This document provides information on sausage making equipment, processes, safety considerations and sanitation. Key points:
1) Thermometers and scales are critical for ensuring meat and finished product temperatures and ingredient ratios are safe. Sausage is fully cooked at 160°F internally.
2) Grinders, choppers, stuffers and casings are used to grind, mix, fill and link sausages. Proper grinding plates and sharp blades are important for quality.
3) Processing involves grinding, mixing spices, stuffing into casings, potential fermentation, drying, smoking and cooking sausages to 160°F. Temperature control and sanitation are essential for safety.
This seminar talks about what is sensory evaluation, types and needs for sensory evaluation. Quality control and quality assurance and the use of sensory evaluation in food industries. Minimum requirement and new developments in QC/Sensory program.
INTRODUCTION:
BREAD is a dietary product obtained from the fermentation and the subsequent baking of a dough mainly made of cereal flour and water, made in many different ways and sometimes enriched with typical regional ingredients.
Ingredients of bread:
Flour is the bulking ingredient of bread, it forms the structure of the product,contains gluten which helps to form an elastic stretchy dough.
Yeast is a raising agent. Yeast produces gases to make the bread rise.
Salt is required to bring out flavour in the bread, it is used in small quantities.Too much of this ingredient will stop the yeast from growing.
Yeast needs energy to grow. Sugar provides the food for the yeast; it is needed to help the yeast grow.
Water is used to bind the flour together and helps to form the structure of the bread.
Fats or oils improve the texture of the bread, preventing it from going stale quickly.
Starter culture:
Baker's yeast is the common name for the strains of yeast commonly used as a leavening agent in baking bread and bakery products, where it converts the fermentable sugars present in the dough into carbon dioxide and ethanol. Baker's yeast is of the species Saccharomyces cerevisiae, which is the same species (but a different strain) commonly used in alcoholic fermentation which is called brewer's yeast.
Bread Making Process
Mixing has two functions: to evenly distribute the various ingredients and allow the development of a protein (gluten) network to give the best bread possible.
Once the bread is mixed it is then left to rise (ferment).
Any large gas holes that may have formed during rising are released by kneading.
Moulding the dough into desired loaf shape.
During the final rising the loaf fills with more bubbles of gas, and once this has proceeded far enough they are transferred to the oven for baking.
The loaf is then placed in a preheated oven to bake. Such a high heat will kill the yeast, thus stopping its process of rising and growth.
The whole loaf is cooled to about 35°C before slicing and wrapping can occur without damaging the loaf.
Types of Bread
1. White Bread
2. Brown Bread
3. Wholemeal bread
4. Rye bread
Apart from above there are several types like Crisp bread, Flatbread is often simple, made with flour, water, and salt.
Microbial spoilage
Molds are the primary spoilage organisms in baked goods, with Aspergillus, Penicillium, and Eurotium being the most commonly isolated genera.
Quality control
As a foodstuff, bread is subject to stringent government food processing regulations, including, but not limited to the percent of additives allowed, sterilization of plant equipment, and cleanliness of plant workers. In addition to adhering to these regulations, processors control the quality of their products to meet consumer expectations by installing checkpoints are various stages of the processing.
This seminar talks about what is sensory evaluation, types and needs for sensory evaluation. Quality control and quality assurance and the use of sensory evaluation in food industries. Minimum requirement and new developments in QC/Sensory program.
INTRODUCTION:
BREAD is a dietary product obtained from the fermentation and the subsequent baking of a dough mainly made of cereal flour and water, made in many different ways and sometimes enriched with typical regional ingredients.
Ingredients of bread:
Flour is the bulking ingredient of bread, it forms the structure of the product,contains gluten which helps to form an elastic stretchy dough.
Yeast is a raising agent. Yeast produces gases to make the bread rise.
Salt is required to bring out flavour in the bread, it is used in small quantities.Too much of this ingredient will stop the yeast from growing.
Yeast needs energy to grow. Sugar provides the food for the yeast; it is needed to help the yeast grow.
Water is used to bind the flour together and helps to form the structure of the bread.
Fats or oils improve the texture of the bread, preventing it from going stale quickly.
Starter culture:
Baker's yeast is the common name for the strains of yeast commonly used as a leavening agent in baking bread and bakery products, where it converts the fermentable sugars present in the dough into carbon dioxide and ethanol. Baker's yeast is of the species Saccharomyces cerevisiae, which is the same species (but a different strain) commonly used in alcoholic fermentation which is called brewer's yeast.
Bread Making Process
Mixing has two functions: to evenly distribute the various ingredients and allow the development of a protein (gluten) network to give the best bread possible.
Once the bread is mixed it is then left to rise (ferment).
Any large gas holes that may have formed during rising are released by kneading.
Moulding the dough into desired loaf shape.
During the final rising the loaf fills with more bubbles of gas, and once this has proceeded far enough they are transferred to the oven for baking.
The loaf is then placed in a preheated oven to bake. Such a high heat will kill the yeast, thus stopping its process of rising and growth.
The whole loaf is cooled to about 35°C before slicing and wrapping can occur without damaging the loaf.
Types of Bread
1. White Bread
2. Brown Bread
3. Wholemeal bread
4. Rye bread
Apart from above there are several types like Crisp bread, Flatbread is often simple, made with flour, water, and salt.
Microbial spoilage
Molds are the primary spoilage organisms in baked goods, with Aspergillus, Penicillium, and Eurotium being the most commonly isolated genera.
Quality control
As a foodstuff, bread is subject to stringent government food processing regulations, including, but not limited to the percent of additives allowed, sterilization of plant equipment, and cleanliness of plant workers. In addition to adhering to these regulations, processors control the quality of their products to meet consumer expectations by installing checkpoints are various stages of the processing.
Fermented sausages
Products are usually made from comminuted meat and fat, mixed with salt, curing agents, sugar and spices, and filled into casings, and are referred to as "fermented sausages".
It is one of the earliest form of meat processing.
Most of their characteristic sensory properties to the action of salt, curing agents, and proteolytic muscle enzymes only.
Fermented sausages have their longest tradition in Southern and Central Europe.
Salting and drying of unground meat was the traditional way of meat preservation in Germany and other European countries
Considering various criteria, such as moisture content, moisture : protein ratio (M : P), a w , surface treatment, meat and geographical region.
These parameters are mainly applied in Europe or in the United States.
In terms of shelf life and safety, moisture content alone is not sufficiently informative compared with a w and pH values.
More specifically, M : P ratio provides information about the extent of drying of the lean meat portion.
Considering various criteria, such as moisture content, moisture : protein ratio (M : P), a w , surface treatment, meat and geographical region.
These parameters are mainly applied in Europe or in the United States.
In terms of shelf life and safety, moisture content alone is not sufficiently informative compared with a w and pH values.
More specifically, M : P ratio provides information about the extent of drying of the lean meat portion.
Considering various criteria, such as moisture content, moisture : protein ratio (M : P), a w , surface treatment, meat and geographical region.
These parameters are mainly applied in Europe or in the United States.
In terms of shelf life and safety, moisture content alone is not sufficiently informative compared with a w and pH values.
More specifically, M : P ratio provides information about the extent of drying of the lean meat portion.
Bread is the product of baking a mixture of flour, water, salt, yeast and other ingredients. The basic process involves mixing of ingredients until the flour is converted into a stiff paste or.
How bread is made step by step?
How is bread produced?
What is the process of making bread?
Where is bread produced?
bread manufacturing process flow diagram
bread manufacturing process
bread making process in factory
how bread is made in a bakery
how is bread made in factories
how is bread processed
production of bread by fermentation
process of making bread from wheat
fermentation an ancient food processing technologies in world,uses of fermentation includes biological enrichment of food,helps to preserve food, decrease cooking time, an ancient tradition method, science of fermentation is Zymology, beneficial bacteria inhibits bad micro organisms growth. fermented foods of africa,asia, china,babylon and pakistan
Fermented sausages
Products are usually made from comminuted meat and fat, mixed with salt, curing agents, sugar and spices, and filled into casings, and are referred to as "fermented sausages".
It is one of the earliest form of meat processing.
Most of their characteristic sensory properties to the action of salt, curing agents, and proteolytic muscle enzymes only.
Fermented sausages have their longest tradition in Southern and Central Europe.
Salting and drying of unground meat was the traditional way of meat preservation in Germany and other European countries
Considering various criteria, such as moisture content, moisture : protein ratio (M : P), a w , surface treatment, meat and geographical region.
These parameters are mainly applied in Europe or in the United States.
In terms of shelf life and safety, moisture content alone is not sufficiently informative compared with a w and pH values.
More specifically, M : P ratio provides information about the extent of drying of the lean meat portion.
Considering various criteria, such as moisture content, moisture : protein ratio (M : P), a w , surface treatment, meat and geographical region.
These parameters are mainly applied in Europe or in the United States.
In terms of shelf life and safety, moisture content alone is not sufficiently informative compared with a w and pH values.
More specifically, M : P ratio provides information about the extent of drying of the lean meat portion.
Considering various criteria, such as moisture content, moisture : protein ratio (M : P), a w , surface treatment, meat and geographical region.
These parameters are mainly applied in Europe or in the United States.
In terms of shelf life and safety, moisture content alone is not sufficiently informative compared with a w and pH values.
More specifically, M : P ratio provides information about the extent of drying of the lean meat portion.
Bread is the product of baking a mixture of flour, water, salt, yeast and other ingredients. The basic process involves mixing of ingredients until the flour is converted into a stiff paste or.
How bread is made step by step?
How is bread produced?
What is the process of making bread?
Where is bread produced?
bread manufacturing process flow diagram
bread manufacturing process
bread making process in factory
how bread is made in a bakery
how is bread made in factories
how is bread processed
production of bread by fermentation
process of making bread from wheat
fermentation an ancient food processing technologies in world,uses of fermentation includes biological enrichment of food,helps to preserve food, decrease cooking time, an ancient tradition method, science of fermentation is Zymology, beneficial bacteria inhibits bad micro organisms growth. fermented foods of africa,asia, china,babylon and pakistan
COMMERCIAL COOKING (complete instructional material) By: Mary Krystle Dawn D....Mary Krystle Dawn Sulleza
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At Taste Of Middle East, we believe that food is not just about satisfying hunger, it's about experiencing different cultures and traditions. Our restaurant concept is based on selecting famous dishes from Iran, Turkey, Afghanistan, and other Arabic countries to give our customers an authentic taste of the Middle East
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2. SAUSAGE MAKING EQUIPMENTS
THERMOMETER
Ensuring that raw meat does not get warmer than 40° F during processing
To measure the internal temperature of cooked sausages
Most sausages are considered fully cooked when they reach an internal
temperature of 160° F
SCALE
A scale that can be calibrated in either ounces or grams before each use will make the task of weighing the meat
and other ingredients .
3. A coarse grind is made with a plate with 1/4, 3/8 or 1/2inch holes;
Fine grind is produced by 1/8 or 3/16-inch holes. It is important to keep the knife
blades sharp because dull equipment produces excessive heat and makes a smeared
product
After the first grinding of the meat and all of the spices have been mixed in, a
stuffing horn may be attached to the grinder for the second grind to fill sausage
casings.
MEAT GRINDER
4. Cuts meat with high-speed rotating blades and a bowl that also rotates.
Produce finely ground, emulsified batter for sausages like bologna or hotdogs
Can used instead of a grinder at slower speeds, although the cost of
a bowl chopper may be outside the price range for most small processors.
The chopper warms the emulsified batter (63° F) through friction to
allow meat proteins to encapsulate microscopic fat particles.
An electric piston sausage stuffer will fill casings much more quickly than a hand-operated,
screw-type, and with fewer air pockets.
BOWL CHOPPER
SAUSAGE STUFFER
5. STEPS FOR PROCESSING
RAW MATERIALS
MEAT PREPARATION
REFRIGERATION
GRINDING
FLAVOURING MIXTURE
KNEADING
REFRIGERATION
FILLING AND TYING
DRYING SMOKING & COOKING
COOLING, PEELING & SLICING
PACKAGING, LABELLING &
STORAGE
6. RAW MATERIAL
• Minced meat
• 1/3 fat cuts + 2/3 low fat cuts
• pH= 5.5 to 5.6
• Initial microbial load= <105 cfu/g
• Listeria monocytogens and salmonella are absent
Removal of tendons and connective tissues
Weighing
Cutting in to pieces
MEAT PREPARATION
7. REFRIGERATION
• To facilitate grinding
• Temperature = 0 to 2˚C
FINE= 1- 4 mm
COARSE = 4- 14 mm
Manual/power grinders
Grind each meat through a 3/8-inch coarse plate. Add the spices and other
ingredients, mix, and then grind again through the final 1/8- or 3/16-inch plate
GRINDING
8. FLAVOURING MIXTURE
cut the meat into 1 to 2 inch squares. Spread the meat in the bottom of a large pan. Then sprinkle
spices (Salt, sugar, spices, additives, ascorbic acid, sodium nitrate and nitrites)
Add water, ice, or wet ingredients last and mix again.
ASCORBIC ACID
Maintains intense red color
Inhibit spoilage and pathogenic microbes
(LAB)+ pediococcus
L. Sakei, L. curvatus, L.plantarum
CNC ( coagulase negative cocci + staphylococcus+ kocuria spp)
S. xyllosus, S. saprophyticus
Helps in stability of color
Penicillium (fungus)
STARTER CULTURE
9. KNEADING
Allow distribution of ingredients & meat fat homogeneously
In low temp& absence of oxygen
PURPOSE:
Time and temperature= 24 hrs at 0 to 2˚C
Salt diffusion
Color formation
REFRIGERATION
Prevents fat melting
Prevents microbial growth
Prevent color changes
10. STUFFING AND LINKING
Simple stuffer – horn (too much air remains in the ground meat)
Sausage stuffer - minimal air pockets and less risk of pathogenic bacteria
Stuffing of meat into casings using vaccuum (avoids air bubbles & aerobes) machine
Casings- soft, elastic ,porous, easy to remove
Natural - intestine based
Artificial- starch based
Tying of casings : to prevent leakage of meat
Put some meat through the stuffing horn until it is filled and the sausage mixture starts to peek out
Hold the casing at the mouth of the horn with the thumb and forefinger, and allow it to slide off
under the fingers as the sausage is pumped in.
formed by tying the casing with cotton string after stuffing.
LINKING OR TYING
11. FERMENTATION
Temperature = 25-27˚C
RH= 65-75%
Species: LAB & pediococcus
Products - lactic acid, acetic acid, ethanol, acetoin, pyruvic acid, CO2
Temperature= 16- 22˚C
RH= 55-65%
Drying and end of lactic acid fermentation
Mold growth on surface
1) creates micro holes-enhances water loss
2) Acts as protective layer( light & autoxidation)
Final pH = 4.9 to 5.3(after fermentation)
DAY 1&2
DAY 3 to5
12. RIPENING
Smoking chamber
Temperature = 50-60˚C
Presence of mold layer prevents excessive drying
1.
• Temp= 13- 15˚C
2. • RH = 75-90%
3. • Time = 2 weeks
4. • Weight loss= 18-35%
5. • Final pH=5.6- 5.7
6. • Development of flavor and color
DRYING
13. SMOKING
• The surface of the sausage must be slightly moist for the smoke to properly penetrate the casing.
• Wood smoke
• Temperatue = 50-60˚C
• Continues until desired aroma and color is achieved
HOT SMOKING = 105–125° F (pre-dring )of surface, at 185° F (proper surface drying),
RH= 35- 45%
COLD SMOKING = 53.6–77° F for several hours up to about 16 days light, color= brown to dark
brown
LIQUID SMOKE = half-teaspoon of liquid smoke to one pound of sausage
In water bath at 160º F to 175º F until the internal temperature reaches 160º F or
loaf pans (like meatloaf) and cooked in the oven at 200º F
TYPES
14. SMOKE HOUSES
Kettle-type barbecue grills , Electric portable smokers
HEAT SOURCE = Electric hot plate, charcoal
Damp sawdust or wood chips
VENTS - Top and bottom for draft control to
regulate the temperature and smoke
15. COOKING
Steam temp= 75˚C
Till core temperature= 72-73˚C
Pork &beef = 158˚F
Poultry= 160˚F
vit A = resistant, but depleted in chopping
16. IMPORTANT CONSIDERATIONS IN SAUSAGE MAKING
Meat products are extremely perishable and must be maintained under refrigeration
(40º F or below).
A calibrated (traced to the National Institute of Standards and Technology [NIST] standard)
thermometer is necessary to ensuring that raw meat and meat ingredients do not exceed 40°
After the product has been formulated, smoke and cook it to the required temperature, and then
return the product to refrigeration.
1) TEMPERATURE
17. 2) WEIGHTS
• A calibrated weighing scale is the second most critical piece of item
• The proper ratio of beef to pork, or of lean meat to fat, is specific to certain types
of sausage.
• The scales must be checked for accuracy using a standard weight according to the
manufacturer’s recommendation and should be recorded on the scale calibration
log.
3) FAT CONTENT
Avoid making the formula too lean as the sausage will be too dry and hard.
Fresh pork sausage contains 30 to 45 % fat.
Smoked or roasted sausage contains 20 to 30% fat
18. STORAGE
The length of time a sausage can be stored depends on the type of sausage.
1.
• Fresh sausage is highly perishable and will only last seven to
10 days under refrigeration (35° to 40° F). However, it may
be frozen for four to six months if wrapped in moisture-vapor
proof wrap (freezer paper) or freezer-weight zip bags.
2.
• Smoked sausages that contain salt and nitrite and have been
cooked, may last from 2 to 4 weeks under refrigeration.
• Eg: smoked, Polish, cotton-salami and bologna.
3.
• Summer sausages that have been fermented to produce the
acidic tangy flavor are more durable and may be stored for
several weeks in the refrigerator
19. SANITATION
Bacterial contamination and foodborne illness are the main food safety concerns during raw
meat handling and sausage making. In order to prevent the spread of pathogenic bacteria,
the food preparation area and equipment must always be cleaned and sanitized before and
after processing sausages.
USDA FSIS requires that meat and poultry establishments should develop and implement a
written Standard Operating Procedure for sanitation (SSOPs).
Sanitation SOPs must address in detailed procedures for the facility, equipment, and utensils
on a daily basis to prevent direct product contamination or adulteration.
20. FOOD MANUFACTURING FACILITIES
Ceiling, walls, and floors must be smooth, sealed, and moisture-free.
Drains should be operative and clean with no standing water.
Pipes and insulation should be dry and well-maintained.
Doors and windows should be tight-fitting and sealed to prevent intrusion by pests or dust.
Overhead pipes, rails, and conveyors should be accessible, easy to clean, and free of condensate
Air supply should be dry and filtered.
Production equipment should be free of recesses, open seams, gaps, protruding ledges, inside threads,
inside shoulders, exposed bolts and rivets, and dead ends where product could build up and cause
problems.
Pallets should be well maintained, clean, and dry.
Blowers and ducts must be cleaned on a routine basis and air filters should be changed as needed.
Refrigeration units and coolers must be cleaned and sanitized on a frequent routine.
21. FOOD CONTACT SURFACES
• Properly cleaned and sanitized food contact surfaces are critical to ensuring a safe, sanitary
operation. Use of recommended and approved cleaners and sanitizers will reduce levels of
pathogenic organisms to prevent cross contamination of the product.
• Detergent cleaners suspend and help remove various food soils.
• Chemical sanitizers reduce the numbers of pathogens and other microorganisms
22. CAUTIONARY MEASURES
Avoid contaminating cleaned surfaces with aerosols or overspray.
Use potable water rinse; without a potable water rinse, USDA regulations permit water mixed
with: 200 parts per million quaternary ammonia, or 25 parts per million iodine, or 200 parts per
million available chlorine.
Verify the effectiveness of sanitation procedures by microbiological monitoring.
Document the results and any corrective action that is taken on the daily production log form.
Do not limit sampling to flat surfaces. Record results of microbiological sampling on the
production log. Re-clean any area that does not meet standards.
23. NON-FOOD CONTACT SURFACES
Clean and sanitize floors routinely. The frequency (e.g., daily, weekly) of cleaning depends upon
the type of operation and whether the floor can be kept clean and dry.
Use extensive cleanup and sanitation procedures following drain backup, prior to resuming the
packaging operation.
Remove excess water from floors after cleanup.
Avoid splashing or the formation of aerosols during the final stages of cleanup when equipment is
clean and ready for sanitizing.
Assure outer protective clothing of cleaning crew is properly washed, sanitized, and dried after
use
24. PREVENTION OF CROSS-CONTAMINATION
Establish traffic patterns to prevent movement of personnel, meat containers, meat, ingredients,
pallets, and refuse containers between raw and finished product areas
Changing of outer clothing and washing and sanitizing tools and hands are required of all
personnel, including maintenance personnel, before entering processing areas.
Employees must change outer clothing before moving to processing product areas.
Hallways common to raw and processing areas must be kept clean and dry. Frequent use of
vacuum scrubbers is recommended.
Restrooms, locker rooms, and lunchrooms should be kept clean and orderly
25.
26. CRITICAL OPERATIONS
EQUIPMENT WASH AREAS
Spread of Listeria and other pathogenic and spoilage microorganisms.
In order to prevent foodborne illness:
Separate wash areas for raw and processed products must be maintained.
Wash areas should be located where clean processing equipment does not cross raw-meat areas of the plant.
A visual pre-operations inspection of all processing areas should be done each morning before the start of
processing and documented on the daily processing form.
SLICING AND PACKAGING EQUIPMENT
Complete mechanical disassembly is required to prevent contaminants from accumulating and to allow
thorough sanitation.
Moisture must be controlled during production and breaks. Use disposable wipes soaked with sanitizers to
clean work areas
Protective covers over control panels, motors and equipment, and other food contact surfaces may be a
source of microbial contamination.
Heat shrinking equipment, including exhaust ducts, must be cleaned and sanitized daily to avoid spreading
contamination from water and steam to packing lines
Install conveyors that are easy to clean. They should be at a height that avoids contamination from floors
and drains.
27. PATHOGENS OF CONCERN IN SAUSAGE MAKING
TRICHINELLA SPIRALIS (parasite)
Deadly disease- Trichinosis, Trichina parasite larvae commonly infest pork muscle, so most
cases occur in persons who have consumed improperly treated or prepared pork products
USDA FSIS requires that all pork be treated to destroy the parasite via heating, refrigeration,
freezing, or curing .A temperature of 144º F is considered fatal to all trichinae organisms.
ESCHERICHIA COLI O157:H7 (E. COLI)
Bacterial contaminant of sausage
cause serious diarrheal illness, sometimes resulting in complications that can lead to death
CONTROL-closely controlling the fermentation heating process and the acid content and
via post-fermentation heating to 145º F or above.
28. SALMONELLA
“Salmonellosis” is a leading cause of foodborne illness in the U.S.
Eliminated from cooked sausages by proper cooking processes, careful control of the product pH, cure,
and salt content.
LISTERIA MONOCYTOGENES (LM)
serious infection in humans called “listeriosis.”
processing environments and has been isolated from floor drains and refrigeration drip pans. From
these niches, the organism gets moved throughout the facility and can end up on food contact surfaces.
Regular sampling the processing lines and environment.
CAMPYLOBACTER JEJUNI
It is the most commonly reported bacterial cause of foodborne infection in the U.S
CONTROL- forced air chilling of swine carcasses and implementation of standard hygienic practices.
YERSINIA ENTEROCOLITICA
The pathogen that causes the gastroenteritis illness, is another pathogen of concern