small packaged products are packaged according to the required product specifications, the net content is satisfied, the seal is flat, and the date is clear and definite. After the packaging is completed, the quality control department conducts sampling inspection, and after passing the inspection, it is put into storage to form the finished product.
