Lesson 1Stuffing and casing selection: portioning accuracy, casing types (collagen, fibrous, natural), casing prep and seam integrityCovers filling sausages and picking casings. Talks about exact portion sizes, collagen, fibrous, natural types, prep, linking, and seam checks to stop bursts, air gaps, and leaks.
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 avoidanceFocuses on grinding and size control for sausage mixes. Covers grinder choice, plates and knives, temp handling, stopping smears, and germ spread between 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 checksDescribes last vacuum packing for sausages, with vacuum strength, chamber use, gas flush if needed, and seal making. Stresses pack checks, leak tests, cleanliness, and labels 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 optimizationCovers receiving meat and ingredients, cold storage, trimming ways, and clean handling. Stresses germ control, right gear use, and better yields by good cutting and 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 denaturationLooks at mixing, massaging, emulsifying sausage mixes. Explains protein pulling, salt and phosphate jobs, add order, and tight temp control to avoid too much pull, fat split, and damage.
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 sausagesDetails heat treatments for sausages like scalding, cooking to core temps, pasteurising vs full cook. Covers time-temp mixes, kill power, feel effects, and beef sausage temp guides.
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 distributionExplains cold storage and sending finished goods for shops. Includes temp targets, humidity, first-in-first-out, pallet stacking, load tying, and loading to 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 controlsLooks at cooling meat and filled sausages, with cooling paths, blast chill, core temp targets. Focus on quick pass through danger temps, air flow, stacking, and hot-cold moves.
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 traceabilityHandles short storage between steps, metal/X-ray checks, fixing visual faults, batch tracking. Stresses holding bad lots, reject rules, and good records.
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
