Abstract
This study investigates microbial contamination pathways during the production of semi-smoked sausages formulated from horsemeat, poultry, and a pumpkin-based emulsion gel. The work examines six production stages: minced meat, batter, stuffing, roasting, cooking, smoking, and pasteurization. It also evaluates four environmental sources: equipment surfaces, personnel hands, ice water, and spice mixes. The combined dataset offers a process-level view of contamination routes within this product line. Microbial counts were obtained for total viable count, Staphylococcus aureus, Escherichia coli, yeasts, molds, and Salmonella spp. Statistical analysis showed strong associations between environmental samples and product stages. Raw materials and spices showed the highest microbial levels. Personnel's hands and equipment surfaces showed moderate levels that influenced microbial patterns along the line. Thermal processing produced marked reductions in total viable count and S. aureus. E. coli and yeast mold were no longer detected after the heating stages. Salmonella spp. did not appear in any sample. Post-packaging pasteurization at 95 °C for 10 min resulted in additional reductions in viable microorganisms. This step served as a post-lethality control measure within the HACCP system. The study also reports microbial behavior in sausages containing a pumpkin-based emulsion gel. This formulation has not been previously examined with respect to microbial load across a full production cycle. All processed samples met regulatory safety limits. The results demonstrate that integrated multi-source monitoring combined with targeted interventions strengthens process hygiene and improves microbiological safety in semi-smoked sausage manufacturing.