Patent Application
20100015299
The invention relates to a food casing having a textile backing material, a process for production thereof, and also use thereof as artificial sausage casing.
Tubular sausage casings based on regenerated cellulose having an inner reinforcement of fiber paper, in particular of hemp fiber paper, have long been known (see G. Effenberger, Wursthüllen-Kunstdarm [Sausage Casings, Artificial Skin], Holzmann Buchverlag, Bad Wörishofen, 2nd edition [1991] pp. 23/24). These casings generally termed cellulose/fiber skins are generally produced by the viscose process. In this process the fiber paper is first shaped to form a tube with overlapping longitudinal seams which is charged with viscose from the outside, from the inside or from both sides using a ring die. The viscose is then regenerated to cellulose hydrate in a precipitation bath.
Cellulose/fiber skins may also be produced by the more recent amine oxide process. In this process the cellulose is dissolved in aqueous amine oxide, preferably in N-methylmorpholine N-oxide monohydrate. This solution is applied to the fiber paper which is shaped to form a tube. The cellulose is then precipitated in a bath which contains a dilute aqueous amine oxide ablution. In this manner a seamless casing may be obtained, as in the viscose process. In contrast to the viscose process, the cellulose in the amine oxide process is not chemically derivatized, but purely physically dissolved. After they are stuffed with sausage emulsion, cellulose/fiber skins are substantially transparent.
It is, furthermore, known to produce tubular food casings from a flat material by corresponding shaping and bonding the longitudinal edges. The bonding can proceed, for example, by gluing, sealing or stitching. The flat material is usually textile material, which can also be coated. The flat material itself can be produced by cutting open a high-caliber tube in the longitudinal direction and dividing the cut-open tube into a plurality of webs of predetermined width. Casings made of such flat material have a particularly uniform extension over their entire periphery.
In addition, acrylic-coated, smoke-permeable textile skins are known (DE-A 31 47 519). The textile material used therein can be a consolidated web, a spun bonded web or a woven fabric made of natural fibers and/or artificial fibers. Those which may be mentioned are fibers of cotton, linen, wool, silk, cellulose esters, regenerated cellulose, polyester, polyamide, poly-acrylonitrile, polypropylene and polyvinyl chloride. The backing material is coated with an acrylic emulsion polymer based on lipophilic esters of (meth)acrylic acid with lower alkanols, in particular butyl acrylate. The coating is applied using conventional coating devices such as air doctor knives, roller doctor knives or rubber cloth doctor knives. Subsequently, the coated web is shaped to form a tube and the longitudinal seam is then sealed by gluing, stitching or sealing. With appropriate selection of the composition of the acrylic coating, the textile skin is water vapor-permeable and gas-permeable and also smokable, so that it is also suitable for long-life sausage. These textile skins have a surface structure which is pleasant to touch; however, they are not transparent, so that the consumer does not have a direct impression of the sausage emulsion.
DE-A 38 26 616 discloses a tubular packaging casing which consists of a textile material coated on both sides with cellulose. It is produced by the viscose process. This casing, however, has interfering spots which are not transparent. Owing to the deficient optical appearance and transparency, the product is not ready for the market.
The object was therefore to develop a food casing with a coated textile backing material which no longer has, or has to a much lower extent, the described disadvantages. In particular, it is intended to be as far as possible as transparent as a cellulose/fiber skin, but simultaneously have the surface structure known and prized from textile skins. The surface structure, depending on requirements, shall be adjustable from matt to glossy. The barrier properties of the casing, that is to say its permeability to water vapor, oxygen and smoke components, shall approximate as close as possible to those of a cellulose/fiber skin. At the same time, the casing must be impervious to fat. The casing, finally, shall be more mechanically stable compared with a cellulose/fiber skin of the same weight per unit area, especially have a higher wet tear strength.
It has been found that viscose can penetrate into the fibers, in such a manner that the textile backing material in the casing coated with regenerated cellulose is virtually invisible, and the casing, after it is stuffed with sausage emulsion, appears substantially transparent and spot-free.
The said objects are achieved by a food casing which has a textile backing material which has been coated with a layer of regenerated or precipitated cellulose.
The present invention accordingly relates to a food casing having a flat textile backing material, wherein the textile backing material is coated on the outside or on the inside and outside with a continuous layer of regenerated or precipitated cellulose. Preferably, the food casing is tubular, particularly preferably, in addition, seamless. “Seamless” designates a casing, the seam of which is scarcely recognizable. The thickening produced on shaping the tube from the textile backing material by overlapping the longitudinal edges is coated with a continuous cellulose coating; therefore, the finished product appears seamless.
If the textile backing material has been pretreated with sizing agents which impair the penetration of the viscose, it must be desized in advance. Sizing agents have also proved to be interfering which dissolve in aqueous precipitation or wash baths and thereby accumulate in these baths. These are, for example, those based on starch or modified starch, mixtures of water-soluble starch and polyvinyl alcohol, in addition, also lubricating agents and lipids. It is assumed that the essential cause of the spots occurring in the food casing according to DE-A 38 26 616 is likewise sizing agents. Interfering sizing agents or else interfering preservatives may be removed, for example, by washing or enzymatic treatment. After removal of the sizing agents, the textile backing material frequently exhibits a decreased mechanical stability, that is it can no longer so readily be shaped to form a tube. By impregnation of the backing material, the required mechanical stability may again be achieved.
In a preferred embodiment, the textile backing material is of a quality such that it can take up viscose, or cellulose dissolved in aqueous amine oxide. Suitable materials are natural fibers, in particular those which have a chemical constitution similar or coming close to cellulose, such as cotton, linen or viscose staple. The expression “natural fibers”, in the context of the present invention, is also taken to mean fibers of animal origin, such as wool and silk. The natural fibers can, in addition, be mixed with synthetic fibers.
In a further embodiment, textile backing materials made of synthetic fibers are used. The synthetic fibers are produced, for example, from polyester, polyamide, polyacrylonitrile, polyolefin (especially poly-propylene), polyvinyl acetate or polyvinyl chloride. Backing materials made of synthetic fibers are preferably pretreated with chemical and/or physical agents in such a manner that the adhesion of the viscose or amine oxide/cellulose is improved. An important purpose of the pretreatment is to ensure that the refractive index does not change abruptly within the casing of the invention. Only then is a satisfactory transparency of the casing after stuffing achieved.
The textile backing material is flat and has the form of a woven fabric, knitted fabric, laid fabric, consolidated nonwoven or spun bonded nonwoven. In the laid fabrics or nonwovens, it also always contains relatively long fibers which are several times longer than, for example, in a hemp fiber paper (there the fiber length is generally no more than 5 mm). “Flat” in the context of the present invention is taken to mean relatively thin, but self-supporting materials which may be shaped to form a tube. Thickness and weight per unit area also depend on the intended application of the casing. Generally, the weight per unit area is 8 to 300 g/m2, preferably 15 to 200 g/m2, particularly preferably 25 to 120 g/m2. The textile backing material can be more or less extensible, depending on the intended application. Non-extensible, or only little-extensible, textile backing materials are expedient for casings in which particularly high caliber constancy is of importance. Particular preference is given to generally thin, longitudinally and transversely stretched fabric made of cotton, cotton/viscose staple mixtures or viscose staple/polyester mixtures.
The surface properties and the uptake or acceptance capacity of the textile backing material can be adjusted to suit by chemical and/or physical pretreatment. Chemically, for example, by treatment with a melamine/formaldehyde resin, a polyamine-polyamide-epichlorohydrin resin, an acrylic resin (particularly an emulsion polymer based on (C1-C6)alkyl(meth)acrylate, especially based on butyl(meth)acrylate. The expression “(meth)acrylate” in this case as is customary means “acrylate and/or methacrylate”. The emulsion polymers can additionally contain units of other monomers. These include, for example, units of styrene, α-methylstyrene, maleic acid di-n-butyl ester and/or vinyl acetate. The fraction of units of such other monomers should be less than 25% by weight, preferably less than 15% by weight. Suitable acrylic resins are adequately known to those skilled in the art, for example from DE-A 31 47 519. It has proved to be expedient to treat viscose staple with a melamine/formaldehyde resin or with a polyacrylic. The textile backing material can also be treated with a dilute viscose solution (which as far as possible contains no more than 2% by weight of cellulose xanthogenate) and the viscose is then regenerated to form cellulose. A treatment with a likewise dilute amine oxide/cellulose solution is less technically complex. The derivatized and also non-derivatized cellulose can, if appropriate, be mixed with acrylics. In each case attention must be paid to the fact that the interstitial spaces between the fibers are not completely filled, in order that the (more highly concentrated) viscose or amine oxide/cellulose solution can penetrate unhindered during the actual coating operation. The textile backing material can be pretreated from one or both sides; particularly expediently, it is subjected to Foularding (immersion coating). For this, use is made particularly of usually aqueous dispersions which contain the corresponding organic polymers. The pretreatment, in addition, increases the mechanical stability of the textile backing material, so that it may more readily be shaped to form a tube.
The textile backing material can be dyed or printed. Also, the materials used in the chemical pretreatment can be mixed with dyes and/or color pigments. In order that the transparency of the casing is retained, particularly in this case, the coating should proceed with undyed viscose or NMMO cellulose solution.
Instead of, or additionally to, a chemical pretreatment of the textile backing material, a physical pretreatment can also be carried out. This is, for example, a corona treatment, treatment with plasma, UV rays, gamma rays or a thermal aftertreatment.
For a tubular food casing, the optionally pretreated textile backing material is cut into webs of appropriate width. These webs are each shaped to form a tube, the longitudinal edges of which to a greater or lesser extent overlap. The overlapping region necessary in each case is also determined by the caliber. Generally it is relatively narrow and is 1 to 6 mm, preferably 2 to 4 mm. The textile backing material shaped to form a tube is then charged with viscose or an amine oxide/cellulose solution from the outside, from the inside or from both sides. In order that the casing remains transparent after it is stuffed, there must be a layer of regenerated or precipitated cellulose at least on its outside. In order to maintain the shape of the tube and to avoid extensive shrinkage on subsequent drying, it has proved to be expedient to charge the tube with supporting air during the coating operation. By regeneration or precipitation, the cellulose layer is formed. As already mentioned, dyes and/or pigments can be added to the viscose or the amine oxide/cellulose solution. In this case an undyed textile backing material is used. A casing having an improved transparency after it is stuffed, however, is achieved by the combination of a dyed textile backing material with an undyed coating medium.
The textile backing material is coated with as much viscose or amine oxide/cellulose solution which, after regeneration or precipitation and washing, forms a closed cellulose hydrate layer. Depending on the type, density and thickness of the textile backing material, this requires about 20 to 250 g of cellulose hydrate, preferably 30 to 150 g, particularly preferably 40 to 120 g, of cellulose hydrate per square meter (dry weight of the cellulose hydrate). The weight of the casing of the invention is thereby (in the dry state) about 60 to 400 g/m2, preferably 80 to 300 g/m2, particularly preferably 100 to 200 g/m2. Expediently, the casing additionally contains a secondary plasticizer, generally glycerol.
The food casing of the invention can additionally contain flavor substances or odor substances, in particular those which are transferable to a food situated in the casing. Those which may be mentioned here are, in particular, dry or liquid smoke.
In order to set the correct level of adhesion to the food, the casing is preferably provided with an impregnation on the side facing the food, for example a release or adhesive impregnation. The type and amount of impregnation depend in turn on the type of food.
If the casing is intended to be particularly impermeable to oxygen and/or water vapor, which is necessary, for example, for a liver sausage casing, it additionally has at least one barrier layer on the inside and/or outside. This is, for example, a PVDC layer. Such a casing particularly effectively prevents the sausage from drying out and oxidative discoloration of the sausage emulsion.
The casing of the invention generally has a water content of about 6 to 20% by weight, preferably about 8 to 12% by weight. If it is intended to be ready to stuff without further soaking, it has a moisture fraction of about 20 to 30% by weight. However, it is equally possible to soak a dry casing and then stuff it.
The water vapor permeability of the casing of the invention is generally about 300 to 1500 g/m2·d, preferably about 700 to 1200 g/m2·d. The oxygen permeability at 65% relative humidity on the basis of a 5 cm2 size piece of the casing having water content of 8 to 10% by weight and a plasticizer content of about 15% by weight is generally about 20 to 100 cm3/m2·d. The water permeability is finally about 70 to 200 l/m2·d, preferably about 80 to 120 l/m2·d, measured in each case at 40 bar of internal pressure.
The casing is usually smoke-permeable. However, if it has additional barrier layers, then it is generally impermeable to cold or hot smoke. The extension behavior of the casing of the invention is essentially determined by the type and thickness of the textile backing material and also by the weight of the cellulose hydrate layer and any further layers present. It can vary between 0.1 and 25%, preferably between 1 and 10%.
Processes and devices for producing the casing of the invention are known in principle to those skilled in the art. For this, first a flat textile backing material is prepared. Sizing agents, if appropriate, are removed from the backing material. If necessary or desired, the backing material can be treated with an impregnating agent which modifies its surface properties and/or improves its mechanical strength. If a seamless product is to be produced, the backing material is shaped to form a tube. The tubular or flat backing material is then charged from one or both sides with a continuous layer of viscose or an amine oxide/cellulose solution. This can be performed, for example, by doctor knife application, roller application, application using an annular die or sheet die or using other coating devices which are familiar in principle to those skilled in the art. Thereafter, the cellulose is coagulated from the viscose in an acidic precipitation bath and regenerated.
Alternatively, the cellulose is precipitated from the amine oxide/cellulose in a bath of a dilute aqueous amine oxide. In both embodiments, the material is then washed and dried, if appropriate also further end-processed.
The casing may be produced in the form of a flat web or equally as a tube. The tube can subsequently be sliced open in the longitudinal direction and it appropriate divided into two or more correspondingly narrower webs. These can in turn be shaped to form tubes of a smaller caliber, wherein the longitudinal edges are bonded to one another permanently by gluing, sealing, stitching or in another manner familiar to those skilled in the art. By means of appropriate cutting to size or bonding the longitudinal edges, tubular casings having variable diameter or irregular contours can also be produced. In this manner, the shapes of a natural skin may be imitated.
After the coating, the cellulose, as described, is regenerated or precipitated. The casing in flat form can in subsequent steps be impregnated, provided with a further coating (for example a barrier layer) and/or printed. If necessary, the casing of the invention is sliced in flat form into webs of appropriate width. The individual webs are then brought into a tubular form and the overlapping longitudinal edges fixed, for example by gluing, sealing, welding or stitching. For production of a glued seam, for example, hot melts or reaction adhesives, for example polyurethane or ethylene/vinyl acetate adhesive may be used.
The tubular food casing of the invention with or without a seam may be stuffed without problems with pasty foods, such as sausage emulsion, using customary stuffing machines. When used as sausage casing, it is expediently pushed onto the stuffing tube in shirred form (as what is termed a shirred stick). Sections closed at one end can also be stuffed. The end closure can in this case be produced by a metal or plastic clip (which can also be connected to a loop for suspending the sausage), by binding with yarn, by knotting, gluing, sealing (wherein generally a flat seam is formed which can be straight, inclined, wavy or irregularly shaped) or produced by stitching. A plurality of said types of closure can also be combined. The sections are pushed individually onto the stuffing tube, stuffed with the pasty food, in particular with sausage emulsion, and closed. Further processing can then proceed as customary by scalding, boiling or smoking.
The tubular casing of the invention may particularly advantageously be used as artificial sausage casing, more particularly not only for raw sausage (such as air-dried or mold-ripened salami) but also for scalded-emulsion or cooked-meat sausage. The casing of the invention may additionally be used for packaging cheese.
If desired, the tubular food casing of the invention can be covered with a net which comprises, for example, honeycomb-shaped, octagonal, square or rectangular structures. The net, if appropriate, is also elastic.
The examples hereinafter are intended to illustrate the invention. Percentages herein are percentages by weight, unless stated otherwise or is clear from the context.
A fabric of 100% viscose staple having a weight of 58 g/m2 which contained water-soluble starch (CMS type) as sizing agent was enzymatically desized, foularded with an aqueous butyl acrylate polymer dispersion and cut into webs having a width of 302 mm. The webs were shaped via a shaping shoulder to form a tube which was then coated from the outside with undyed viscose. After coagulation and regeneration of the cellulose from the viscose and subsequent washing and drying, a casing having a weight of 136 g/m2 was obtained. The casing was divided into individual sections each of which were bound at one end. The sections were then stuffed with salami emulsion and closed with a clip. After a ripening time of 12 days, the textile structure of the casing was still clearly recognizable, but the casing was sufficiently transparent that the emulsion was readily visible. The surface of the casing was slightly glossy.
A mixed fabric of 80% cotton and 20% polyester having a weight of 102 g/m2 which contained starch as sizing agent was enzymatically desized, foularded with a melamine/formaldehyde resin and charged with viscose using a sheet die. After regeneration and drying, the coated textile had a total weight of 172 g/m2. The flat product was cut into webs having a width of 206 mm. The individual webs were shaped to form tubes having overlapping longitudinal edges. The longitudinal edges were fixed with a hot melt adhesive. The tubular casings with seam produced in this manner were stuffed with raw sausage emulsion. They had a stuffing caliber of 67 mm. Sausages having a textile surface structure which were additionally transparent were obtained. After a ripening and smoking time of 21 days, the casings showed a slight gloss, without in this case having lost transparency.
A fabric of 100% cotton having a weight per unit area of 75 g/m2 was washed in order to remove sizing agent and subsequently foularded with an aqueous butyl acrylate polymer dispersion. The fabric was subsequently cut into webs having a width of 302 mm which were then shaped to form a tube via a shaping shoulder. The tube was coated from the inside and outside with viscose which contained no dyes or coloring pigments. After coagulation and regeneration of the cellulose from the viscose, washing and drying, a food casing having a total weight of 170 g/m2 was obtained. The seamless casing was divided into sections each of which were tied off at one end. The sections were then stuffed with salami emulsion. After 14 days ripening duration of the sausages, the textile structure of the casing was still clearly visible. At the same time, the casing was transparent, so that the salami emulsion was readily visible. The casing had a relatively high surface gloss.
A fabric of 100% viscose staple having a weight of 65 g/m2 which contained water-soluble starch (CMS type) as sizing agent was enzymatically desized, foularded with an aqueous butyl acrylate polymer dispersion and cut into webs having a width of 198 mm. The webs were shaped via a shaping shoulder to form a tube which was then coated from the outside with viscose which contained no dyes or coloring pigments. After coagulation and regeneration of the cellulose from the viscose, the tube was finished using an adhesive impregnation. The tube had a total weight of 131 g/m2. Then it was cut open into three strips each of 66 mm width. These strips were stitched on the longitudinal edges and thereby processed to an optically upgraded casing. The three-seam casing was cut to a length of 95 cm, tied off at one end, stuffed with raw sausage emulsion and closed with a clip. After a ripening time of 12 days, the surface was transparent and slightly glossy.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2005 020 965.3 | May 2005 | DE | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/EP2006/004057 | 4/29/2006 | WO | 00 | 6/24/2008 |
