The Sausage Factory

[IronNoggin]

The Sausage Factory


This is an excellent example of the Student FAR surpassing the teacher.


Many years ago a Buddy, both an excellent fishing guide & deadly cook, asked me if I would show him the ropes for making sausage. At that time my partner & I were producing several hundred pounds a year, so I simply said Sure, Come On Down. He caught on very quickly, and asked the odd piece of advice over the next year or so...


Then after a few more years he went to work in a butcher shop specializing in sausages and more.
Leap forward another few years, and now with one hell of a lot of experience under his belt. he began to build and outfit his own custom butchering and sausage making shop. That was around 5 years ago, and he has been hounding me since to come down and have a boo. Unfortunately until now I was unable to do so. But this year he basically demanded I show up, bring down some meat and my Polish Hunter Sausage recipe, noting he was willing to make that plus whatever else I wanted. How could I say no?


So I saddled up and made the run down there with the meat in tow. Been a spell since we had seen each other, and it was really great to do so once again! After a little BS'ing, we got down to the task at hand.


Here is Roy running the first batch (Hunter Sausage) through his massive meat grinder. I swear you could drop a whole cow into that and see it done within minutes!


https://i.imgur.com/RdTay3Y.jpg


The Beast:


https://i.imgur.com/PleYvrH.jpg


A better shot showing more of the shop:


https://i.imgur.com/4VOJ7J7.jpg


From there the ground meat goes into the mixer (another Beast!) along with the spices, binder & ice water. That machine made extremely fast work of a job I always dreaded (doing it by freezing hands):


https://i.imgur.com/lfKwlxS.jpg


Once it reaches the right consistency, the product goes into the Hydraulic Stuffer (which can take up to 60 pounds!) and is shot into the casings. Smoothest way I have ever seen that done:


https://i.imgur.com/qVr8bkZ.jpg

Continued...

[IronNoggin]

Then racked and off to the Smoker:


https://i.imgur.com/RwRhSRC.jpg


Roy's smoker is huge (the Man never does anything in a small way!). You can see the external firebox to the left behind him. That gets filled with alder chunks and fired up once the smoker has reached the correct internal temperature.


https://i.imgur.com/ATCcAXT.jpg


The amount of smoke that produces it literally mind blowing! So much so that the smoking time is not a heck of a lot more than an hour!


https://i.imgur.com/dZBxTti.jpg


The product turns out damned amazing!


https://i.imgur.com/4hOewpj.jpg


Then it goes into a hot water bath to bring the internal temp up to snuff:


https://i.imgur.com/jHDE8f4.jpg

[IronNoggin]

Once that temperature is realized, it goes into an ice water bath to instantly cool it down. Then onto racks to hang overnight to bloom. Forgot to take pix of those last two steps, but methinks you can visualize what I am getting at.


We then ran 40 pounds of brats through the process, and wrapped all of those before having a couple celebratory rums. Then up to the house for din-din. Roy bar-beed some wonderful moose burgers, topped with onion, cheese and fancy mushrooms, accompanied by home made fries and a fresh garden salad! Awesome hospitality, and of course awesome food!


https://i.imgur.com/so3IQ6A.jpg

[IronNoggin]

Although Roy has one of the best chamber vacuum sealers going, I declined his generous offer to wrap all my smoked product. I knew this was coming, and had stocked up on a lot of rolls for my machine at home. So we chatted a spell over coffee before loading up my stuff. He did note that he rather liked the Polish Hunter Sausage (it is very unique and indeed excellent), so I left him with a coil and a half of that to enjoy.
I thanked him profusely, and then bade the Man a fond farewell noting I may well make this an annual trip!!


The run home was uneventful despite it being a long weekend.
But the truck certainly smelled Wonderful all the way home & still does!
Made it back in record time, and set up to put the product to bed.


Jalipino / Cheddar Smokies:


https://i.imgur.com/rcyTg43.jpg


https://i.imgur.com/0FLUBMe.jpg


Polish Hunter Sausage:


https://i.imgur.com/I77RTHl.jpg


https://i.imgur.com/uG7k8se.jpg


https://i.imgur.com/2oCyvAJ.jpg


The latter hit my taste buds so well I ate so much that I damn near did do supper any justice whatsoever!!


All in all a classic example of the Student really excelling the Teacher!
Roy's set up is one of the most professional I have ever seen, and a lot of folks have come to rely on his expertise to transform their meat into incredibly delicious products! Professionalism to the extreme!


Many MANY THANKS my Friend! Sincerely Appreciated!

And don't be surprised to hear a knock on your door following next year's hunting season!!



Cheers!
Nog

[MRP]

My My My.... my tummy just jumped up and started chewing on my ribs.

[VLD43]

Nog
Where do we find this guy. I take it he is running a business?

[Wentrot]

I am drooling

[ekul246]

Nog
Where do we find this guy. I take it he is running a business?
Is he in the Lower Mainland? Looks delicious!

[TARCHER]

Now that ius a job well done. Good looking sausage right there.

[IronNoggin]

Nog
Where do we find this guy. I take it he is running a business?

He is just outside of Sooke on a rather large acreage.

Yes, be is running Carver's Custom Cuts.

To abide by the rules here, anyone who wants his contact intel, please pm...

Cheers,
Nog

[VLD43]

He is just outside of Sooke on a rather large acreage.

Yes, be is running Carver's Custom Cuts.

To abide by the rules here, anyone who wants his contact intel, please pm...

Cheers,
Nog

Nog
Thanks. He's right in my backyard. Who knew.

[IronNoggin]

Nog
Thanks. He's right in my backyard. Who knew.

Only advertises by word of mouth, and even that keeps him rather busy.

Hell of a Fine Fellow, he and I go wayyyyyy back.

Cheers

[Arctic Lake]

Well that’s a great story of success Nog . Good job mentoring him in those early days !
Arctic Lake

[IronNoggin]

Was asked to post this, so...

Polish Hunter Sausage

Ingredients

20 pounds ground pork

5 lbs ground deer

Total 25 Pounds - Note can increase the amount of deer, but never go over 1/3 of that overall.

6 Tblsp salt

2 Tblsp Prague Cure # 1

4 Tblsp Ground Black Pepper

8 Tblsp Fresh Chopped Garlic

4 Tblsp Garlic Powder

3 Tblsp Ground Juniper Berries

8 Tblsp Marjoram

3/4 bag Yellow Mustard Seed

4 Tblsp Coriander Seed

4 Cups Ice Water

1/2 Mickey London Dry Gin

8 to 10 ounces Soy Binder

4 ounces powdered milk (binder)

Mix until "sticky" consistency.
Shoot into standard hog casings.

Put them into the smoker while you bring the heat up.
Smoke at medium heat.

Finish in Hot Bath to temp (155 is what I aim for internal temp).

Ice bath, then hang to bloom for at least 4 - 5 hours.

[IronNoggin]

Had some of the Brats last night along with real German red Cabbage, Perogies and a fine Merlot

Truly Outstanding!!

Cheers

[srthomas75]

I've had a number of different items that Roy has made. All good stuff. great post by the way, nice to see photos of the process

[high horse Hal]

4 pork / 1 venison?

any problem with doing 1/1 ?

[IronNoggin]

4 pork / 1 venison?

any problem with doing 1/1 ?

Original recipe was based on a mix of wild boar and domestic pork.

I cannot see any reason not to try the one on one as you suggest.

If you do so, please let us know how it turns out!!

Cheers

[ACB]

Had some of the Brats last night along with real German red Cabbage, Perogies and a fine Merlot

Truly Outstanding!!

Cheers
Pickled red cabbage? yummmmmmm.

[wildcatter]

Was asked to post this, so...

Polish Hunter Sausage

Ingredients

20 pounds ground pork

5 lbs ground deer

Total 25 Pounds - Note can increase the amount of deer, but never go over 1/3 of that overall.

6 Tblsp salt

2 Tblsp Prague Cure # 1

4 Tblsp Ground Black Pepper

8 Tblsp Fresh Chopped Garlic

4 Tblsp Garlic Powder

3 Tblsp Ground Juniper Berries

8 Tblsp Marjoram

3/4 bag Yellow Mustard Seed

4 Tblsp Coriander Seed

4 Cups Ice Water

1/2 Mickey London Dry Gin

8 to 10 ounces Soy Binder

4 ounces powdered milk (binder)

Mix until "sticky" consistency.
Shoot into standard hog casings.

Put them into the smoker while you bring the heat up.
Smoke at medium heat.

Finish in Hot Bath to temp (155 is what I aim for internal temp).

Ice bath, then hang to bloom for at least 4 - 5 hours.

What happens of you omit the Prague #1 powder?
I'm not a fan of sodium nitrite.

[high horse Hal]

What happens of you omit the Prague #1 powder?
I'm not a fan of sodium nitrite.understand botulism and food safety , then take precautions
Cdn Food says 165 for game meat and sausage, then no warm temps until consumption

[cdub]

Watch 2guysandacooler on youtube, he has done a video on nitrates just recently.

understand botulism and food safety , then take precautions
Cdn Food says 165 for game meat and sausage, then no warm temps until consumption

[IronNoggin]

What happens of you omit the Prague #1 powder?
I'm not a fan of sodium nitrite.

Smoked sausages require this cure in order to be safe.

I strongly suggest not missing it in the recipe!!

Cheers,
Nog

[high horse Hal]

Hot bath after smoking should do it?

[cdub]

it depends on how long you leave the meat in the danger temp zone allowing the bacteria to grow. Cures eliminate this. Cures if used correctly are safe. Watch the video i mentioned.

Hot bath after smoking should do it?

[IronNoggin]

Cures if used correctly are safe. Watch the video i mentioned.


https://www.youtube.com/watch?v=Oo9dLKcqf4Y

[IronNoggin]

https://www.youtube.com/watch?v=m4OuOZulHUQ

[OOBuck]

What happens of you omit the Prague #1 powder?
I'm not a fan of sodium nitrite.

If you dont want to use Cure#1 eliminate the smoking process all together, the majority of true brats are poached not smoked. If you want the smoked taste use a liquid smoke, but then again the jury is still out on potential heath risks with their use. I always find poaching after smoking seems like a waste as it washes I good amount of the smoke taste out. As far as liquid smoke a little goes an extremely long way.

[cdub]

I quite often hot water bath with sous vide. It finishes to temp without over drying sausage, unless you have a steam function in your smoker.

[IronNoggin]

If you dont want to use Cure#1 eliminate the smoking process all together, the majority of true brats are poached not smoked.

We never smoke brats.
The ones we did smoke this time around were Hunter Sausage and Smokies.
To which the cure was added, as always.
Certainly not the brats.


I always find poaching after smoking seems like a waste as it washes I good amount of the smoke taste out.

Not nearly as much as you might think.
Given the extreme density of the smoke Roy's smoker produces, the little that is lost due to the hot water bath is negligible.
The vast majority of professional smokers I know do this.

Cheers

[OOBuck]

Not nearly as much as you might think.
Given the extreme density of the smoke Roy's smoker produces, the little that is lost due to the hot water bath is negligible.
The vast majority of professional smokers I know do this.

Cheers


Actually the "majority" of smokers now adays dont actually smoke due to provincial and muninicipal regs not allowing business to use actual wood and use a spray system with liquid smoke is used during the cooking process. There was a lot of cheap commercial smokers that went on line a few years back just due to this reason.
I still use wood with a Southen Pride convection ⁴smoker I use as hands down you can beat the smoke.
Poaching after smoking is old school..
We do need more guys doing what we do tho.. Seem butchering and sausage making is a dying art form.

[IronNoggin]

I still use wood with a Southen Pride convection ⁴smoker I use as hands down you can beat the smoke.
Poaching after smoking is old school..
We do need more guys doing what we do tho.. Seem butchering and sausage making is a dying art form.

I too run with real wood smoke in my custom build. Always have, always will.
The three local adz that do this professionally here in Port are the same, as obviously is my Buddy Roy.
I guess what you're referring to must be in regards to larger centers?

If I am anything, it is indeed Old School.

And I firmly agree on your last comment there!
While I know a few Gentz that are still into doing what we do, there sure doesn't seem to be many Young Guns following in our footsteps!!

Cheers,
Matt

[OOBuck]

I guess what you're referring to must be in regards to larger centers?
Matt

Nope.. unfortuneately its getting really stupid in regards to butcher shops smoking meat. It is now a requirement to use a smoke free smokers. Roy and myself and all the other game cutters south of Duncan are currently flying under the radar. There was a huge smoker sold last year up in Port that wasnt that old jusy for that fact. Owner last his shirt on it.. The idiots aka government down this way also want to ban wood stoves, but there are enough numbers to put a stop to it.

[IronNoggin]

Nope.. unfortuneately its getting really stupid in regards to butcher shops smoking meat. It is now a requirement to use a smoke free smokers. Roy and myself and all the other game cutters south of Duncan are currently flying under the radar. There was a huge smoker sold last year up in Port that wasn't that old just for that fact. Owner last his shirt on it.. The idiots aka government down this way also want to ban wood stoves, but there are enough numbers to put a stop to it.

Did not hear about the one from here. Sad.

KeRist! Effing government interference.
Had more than enough of it alright!
Hope you get to carry on, same with Roy & myself.

Cheers

[Arctic Lake]

As far as I know all the big Processors are still using wood chips . Some of them import their chips from Europe .
I was in the meat business for 25 years
Arctic Lake

[OOBuck]

As far as I know all the big Processors are still using wood chips . Some of them import their chips from Europe .
I was in the meat business for 25 years
Arctic Lake

This has been within the last 5 years, dont know if there is a grandfather clause, but every local medium scale outfit locally including a local fish processor has had to swap out their smokers.. Coming to a shop near you..

[high horse Hal]

Sad when neighbours despise the smell of smoke instead of relishing it and all it embraces

[IronNoggin]

Sad when neighbours despise the smell of smoke instead of relishing it and all it embraces

Mine usually come running... :lol:

[Arctic Lake]

Another B.S. government intervention Geeezz !
Arctic Lake
This has been within the last 5 years, dont know if there is a grandfather clause, but every local medium scale outfit locally including a local fish processor has had to swap out their smokers.. Coming to a shop near you..