process control in smallgoods manufacture for smes · factory layout and operation (gmps and ssops)...
TRANSCRIPT
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Process control in smallgoods manufacture for SMEs
Steve Bonney and John Sumner
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Process control
Two aspects:
1. Control process for product quality (appearance, odour, taste) STEVE
2. Control process for food safety (HACCP) JOHN
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Modules we’ll cover
1. Basic unit operations: Ingredient addition, cutting/grinding/emulsifying, cooking, cooling, packing
2. Basics of HACCP: Hazards, Critical Control Points (CCPs), Critical Limits (CLs)
3. Low risk smallgoods: products consumed after cooking
4. High risk products: ready to eat smallgoods
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Smallgoods resources
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Controlling smallgoods processing
1. Process control – validation and verification of each process
2. Factory layout and operation (GMPs and SSOPs)3. Cleandown – trained staff, effective equipment/chemicals4. Microbiological monitoring of environment and product5. Interventions which give reductions in pathogens6. Ingredients to prevent growth of L. monocytogenes7. Sanitary slicing and packing8. Post-process pasteurisation in-pack (thermal and non-
thermal)
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There are a number of unit operations which are common to making all categories of smallgoods:
1.Size reduction of meat and fat – grinding – particle size
2.Emusifying – combining fat and meat into a smooth paste
3.Ingredient addition – colour, flavour, texture, food safety, shelf life
4.Filling into casings
5.Temperature control – cooking, cooling, storage
Unit operations combined into a process flow diagram
Module 1: Unit operations
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Unit operations
Raw materials
Brining
Ingredient addition*
Cooking* Fermenting
Cooling* Maturing
Slicing/packing
Comminuting
Filling
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Curing salts
Nitrite is a chemical hazard – important not to put in too muchCCPs:• Use premix• Weigh in isolation – no distraction – trained person needed• Use nitrite register
Nitrite is also necessary to inhibit germination of ClostridiumAdd so that it’s as close as possible to125ppm after cooking
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Process control for consistency
• Preparation of brine -Accurate mixing of ingredients using calibrated scales• Mixing of brine -Curing mix first, salt lastWater temperature: Less than 5° during pumping =
ideally < 2° atmixing
Brine ingredients precisely measured and mixed
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Process control for consistency
• Injection method hand pump or machine, pumping cycles
• Injection rate: green weight, pumped weight
• Product temperature: • < 5° at all times
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Process control for consistency
• Injection rateMust meet target %Starting weight/pumped weightPumping pressure
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Process control for consistency
Evenly cured pork loin
Un cured pork loin
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Process control for consistency
• Massaging/restingHelps with:Cure distributionMechanical massage action activates proteins to assist in muscle bindingResting time/holding cure approx. 48 h at 33% strengthCured product should be protected from light
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Process control for consistency
• Comminuting
• Temperature of product means clean cut & less protein damage
• Machine maintenance sharp blades & plates
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Process control for consistency
Correct mixing time and ingredient addition to activate proteins and achieve:• Solid bind• Uptake of water &
ingredients• Correct texture
Typical mincer/mixer
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Process control for consistency
• FillingCorrect filling techniques ensure:Consistent size/weight
Less oxygen in product
Better casing yield
More visually appealing
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Process control for consistency
• Poor filling technique results in:
Shorter shelf lifeInconsistent sizeLess casing yieldLess visually appealing
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Process control for consistency
• CookingImportant steps for consistency are:ReddeningDryingSmokingSteamingCore temperature
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Cooking kills target bacteria and changes meat into food
Australian Standard stipulates 65°C/10 min or an equivalent process at a higher and lower temperature
Cooking
Hams cooked in smoker oven
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Cooking
Australian Standard specifies 65°C/10min or equivalent heating at the site of microbiological control
Site of microbiological concern is where bacteria are located:• Entire muscle - bacteria are only on outside (can cook an
unpumped roast “rare”)• Injected muscle, comminuted sausages - bacteria are also
at slowest heating point Validate cooking (one time/worst case) using data logger and
probeVerify each batch using gauge or probeWorst case means items of largest diameter
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Cooling
Australian Standard specifies 2-stage process for cured and uncured meats (13.15)
Stage Cured Uncured52-12°C 7.5h 6h12-5°C 24h after cooking 24h after cookingValidate process (one time/worst case) using data loggerVerify each batch by monitoring chiller gaugeWorst case means big items (Mortadella, leg hams) during
peak production – when chiller is flat outNote – you won’t be able to achieve 12-5°C time for large
items – working party examining alternatives
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Cooling
• Rapid reduction in core temperature is vital for the control of target bacteria
• Initial product hosing
• Hose, rest, hose, rest
• Exhaust on during initial cooling
• Reducing the potential to re-contaminate• When to transfer to the chiller
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Slicing and vacuum packing
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Difficult to keep Listeria out of slicing and packing
John will cover this in detail
Slicing and packing
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Module 2: HACCP revisited
1. Hazards and risks – what’s the difference?2. Key hazards
– Bacteria– Allergens– Preservatives (nitrite, sulphur dioxide)
Appendix in Guidelines deals with each target bacterium in detail
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Hazards and risks
HazardAgent which has bad effects on consumers• Biological – bacteria, viruses• Chemical – preservatives, allergens• Physical – metal, plastic
RiskMix of Severity of the hazard plus Likelihood it will occur
For every hazard we need a Critical Control Point (CCP) and a Critical Limit (CL)
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CCPs and CLs
1. A CCP is defined as:
2. A step or operation where the hazard is prevented, eliminated or reduced to an acceptable level
3. A Critical Limit is the boundary at which the hazard is controlled
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Bacteria on surface of meat
Bacteria on a stainless steel surface
Bacteria are major hazards
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How do bacteria grow?
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Module 3 – low risk products
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Low-risk products
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Low risk products
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CCPs, CLs for low-risk
Risk is very low because these products are almost always well cooked
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Module 4: high risk products
Two big problems in UK show us what can go wrong
Scottish butcher of the year to Scottish murderer of the year
Cases are described in the Smallgoods Guidelines
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Module 4: high risk products
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Cured, cooked meats
• Country Product Pathogen Cases
• Aus 1981 Salami Salmonella >300, 1 death
• Aus 1995 Mettwurst E. coli O111 >20, 1 death
• Aus 1997 Cooked meats Salmonella >900, 3 deaths
• Aus 2005 Corned beef Listeria 3 deaths
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Target bacteria
Bacterium Source Control
Clostridium Raw meat Chilling regimeperfringens
E. coli Raw meat Process
Salmonella Raw meat Process
Listeria Environment Factory hygieneand traffic
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CCPs
For most cured, cooked smallgoods there are CCPs which are common to each process:
• Curing – addition of curing salts• Cooking – Listeria cook• Cooling – Australian Standard
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Listeria monocytogenes
Environmental pathogen – likes damp, cold places (chillers, aircon units)
Can move around plant on people, traffic and in drains
Can grow under refrigeration
Grows in long shelf-life smallgoods such as deli meats, pate, franks
Controls:
Cooking process (65C/10 min or equivalent) is a CCP
Chilled storage is not a CCP but is important in slowing it down
GMPs/SSOPs vital
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Listeria - the bug from hell
Each year 50-60 cases reported in AustraliaLikely that there are 100-120 cases
Vulnerable groups are affected:• Young (< 30 days old)• Old (>60 years)• Pregnant• Immunocompromised
20-30% of cases result in death
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Listeria - the bug from hell
• Tenacious - can colonise butcher shops
• Salt-tolerant - well suited to growing in cured products
• Grows in vacuum packs and MAPs
• Grows at refrigeration temperatures
• Can increase 10-fold in a week if we have 1 present at packing, how many will we have after 42 days?
• Infectious dose – how many will make you ill?
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Clostridium
Makes spores which survive cooking and can grow quickly during cooling.
Is anaerobic – can only grow when oxygen is absent
Centre of meat and sausages which have been cooked is anaerobic
CCPs:
Nitrite to prevent spores germinating
Rapid cooling from 50-25°C
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Sliced meats
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Sliced RTE meats
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Recontamination
Recontamination is the big problem in controlling Listeria
Especially difficult in retail butchers because front and back doors let the bug enter
Once in the shop it can colonise surfaces and equipment
Ways that butchers can reduce the risk include:
• Separating slicing and packing in time (e.g. Monday first thing)
• Super clean of slicer and vacuum packer
• Clean clothing and gloves
• Use antimicrobials on surfaces and on product
Read a lot more in the Guidelines
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UCFM
• Very complicated products
• History of problems in Australia
• Garibaldi outbreak – 150 ill
22 seriously, one died
• Problems due to poor fermenting or drying of product
• Now mandatory to use starter cultures which work
• Standard 4.2.3 also spells out the hoops manufacturers need to jump through
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The Garibaldi Incident
More than 20 children in SA seriously injured after eating Mettwurst
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Standard 4.2.3
Australian Meat Standard 4.2.3 says UCFM must be manufacturedby a process which:
(a) has been verified and audited to ensure the number of Escherichia coli organisms in the final UCFM comply with the microbiological limits in Standard 1.6.1 in this Code
n c m ME. coli/g 5 1 3.6 9.2Salmonella/25g 5 0 0
(b) demonstrates that the production process handles the variations of Escherichia coli contamination in the ingoing raw meat ingredients.
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Garibaldi outbreak led to heating CFM
Process similar to UCFM - fermenting (starters) and maturing
Cooking step is 65°C/10 minutes at the centre, or an equivalent process
Cooking done after fermenting and before maturing
Cooking is a CCP
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Smallgoods are difficult to make.
Safely
Especially UCFM
Smallgoods Guidelines is a great resource for trainers
Two useful tools described for helping make sliced RTE meats
and judging whether a UCFM process meets Standard 4.2.3
Final thoughts