Lesson 1Stuffing and casing selection: portioning accuracy, casing types (collagen, fibrous, natural), casing prep and seam integrityCover stuffing operations an casing selection fi sausages. Discuss portioning accuracy, collagen, fibrous, an natural casings, casing preparation, linking, an seam integrity checks to avoid burst, air pockets, an leakage.
Selection of collagen, fibrous, and natural casingsCasing soaking, flushing, and handling hygienePortioning accuracy and stuffer calibrationLinking, clipping, and loop formationSeam integrity checks and defect controlLesson 2Grinding and particle size control: grinder settings, follower plates, temperature control, and cross-contamination avoidanceFocus pon grinding operations an particle size control fi sausage batters. Cover grinder selection, plate an knife combinations, temperature management, prevention a smear, an cross-contamination control between meat batches.
Grinder capacity, knives, and plate selectionTarget particle sizes for sausage stylesTemperature control to prevent fat smearSanitary changeover between meat batchesMetal-to-metal contact and wear checksLesson 3Final vacuum packaging steps: vacuum levels, vacuum chamber operation, gas purge considerations if used, seal formation and integrity checksDescribe final vacuum packaging operations fi sausages, including vacuum level settings, chamber operation, optional gas purge, an seal formation. Emphasis pon pack integrity checks, leak testing, hygiene, an labeling before cold storage.
Vacuum level selection and pump performanceChamber loading, cycle setup, and timingGas purge options and residual oxygen limitsSeal bar setup, width, and temperatureSeal inspection, leak tests, and reworkLesson 4Reception, storage, and trimming: objectives, equipment, contamination control, and yield optimizationCover reception a meat an ingredients, chilled storage conditions, trimming methods, an hygienic handling. Emphasis pon contamination control, correct equipment use, an yield optimization through precise cutting an waste reduction.
Raw material receiving checks and documentationChilled storage temperatures and time limitsHygienic trimming methods and tool sanitationTrimming specs for fat, sinew, and defectsYield calculation and loss minimizationLesson 5Mixing and massaging/emulsifying: protein extraction principles, salt and phosphate function, sequence of ingredient addition, temperature control to prevent protein denaturationExplore mixing, massaging, an emulsifying a sausage batters. Explain protein extraction, salt an phosphate roles, order a ingredient addition, an strict temperature control to avoid over-extraction, fat separation, an denaturation.
Myofibrillar protein extraction principlesSalt, phosphates, and functional ingredientsSequence of ingredient and ice additionMixer speed, time, and vacuum mixingTemperature limits to prevent denaturationLesson 6Thermal treatment options and parameters: scalding, cooking to internal core temperature targets, pasteurization vs full cook, and recommended core temperatures for beef sausagesDetail thermal treatments fi sausages, including scalding, cooking to target core temperatures, an pasteurization versus full cook. Discuss time–temperature combinations, lethality, texture impacts, an beef sausage temperature guidelines.
Scalding conditions and surface decontaminationTime–temperature profiles for cookingPasteurization versus full cook decisionsCore temperature targets for beef sausagesVerification of thermal process lethalityLesson 7Finished product cold storage and dispatch: storage temperature targets, FIFO, pallet and load management for supermarket distributionExplain finished product cold storage an dispatch fi supermarket supply. Include storage temperature targets, humidity, FIFO systems, palletizing, load securing, an loading practices dat maintain product safety an shelf life.
Cold room temperature and humidity targetsFIFO and stock rotation documentationPallet configuration and wrapping methodsTruck pre-cooling and loading sequenceTemperature monitoring during transportLesson 8Cooling and chilling processes: cooling curves, blast chilling, core cooling times to reach safe storage temperatures, cold-hot transfer controlsExplore cooling an chilling a meat an stuffed sausages, including cooling curves, blast chilling, an core temperature targets. Focus pon rapid passage through danger zone, airflow control, loading patterns, an monitoring a cold-hot transfers.
Cooling curve interpretation and validationBlast chiller settings and loading patternsCore temperature targets and probe useControl of cold-hot transfers between roomsRecording and verification of chilling dataLesson 9Temporary storage, metal detection/X-ray, trimming of defects, and batch traceabilityAddress temporary storage between steps, in-line metal detection or X-ray inspection, trimming a visual defects, an batch traceability. Emphasis pon segregation a holds, rejection criteria, an accurate record keeping.
Time and temperature limits for interim storageMetal detector and X-ray sensitivity settingsDefect trimming standards and rework rulesBatch coding, labels, and data captureHandling of nonconforming or held product
