The size difference comes from the natural skins. They are graded but usaly have a 3-5mm variance over the diameter of the skin doesn't sound like much but makes a big difference in the girth of the sausage. As for length because they are hand tied they will vary too then when filling if you get air pockets in the filler or not concentrating and under fill the skin a little there is a bit of work in the old humble sausage. Some of it can be from the amount of water used when mixing or fat content or the way they are cooked aslong as they still taste good I wouldn't panic
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