Why Sheep Casing Breaks During Stuffing — Causes & Fixes

One of the most common problems sausage manufacturers face is sheep casing breaking during stuffing.

Broken casings slow production, waste meat, increase labor costs, and reduce product quality.

If you are using natural sheep casings (18/20, 20/22, etc.), this guide will help you understand:

• Why breakage happens

• How to fix it

• How to prevent it permanently

🔎 Main Reasons Sheep Casings Break

1️⃣ Insufficient Soaking

Natural sheep casings are preserved in salt. If they are not properly soaked:

• They remain stiff

• They lose elasticity

• They tear easily during stuffing

✅ Fix:

• Soak in lukewarm water (30–35°C) for 30–60 minutes

• Flush water through the inside before stuffing

• Do not use hot water (it weakens structure)

Proper hydration restores elasticity and reduces breakage.

2️⃣ Overstuffing (Too Much Pressure)

One of the biggest causes is excessive stuffing pressure.

Signs:

• Casing stretches too tight

• Sausages look overly firm

• Immediate splitting during linking

✅ Fix:

• Reduce stuffing pressure

• Adjust machine speed

• Allow slight flexibility (do not make sausages rock-hard)

Remember: Natural casings need slight flexibility to maintain strength.

3️⃣ Wrong Caliber for the Filling Tube

Using the wrong stuffing horn size causes friction and tearing.

Example:

• 18/20 casing on oversized tube → overstretching

• Too small tube → excessive tension

✅ Fix:

Match horn size with casing caliber:

• 18/20 → small diameter tube

• 20/22 → medium tube

Proper equipment matching prevents stress damage.

4️⃣ Poor Quality Casings

Low-grade casings may have:

• Thin weak spots

• Inconsistent diameter

• Poor cleaning process

Quality grading matters (AB Mix, IA, etc.).

Reliable suppliers are critical. Large processors such as Johnsonville use strict quality standards for casing consistency.

✅ Fix:

• Source from reputable exporter

• Request uniform caliber grading

• Inspect before production

5️⃣ Dry Environment During Production

If casings dry out during stuffing:

• Surface becomes brittle

• Elasticity decreases

• Breakage increases

✅ Fix:

• Keep casings covered in water until use

• Maintain humidity in production room

• Avoid long exposure to air

6️⃣ High-Speed Stuffing Without Adjustment

Industrial production lines may run too fast for natural casings.

Natural casings behave differently than synthetic ones.

Synthetic casings can handle high-speed automation better, but natural casings require fine adjustment.

Companies like Tyson Foods often adjust machine settings depending on casing type.

✅ Fix:

• Reduce RPM

• Adjust vacuum levels

• Calibrate pressure for natural casings

⚙️ Quick Troubleshooting Table

ProblemLikely CauseSolutionImmediate tearingDry casingSoak longerBursting during linkingOverstuffingReduce pressureSplitting at one spotWeak casingImprove supplierFrequent random breaksHigh machine speedSlow stuffing

💡 Pro Tips to Prevent Breakage

✔ Always pre-flush inside casing
✔ Use correct stuffing horn
✔ Maintain moderate pressure
✔ Keep casings hydrated
✔ Store properly (2–8°C, fully salted)
✔ Work with consistent quality supplier

Why Prevention Matters

Casing breakage can:

• Increase meat waste

• Slow production

• Reduce yield

• Damage brand reputation

For USA meat processors, consistent casing performance ensures:

• Production efficiency

• Better product appearance

• Higher customer satisfaction

Final Thoughts

Sheep casing breakage during stuffing is usually caused by:

• Improper soaking

• Excessive pressure

• Wrong equipment

• Low-quality supply

With correct handling and proper supplier selection, natural sheep casings perform reliably and provide the premium snap and texture that consumers prefer.