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Validation of a Haccp Program for the Production of Artisan Fermented Dry Cured Pork Products a Thesis Submitted to the Faculty

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Validation of a Haccp Program for the Production of Artisan Fermented Dry Cured Pork Products a Thesis Submitted to the Faculty 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 a 1. Table 1: Vecchio processing steps and the corresponding log10 CFU/g of E. b faecium, pH, and aw of the samples taken for all three trials ....................45 2. Table 2: Log10 Reduction of Enterococcus faecium in Vecchio Salami Production. ....................................................................................................................46 a 3. Table 3: Chuck Fred processing steps and the corresponding log10 CFU/g of E. b faecium, pH, and aw of the samples taken for all three trials ....................47 4. Table 4: Log10 Reduction of Enterococcus faecium in Chuck Fred Salami Production. .................................................................................................48 a 5. Table 5: Pork Queen processing steps and the corresponding log10 CFU/g of E. b faecium, pH, and aw of the samples taken for all four trials .....................49 6. Table 6: Log10 Reduction of Enterococcus faecium in Pork Queen Salami Production. .................................................................................................50 a 7. Table 7: Extra Vecchio processing steps and the corresponding log10 CFU/g of E. b faecium, pH, and aw of the samples taken for all three trials ....................51 8. Table 8: Log10 Reduction of Enterococcus faecium in Extra Vecchio Salami Production. .................................................................................................52 a 9. Table 9: Big Chet processing steps and the corresponding log10 CFU/g of E. b faecium, pH, and aw of the samples taken for all three trials ....................53 10. Table 10: Log10 Reduction of Enterococcus faecium in Big Chet Salami 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
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