Article Type : Research Article
Authors : Eldein Shaltout FA
Keywords : Product safety; Public health; Microbial contamination; Consumer health
Sausages
are among the most widely consumed processed meat products worldwide,
appreciated for their flavor, convenience, and versatility. However, their
production involves various chemical and microbiological risks that can
significantly affect consumer health. This review discusses the formulation and
processing of different sausage types, focusing on the safety and nutritional
aspects. Key concerns include the use of food additives such as nitrites,
potential microbial contamination, and the impact of processing on nutritional
quality. The review also explores consumer trends and the increasing demand for
healthier and safer sausage products. Finally, it emphasizes the importance of
stringent regulatory frameworks, quality assurance systems, and continuous
research to ensure product safety and public health.
Sausages
are a class of processed meat products prepared by grinding meat and mixing it
with fat, salt, spices, and various additives. The mixture is typically stuffed
into a casing and subjected to different processing methods such as cooking,
fermentation, or smoking. Sausages can be made from various meat sources
including beef, pork, poultry, and sometimes seafood [1-7]. The popularity of
sausages stems from their taste, convenience, extended shelf-life, and
adaptability to diverse culinary traditions. In countries like Egypt, sausages
are commonly found in both traditional and industrial forms, contributing
significantly to meat consumption [8-15]. Despite their popularity, sausages
are also associated with public health concerns. The use of certain additives
such as nitrites, the potential for microbial contamination, and high levels of
salt and fat are all important safety issues. Moreover, the global rise in
non-communicable diseases (e.g., hypertension, cardiovascular disease) has
placed greater scrutiny on processed meats, prompting a push for healthier
alternatives [16-23]. The food industry must ensure that sausage production
adheres to safety standards and nutritional guidelines. This necessitates a
thorough understanding of the ingredients used, the technologies employed in
processing, and the safety and quality management systems applied. This paper
aims to comprehensively review these elements, offering a scientific
perspective for professionals and researchers in the food and veterinary sectors
[24-30].
The
formulation of sausages involves a complex interplay of ingredients that
contribute to their taste, texture, appearance, shelf-life, and safety.
Understanding each component is essential for optimizing quality and ensuring
compliance with food safety standards [31-37]. Meat Types Used, The primary
ingredient in sausages is meat, which may be derived from Beef wwhich is Common
in many regions; offers a firm texture and rich flavour. Pork is traditionally
used in European-style sausages due to its fat content and binding properties.
Poultry (chicken, turkey). Gaining popularity for its lower fat content and
health appeal. Others as Fish, mutton, or exotic meats may be used in niche or
regional varieties. The choice of meat affects not only sensory properties but
also nutritional content, microbial risks, and consumer acceptability [38-44].
Fats, Fat contributes to juiciness, flavour, and mouthfeel. Typically, sausages
contain about 15–30% fat in traditional recipes. Lower-fat versions (below 15%)
are available to meet dietary preferences. Fat sources include pork back fat,
beef fat, or poultry skin. The quality and stability of fat are crucial, as
oxidized fats can lead to rancidity and health concerns [45-51]. Non-Meat
Ingredients, These are added for functional, sensory, and safety purposes as
Salt (NaCl) to Enhances flavour. Aids in protein extraction for emulsion
formation. Has preservative properties. However, excessive salt intake is
linked to hypertension, so reduced-salt formulations are encouraged [52-58].
Spices and Flavourings as Pepper, garlic, paprika, coriander, and nutmeg are
common. Spices not only enhance flavour but may offer antimicrobial and
antioxidant benefits. Binders and Fillers which are used to improve
water-holding capacity and texture as Starch, soy protein, milk protein,
carrageenan. Some consumers avoid certain binders due to allergies or dietary
restrictions. Water and Ice Added to Aid mixing. Control temperature. Improve
texture and juiciness. Curing Agents (e.g., Sodium Nitrite) which are Essential
in cured sausages for Colour development (stable pink colour). Inhibition of
Clostridium botulinum. Flavour enhancement [59-65]. Health concern, Nitrites
can form carcinogenic nitrosamines under certain conditions, so their use is strictly
regulated. Food Additives In addition to nitrites, sausages may contain
Phosphates to improve water retention and texture. Antioxidants (e.g., ascorbic
acid, BHA/BHT) – Prevent fat oxidation. Preservatives (e.g., sorbates,
lactates) – Extend shelf-life. Colorants are occasionally used in uncured
sausages for uniform appearance. Food safety authorities (like Codex
Alimentarius and national bodies such as the Egyptian Organization for
Standardization) set maximum residue limits (MRLs) for these additives to
ensure consumer safety [66-72]. Casings, Sausage casings may be Natural are
made from cleaned animal intestines (commonly pork or sheep). Artificial are
Made from collagen, cellulose, or plastic (for non-edible casings). Natural
casings are preferred for traditional sausages due to their texture and
appearance, while artificial ones offer uniformity and convenience in
industrial production [73-79].
The
technology used in sausage production significantly influences the product’s
texture, flavour, shelf-life, and safety. Processing steps may vary depending
on the type of sausage (e.g., fresh, cooked, fermented), but the core
procedures remain largely consistent across products [80-86]. Grinding, Purpose
To reduce meat particle size for easier mixing and uniform distribution of fat
and other ingredients. Equipment include Bowl choppers, mincers, or grinders
with varying plate sizes. Impact, Fine grinding improves emulsion stability but
may increase exposure to microbial contamination if hygiene is poor [87-93].
Mixing and Emulsification, Mixing to Ensures uniform distribution of salt,
spices, fat, and additives. Emulsification is especially critical in emulsified
sausages like frankfurters and mortadella. Proteins form a stable matrix that
traps fat and water. Overmixing can cause emulsion breakdown or texture
defects. The Ice or cold water is often added during mixing to control
temperature and prevent protein denaturation [94-100]. Stuffing, The meat
mixture is filled into casings using vacuum fillers or piston stuffers. Vacuum
stuffing helps eliminate air pockets, which could lead to spoilage or
discoloration. Proper casing selection and filling pressure are important to
avoid casing rupture or inconsistent product shape [101-108]. Linking and
Shaping, Sausages are formed into individual units by twisting or using
automated linkers. The shape depends on market expectations (e.g., short links
for breakfast sausages vs. long coils for traditional varieties) [109-115].
Thermal Processing (Cooking/Smoking), Cooking, Cooked sausages are heated to
internal temperatures of >70°C to ensure microbial safety. Methods, Water
bath, steam, or oven cooking. Benefits, Inactivation of pathogens (e.g.,
Salmonella, Listeria monocytogenes), protein coagulation, and flavour
development [116-122]. Smoking, Applied in some products for flavour, colour,
and preservation. Types, Cold smoking (<30°C) and hot smoking (above 60°C).
Smoke contains natural antimicrobials and antioxidants (e.g., phenols), but
excessive smoking can introduce carcinogenic polycyclic aromatic hydrocarbons
(PAHs) [123-129]. Fermentation and Drying (for dry and semi-dry sausages),
Fermentation by Lactic acid bacteria (LAB) convert sugars into lactic acid,
lowering pH and enhancing safety. Drying to Reduces water activity (aw),
inhibiting microbial growth. Examples as Salami, pepperoni. This method imparts
characteristic tangy flavour and extended shelf-life but requires strict
control of temperature, humidity, and pH [130-136]. Chilling and Packaging, after processing,
sausages are rapidly cooled to <4°C to prevent microbial growth. Packaging
options, Vacuum packaging, Extends shelf-life by removing oxygen. Modified
Atmosphere Packaging (MAP) Uses gases like CO? and N? to inhibit spoilage
organisms. Active packaging May include antimicrobial agents or oxygen
scavengers. Proper packaging protects against oxidation, contamination, and
moisture loss [137-134]. Storage and Distribution, Storage temperatures depend
on sausage type, Fresh: 0–4°C, short shelf-life. Cooked/fermented as Chilled or
ambient, depending on water activity and preservation. Cold chain maintenance
is essential during transport and retail to ensure safety and quality
[135-141].
Microbiological
safety is a major concern in sausage production due to the nature of raw
materials, high moisture content, and multiple processing steps that can
introduce or allow the growth of pathogenic microorganisms. Ensuring
microbiological safety is essential to prevent foodborne illnesses and protect
public health [142-148]. Sources of Microbial Contamination, Raw Meat and Fat
the Contamination may occur at slaughterhouses or during transportation.
Processing Environment as Equipment, workers' hands, and surfaces can harbor
pathogens. Additives and Spices, Though generally considered safe, these may
introduce Salmonella or Bacillus spores if not properly treated. Water, Poor
water quality can serve as a vehicle for microbial pathogens [149-155]. Common
Pathogens in Sausages as Listeria monocytogenes which can survive
refrigeration. Particularly dangerous in ready-to-eat (RTE) cooked sausages.
Causes listeriosis, which is life-threatening to pregnant women, elderly, and
immunocompromised individuals [156-162]. Salmonella spp. often linked to raw
meat and undercooked products. Causes gastrointestinal illness with fever,
diarrhea, and abdominal cramps. Escherichia coli O157:H7 are Found in
undercooked or contaminated raw meat sausages. Can lead to hemorrhagic colitis
and hemolytic uremic syndrome (HUS) [163-170]. Clostridium botulinum Forms
heat-resistant spores. Produces a lethal neurotoxin in anaerobic conditions
(e.g., vacuum-packed sausages). Controlled by nitrites, low pH, low water
activity, and proper thermal treatment. Staphylococcus aureus produces
heat-stable enterotoxins. Often due to poor hygiene and temperature abuse
during handling [171-176]. Factors Affecting Microbial Growth in Sausages as
pH, Lower pH (<5.3 in fermented sausages) inhibits many pathogens. Water
Activity (aw), Dry sausages with low aw resist microbial growth. Temperature,
Time-temperature abuse during processing or storage can lead to rapid microbial
multiplication. Oxygen Availability, Anaerobic conditions in packaging favour
certain pathogens like C. botulinum. Competition, in fermented sausages,
beneficial bacteria like LAB inhibit pathogens through acidification and
bacteriocin production [170-176]. Control Measures and Hygiene Practices, Good
Manufacturing Practices (GMPs), strict personal hygiene. Equipment sanitation.
Pest control and facility design. Hazard Analysis and Critical Control Points
(HACCP), Identifies points where hazards can be prevented or reduced. Examples
of CCPs, Cooking (temperature >70°C). Chilling (<4°C within 2 hours).
Nitrite levels (within legal limits for effective C. botulinum control)
[11-17]. Testing and Monitoring, Regular microbial testing (e.g., total plate
count, coliforms, pathogens). Environmental swabbing and water quality
monitoring. Use of Antimicrobials, Natural (e.g., rosemary extract, vinegar).
Chemical (e.g., lactates, diacetates) – must be within allowed limits.
Maintaining microbiological safety requires a multi-hurdle approach combining
hygiene, correct formulation, proper processing, and rigorous monitoring
[31-37]. Chemical Safety of Sausages, Chemical safety concerns in sausage
production revolve around the use of additives, the presence of environmental
contaminants, residues, and chemical changes during processing and storage.
These factors can pose significant risks to consumers if not properly
controlled [41-47]. Use of Food Additives, Additives are essential in sausage
production for preservation, flavour, colour, and texture. However, excessive
or improper use can lead to health concerns. Nitrites and Nitrates Purpose,
Preserve colour (stable pink), inhibit Clostridium botulinum, and enhance
flavour. Concern, Nitrites can react with amines in meat to form nitrosamines,
some of which are carcinogenic. Regulation, Strict limits on sodium nitrite
levels (e.g., Codex allows max 150 ppm in cured meats). Mitigation, Adding
antioxidants like ascorbic acid can reduce nitrosamine formation [131-137].
Phosphates Improve water-binding capacity and texture. Excess intake may affect
calcium metabolism and kidney function. MRLs are set to ensure consumer safety.
Antioxidants Examples Butylated hydroxyanisole (BHA), butylated hydroxytoluene
(BHT), tocopherols. Used to prevent lipid oxidation. Generally Recognized as
Safe (GRAS) in regulated amounts. Preservatives, Include sorbates, benzoates,
lactates to inhibit spoilage microbes. Overuse may cause gastrointestinal
discomfort or allergic reactions in sensitive individuals [151-157]. Chemical
Contaminants and Residue, Veterinary Drug Residues, Improper withdrawal times
in livestock may leave residues in meat. Examples: Antibiotics (e.g.,
tetracycline), antiparasitics. Residues can lead to antimicrobial resistance
and allergic reactions. Controlled by pre-slaughter testing and adherence to
withdrawal periods. Heavy Metals, Contamination from water, spices, machinery,
or packaging. Common metals as Lead (Pb), Cadmium (Cd), Mercury (Hg), Arsenic
(As). Toxic even at low levels; monitored under international safety limits.
Mycotoxins, Toxins from molds in spices or cereal-based fillers. Aflatoxins are
the most potent and carcinogenic. Controlled by screening raw materials and
proper storage. Oxidative Rancidity, Cause Reaction of oxygen with unsaturated
fats in meat and fat. Effects, Off-flavours, discoloration, nutrient loss, and
formation of harmful aldehydes. Prevention, Use of antioxidants, vacuum
packaging, oxygen barrier films, and cold storage. Residual Cleaning Agents or
Packaging Migration, Improper rinsing of equipment after cleaning can leave
residues (e.g., quaternary ammonium compounds). Poor-quality packaging
materials may release chemicals like phthalates or bisphenol A (BPA) into
sausages, especially during storage at high temperatures. Chemical safety in
sausage production requires strict regulatory compliance, good manufacturing
practices, careful ingredient sourcing, and regular product testing. Continuous
monitoring and risk assessment are necessary to safeguard public health and
ensure product integrity [161-167].
Nutritional
Value of Sausages, Sausages provide a rich source of essential nutrients but
can also be high in undesirable components like saturated fat and sodium. Their
nutritional profile varies depending on the type of meat used, fat content,
additives, and processing methods. Macronutrient Composition, Protein, Sausages
are a good source of high-quality animal protein, containing all essential
amino acids. Protein content typically ranges from 10–20%. Emulsified and
poultry-based sausages may have slightly lower protein levels, especially if
fillers are used. Fat, Traditional sausages may contain 15–30% fat, often high
in saturated fatty acids (SFAs). Fat provides energy (9 kcal/g), enhances
flavour and texture. Healthier options now include Reduced-fat formulations.
Use of lean meat and vegetable oils (e.g., sunflower or olive oil). Fat
replacers like inulin, carrageenan, or oat fiber. Carbohydrates, generally low
in pure meat sausages. Present in small amounts if binders/fillers (e.g.,
starch, bread crumbs) are added. Micronutrients, Iron and Zinc, Present in good
amounts; essential for oxygen transport and immune function. B Vitamins
Especially B1 (thiamin), B2 (riboflavin), B6, and B12 – important for
metabolism and nervous system health. Sodium, Often high due to added salt and
curing agents. Excess sodium intake is linked to hypertension and
cardiovascular disease. WHO recommends <2g sodium/day (?5g salt) per adult.
Caloric Value, The caloric value depends on fat and moisture content. Standard
sausages range from 250–350 kcal/100g. Low-fat or poultry-based options may
offer 150–220 kcal/100g. Health Concerns and Processed Meat Classification, The
World Health Organization (WHO) and International Agency for Research on Cancer
(IARC) classify processed meats (including sausages) as Group 1 carcinogens
based on evidence linking high consumption with colorectal cancer. Concerns
Include Presence of nitrosamines. High sodium and saturated fat content.
Frequent consumption associated with increased risk of heart disease, cancer,
and obesity [111-117]. Recommendations, Moderate intake of processed meats.
Prefer leaner varieties, lower in sodium and fat. Look for clean-label sausages
(with fewer chemical additives and more natural ingredients). Functional and Fortified
Sausages, in response to health concerns, manufacturers now produce Functional
sausages enriched with Omega-3 fatty acids. Dietary fiber, Probiotics,
Antioxidants (e.g., polyphenols). Fortified sausages may include added as
Calcium, Iron, Vitamin D or E. These innovations aim to turn sausages from
indulgent foods into nutritionally enhanced options.
Quality
Control and Assurance Systems in Sausage Production, Quality control (QC) and
quality assurance (QA) systems are essential in sausage manufacturing to ensure
products meet safety, regulatory, and consumer standards. These systems involve
monitoring every stage of production, from raw materials to final packaging.
Raw Material Inspection, Meat Quality Checks, pH measurement (ideal: 5.4–5.8
for fresh meat). Colour evaluation. Absence of off-odors or spoilage signs. Fat
and Additive Quality, Visual and chemical inspection of fat (oxidation status,
purity). Verification of the identity and concentration of preservatives,
spices, and binders. Microbial Screening, Testing for Salmonella, Listeria, and
E. coli in incoming meat. Spices and non-meat ingredients tested for microbial
loads and contaminants. In-Process Quality Control, Process Parameters, Mixing
time, temperature, and order of ingredient addition. Emulsion stability tested
by cooking loss or oil separation. Stuffing pressure and casing integrity.
Temperature Control, Continuous monitoring during mixing, filling, cooking, and
chilling. Real-time data logging helps detect deviations that may impact
product safety or texture. Metal Detection, Metal detectors or X-ray scanners
installed to detect foreign bodies. Essential for consumer safety and
compliance with food standards. Finished Product Testing, Microbiological
Analysis, Total Plate Count (TPC). Pathogens: Listeria, Salmonella, E. coli
O157:H7. Yeasts and molds in certain sausage types. Chemical Testing, Moisture,
protein, fat, and salt content. Nitrite/nitrate levels. Presence of
contaminants (heavy metals, residual cleaning agents, mycotoxins). Sensory
Evaluation, Appearance, texture, taste, and aroma assessed by trained panels.
Helps ensure consumer acceptability and product consistency. Packaging and
Labelling Quality, Packaging Integrity, Leak testing, seal strength. Oxygen
permeability checked to ensure shelf-life. Label Verification, Ingredient list,
allergen declarations, expiration dates. Nutritional information and regulatory
claims (e.g., “low sodium”, “organic”). Quality Assurance Systems, Good
Manufacturing Practices (GMPs), Standardized hygiene protocols, facility
maintenance, and staff training. Prevent cross-contamination and ensure clean
processing environments. Hazard Analysis and Critical Control Points (HACCP).
Systematic approach to identifying and controlling food safety hazards. Key
CCPs in sausage production, cooking temperatures. Metal detection. Chilling
times and temperatures. ISO Certifications, ISO 22000: Food safety management
system. ISO 9001: General quality management. Certification improves
traceability, accountability, and market trust. Traceability Systems, Barcode
or RFID tagging from raw materials to final product. Enables fast recalls and
quality audits in case of complaints or contamination. Regulatory Compliance,
Products must comply with, Codex Alimentarius standards. National food safety
laws (e.g., FDA, EFSA). Halal/Kosher certification (where applicable). Regular
audits and inspections by food safety authorities ensure compliance with
national and international standards [151-157].
Conclusions
Sausages
are among the most widely consumed processed meat products globally,
appreciated for their flavour, convenience, and variety. However, they present
a complex matrix from a food safety and quality perspective, involving
physical, microbiological, chemical, and nutritional factors. Microbiological
safety remains a primary concern, especially in ready-to-eat and raw-fermented
varieties, with pathogens such as Listeria monocytogenes, Salmonella spp., and
Clostridium botulinum posing significant risks. Chemical hazards, including
nitrites, heavy metals, drug residues, and oxidative by-products, must be
rigorously controlled to protect consumers from chronic exposure and
carcinogenic risks. Nutritionally, sausages are rich in high-quality protein,
iron, and B-vitamins, but often contain high levels of saturated fat and
sodium, contributing to non-communicable diseases when consumed excessively.
Quality control systems, such as HACCP and ISO 22000, are critical in managing
risks and ensuring product consistency and safety throughout the processing
chain. Sausages are evolving beyond traditional formulations, with new products
focusing on low-fat, low-sodium, and functional health-enhancing ingredients to
meet modern consumer demands. Recommendations, For Producers, Adopt
multi-hurdle approaches to safety, combining thermal processing, low pH,
preservatives, and packaging innovations. Shift toward clean-label formulations
by reducing artificial additives and incorporating natural alternatives. Invest
in continuous training for workers on hygiene and food safety protocols.
Regularly update and maintain quality assurance systems and traceability tools.
For Regulatory Authorities, Enhance surveillance for emerging contaminants and
antimicrobial-resistant bacteria. Standardize limits on nitrite/nitrate levels
and enforce stricter labelling of additives and allergens. Support public
awareness campaigns promoting balanced consumption of processed meats. For
Researchers, Explore alternative preservation techniques (e.g., high-pressure
processing, bacteriocins, plant extracts). Investigate bioactive ingredients
that can improve sausage health benefits without compromising safety or sensory
appeal. Conduct epidemiological studies linking sausage consumption patterns
with public health trends in different populations. For Consumers, Moderate
intake of sausages and processed meats as part of a balanced diet. Choose
products with lower fat, sodium, and fewer synthetic additives. Be informed
about labelling, including allergen declarations, expiry dates, and nutrition
claims.
The
author declare no conflicts of interest.