Meat + Poultry - October 2009 - 62

VIENNA BEEF
(Continued from Page 59)

son of co-owner Jim Bodman. "Our
labor force fluctuates between 180
and 250 people," he adds. "We have
some services we outsource; sanitation is one."
The plant operates fi ve days a
week, 24 hours a day, which includes
sanitation. "We'll occasionally add
a sixth day for sausage processing,"
Bodman says.
Maintaining the quality of Vienna's growing stable of meat products

Vienna's most popular
products are Vienna hot
dogs, Polish sausage,
turkey breast pastrami,
corned beef brisket,
Chipico pickles and
Vienna chili.
is key for continuing success, Eirinberg says. And ensuring quality
products requires the craftsmanship
of its production workers more than
processing technology.
"We're afraid to automate too
many parts of our process," he adds.
"We have an Old World sausage recipe. There are a million ways we can
take costs out of [Vienna hot dogs] on
the production floor, but we're afraid
automating too much may change the
product taste, texture and other premium qualities that make Vienna hot
dogs what they are today. This product is largely responsible for us being
in business for 116 years."
Vienna's meat plant processes approximately 20 million lbs. of sausage

per year, while its deli meat and soup
and chili business produce about 5
to 7 millions lbs. a year each, Bodman says.
The company also has several meat
products co-packed, such as beef brisket jerky, hamburgers and turkey, as
well as its No. 2 SKU - hot dog buns.
Vienna's most popular products are
Vienna hot dogs, Polish sausage, turkey breast pastrami, corned beef brisket, Chipico pickles and Vienna chili.
Bodman says the plant produces a
large variety of specialty products for
its vending customers.
"We cater to about 2,000 hot dog
stands in the metropolitan Chicago
area," he says, "and they all want different shapes and sizes of basically the
same product."
The plant is set up for flexibility
rather than volume, he adds. "We
make some very 'hand-made products' like natural-casing sausages,"
Bodman says. "This used to be a totally hand-made operation, but now
we use some machinery. There's still
labor, but we now get more out of the
process and can make a more consistent length and weight product, which
our customers demand."
Vienna has added automatic loading equipment to handle some of the
higher-volume skinless products, Bodman continues. One technology supplier customized a loader that places
five layers of 10 hot dogs into the case,
oriented and automatically.
"We have a very fragmented approach in the meat area," Bodman
says. "We have many machines, but

62 * Meat&Poultry * October 2009 * www.MeatPoultry.com

we don't use them all of the time. In
sausage manufacturing, we use grinders, blenders and bowl choppers. We
produce sausages using an array of
different skinless equipment, natural casing equipment and handmade
craftsmanship...we also use cellophane
and natural casings."
Vienna's deli-meat operation includes a butcher room where skilled
cutters debone briskets and navels.
"We process several different cuts of
boneless beef - flats, top rounds and
even some specialty products," Bodman says. "We still make an offal product - tongue. We do basic injection,
tumbling and even vat curing on some
cuts. We vacuum pack and water cook.
We hang and smoke cooked deli meat.
"We also have various packaging
machines and loaders, mostly horizontal vacuum packaging machines.
Foodservice is the bulk of our business," he adds.
Vienna uses bull meat for its hot
dogs and prefers more natural ingredients for all of its products.
"Bull meat is not an easy protein to
find, but we have several vendors who
supply us regularly," Bodman says.

Test kitchen
Vienna's test kitchen was testing several different brisket products during
the plant tour and company execs
were also taking note of how the cure
color held up on its natural sausages.
"We get a good, steady source of
high-quality briskets and we try to
develop new products," explains Chef
Scott Kerfman.
On most days, Vienna's test kitchen hosts meetings consisting of six to
eight company executives who view
and taste products to ensure they
comply with specifications, Bodman says.
Vienna uses fresh briskets, which
are deboned on the butcher table,
for some of its deli meats. "Here are
the boneless navels for pastrami or
corned beef," Bodman points out.
"We have to have boneless round cuts
like flats or top rounds."


http://www.MeatPoultry.com

Meat + Poultry - October 2009

Table of Contents for the Digital Edition of Meat + Poultry - October 2009

Contents
Meat + Poultry - October 2009 - 1
Meat + Poultry - October 2009 - 2
Meat + Poultry - October 2009 - 3
Meat + Poultry - October 2009 - Contents
Meat + Poultry - October 2009 - 5
Meat + Poultry - October 2009 - 6
Meat + Poultry - October 2009 - 7
Meat + Poultry - October 2009 - 8
Meat + Poultry - October 2009 - 9
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