09/04 Curing and Sausage page 1

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1 Slide 1 Curing and Sausage Making Safe Food Principles Retail Meat & Poultry Processing Training Modules Speaker Notes The Curing and Sausage Making module looks at the hazards associated with curing and making sausage. It focuses on safe food handling practices and principles to consider so a safe and tasty product is produced. Slide 2 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 This module was developed by the Minnesota Department of Agriculture with expertise and resources from the Hennepin County Environmental Health, Minnesota Department of Health and the University of Minnesota Extension Service. The Retail Meat and Poultry Processing Training Modules were produced under a cooperative agreement with the United States Department of Agriculture Food Safety Inspection Service. Food safety regulators, trainers and representatives from the food industry provided input on the final product at prior training sessions showcasing the Retail Meat and Poultry Processing Training Modules. Note: Rules and regulations cited may be specific to the Minnesota Food Code. These may differ for you, if you adhere to other standards and regulations. 09/04 Curing and Sausage page 1

2 Slide 3 Pretest Administer Pretest: Before we start the Curing and Sausage Making training, let s see how much you already know. I ll be giving you a test before the training and the same test after the training. The results will show what you already know and what you have learned during the presentation. Note: Make two copies of the Curing and Sausage Making pretest/posttest for each student. Copy on different colored paper to separate the pretest and the posttest. Ask participants to circle the word pretest. Pretest/posttest is found on the CD (Curing and Sausage Making folder) and in the Curing and Sausage Making Activity section of this guide. Slide 4 History Sausage definition Types of sausage Role of ingredients Function of cure Cure rates Casing label requirements HACCP Plan Topics Critical control points Steps in processing Cooking temperatures Cooling guidelines Packaging Labeling requirement Storage and display Jerky Review topics in slide. Question: Any thing else that you hoped would be covered in this session today? Slide 5 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. After this training you should be able to: 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. 09/04 Curing and Sausage page 2

3 Slide 6 Slide 7 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 The production of sausage has a long history. It is one of the earliest forms of food preservation. The word sausage is derived from the Latin word Salsus which means salted meat. According to the Meat Processing, North American Division, today, U.S. meat processors produce 500 million pounds of cooked sausage each year. Reference: Meat Processing, North American Division, Best Practices for Cooked Sausage: Controlling the Process for Safety and Quality #588, November Because of lack of refrigeration, salt was used in amounts needed to preserve sausage to a level safe at room temperature. Today, sausage formulas/recipes call for 1-3% salt. This is not at preservation levels but added for flavor. Slide 8 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 Sausage is a mixture of ground or chopped meats combined with spices and other ingredients and usually formed or shaped in casings of various sizes. 09/04 Curing and Sausage page 3

4 Slide 9 Slide 10 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 There are four main types of sausage: 1. Fresh sausage no cure added for preservation, product not cooked. 2. Cooked sausage fully cooked and ready-to-eat. 3. Fermented sausage fermented to increase shelf life of product tangy summer sausage is an example of a fermented sausage. 4. Meat loaves and jellied products meat chunks are added to the product. Activity: Food Safety Hazard Quiz (See Activities for Curing and Sausage Making). There are food safety hazards associated with sausage products. Controlling for these hazards throughout the entire process is needed for a high quality and safe product. (Distribute copies of the Food Safety Hazard Matching Quiz to each student. Allow 3-5 minutes to complete it. Discuss and review answers.) Support Material: Foodborne Microorganism Chart Fresh sausage is just what its name says. It is made from raw/uncooked ground meat. It may be flavored with added spices but no curing agents nitrite or nitrate have been added. Examples are fresh pork sausage, fresh bratwurst and fresh Italian sausage. These products need to be cooked before eating. Question: Can you think of any other examples of a fresh sausage product? 09/04 Curing and Sausage page 4

5 Slide 11 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 Cooked sausage is a fully cooked readyto-eat sausage. Product needs to be refrigerated. It does not need to be reheated to 165 F unless you are going to hold it hot. Wieners, smoked sausages, bologna and cooked bratwurst are examples. Question: Are there other sausage products you make or stock that are cooked? Slide 12 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 Fermented sausages are known for there tangy flavor. This type of sausage has gone through a fermentation process by lactic acid producing bacteria or adding encapsulated acids. If properly acidified and dried, fermented sausages can be shelf-stable. Semi-dry and dry are two types of fermented sausages. Summer sausage and snack sticks are semi-dry. Pepperoni and hard salami fall under the dry category. Slide 13 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 Meat loaves are mixtures of chopped meat that are usually formed and cooked in pans or metal molds for shaping. Here s a picture of a pepper loaf. Pickle and pimento loaf and honey loaf are other examples of meat loaves. A cooked mixture of meat chunks placed in gelatin is called a jellied product. Examples include jellied roast beef and head cheese. 09/04 Curing and Sausage page 5

6 Slide 14 Slide 15 Sausage Ingredients: 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. Common sausage ingredients include meat, salt, spices, cure, reducing agents, binders and extenders, water and casings. Each ingredient plays a role in the type of sausage produced. In the next few slides we will look at each of these ingredients. Activity: It s All About Sausage! (See Activities for Sausage Making Section). It s All About Sausage! Is a matching quiz of the ingredients used in sausage making and the role they play. This activity can be used to introduce the topic on ingredients or can be used at the end to assess understanding. Meat is the main ingredient in sausage. Use only fresh quality meat. Question: What will happen if you bury old meat in sausage? (Answer: off-flavors, spread of bacteria, and spoilage problems.) Check raw materials upon receiving to make sure they meet requirements and specifications. Use raw materials on a first in, first out basis. Keep meat cold, 41 F or less during storage and throughout the production process. Question: How do you know the meat is 41 F or colder? (Answer: Use a thermometer.) Thawing frozen raw meat needs to be done under refrigerated conditions of 41 F or cooler. Check product during thawing for product drip and temperature. Separating raw product in preparation from finished cooked product is important to prevent potential contamination. 09/04 Curing and Sausage page 6

7 Slide 16 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 Salt is a standard in a sausage recipe. 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 Slide 17 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 For best flavor and consistency, use fresh spices and seasonings. If using pre-packaged spices, check use-by dates. Store spices and seasoning mixes at 55 F or below in airtight containers. This maintains freshness and prevents insects from hatching out. Slide 18 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 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. Slide 19 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 has several functions. It provides protection against the growth of clostridium botulinum the bacterium that causes the foodborne illness called botulinum. It extends the shelf life of the product. It also helps to stabilize the flavor of the cured meat. Cure is also used to achieve the characteristic flavor and color of the sausage product. 09/04 Curing and Sausage page 7

8 Slide 20 Slide 21 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 Nitrate is converted to nitrite during the fermentation/cooking process. 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 Most sausage makers used commercial pre-mixes. In your recipe make sure you include pre-mix name and pre-mix code number. Update recipe if you change brands. Following manufacturer directions is critical to the process. Not following the manufacturer s directions will produce an unsafe and illegal product. Precise measuring by a digital scale needs to be part of the plan. Slide 22 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 Once we have the correct amount of cure, we need to add it to the meat. A variety of methods commonly used in sausage making are: injecting the cure with a syringe, using a tumbler to force the cure in the muscle or soaking in brine containing the cure. Question: What method do you use to add cure? 09/04 Curing and Sausage page 8

9 Slide 23 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 Regulations allow the use of 7/8 ounce per 100 lbs of meat for curing accelerators to speed up the curing process and reduce the amount of holding time. Ascorbic acid or (Vitamin C) or sodium erythorbate (isoascorbic acid) are often used as a curing accelerator. Follow manufacturer directions on label. Slide 24 Slide 25 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 Binders and extenders are commonly found in a sausage formula. A binder improves flavor and retains natural juices. An extender can reduce production costs by adding an ingredient to replace some of the meat that is needed. Nonfat dry milk, cereal flours and soy protein products are often used. Milk, soy and wheat are common food allergens. You must list these on the ingredient list of the label. Support Material: Allergen Facts: Food Allergies and Food Ingredients 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. Its Standard of Identity regulates the amount of water added to the product. 09/04 Curing and Sausage page 9

10 Slide 26 Slide 27 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). 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. There must be concern for potential allergen exposure with different casing types, as well as, religious and ethnic preferences. Allergen and Kosher label requirements must be met. 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). Slide 28 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. Each sausage product should comply with Standard of Identity for meat processors. Variety meats include organ meats, glands and other meats that are not part of a dressed carcass. This may include liver, kidneys, brains, heart, tongue, tripe, feet, tail, and cheek meat. Liver and heart may be frozen as well as fresh. Tongue may be fresh, pickled, corned and smoked. Tripe is the lining of a cow s stomach. Pig s feet, or trotters, are available fresh, pickled and smoked. 09/04 Curing and Sausage page 10

11 Slide 29 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. Smoked or cured products require a HACCP Plan for safe production of products. A HACCP (Hazard Analysis Critical Control Points) Plan identifies all of the hazards in the sausage making process. Let s look at each HACCP step for sausage making. Slide 30 Slide 31 Steps in Processing Particle Size Reduction: 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 Step 1 is to conduct a hazard analysis looking at different factors that could affect the safety of your product. The purpose of HACCP is to identify food safety hazards not quality factors. Hazards are categorized as chemical, physical or biological hazards; only those that are reasonably likely to occur are to be considered. The hazard analysis must look at all of the processes for making sausage. Once the hazards are identified, you must identify critical control points. These are steps or procedures in the process where those identified hazards can be prevented, eliminated, or reduced to acceptable levels. Cooking in a cooked sausage product is a critical control point. The cook or smoking step is critical to kill disease-causing organisms in cooked sausage. The next step is to establish critical limits. These are a maximum or minimum value to which the hazard must be controlled at the critical control point. 158 F is considered adequate for pork and beef and 160 F is considered adequate for poultry. Corrective actions are taken when the monitoring shows that a food safety hazard is out of control at a critical control point. After the critical limit values are established, you must determine how 09/04 Curing and Sausage page 11

12 Slide 32 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 that value will be monitored and how often it will be monitored. Temperature records should follow a lot or sub-lot all the way through production. FSIS regulations require temperature to be monitored and recorded. Record keeping procedures are important in making and keeping a HACCP system effective. Temperature logs and batch records are examples of records that demonstrate that the plan is being followed. Verification procedures help make the HACCP plan work correctly. Documentation throughout the sausage making process is needed to document batch identification so it can be traced throughout the production chain. USDA s FSIS defines a production lot as being from full sanitation to full sanitation. Activity: Name That Temperature (See Activities for Curing and Sausage Making Section) This activity reviews all of the required temperatures throughout the flow of the sausage making process. Reference: FSIS: Appendix A: Compliance Guidelines for Lethality USDA Cooling Curve: 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. Sausage products must be cooled properly after cooking. Put in covered container or package as soon as possible after the product is cooled. Reference: FSIS Appendix B: Compliance Guidelines for Cooling Heat- Treated Meat and Poultry Products, Stabilization 09/04 Curing and Sausage page 12

13 Slide 33 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 Care must be taken to prevent cross contamination of cooked meats prior to packaging. Keep food covered or packaged at all times to significantly reduce the possibilities of being contaminated by other foods or the environment. Specific procedures must be followed if cooked meat products are vacuum packaged. When packaging ready-toeat sausages limit bare hand contact. Use utensils, tissues or gloves. As you are preparing to package the product cutting, slicing and preparing foods temperature is again a consideration. Extended periods of time out of refrigerated storage could allow for bacteria to grow. Only take out a limited quantity of foods at a time and return them to the cooler or place in a retail display case immediately. If the packaging operation gets interrupted for any reason, put the products back into the cooler until you resume the operation. Always be sure the vacuum packaged products are re-chilled to 41 F or less. Leave plenty of space for the cold air to circulate around the packages; if stacked too tightly, food might not cool quickly enough. Another of the primary controls is the limitation on the kinds of products that can be vacuum packaged at retail. Remember the only foods that can be vacuum packaged at retail are raw meat and poultry, hard and semi soft cheeses, and any cooked or smoked meats (only if they are cured). Foods that CAN NOT be vacuum packaged at retail include cooked turkey (like turkey lunch meats), cooked roast beef or pork (like products for slicing, prime rib, or shredded beef or pork), cooked sausages that do not contain cure (bratwurst), soft cheese such as brie, cheese spreads, sandwich 09/04 Curing and Sausage page 13

14 spreads, salads, cooked or raw vegetables, or any raw or cooked fish that is not frozen. Support Materials: Food Products that can or cannot be ROP Slide 34 Slide 35 When packaging ready-to-eat foods, limit bare hand contact Utensils, tissues or gloves must be used Packaging 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 When preparing foods for packaging and when placing the foods in the ROP vacuum packaging bags, employees must not touch the food with their bare hands. A utensil, tissues or single use gloves must be used. While single use gloves can provide a barrier to transferring bacteria onto foods, they must be used properly. Hands must be properly washed before putting gloves on and when they are removed. Gloves must be changed frequently, especially after any interruption in the process when the gloves may have become contaminated. Support Materials: Hand Sanitizers and Gloves, Minnesota Food Code Fact Sheet Bare Hand Contact Fact Sheet Hand Washing, Minnesota Food Code Fact Sheet 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. 09/04 Curing and Sausage page 14

15 Slide 36 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 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. Slide 37 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 doesn t fall into the sausage category. Many retail and small meat processors make jerky. Jerky processing requires special procedures for a safe product. 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 Slide 38 Slide 39 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 is usually 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. To dry jerky lay out strips on a sheet in a single layer. Lay the meat slices on a grill or grate that allows air to reach all parts of the slice. After jerky is cooled, store in a cool dry area, in a sealed container. Jerky must be stored in a sealed container to prevent it from taking on moisture from the air. It will rehydrate if in contact with moisture. Refrigerate at retail level. 09/04 Curing and Sausage page 15

16 Slide 40 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 160 ºF 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. Slide 41 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 To summarize: 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 Slide 42 Wrap-Up Do you have any questions? What information was new? How will you apply what you learned today? Posttest Are there any questions?? (Answer questions.) I have a couple of questions for you: 1. What information was new today? 2. How will you apply what you learned today? Administer Posttest: Now it s time to take the posttest. Let s see what you have learned during the presentation. Note: Distribute a copy of the Curing and Sausage Making pretest/posttest to each student. Ask participants to circle the word posttest. Pretest/posttest is found on the CD (Curing and Sausage Making folder) and in the Curing and Sausage Making Activity section. 09/04 Curing and Sausage page 16