Lesson 1Stuffing and casing selection: portioning accuracy, casing types (collagen, fibrous, natural), casing prep and seam integrityCover stuffing and casing pick for sausage. Talk portion exact, collagen, fibrous, natural casing, prep, link, seam check to avoid burst, air pocket, leak.
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 grind work and particle size for sausage mix. Cover grinder pick, plate knife mix, temp manage, stop smear, cross-contam between batch.
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 pack for sausage, vacuum level, chamber work, gas purge if use, seal make. Stress pack strong check, leak test, clean, label before cold store.
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 receive meat ingredient, cold store condition, trim method, clean handle. Stress contam control, right machine use, yield better by exact cut, less waste.
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 mix, massage, emulsify sausage mix. Explain protein pull, salt phosphate role, order add ingredient, strict temp to avoid over-pull, fat split, spoil.
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 heat treat for sausage, scald, cook to core temp target, pasteurize vs full cook. Talk time-temp mix, kill power, feel effect, beef sausage temp guide.
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 finish product cold store and send for supermarket. Include store temp target, humidity, FIFO, pallet stack, load safe, load practice keep safety 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 cool chill meat stuffed sausage, cool curve, blast chill, core temp target. Focus quick pass danger zone, air flow control, load pattern, watch cold-hot move.
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 temp store between step, line metal detect or X-ray check, trim defect, batch trace. Stress separate hold, reject rule, good record.
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
