Luga-Bar

PURPOSE

Luga-Baris mono-layer artificial casing intended for manufacturing of all kinds of frankfurters, wieners and mini-sausages.

COMPOSITION

Luga-Bar casing is produced according to up-to-date technology by co-extrusion method, of high quality polyamide raw materials manufactured by leading polymer producers. All raw materials are certified for contact with foodstuffs.

ASSORTIMENT

Luga-Bar casing is divided info the following types:

Types of casing

Length of casing in one roll, m

Nominal caliber, mm

Characteristics

Luga-Bar

1500

16-36

Using on any automatic and semi-automatic lines

Luga-Bar M

1500

The casing has big stuffing capacity, the line is recommended to use is semi-automatic

Shirred casing Luga-Bar

Nominal caliber, mm

Type of casing

Type of shirring

Dimensions of shirred (max) briquette, mm

Length of casing in shirred briquette, m

Length of casing in packing box * , m

Quantity of packing boxes in one shipping box, pieces.

Length of casing in one shipping box * , m

Gross weight, max, kg

Length of briquette

 

External diameter of briquette (max)

Inner diameter of briquette (min)

16

А,P

rigid

245

18,0

9,5

25,0

1400

6

8400

12,0

17

19,0

10,5

25,0

1200

7200

12,0

18

20,0

10,5

25,0

1050

6300

12,0

19

21,0

11,5

30,0

1260

7560

12,5

20

22,0

11,5

33,34

1167

7002

13,5

21

24,0

12,5

33,34

1000

6000

11,5

22

25,0

12,5

33,34

1000

6000

12,5

23

26,0

13,6

35,8

1000

6000

12,5

24

27,0

13,6

35,8

895

5370

12,0

26

29,0

13,6

35,8

716

4296

12,0

28

31,0

18,0

30,0

540

3240

9,0

29

32,0

18,0

30,0

540

3240

9,5

30

34,0

18,0

33,34

600

3600

12,0

32

35,0

22,0

33,34

467

2800

10,0

34

37,0

22,0

33,34

467

2800

11,0

36

39,0

22,0

33,34

400

2400

11,0

* – dimensions of packing box (length хwidth хheight), mm:  255х165х130
* – dimensions of shipping box, mm:  510х280х275
Type A – shirred briquette with closed end;
Type P – shirred briquette with open end.
 

Luga-Bar casing in rolls

Nominal caliber, mm

Length of casing in one roll, m

Quantity of rolls in one shipping box, pieces

Length of casing in one shipping* box, m

16 - 26

1500

5

7500

28 - 36

4

6000

* – dimensions of shipping box (length хwidth хheight), mm  314х314х410

Colours of Luga-Bar casing

Colour

Code

1

Red

2.0

2

Pink

2.5

3

Orange

3.0

4

Gold

5.1

5

Bronze

7.0

6

Transparent

8.0

7

Smoke

shades

Caramel

9.1

8

Salmon

9.3

9

Terracotta

9.5

Casing can be printed onto one or both sides. Paints used for printing are permitted to contact with food and they are resistant to mechanic action, fat and boiling.

Quantity of printed colors – from 1 up to 5. Full-color printing is available.

PROPERTIES AND ADVANTAGES

1. High barrier properties.

Luga-Bar casing possesses ten times lower permeability to oxygen and vapor, in comparison to collagen and cellulose casing. It brings following advantages:

  • Minimal losses during thermal treatment and storage of frankfurters and wieners..
  • Prolonged shelf of frankfurters and wieners. Shelf life of final products packed in polyamide casing Luga-Bar is 20 days. This term approved by Ukrainian and Russian Ministries of Health.
  • Attractive appearance of final product during whole period of shelf life.

2. Excellent physic mechanical properties.

  • Allow to use Luga-Bar casing with all types of stuffing equipment.
  • Provide efficient production of stuffing equipment.
  • Permit to overstuff the casing for increasing profitability of production.

3. Caliber stability.

Caliber stability of Luga-Bar casing provides excellent functioning of automatic and semi-automatic equipment and allows to plan casing consumption.

4. High level of thermo-shrinkage.

Thermo-shrinkage properties ofLuga-Bar casing is the best preventer against forming of fat and gel pockets as well as wrinkles, and they give organoleptic properties to final products.

5. High level of thermo-shrinkage.

Casing is resistant not only to high temperature, but also to its lasting effect. That is why the range of thermal treatment of frankfurters and wieners in Luga-Bar casing is wider, in comparison with natural, cellulose and collagen casing.

6. Biological inactivity.

Polymeric materials used for production of Luga-Bar casing are inert to bacteria and moulds. This property improves hygienic characteristics of casing and sausage production as well.

PREPARATION OF THE CASING

Correct casing soaking provides regular stuffing with recommended stuffing diameter.

Luga-Bar casing should be soaked in cold water at temperature 15-20°Сin the following way:

  1. Sections of casing– 30-40 minutes;
  2. Briquettes of rigid shirring, type "А"and"P"– should be submerged completely into cold water for 30-40 minutes;
  3. Briquettes of rigid shirring type "А" could be used without any soaking before-hand.

Correct soaking gives to the casing additional elasticity, coupled with high durability, that makes easy manual stuffing process as well as stuffing at automatic equipment.

It is forbidden:

  1. To soak casing in warm or hot water.
  2. To soak repeatedly once soaked, but unused casing.

MEAT STUFF COMPOSITION

As Luga-Bar casing is impermeable to gas, vapor and moisture, so when preparing the stuff it is recommended to lower quantity of water by 5-10 % in comparison to norm for natural and cellulose casing. More precise needed quantity of water can be determined by accounting of kind and characteristic of meat (ratio of flash to flat), rate of overstuffing, type and amount of stabilizing, binding, emulsifying and preserving ingredients, adjusting of stuffing equipment, etc. Practice shows that in spite of water quantity lowering, output of final product does not lessen.   

STUFFING

Luga-Barcasing can be stuffed in any automatic equipment like Frank-A-Matiс, Super-Matic, as well as in machines with twister like Handtmann, Vemag, etc.
 
Stuffing should be done up to recommended diameter. Overstuffing exceeding may cause rupture of casing during thermal treatment or slicing while serving.
It is important to observe recommended stuffing diameter, which is determined by casing elasticity, consistence and pressure of meat stuff.
 
Stuffing horn should be strictly centered to twister and this centering should be checked before stuffing (still without casing) and during stuffing if something goes wrong.
 
Shirred briquettes should be oriented to stuffing tube as it shown on the scheme.
 

Puncture either of casing itself or onto product is forbidden.

RECOMMENDATIONS ON STUFFING TECHNOLOGY OF LUGA-BAR CASING

Nominal diameter of casing, mm

Stuffing diameter, mm

Luga-Bar

Stuffing diameter, mm

Luga-Bar M

Outer diameter of stuffing horn, mm

№ of plastic chuck

min

max

min

max

Frank-A-Matiс

16

17,0

17,5

17,5

18,5

8

17

17

18,0

18,5

18,5

19,5

8

17

18

19,0

19,5

19,5

20,5

8-9

17-18

19

20,0

20,5

20,5

21,5

9-10

18-19

20

21,0

21,5

21,5

22,5

10

19-20

21

22,0

22,5

22,5

23,5

11-12

20-21

22

23,0

23,5

23,5

24,5

11-12

21-22

23

24,0

24,5

24,5

25,5

12-13

22-23

24

25,0

25,5

25,5

26,5

12-13

23-24

26

27,0

27,5

27,5

28,5

12-13

28

28

29,0

29,5

29,5

30,5

14-16

28-29

29

30,5

31,0

31,0

32,0

14-16

29

30

31,5

32,0

32,0

33,0

14-16

29

32

33,5

34,0

34,0

35,0

14-16

29

34

35,5

36,0

36,0

37,0

36

37,5

38,0

38,0

39,0

SHEME OF PLACING LUGA-BAR M BRIQUETTES IN SEMI-AUTOMATIC STUFFERS WITH TWISTER BL° CK

 

THERMALTREATMENT

Thermal treatment of product in Luga-Bar casing does not differ from one covered by similar casing and can be conducted by traditional technology.

As Luga-Bar casing is practically impermeable for gas, so product packed into it should not be exposed to real smoking. Taste of smoking can be reached by addition into stuff of ingredients giving peculiar aroma of final product. For this purpose smoking shades of Luga-Bar casing were developed too.

Conditions of thermal treatment should be determined by producer depending on equipment used for production.

Drying stage could be excluded, but boiling should be made with step-by-step temperature increasing. Abrupt temperature increasing can lead to stuff emulsion exfoliation, color irregularity of final product and physical defects of the casing.

RECOMMENDED TECHNOLOGY OF THERMAL TREATMENT

method 1

CURINGSTEAM HEATINGBOILING SHOWERINGCOOLING

  • CURING – for 1.5-2 hours at 0...4°Сin curing chamber.
  • STEAM HEATING – 15 minutes at 40°Сand 100% relative humidity, at 60°Сand relative humidity 100% until getting 47°Сin centre of the stick.
  • BOILING – approximately 10-15 minutes at 76-80°Сand 100% relative humidity until getting 72°Сin the centre of the stick.
  • SHOWERING - COOLING: after thermal treatment, frankfurters and wieners should be intensively cooled by cold water until getting +25…+30°Сin the center of the stick. Cooling by cold air or draft influence is inadvisable – it can lead to wrinkles forming. Final products should be placed in refrigerator at +4…+6°Сuntil delivery to a customer.

method 2

CURINGSTEAM HEATINGBOILING SHOWERINGCOOLING

  • CURING – for 1.5-2 hours at 0...4°Сin curing chamber.
  • DRYING (in three stages) – for 15 minutes at 50°Сand 30% relative humidity, for 25 minutes at 60°Сand 30% relative humidity, for 15 minutes utes at 70°Сand 30% relative humidity.
  • BOILING – approximately 10-15 minutes at 76-80°Сand 100% relative humidity until getting 72°Сin the centre of the stick.
  • SHOWERING - COOLING: after thermal treatment, frankfurters and wieners should be intensively cooled by cold water until getting +25…+30°Сin the center of the stick. Cooling by cold air or draft influence is inadvisable – it can lead to wrinkles forming. Final products should be placed in refrigerator at +4…+6°Сuntil delivery to a customer.
POSSIBLE SITUATIONS WHILE STUFFING LUGA-BAR CASING IN AUTOMATIC MACHINES LIKE
FRANK-A-MATIC, SUPER-MATIC, HANDTMANN

Situation

Reason

Recommendations

Greasy surface

Exceeding temperature of thermal treatment

Lower the temperature

Fat and gel pockets

Low indexes of meat stuff moisture binding properties

Apply technological methods of moisture binding increasing and/or lower quantity of water

Under-stuffing

Increase stuffing diameter to recommended

Exceeding temperature of thermal treatment

Lower the temperature

Pale color

Wrong temperature and humidity level during thermal treatment

Adjust to required

Non-uni-form color

Non-uniform temperature and relative humidity in space of thermal chamber

Adjust to uniform

Wrinkles

Exceeding air circulation in thermal chamber

Lower to required

Under-stuffing

Increase to recommended stuffing diameter

Exceeded quantity of moisture in stuff

Lower to required

Non-dense outer layer of product

Exceeding temperature and relative humidity while intensive heat treatment

Lower to required

Low output of final product

Wrong quantity of water in meat stuff

Correct meat stuff composition

Wrong temperature in regimes of thermal treatment

Correct the temperature in each stage of thermal treatment

Wrong circulation and/or humidity of air in treatment chambers

Correct to required

Error in measuring of humidity

Maintain meter of humidity

POSSIBLE SITUATIONS WHILE STUFFING LUGA-BAR CASING IN AUTOMATIC MACHINES LIKE
FRANK-A-MATIC, SUPER-MATIC, HANDTMANN

Situation

Reason

Recommendations      

Casing is winding onto stuffing horn

Wear and tear of twister plastic chuck

Replace the chuck

Stuffing horn is bent

Replace or straighten stuffing horn

No centering of stuffing horn to twister

Get centered

Stuffing horn is stained by something

Fix and delete the source of staining

Abnormal pressure

Adjust pressure to norm

Rupture

Burrs on TPC, LC, stuffing horn, etc.

File the burrs off

Exceeding of recommended stuffing diameter

Adjust stuffing, lower speed

Wrong choice of size of TPC

Replace the TPC

Wrong adjusting of linker chain

Adjust linker chain correctly

TBRR too squeezed

Adjust friction

Wrong choice of linker chain

Replace linker chain

Rupture of casing after stuffing

1. Repeated ruptures in the beginning of twisting

Wrong choice of size of TPC

Replace to correct one

No centering of shirred of briquette

Get centered

Burrs on stuffing horn

File the burrs off

2. Repeated ruptures in the middle of twisting

Stuffing horn is bent

Replace or straighten it

3. Repeated ruptures in the end of twisting

Wrong choice of size of stuffing horn

Replace to right one

Burrs on stuffing horn

File the burrs off

Wobbling of stuffing horn

Replace stuffing horn or adjust feeding support or replace the whole worn of stuffing horn

4. Repeated ruptures in the same area on body of frankfurter

Burrs in some part of machine

Check the whole technological stream, find the burrs and file them off

5. The only one rupture on length of linker chain

Bad chain

Replace it

6. Random ruptures

Bending in stuffing horn

Replace or straighten it

Exceeding size of stuffing horn

Replace to right one

Too tight position of casing in TPC

Loosen the friction in TPC or replace it to another with bigger diameter

Defect in twister plastic chuck

Replace to another

Exceeding overstuffing

Lower to recommended stuffing diameter

Exceeding pressure

Adjust to normal

Burrs somewhere in machine

Find and file them

 

Rupture at closed end

Worn or too small twister plastic bush

Replace it

Too tight position of casing in TPC

Loosen the friction in TPC or replace it to another with bigger diameter

Exceeding pressure

Adjust to normal

Bending in stuffing horn

Replace or straighten it

Closed end winding onto linker chain

Fault in pump

Check and fix it

Too tight position of casing in TPC

Loosen the friction in TPC or replace it to another with bigger diameter

Wrong twisting – exceeding or not enough

Incorrect speed of twister

Adjust to required

Too tight position of casing in TPC

Loosen the friction on TPC or replace it to another with bigger diameter

End of frankfurter is not filled with stuff

Too short motion of feeling lever

Increase to required

Different mass of frankfurters

Linker chain is not adjusted

Adjust

Defect in doser pump

Fix or replace

Under-stuffing, exceeding over-stuffing

Adjust to recommended stuffing diameter

Random length of frankfurters

Wrong size of twister plastic chuck

Replace to right one

Wrong choice or adjusting of linker chain

Replace or adjust

High-speed modes

Reduce the rate of forming

Fault in block of feeding lever

Fix

Rupture of twisting segment before thermic treatment

Defect in linker chain

Fix

Burrs in conveyer or frame

Fix

Abbreviations used in table:
 
TPC – twister plastic;
LC – linker chain;
TBRR – twister braker rubber ring.

STORAGE AND TRANSPORTATION

Casing is supplied in cardboard packages wrapped into thermo-shrinkable polyethylene film. This way of packing provides safety of casing during storage and transportation.
Casing should be stored in dry warehouse, without direct sunlight, no closer one meter to heating devices, at temperature below 30°Сand relative humidity below 70-80 %.
Providing observing conditions of storage and transportation, casing can be stored and used for 12 months.
If casing happened frozen at temperature below 0°Сthen before using it should be readapted for 24 hours at temperature higher 5°С.
Unpacking of package with casing should be done right before using but not in advance.
Packages with casing and casing itself should be handled avoiding shocks.