Lesson 1Stuffing and casing selection: portioning accuracy, casing types (collagen, fibrous, natural), casing prep and seam integrityCover stuffing work and casing pick for sausages. Talk portion accuracy, collagen, fibrous, natural casings, prep, linking, 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 on grinding and particle size for sausage mix. Cover grinder pick, plate knife combo, temp manage, stop smear, cross-contam 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 pack for sausages wid vacuum levels, chamber work, gas purge if any, seal make. Stress pack 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 meat and ingredient receive, chilled store, trim methods, clean handle. Stress contam control, right equipment, yield max wid cut right and waste less.
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, emulsify sausage mix. Explain protein pull, salt phosphate role, add order, strict temp to avoid over pull, fat separate, denature.
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 treatments for sausages wid scald, cook to core temp, pasteurize vs full cook. Talk time-temp combo, kill power, texture 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 secure, load practice wey keep safety and 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 and chill meat and stuff sausages wid cool curves, blast chill, core temp target. Focus quick pass danger zone, air flow control, load pattern, monitor 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 traceabilityHandle temp store between steps, metal detect or X-ray check, trim defects, batch trace. Stress separate holds, reject rules, good record keep.
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
