validation of a haccp program for the production of artisan fermented dry cured pork products a

110 Pages·2015·0.44 MB·English

by  Christopher Michet

VALIDATION OF A HACCP PROGRAM FOR THE PRODUCTION OF ARTISAN
FERMENTED DRY CURED PORK PRODUCTS

A THESIS SUBMITTED TO THE FACULTY OF THE
UNIVERSITY OF MINNESOTA

BY

CHRISTOPHER JOHN MICHET

IN PARTIAL FULFILLMENT OF THE REQUIREMENTS
FOR THE DEGREE OF
MASTER OF SCIENCE

JOELLEN M. FEIRTAG, ADVISOR

NOVEMBER, 2015
© Christopher John Michet 2015
ACKNOWLEDGMENTS
I would like to acknowledge my advisor, Dr. Joellen Feirtag, for her continuous
guidance, knowledge, patience, and time during the course of my studies at the
University of Minnesota. I truly appreciate her encouragement and support, which
enabled me to complete my goal of achieving a Master’s in Food Science.

i
DEDICATION
I dedicate this thesis to my parents and my family for their never-ending love,
support and patience throughout my life and particularly during my time at the University
of Minnesota. Without them, I would not have been able to pursue my degree with the
hope of a better future. I cannot thank them enough.

ii
Table of Contents

Page

List of Tables ......................................................................................................... vi
List of Figures ...................................................................................................... viii

CHAPTER ONE
Literature Review.........................................................................................2
1.0 Artisan Meat Products................................................................2
1.1 Definition .......................................................................2
1.2 Background ....................................................................2
1.3 Why the resurgence of popularity in U.S...................... 4
2.0 Fermented/Aged Meat Products ................................................6
2.1 Fermentation of Meat .....................................................6
2.2 Aging of Meat ................................................................6
2.3 Effect of Meat Composition on Fermentation and Aging
........................................................................................7
3.0 Types of Dry-Cured Fermented Meat: Whole Muscle vs. Comminuted
(Salami) ....................................................................................10
3.1 Manufacture of Dry-Cured Whole Muscles ................11
3.2 Manufacture of Dry-Fermented Sausages ...................13
4.0 Hurdle Technology Concept ....................................................16
4.1 Definition .....................................................................16
4.2 Hurdles in Dry-Cured Whole Muscle Production .......17
4.3 Hurdles in Fermented Sausage Production ..................17
5.0 Risk Assessment of Artisan Pork Products ..............................20
5.1 Definition .....................................................................20
5.2 FSIS Salmonella Compliance Guidelines ....................21
5.3 FSIS Risk Assessment Model ......................................22
6.0 Hazard Analysis Critical Control Point (HACCP) ..................25
6.1 Definition .....................................................................25
iii
6.2 Critical Control Points (CCPs) of Dry-Cured Whole Muscle
Products........................................................................27
6.3 Critical Control Points (CCPs) of Dry Fermented Sausages
......................................................................................28
7.0 Good Manufacturing Practices (GMPs)...................................30
7.1 AMIF Process Control Points ......................................30
7.2 AMIF Sanitation Requirements ...................................31
7.3 AMIF Production and Process Controls ......................32
7.4 Critical Operations .......................................................32
8.0 Objectives of Current Study.....................................................34
8.1 Chapter 2 ......................................................................34
8.2 Chapter 3 ......................................................................34
CHAPTER TWO
Fermented Aged Salami .............................................................................36
1.0 Introduction ..............................................................................36
2.0 Material and Methods ..............................................................37
2.1 Sausage Preparation and Inoculation of Surrogate ......37
2.1.1 Carcasses ....................................................37
2.1.2 Cure Ingredients and Processing ................37
2.1.3 Fermentation and Aging ............................38
2.2 Microbiological and Physiochemical Analysis ............38
3.0 Results ......................................................................................44
3.1 Microbiological Analysis .............................................44
3.2 Enterococcus faecium Reduction Results ....................44
3.3 Salami Moisture, Protein, and Moisture/Protein Ratios ..
......................................................................................55
3.4 Salami Additional pH Trials ........................................56
4.0 Salami Discussion ....................................................................58
5.0 Conclusion ...............................................................................67
CHAPTER THREE
Cured Aged Whole Muscle Pork Products ................................................69
1.0 Introduction ..............................................................................69
2.0 Material and Methods ..............................................................71
iv
2.1 Whole Muscle Preparation and Inoculation of Surrogate
......................................................................................71
2.1.1 Carcasses ....................................................71
2.1.2 Cure Ingredients and Process .....................71
2.1.3 Fermentation and Aging ............................72
2.2 Microbiological and Physiochemical Analysis ............72
3.0 Results ......................................................................................78
3.1 Microbiological Analysis .............................................78
3.2 Enterococcus faecium Reduction Results ....................78
4.0 Whole Muscle Discussion........................................................89
5.0 Conclusion ...............................................................................96
CITATIONS ..........................................................................................................97

v
List of Tables
Table Page

CHAPTER TWO
1. Table 1: Vecchio processing steps and the corresponding log CFU/ga of E.
10
faecium, pH, and a b of the samples taken for all three trials ....................45
w
2. Table 2: Log Reduction of Enterococcus faecium in Vecchio Salami Production.
10
....................................................................................................................46
3. Table 3: Chuck Fred processing steps and the corresponding log CFU/ga of E.
10
faecium, pH, and a b of the samples taken for all three trials ....................47
w
4. Table 4: Log Reduction of Enterococcus faecium in Chuck Fred Salami
10
Production. .................................................................................................48
5. Table 5: Pork Queen processing steps and the corresponding log CFU/ga of E.
10
faecium, pH, and a b of the samples taken for all four trials .....................49
w
6. Table 6: Log Reduction of Enterococcus faecium in Pork Queen Salami
10
Production. .................................................................................................50
7. Table 7: Extra Vecchio processing steps and the corresponding log CFU/ga of E.
10
faecium, pH, and a b of the samples taken for all three trials ....................51
w
8. Table 8: Log Reduction of Enterococcus faecium in Extra Vecchio Salami
10
Production. .................................................................................................52
9. Table 9: Big Chet processing steps and the corresponding log CFU/ga of E.
10
faecium, pH, and a b of the samples taken for all three trials ....................53
w
10. Table 10: Log Reduction of Enterococcus faecium in Big Chet Salami
10
Production. .................................................................................................54
11. Table 11: Vecchio Salami Moisturea and Proteinb Content, and Moisture/Protein
Ratios. ........................................................................................................55
12. Table 12: Chuck Fred Salami Moisturea and Proteinb Content, and
Moisture/Protein Ratios. ............................................................................55
13. Table 13: Pork Queen Salami Moisturea and Proteinb Content, and
Moisture/Protein Ratios. ............................................................................55
14. Table 14: Extra Vecchio Moisturea and Proteinb Content, and Moisture/Protein
Ratios. ........................................................................................................55
15. Table 15: Vecchio Additional pH Trials ....................................................56
16. Table 16: Chuck Fred Additional pH Trials ..............................................56
17. Table 17: Pork Queen Additional pH Trials ..............................................57
vi
18. Table 18: Extra Vecchio Additional pH Trials ..........................................57
19. Table 19: Big Chet Additional pH Trials ...................................................57

CHAPTER THREE
20. Table 1: Coppa processing steps and the corresponding log CFU/ga of E.
10
faecium, pH, and a b of the samples taken for all three trials ....................80
w
21. Table 2: Log Reduction of Enterococcus faecium in Coppa Production ....
10
....................................................................................................................81
22. Table 3: Lonza processing steps and the corresponding log CFU/ga of E.
10
faecium, pH, and a b of the samples taken for all three trials ....................82
w
23. Table 4: Log Reduction of Enterococcus faecium in Lonza Production ....
10
....................................................................................................................83
24. Table 5: Filetto processing steps and the corresponding log CFU/ga of E.
10
faecium, pH, and a b of the samples taken for all three trials ....................84
w
25. Table 6: Filetto Second Validation processing steps and the corresponding log
10
CFU/ga of E. faecium, pH, and a b of the samples taken for all three trials ..
w
....................................................................................................................85
26. Table 7: Log Reduction of Enterococcus faecium in Filetto Production. ...
10
....................................................................................................................86
27. Table 8: Speck processing steps and the corresponding log CFU/ga of E.
10
faecium, pH, and a b of the samples taken for all three trials ....................87
w
28. Table 9: Log Reduction of Enterococcus faecium in Speck Production .....
10
....................................................................................................................88

vii
List of Figures
Figure Page

CHAPTER ONE
Figure 1: Sequence of Hurdles in Raw Sausage (Leistner, 1995) .............19

viii