Transcript Curing and Sausage Production at Retail

Curing and Sausage Making
Safe Food Principles
Retail Meat & Poultry Processing
Training Modules
Produced under a Cooperative Agreement from the
United States Department of Agriculture Food Safety
and Inspection Service (FSIS)
Developed by:
Minnesota Department of Agriculture,
Dairy and Food Inspection Division
Hennepin County Environmental Health
Minnesota Department of Health
University of Minnesota Extension Service
September 2004
Pretest
Topics
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History
Sausage definition
Types of sausage
Role of ingredients
Function of cure
Cure rates
Casing label
requirements
• HACCP Plan
• Critical control
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points
Steps in processing
Cooking
temperatures
Cooling guidelines
Packaging
Labeling
requirement
Storage and display
Jerky
Learning Objectives
1. List 3 types of sausage.
2. Name 4 main ingredients and their purpose.
3. Explain the function of cure and acceptable
cure rates.
4. Identify the critical control points of a
HACCP plan in sausage making.
5. Recite the cooling requirements for
sausage.
6. List 4 items that are required on a sausage
label.
Sausage History
• Sausage production is one of the earliest
forms of food preservation
• The word sausage is derived from the
Latin word “Salsus” which means salted
meat
Role of Salt
• Salt plays a more limited role in sausage
preservation today
• Present day salt levels provide less of a
preservative effect than the higher levels
of the past
• Most sausage recipes contain 1-3% salt
• Salt levels are usually adjusted for taste
Sausage Definition:
A mixture of ground or chopped meats
combined with spices and other
ingredients and usually formed or shaped
in casings of various sizes
Primary Sausage Types
• Fresh Sausages
• Cooked Sausages
• Fermented Sausages
• Meat Loaves and Jellied Products
Fresh Sausages
• Raw/uncooked meat product
• Does not contain the “curing” ingredient
nitrite or nitrate
• Examples are: fresh pork sausage, fresh
bratwurst, and fresh Italian sausage
Cooked Sausage
• Fully cooked ready-to-eat sausages
• Most are also smoked but may be water or
steam cooked as well
• May be eaten without reheating
• Examples include: wieners, smoked
sausages, bologna, cooked bratwurst
Fermented Sausages
• Have a characteristic “tangy” flavor
• Produced through fermentation by lactic acid
producing bacteria or the direct addition of
encapsulated acids
• These sausages can be shelf-stable with the
proper amount of drying and acidification
• Semi-dry: summer sausage and snack sticks
• Dry: pepperoni, hard salami
Meat loaves and
Jellied Products
• Loaves: Mixtures of chopped
meat that are usually “formed” and
cooked in pans or metal molds
• Examples: pickle and pimento
loaf and honey loaf
• Jellied products: consist of a
cooked mixture of meat chunks
placed in gelatin
• Examples: jellied roast beef and
head cheese
Head Cheese
Sausage Ingredients:
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Meat
Salt
Spices
Cure
Reducing Agents
Binders and Extenders
Water
Casings
Meat
Use only fresh
meat in good
condition and
from an
approved
source.
• Maintain all meats at a temperature of
41°F or less during storage and production
prior to cooking.
Salt
• Salt is a necessary ingredient for flavor
• It aids in preserving some sausages
• It is essential for extracting the “soluble”
meat protein that is responsible for binding
the sausage together when the sausage is
heated
• Most sausages contain 1-3 % salt
Spices
• All spices and seasoning should be fresh
to achieve maximum and consistent
flavors
• Store seasonings at 55°F or below in air
tight containers to maintain freshness
Meat Curing Ingredients
• Nitrates and nitrites are the common
“curing” ingredients used in the production
of sausage
• Nitrite is the compound that distinguishes
fresh products from cured products
• Nitrate is converted to nitrite during the
fermentation and cooking process
Function of Cure
• provides protection against the
growth of botulism
• extends shelf life
• stabilizes the flavor of the cured
meat
• used to achieve the characteristic
flavor and color
Cure: Caution !!
• Too much: can be toxic to humans!
• Too little: can result in the growth of
harmful bacteria!
• Federal regulations:
• maximum of 2.75 ounces of sodium or
potassium nitrate per 100 pounds of chopped
meat, or
• 0.25 ounces of sodium or potassium nitrite
per 100 pounds of chopped meat
Cure Rates are Critical!
• Most cures are added in the form of
commercial premixes
• Use the cure premixes according to
labeled directions only
• Any use other than according to labeled
directions will produce an unsafe and
illegal product
Addition of Cure Ingredients
• Today we use injection, tumbling and
direct mixing of cure ingredients
• Tumbling forces the cure into the muscle
under vacuum
• Other methods include:
• Dry rubbing
• Artery pumping
• Soaking in brine containing cure
Curing Accelerators
• Speed up the curing process, reduce the
holding time
• Examples are ascorbic acid (vitamin C) or
sodium erythorbate (isoascorbic acid)
• Must be used according to labeled
directions
Binders and Extenders
Binders • Help to improve flavor and retain natural
juices.
Extenders • Can reduce the cost of sausage
formulation.
• Examples: nonfat dry milk, cereal flours,
and soy protein products
Water
• Added to rehydrate the nonfat dry milk and
to replace the expected moisture loss
during smoking and cooking
• Up to 10 percent by weight of water may
be added to most sausages
• No water is added to sausages that will be
dried
Casings
• Casings are either natural or synthetic
• Natural casings are from sheep, hog, or
cattle intestines or manufactured from
collagen (an animal protein)
• Synthetic casings are usually made from
cellulose
Casing Label Requirements
• Beginning Sept. 5, 2001 FSIS regulations
require sausage manufacturers to label the
source of natural sausage casings if they are
derived from a different type of meat or poultry
than the meat or poultry encased in the
sausage.
• Sausage products encased in regenerated
collagen casings will have to have a statement
on the label disclosing the use of regenerated
collagen. (The processing of regenerated
collagen casings renders the detection of the
species proteins impossible).
Product Identity and Standards
• Processor must be familiar with the
Standard of Identity for the products
produced.
• Federal regulations are very specific in
limiting the fat content, the amount of
water added, the presence of extenders
and variety meats in sausages.
HACCP Plan
• A proper HACCP plan should be followed
for the safe production of meat products.
• A HACCP plan provides a careful analysis
of the hazards and describes critical
control points in the process to control
these hazards.
Steps in Processing
• Particle Size Reduction:
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• Grind; Chop; Mince; Shred; Chunk
Mixing:
• Mixers; Massager; Tumblers: Chopper: Emulsifier
Stuffing
Linking/Tying
Fermenting (optional)
Smoking/Cooking
Chilling
Peeling/Packaging
Cooking (CCP)
• All meat products must be cooked to the
required temperature to kill pathogens
• 158°F is considered adequate for pork and
beef
• 160°F is considered adequate for poultry
• Internal cook temperature and cook times
must be carefully monitored and recorded
Cooling
• FSIS Compliance Guidelines recommend
that cooked meat products be cooled to
below 80°F in less than 1.5 hours and
below 40°F in less than 5 hours
Packaging
• Care must be taken to prevent cross
contamination of cooked meats prior to
packaging
• Specific procedures must be followed if
cooked meat products are vacuum
packaged
Packaging
• When packaging
ready-to-eat foods,
limit bare hand
contact
• Utensils, tissues or
gloves must be
used
Labeling
All prepackaged meat products must be
properly labeled to include the following:
 Product name
 Ingredient statement containing a complete list
of ingredients.
 Handling/perishability statement- “Keep
Refrigerated” or “Keep Frozen” must be
provided on all products that are not shelf stable.
Safe handling instructions must be provided on
prepackaged raw meats.
 Statement of net weight
 Name and address of the manufacturer/
distributor
Storage and Display
• All meat products must be held at a
temperature of 41°F or below while in
storage or display
• Raw meats must be stored below and
away from cooked meats
Jerky
• Meat cut into thin strips and then dried to
preserve it
• It can be flavored or treated during the
drying process to improve flavor or
nutritional content
Jerky
• Made from beef, venison, moose, elk,
antelope and other game animals
• Trim all of the fat and membrane that you
can as you cut up the meat
• Cut the meat into thin strips across the
grain of the meat
• The thinner the strips are, the
quicker it will dry
Drying Jerky
1. Lay out strips on a sheet in a single layer
2. Lay the meat slices on a grill or grate that
allows air to reach all parts of the slice
3. Store in a cool dry area in a sealed
container after it is well cooled
Jerky
• Jerky meat with cure can be cold smoked
or dried at lower temperatures
• Jerky meat without cure must be cooked
or processed at temperatures greater than
160ºF
Summary
Properly prepared sausage and
meat products:
add to consumer convenience
• enhance color and flavor
• upgrade the value of raw materials
• increase the shelf life
• add to the safety of the product
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Wrap-Up
• Do you have any questions?
• What information was new?
• How will you apply what you
learned today?
• Posttest