HACCP Poultry Best

8/20/2019 HACCP Poultry Best

1/49

HACCP MODEL FORPOULTRY SLAUGHTER/FURTHER PROCESSING

The Hazard Analysis Critical Control Point (HACCP) system is a scientific approach toprocess control. It is designed to prevent the occurrence of problems by assuring thatcontrols are applied at any point in a food production system where hazardous or criticalsituations could occur. Hazards include biological, chemical, or physical contaminationof food products.

HACCP is a systematic and preventive approach to achieve food safety standards.Originally developed in the United States to guarantee the safety of astronauts’ food inspace, HACCP is now being adopted worldwide as a scientific, straightforward andeffective approach to enhance food safety.The HACCP approach can be used by all segments of the food production continuumand can be tailored to any individual product or process line. The advantage of usingthe HACCP system lies in the control it provides at all times over food safety in theprocessing plant, from receiving raw materials to shipping the final products.For the food processor, producing a safe product will be structured around criticalcontrol points (CCPs). CCPs are designed to control potential hazards that arebiological, chemical or physical in nature and that may pose a food safety risk.

The Seven Principles of HACCP

The HACCP approach is based on sevenprinciples aimed at identifying hazards infood production, controlling hazards atcritical control points in the process, andverifying that the system is working

properly. The key element of the HACCPsystem is its preventive nature meaningthat potential food safety hazards arecontrolled throughout the process. Theapplication of HACCP principles in theproduction of food is recommended byC d Ali t i th i t ti l

The seven basic principles of HACCPare:

1. Identify the hazards and listpreventive measures to controlthem.

2. Determine the critical control points.

3. Establish limits at each criticalcontrol point.

4 Establish procedures to monitor the


2/49

Hazard AnalysisHazard analysis is the first principle and starting point of the Hazard Analysis CriticalControl Point (HACCP) system. Hazards can arise at any stage of food production,from growing, harvesting and dealing with raw materials and ingredients, throughprocessing and manufacturing, and on through distribution, marketing, preparation andconsumption of food products. Proper identification and analysis of hazards are centralto the hazard analysis process. Hazards may vary from one processing plant to anotherdue to differences in the source of ingredients, formulations, equipment, plant layout,preparation, etc.

A Five-step Process

The five steps of hazard analysis are: 1. Review the incoming material,

including ingredients and packagingmaterial.

2. Evaluate each step of theprocessing operations.

3. Observe the actual operatingpractices.

4. Take accurate measurements.

5. Analyze the measurements.

In each case, the analysis must considerall possible biological, chemical andphysical hazards.Once all hazards have been identified andanalyzed, the next stage of the HACCPapproach is to determine the critical controlpoints necessary to control the hazards.

Critical Control Points (CCP)

A Critical Control Point (CCP) is a point or step in the manufacturing process at whichcontrol can be applied and a food safety hazard can be prevented, eliminated orreduced to an acceptable level. For example, a specified heat process, applied for aprescribed time and temperature to destroy bacteria, is a CCP.Determining CCPs required to control identified hazards is the second major principle ofa Hazard Analysis Critical Control Point (HACCP) system. CCPs are located at any

f


3/49

verification of each CCP will ensure that monitoring procedures are in place and areeffective in controlling the potential hazard.

Definitions.

For purposes of this part, the following shall apply:

Corrective action. Procedures to be followed when a deviation occurs.

Critical control point. A point, step, or procedure in a food process at whichcontrol can be applied and, as a result, a food safety hazard can be prevented,eliminated, or reduced to acceptable levels.

Critical limit. The maximum or minimum value to which a physical, biological, orchemical hazard must be controlled at a critical control point to prevent,eliminate, or reduce to an acceptable level the occurrence of the identified foodsafety hazard.

Food safety hazard. Any biological, chemical, or physical property that maycause a food to be unsafe for human consumption.

HACCP System. The HACCP plan in operation, including the HACCP plan itself.

Hazard. SEE Food Safety Hazard.

Preventive measure. Physical, chemical, or other means that can be used tocontrol an identified food safety hazard.

Process-monitoring instrument. An instrument or device used to indicateconditions during processing at a critical control point.

Responsible establishment official. The individual with overall authority on-site ora higher level official of the establishment.


4/49

HACCP PLAN

Assembling the HACCP Team:

An important step in developing a plan is to gain management commitment andassemble a HACCP team. Top management must be fully committed to product safetythrough HACCP to make the program effective. After commitment is obtained, theHACCP team should be assembled. The team should consist of individual(s) from allaspects of production and should include at least one HACCP trained individual.

Process Flow Diagram and Product Description

To begin using this model, the company's HACCP team should first describe theproduct(s) that are part of this process category and covered by this HACCP plan. Theproduct(s) should be described in two ways:

(1) by a simple diagram which shows the steps the company uses when it produces theproduct, and(2) in a brief written description that provides key facts about the product and its use.

Hazard Analysis

Once your product(s) are accurately described through the flow diagram and productdescription, the HACCP team should begin work on the HAZARD ANALYSIS. Thehazard analysis is fundamental to developing a good HACCP plan and one that meetsregulatory requirements. The regulatory requirements for a hazard analysis are foundbelow:

Hazard Analysis and HACCP Plan.

(a) Hazard analysis.(1) Every official establishment shall conduct, or have conducted for it, a hazardanalysis to determine the food safety hazards reasonably likely to occur in the


5/49

(2) A flow chart describing the steps of each process and product flow in theestablishment shall be prepared, and the intended use or consumers of thefinished product shall be identified.

Generic establishment X, which we are using for our example, is capturing theseregulatory requirements on a 6-column Hazard Analysis Form (See APPENDIX III &VII). A good way to use a form like this is to create the first column by using theProcess Flow Diagram and the second by answering the question. Once the HACCPteam has considered all the steps in the flow diagram and determined if a food safetyhazard could be introduced, it needs to consider whether the hazard is "reasonablylikely to occur". On the 6-column form used by generic establishment X, the third andfourth columns address this issue. If the establishment's HACCP team has decided thatthe hazard is not reasonably likely to occur, they enter "No" in column three, explain thebasis for their determination in column four, and do not need to further consider activityto address this hazard.

If, however, the team has determined there is a "food safety hazard reasonably likely tooccur" introduced at a certain point in the process, column five is used to describe ameasure which could be applied to "prevent, eliminate, or reduce to acceptable levels"the food safety hazard identified in column three. Column six is used when a criticalcontrol point (CCP) is identified based upon the decision made in the hazard analysis.Each CCP has a number – the order corresponds to steps in the process. For example,1 is the first CCP in the process flow, 2 the next, etc. The letter indicates whether thehazard is biological – B; chemical – C; or physical – P.

Developing Your HACCP Plan

The contents of the HACCP plan. The HACCP plan shall, at a minimum:

(1) List the food safety hazards identified in accordance with paragraph (a) of thissection, which must be controlled for each process.

(2) List the critical control points for each of the identified food safety hazards


6/49

(3) List the critical limits that must be met at each of the critical control points.Critical limits shall, at a minimum, be designed to ensure that applicable targetsor performance standards established by the regulatory authority, and any otherrequirement set forth in this chapter pertaining to the specific process or product,are met;

(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points toensure compliance with the critical limits;

(5) Include all corrective actions that have been developed to be followed inresponse to any deviation from a critical limit at a critical control point; and

(6) Provide for a record keeping system that documents the monitoring of thecritical control points. The records shall contain the actual values andobservations obtained during monitoring.

(7) List the verification procedures, and the frequency with which those procedures will be performed, that the establishment will use.

Signing and dating the HACCP plan.

(1) The HACCP plan shall be signed and dated by the responsibleestablishment individual. This signature shall signify that the establishmentaccepts and will implement the HACCP plan.

(2) The HACCP plan shall be dated and signed:

(i) Upon initial acceptance;

(ii) Upon any modification; and

(iii) At least annually, upon reassessment, or as required by the regulatoryauthority.


7/49

contamination at reprocessing, pathogen cross-contamination and proliferation atchilling, and pathogen proliferation at finished products storage (cold). Theestablishment HACCP team has chosen to have four CCPs to address these fourhazards: proper evisceration/presentation, proper reprocessing, proper chilling ofproduct, and proper maintenance of finished product temperatures during storage.

After identifying its CCPs, the HACCP team proceeded to consider critical limits,monitoring procedures and their frequencies, and verification procedures and theirfrequencies, and HACCP records.

In deciding what would be the critical limits, the HACCP team first considered whetherthere were any regulatory requirements which had to be met and would function ascritical limits.They found some regulatory requirements for chilling and realized that if the properchiller procedures were not followed pathogen proliferation was possible. The HACCPteam knew that the chilling process should start as soon as possible, so they set thecritical limit for the temperature of product to reach 40° F or less within four hours fromthe stunning/killing step.

Once they had decided on their critical limits, they needed to identify how the monitoringprocedures would be carried out and at what frequency.

For their chilling step, the establishment had the QA technician do a producttemperature check at the end of the chilling procedure every hour of production. At thechilling step the carcass chiller and neck/giblet chiller temperatures are monitoredcontinuously with recording charts.

These decisions by the HACCP team regarding critical limits, plus monitoringprocedures and their frequencies are written up in columns two and three of the HACCPPlan.

The regulatory requirements for ongoing verification are:

(2) Ongoing verification activities. Ongoing verification activities include, but arenot limited to:


8/49

accuracy of the carcass chiller and necks/giblets chiller temperature recording chartsonce per shift.

There is a regulatory requirement for including as verification, the calibration of process-monitoring instruments. Each day QA checks the hand-held thermometers for accuracyin slush ice water and calibrates them to within 2° F accuracy.

The HACCP team described the verification procedures and their frequencies in the fifthcolumn of their HACCP plan.

Records.

(a) The establishment shall maintain the following records documenting theestablishment's HACCP plan:

(1) The written hazard analysis prescribed in this part, including all supportingdocumentation;

(2) The written HACCP plan, including decision making documents associatedwith the selection and development of CCP's and critical limits, and documentssupporting both the monitoring and verification procedures selected and thefrequency of those procedures.

(3) Records documenting the monitoring of CCP's and their critical limits,including the recording of actual times, temperatures, or other quantifiablevalues, as prescribed in the establishment's HACCP plan; the calibration of

process-monitoring instruments; corrective actions, including all actions taken inresponse to a deviation; verification procedures and results; product code(s),

product name or identity, or slaughter production lot. Each of these records shallinclude the date the record was made.

(b) Each entry on a record maintained under the HACCP plan shall be made atthe time the specific event occurs and include the date and time recorded, andshall be signed or initialed by the establishment employee making the entry


9/49

The Temperature Recording Chart for the carcass chill was already in use and the teamknew that they needed to do some personnel training to ensure that all record keepingrequirements are included on the recording chart.

QA already had a Thermometer Calibration Log and this form was modified to meet theHACCP regulatory record keeping requirements. The HACCP team decided that thisform could be used by QA for more than one day because there are very limitednumbers of thermometers issued for product temperature measurements. If at any timeduring the shift a thermometer is dropped or if the employee questions the accuracy ofthe thermometer he is to immediately take the thermometer to the QA lab for anaccuracy check.

On its HACCP Plan, generic establishment X has listed the names of the forms it will beusing for monitoring and verification records. The team also devised the antimicrobialintervention log to record monitoring results for pressure and antimicrobialconcentrations.

There is one other form included in column four, where the establishment has describedits record keeping system. That is the Corrective Actions Log; it is used to create therecords of any corrective actions taken because of deviations from critical limits atCCPs. Column six references the planned corrective actions for each CCP. TheHACCP team carefully reviewed the regulatory requirements for planned correctiveactions.

Corrective actions.

(a) The written HACCP plan shall identify the corrective action to be followed inresponse to a deviation from a critical limit. The HACCP plan shall describe thecorrective action to be taken, and assign responsibility for taking correctiveaction, to ensure:

(1) The cause of the deviation is identified and eliminated;

(2) The CCP will be under control after the corrective action is taken;


10/49

Planned Corrective Actions for CCP 3

1. QA will reject or hold product until temperature is achieved dependent on time andtemperature deviation. For example, the ARS cooling program can be used to makea determination.

2. QA will identify the cause of the deviation and prevent reoccurrence byreassessment of the HACCP plan and review of the cause of the deviation.Monitoring will be more frequent to assure the process is in control.

3. QA will assure that no adulterated product has been shipped.

The HACCP team also develops planned corrective actions for each of the other CCPsand attaches them to the HACCP plan. Whenever a deviation from a critical limitoccurs, company employees follow the corrective action plan and use the Corrective

Action Log to create a record of their actions. The Corrective Action Log forms areavailable at CCPs, so they can be used immediately when an employee performing amonitoring check discovers and records a deviation. All Corrective Action Logs, whichhave been used during the day, are turned in to the HACCP coordinator.

There is one final verification/record-keeping requirement that the company must

perform;(c) Prior to shipping product, the establishment shall review the recordsassociated with the production of that product, documented in accordance withthis section, to ensure completeness, including the determination that all criticallimits were met and, if appropriate, corrective actions were taken, including the

proper disposition of product. Where practicable, this review shall be conducted,dated, and signed by an individual who did not produce the record(s), preferablyby someone suitably trained, or the responsible establishment official.

In generic establishment X, product is shipped out, often in small lots, throughout theday. This means that pre-shipment verification checks must be as complete as possiblewhen finished product is in storage, so that a shipment can be made up quickly andmoved into distribution channels.


11/49

The HACCP team believes it has now completed preparation of the documents that arenecessary to meet regulatory requirements for a Hazard Analysis and a HACCP Planfor their poultry slaughter production process. They have secured a copy ofEnforcement of Regulatory Requirements in Establishments Subject to HACCP SystemRequirements, the HACCP Basic Compliance Checklist that will be used by inspection

program personnel. The HACCP team has modified the inspection form to make thestatements into positives, and now has a checklist for its own use to make sure theyhave not omitted anything in their plan development and preparation. When they areconfident that they have done what is necessary, they will turn their Hazard Analysisand HACCP Plan over to the establishment owner for decisions about implementation.


12/49

PROCESS CATEGORY: SLAUGHTER

PRODUCT: YOUNG CHICKEN

RECEIVINGPACKAGINGMATERIALS

RECEIVING/HOLDINGLIVE POULTRY

UNLOADING/HANGING/STUNNING/KILLING/BLEEDING

SCALDING/PICKING/HEAD REMOVAL/ SINGEING/WASHING/HOCK CUTTER/TRANSFER/REHANG/PINNING

OIL GLAND REMOVAL/NECK BREAKING/VENTING/OPENING

EVISCERATION/PRESENTATION

LUNG/CROP REMOVAL NECK REMOVAL/HARVEST

HOUSE INSPECTION/TRIM

FINAL WASH*

REPROCESSING* SALVAGE*

CHILLING – CARCASS/NECK/GIBLETS*

PACKAGING/LABELING*STORAGE

PACKAGINGMATERIALS

LIVER/HEART HARVESTGIZZARD HARVEST/PEEL

PROCESS FLOW DIAGRAM

APPENDIX I


13/49

PROCESS CATEGORY: SLAUGHTER

PRODUCT: YOUNG CHICKEN

1. COMMON NAME? CHICKEN

2. HOW IS IT TO BE USED? READY TO COOKCARCASSES/PARTS

3. TYPE OF PACKAGE? CARCASSES – VACUUMPACKAGED INDIVIDUALLY;PARTS – VACUUM PACKAGED,TRAY PACKS

4. LENGTH OF SHELF LIFE, 3-6 MONTHS AT 0° F ORAT WHAT TEMPERATURE? BELOW;7 DAYS AT 40° F

5. WHERE WILL IT BE SOLD? WHOLESALE TO DISTRIBUTORS;CONSUMERS? RETAIL TO CONSUMERSINTENDED USE?

6. LABELING INSTRUCTIONS? SAFE FOOD HANDLING LABELS;KEEP REFRIGERATED OR KEEPFROZEN; COOKING LABEL

7 IS SPECIAL DISTRIBUTION KEEP REFRIGERATED OR KEEP

PRODUCT DESCRIPTION

APPENDIX II


14/49

122

HAZARD ANALYSIS – YOUNG CHICKEN SLAUGHTER

Process Step Food SafetyHazard

ReasonablyLikely toOccur?

Basis If Yes in Column 3,What Measures Couldbe Applied to Prevent,Eliminate, or Reduce

the Hazard to anAcceptable Level?

Critical ControlPoint

Biological – None

Chemical – None

Receiving/Holding – Live Poultry

Physical – None

Biological – None

Chemical – Notacceptable for

intended use

No Letters of guaranty arereceived from all suppliers

and packaging materials.

Receiving – PackagingMaterials

Physical – Foreignmaterials

No Plant records demonstratethat foreign material

contamination has notoccurred during the pastseveral years.

Biological – NoneChemical – None

Storage– Nonmeat

Ingredients/PackagingMaterials

Physical – None

APPENDIX III


15/49

123







Biological – None

Chemical – None

Unloading/Hanging/Stunning/Killing/

Bleeding Physical – None

Biological – None

Chemical – None

Scalding/Picking/HeadRemoval/Singeing/

Washing/Hock cutter/Transfer/Rehang / Physical – None

Biological – None

Chemical – None

Oil Gland Removal/Neck Breaking/Venting/

Opening Physical – None

Biological

SalmonellaCampylobacter

Yes Significant contamination

can occur from leakage of gut material, which may beassociated with pathogens.

Proper adjustment of evisceration equipment andpresentation training of employees will reduce the levelof contamination. Visualinspection of carcasses forfecal contamination.

1B

Chemical – None

Evisceration/

Presentation

Physical - Fecalcontamination from gut

breakage.

Yes


16/49

124







Biological – None

Chemical – None

Lung/Crop RemovalNeck Removal/Harvest

Physical – NoneBiological – None

Chemical – None

House Inspection/Trim

Physical – None

Biological – Pathogens Salmonella

Generic E.coli

Yes Potential for contaminationand pathogen proliferation.Subsequent chilling will

help reduce the risk of

pathogen growth.

Proper washing (use of anantimicrobial), trimming,and temperature control

will reduce the numbers

and limit the growth of pathogens.

2B

Chemical – None

Reprocessing

Physical – None


17/49

125







Biological – Sep/Tox

No Young chickens historicallyhave a low incidence of

sep/tox the only poultrydisease of public healthsignificance.

Chemical – None

Salvage

Physical – NoneBiological – None

Chemical – None

Final Wash

Physical – None

Biological – NoneChemical – None

Liver/Heart HarvestGizzard Harvest/Peel

Physical – None

Biologicalcross-contaminationSalmonella

Yes Product to product contact.Literature indicates thatimproperly controlled chill-ing systems can result inhigher prevalence of pathog-ens in the final product. FSISperformance standard forSalmonella can be met using

an antimicrobial intervention

at this process step.

Product will be chilledproperly to prevent pathogengrowth.

Chlorine dioxide use canprevent further growth of Salmonella.

3B

Chemical – None

Chilling – Carcass/Necks/Giblets

Physical - None


18/49

126







Biological – None

Chemical – None

Packaging/Labeling

Physical – None

Biological – Pathogens

Yes Pathogens are reasonablylikely to grow if temperature is not

maintained at or below alevel sufficient to precludetheir growth.

Maintain producttemperature at or below alevel sufficient to preclude

pathogen growth.

4B

Chemical – None

Finished ProductStorage (Cold)

Physical – None

Biological - None

Chemical – None

Shipping

Physical – None


19/49

127

HACCP PLANPROCESS CATEGORY: SLAUGHTER PRODUCT EXAMPLE: YOUNG CHICKEN

CCP# andLocation

CriticalLimits

MonitoringProcedures and

Frequency

HACCPRecords

Verification Procedures andFrequency

Corrective Actions

1P/BEvisceration/Presentation

Zero visiblefecalcontamina-tion after processing;equipmentkept properlyadjusted; nogut breakagedue toimproper equipment

adjustment;range of 20-50 ppmchlorine or other approvedantimicrobialrinse onequipmentand product.

Visible check (atleast once per hour of production);check chlorine or other approvedantimicrobial rinseat start up andevery 2 hours usingdocumentedrandom sampling procedures todemonstrate

control. DesignatedQuality Assuranceemployee willrecord results inappropriate Log.Equipmentadjustment will bechecked at start of each shift.

Plant FinishedProduct StandardsForm

Antimicrobial Log

EquipmentMaintenance Log

Corrective ActionLog

Once per shift the QA supervisor will review the Plant AntimicrobialLog and observe chlorine leveltesting.

Twice per shift MaintenanceSupervisor will review EquipmentMaintenance Log

QA will reject or hold product until zerofecal tolerance is achieved.Equipment will be properly adjusted toassure contamination is not occurring after line is stopped. All suspect product will bevisually examined between eviscerationand after final wash. Contaminated product will be condemned or reconditioned. Equipment maintenanceand adjustments will be reviewed andcompared to flock size and manufacturersspecs.

QA will identify the cause of the deviationand prevent reoccurrence.

Signature: __________________________________ Date: __________________________

APPENDIX IV


20/49

128


CCP# andLocation

CriticalLimits


Frequency

HACCPRecords


Corrective Actions

2P/BReprocessing

Zero visiblefecalcontamina-tion after reprocessing;equipmentkept properlyadjusted;range of 20-50 ppmchlorine or other

approvedantimicrobialrinse onequipmentand product.

Visible check oneach lot (at leastonce per hour of production);check chlorine or other approvedantimicrobialrinse at start upand every 2 hoursusing documentedrandom sampling procedures to

demonstratecontrol.DesignatedQuality Assuranceemployee willrecord results inappropriate Log.

Reprocessing Log(using PlantFinished ProductStandards)

Antimicrobial Log

EquipmentMaintenance Log


Once per shift the QA supervisor will review the Reprocessing Logand Antimicrobial Log.

Twice per shift MaintenanceSupervisor will review EquipmentMaintenance Log

QA will reject or hold product until zerofecal tolerance is achieved.

Product will be reworked and reinspected by QA for fecal contamination.

Any equipment adjustments will be made.

Frequency of monitoring will be reassessedand CCP will be monitored once per hour to assure it is under control.


Signature: __________________________________ Date: __________________________


21/49

129


CCP# andLocation

CriticalLimits


Frequency

HACCPRecords


Corrective Actions

3BChilling (AllProducts)

Temperature

of 40° F or

less will bereachedwithin 4hours on all product.

Chlorinedioxide levelin chiller will be maintained

at > 20 ppm.

Producttemperature check monitored by QAtechnician at end of chilling procedure(every hour of production).

Chill water will betested for Chlorinelevel every 2 hours by QA.

Chilling Log

Carcass Chiller Recording Chart

Neck/Giblet Chiller Recording Chart

Thermometer Calibration Log

Corrective Action

Log

Antimicrobial Log

Once per shift the QA supervisor will review the Chilling Log, PlantPost Chill Product Standards Form,and Antimicrobial Log.

Maintenance supervisor will verifyaccuracy of the carcass chiller andneck/giblet chiller temperaturerecording charts once per shift.

QA will verify the chlorineconcentration in the chiller once per

week.

QA will check all thermometersused for monitoring and verificationfor accuracy daily and calibrate towithin 2° F accuracy as necessary.

QA will reject or hold product dependenton time, temperature and or antimicrobiallevel deviation.


Maintenance will check chiller circulationand water exchange rate and makeadjustments as required. Any necessaryrepairs will be made.

QA will monitor temperature andantimicrobial level in chiller every 2 hoursuntil assured that process step is under control.

Signature: __________________________________ Date: __________________________


22/49

130

HACCP PLAN

PROCESS CATEGORY: SLAUGHTER PRODUCT EXAMPLE: YOUNG CHICKEN

CCP# andLocation

CriticalLimits


Frequency

HACCPRecords


Corrective Actions

4BFinishedProductStorage(Cold)

(Continuedon nextpage.)

Finished product willnot exceed40° F.

Maintenance personnel willcheck producttemperature oncarcasses everytwo hours.

Chilling Log



Maintenance supervisor will verifythe accuracy of the producttemperature log once per shift.

QA will check all thermometersused for monitoring and verificationactivities for accuracy daily andcalibrate to within 2° F accuracy asnecessary.

QA will observe maintenance personnel check finished product

storage area once per shift.

If a deviation from a critical limit occurs,the following corrective actions will betaken:1. The cause of the temperature

exceeding 40° F will be identified andeliminated.

2. The CCP will be monitored hourlyafter the corrective action is taken toensure that it is under control.

3. When the cause of the deviation isidentified, measures will be taken to prevent it from recurring e.g., if the

cause is equipment failure, preventivemaintenance program will be reviewedand revised, if necessary.

Signature: __________________________________ Date: __________________________


23/49

131

HACCP PLAN

PROCESS CATEGORY: SLAUGHTER PRODUCT EXAMPLE: YOUNG CHICKEN

CCP# andLocation

CriticalLimits


Frequency

HACCPRecords


Corrective Actions

4BFinishedProductStorage(Cold)

4. If product temperature exceeds thecritical limit, the processing authoritywill evaluate the producttime/temperature deviation beforerelease for shipment. If time/temperature is not sufficient, product will be cooked in theestablishment to ensure destruction of pathogens or condemned.

Signature: __________________________________ Date: __________________________


24/49

132

REPROCESSING INSPECTION LOG

Date: _________________ Critical Limit: No visible fecal contamination entering chiller

TIME

Product ID Results of Inspection

MonitorInitials

VerificationInitials

Corrective Actions and/orComments

Reviewed by: __________________________________ Date: ______________________


25/49

133

CHILLING LOG

Date: _________________ Critical Limit: Internal temperature of 400 F when product exits chiller

TIME

Product ID InternalTemperature

MonitorInitials

VerificationInitials

Corrective Actions and/or Comments

Reviewed by: __________________________________ Date: ______________________


26/49

134

THERMOMETER CALIBRATION LOGCalibrate to 32

0F while thermometer is in slush ice water

Date Time Department or Area

Thermometer ID# PersonalThermometer Reading

AdjustmentRequired(Yes or No)

Initials Comments *

6/15 1:00 PM CarcassChilling

2A 32°F No HK

* If a thermometer is broken or taken out of service, document this in the comment column.

Reviewed by: _______________________ Date: _______________________


27/49

135

GENERIC ESTABLISHMENT X: ROOM TEMPERATURE LOG

ROOM:__________ DATE:_________

TIME TEMP Deviation fromCL? (Check if

yes)

If Yes,Action?

Monitored by: Verified by:


28/49

135

ESTABLISHMENT X: Antimicrobial Intervention Monitoring Log

Date Lot # Time SolutionConcentration

Pressure Corrective Actions Monitored by:

Verified by:


29/49

136

CORRECTIVE ACTIONS LOG

Product: ___________________________________________ Lot # ______________________

CCP Deviation/Problem

Corrective ActionProcedures/Explain

Disposition of Product

ResponsiblePerson

Date/Time

SIGNATURE: __________________________ DATE: ______________________


30/49

137

PRE-SHIPMENT REVIEW LOGDate:______________

PRODUCT LOTID

TIMERECORDS

REVIEWED

BYWHOM

LOT RELEASED FOR SHIPMENT?

SIGNATURE

COMMENTS *

*Monitoring frequency as per plan; Critical limits met; Certification (if applicable) as per plan; Deviations if occurred were

reviewed for appropriate corrective actions; Records complete and accurate.


31/49

PROCESS FLOW DIAGRAM

PRODUCT: SMOKED SAUSAGE, PARTIALLY COOKED CHICKEN PATTIES

RECEIVINGRAW MEAT/POULTRY

RECEIVINGPACKAGINGMATERIALS

RECEIVINGNONMEAT/

NONPOULTRYFOOD

INGREDIENTSSTORAGE

(COLD – FROZEN/REFRIGERATED)RAW MEAT/POULTRY

TEMPERINGFROZEN MEAT/POULTRY

WEIGHINGRAW MEAT/POULTRY

COMBINE INGREDIENTS

MECHANICAL PROCESSES(Note: List all used) *

SMOKING/PARTIAL COOKING

PACKAGING/LABELING

REWORK

STORAGEPACKAGINGMATERIALS

STORAGENONMEAT/

NONPOULTRYFOOD

INGREDIENTS

WEIGHINGNONMEAT/

NONPOULTRYFOOD

INGREDIENTS

*Examples

DeboningSkinningBrine injectionComminutionMarinationTumblingPortioning

APPENDIX V


32/49

PRODUCT DESCRIPTION

PROCESS CATEGORY: HEAT TREATED BUT NOT FULLY COOKED, NOT SHELF STABLE

PRODUCT: SMOKED SAUSAGE, PARTIALLY COOKED CHICKENPATTIES

1. COMMON NAME? SMOKED SAUSAGE, PARTIALLYCOOKED CHICKEN PATTIES

2. HOW IS IT TO BE USED? ENTREES, NUGGETS, SNACKFOODS, SALADS

3. TYPE OF PACKAGE? BULK-PACKED (E.G., PLASTIC

BAG, VACUUM PACKED)

4. LENGTH OF SHELF LIFE, 3-6 MONTHS AT 0° F ORAT WHAT TEMPERATURE? BELOW;7 DAYS AT 40° F

5. WHERE WILL IT BE SOLD? WHOLESALE TO DISTRIBUTORSCONSUMERS? ONLY

INTENDED USE?

6. LABELING INSTRUCTIONS? KEEP FROZEN; KEEPREFRIGERATED

APPENDIX VI


33/49

140

HAZARD ANALYSIS – HEAT TREATED BUT NOT FULLY COOKED, NOT SHELF STABLE -Smoked Sausage, Partially Cooked Chicken Patties






Biological:Pathogens Salmonella

Trichina

Yes Salmonella may bepresent on incomingraw product.

Certification from suppliersthat product has beensampled for Salmonellameets performancestandards

1B

Chemical – None

Receiving – RawMeat/Poultry

Physical – Foreign

materials such asbroken needles,bone/ bonefragments

Yes Bone/bone fragments

(size/shape) that wouldrepresent a hazard toconsumers have beenfound in incomingproduct.

Supplier specification that allproduct must have been run

through a bone detector/bonecollector in process or if wholemuscle product received useof a bone detector/bonecollector in process.

Biolo ical – NoneChemical – Notacceptable for intendeduse

No Letters of guaranty arereceived from all suppliers of packaging materials.

Receiving – Nonmeat/Nonpoult

ry Food

Ingredients;PackagingMaterials

Physical – Foreignmaterials (wood,metal, glass, etc.)

No Plant records demonstratethat foreign materialcontamination has notoccurred during the pastseveral years.

APPENDIX VII


34/49

141







Biolo ical – NoneChemical – None

Storage – Nonmeat/Nonpoult

Physical – NoneBiologicalSalmonella Listeriamonocytogenes

Yes Pathogens are reasonablylikely to grow in this productif temperature is not

maintained at or below alevel sufficient to precludetheir growth and coolers arenot maintained to holdtemperatures.

Maintain producttemperature at orbelow a level sufficientto preclude or abatepathogen growth.

2B

Chemical – None

Storage (Cold – Frozen/Refrigerate

d) – RawMeat/Poultry

Physical – NoneBiolo ical – NoneChemical – None

Tempering FrozenMeat/Poultry


WeighingNonmeat/Nonpoult

Physical – None


35/49

142








Weighing RawMeat/Poultry


CombineIngredients


MechanicalProcess

* See list on flow

chart on page 21

Physical – MetalContamination

Yes Plant records show that duringmechanical processing metal

contamination is likely tooccur.

Metal detectors areinstalled prior topackaging.

3P


Smoking/PartialCooking

Physical – NoneBiological – No Rework at the end of

Chemical – None

Rework

Physical – None


36/49

143







Biological – Pathogens-parasitic(Trichina)

Yes Trichina hashistorically occurred inraw pork products.

Labels that clearlyindicate this is a rawproduct, along withcooking instructions

4B

Chemical – None

Packaging/Labeling

Physical – NoneBiological -Pathogens

Yes Pathogens arereasonably likely togrow if improper

Proper chillingprocedures are used.

5B

Chemical – None

Chilling

Physical – None


37/49

144







Biological –

Pathogens

Yes Pathogens are

reasonably likely togrow in this product if temperature is notmaintained at or below

Maintain product

temperature at orbelow a level sufficientto preclude pathogengrowth.

6B

Chemical – None

Finished Product

Storage (Cold)


Shipping

Physical – None


38/49

145

HACCP PLANPROCESS CATEGORY: HEAT TREATED BUT NOT FULLY COOKED, NOT SHELF STABLE

PRODUCT EXAMPLE: SMOKED SAUSAGE, PARTIALLY COOKED CHICKEN PATTIESCCP# andLocation

CriticalLimits

MonitoringProcedures

and Frequency

HACCPRecords


Corrective Actions

1BReceiving – RawMeat/Poul

try

Supplier certification that product has

beensampledfor Salmonellamustaccompanyshipment.

Receiving personnel willcheck eachshipment for

Salmonellacertification.

Receiving Log

CorrectiveAction Log

Every two months QA willrequest FSIS Salmonella dataresults from company for atleast 2 suppliers.

Will not receive productunaccompanied by Salmonellacertification.Product found not meeting

Salmonella performance standardswill not be accepted. If supplier hasfailed 2 consecutive sets of Salmonella tests, the supplier willnot be used until they certify thatthe results of a sample set meets baseline standard.

2B

Storage(Cold– Frozen/Refrigerated – RawMeat/Poultry

Raw

productstorageareas shallnot exceed40° F.

Maintenance

personnel willcheck raw product storageareatemperatureevery twohours.

Room

Temperature Log



Maintenance supervisor will

verify accuracy of the RoomTemperature Log once per shift and observe temperaturechecks.

QA will check allthermometers used for monitoring and verification

for accuracy daily andcalibrate to within 2°Faccuracy as necessary.

Product internal temperature will be

determined. QA will reject or hold product dependent ontime/temperature deviation.Volume or manner of storage will be adjusted if determined tocontribute to the deviation. Coolingcurve or Process Authority will beused to make product disposition

determination.QA will identify the cause of thedeviation and prevent reoccurrence.Cooler will be repaired &maintenance schedule revised if necessary.

Signature: __________________________________ Date: __________________________

APPENDIX VIII


39/49

146

HACCP PLAN

PROCESS CATEGORY: HEAT TREATED BUT NOT FULLY COOKED, NOT SHELF STABLEPRODUCT EXAMPLE: SMOKED SAUSAGE, PARTIALLY COOKED CHICKEN PATTIES

CCP# andLocation

CriticalLimits


and Frequency

HACCPRecords


Corrective Actions

3PMechanical

Processes

No metal particles

to exceed1/32inches.

Maintenance personnel will

check the metaldetector with aseeded sampleonce per shift &determine thatkick out deviceis functioningas intended.

Metal DetectionLog


Maintenance supervisor willverify metal detector is

functioning and performroutine maintenance asrequired by manufacturer.

QA will verify that the metaldetector is functioning asintended by observingmaintenance test with seeded

sample once every other day.

Mechanical separation linesupervisor will control and

segregate affected product.

Maintenance personnel will identifyand eliminate the problem with themetal detector.

Preventive maintenance programwill be implemented and revised as

required.

QA will run seeded sample throughmetal detector after repair.

All potentially contaminated product will be visually examined& metal removed. Product will be

x-rayed prior to rework or shipment.

Signature: __________________________________ Date: __________________________


40/49

147

HACCP PLAN


CCP# andLocation

CriticalLimits


and Frequency

HACCPRecords


Corrective Actions

4BPackaging/

Labeling(Trichina)

Productmust

clearly belabeled asraw or partiallycookedandrequiringcooking.

Cookinginstructions must beon the package.

Safe food

handlingstatementmust be part of thelabel.

Packaging linesupervisor will

select 2 packages of each type of product produced at thestart & finish of each lot andensure labeling

requirementsare met.

Labeling Log


QA will observe packagingline supervisor perform

monitoring activity once per shift.

QA will select 3 labelsintended for use from labelstorage area twice weekly toensure label accuracy.

QA will check labels once aday on packaged product toensure label accuracy on packaged product.

QA will segregate and hold allaffected product.

QA will ensure that proper labelingis applied to all affected product prior to shipment.

Labeling equipment will beadjusted if required. Labelmanufacturer will provide

certification that all requiredfeatures are printed properly.Incoming labels will examined toassure they are correct.

Signature: __________________________________ Date: __________________________


41/49

148

HACCP PLAN

PROCESS CATEGORY: HEAT TREATED BUT NOT FULLY COOKED, NOT SHELF STABLEPRODUCT EXAMPLE: SMOKED SAUSAGE, PARTIALLY COOKED CHICKEN PATTIESCCP# andLocation

CriticalLimits


and Frequency

HACCPRecords


Corrective Actions

5BChilling

Internal producttemperatur

e< 70°Fwithin 3hours andwill reach< 41°Fwithin anadditional6 hours

after reaching< 70 °F(Totalchillingtime of 9hours).

QA technicianwill observechilling

handling procedures toensure criticallimits are met.Product coolerswill bemonitored andrecorded

continuously ontemperaturerecordingcharts.QA technicianwill randomlyselect 5 samplesof each type of

product at 3 and9 hours fromstart of chillingand determineinternaltemperature.

Product ChillingLog

Product CoolersTemperatureRecordingCharts



Once per shift the QAsupervisor will review theProduct Chilling Log and

observe temperaturemonitoring activity.

Maintenance supervisor willverify accuracy of the productcooler temperature recordingcharts once per shift.

QA will check allthermometers used for monitoring and verificationfor accuracy daily andcalibrate to within 2°Faccuracy as necessary.

QA will reject or hold productdependent on time and temperaturedeviation. Internal product

time/temperature curve will bedetermined & used to make productdisposition. Product will becondemned or fully cooked.

QA will identify the cause of thedeviation and prevent reoccurrence.

Cooler will be repaired if required& maintenance schedule revised if required.

Signature: __________________________________ Date: __________________________


42/49

149

HACCP PLAN


CCP# andLocation

CriticalLimits


and Frequency

HACCPRecords


Corrective Actions

6BFinished

ProductStorage(Cold)

(Continued on nextpage)

Finished product

storageareas willnot exceed40° F.

Maintenance personnel will

check finished product storageareastemperaturesevery twohours.

RoomTemperature Log



Maintenance supervisor willverify the accuracy of the

room temperature log once per shift.

QA will check allthermometers used for monitoring and verificationactivities for accuracy dailyand calibrate to within 2° F

accuracy as necessary.

QA will observe maintenance personnel check finished product storage area once per shift.

If a deviation from a critical limitoccurs, the following corrective

actions will be taken:4. The cause of the temperature

exceeding 40° F will beidentified and eliminated.

5. The CCP will be monitoredhourly after the correctiveaction is taken to ensure that itis under control.

6. When the cause of the deviationis identified, measures will betaken to prevent it fromrecurring e.g., if the cause isequipment failure, preventivemaintenance program will bereviewed and revised, if necessary.

Signature: __________________________________ Date: __________________________


43/49

150

HACCP PLAN


CCP# andLocation

CriticalLimits


and Frequency

HACCPRecords


Corrective Actions

6BFinished

ProductStorage(Cold)

If a deviation from a critical limitoccurs, the following corrective

actions will be taken:7. If room temperature exceeds the

critical limit, the processingauthority will evaluate the product temperature to ensurethe temperature is sufficient to preclude pathogen growth before release for shipment. If

temperature is not sufficient to preclude pathogen growth, product will be cooked in theestablishment to ensuredestruction of pathogens or condemned.

Signature: __________________________________ Date: __________________________


44/49

151

FORM LETTER Confirming Salmonella Compliance with Performance Standards

Date

To: Plant XYZ

This is to confirm results of any Salmonella performance standard sample sets completed during the past six months from your establishment listed below.

Thank you.

Product Date ResultsReceived

Test Results Two Consecutive Failed Tests


45/49

152

THERMOMETER CALIBRATION LOGCalibrate to 32

0F while thermometer is in slush ice water

Date Time Departmentor Area

Thermometer ID# PersonalThermometer Reading

AdjustmentRequired (Yesor No)

Initials Comments

1. If a thermometer is broken or taken out of service, document this in the comment column.

Reviewed by: ______________________________ Date: _______________________


46/49

153

GENERIC ESTABLISHMENT X: ROOM TEMPERATURE LOG

ROOM:__________ DATE:_________

TIME TEMP Deviation fromCL? (Check if yes)

If Yes,Action?

Monitored by: Verified by:


47/49

154

GENERIC ESTABLISHMENT X: METAL DETECTION LOG

Date Product Lot # Results SeededSample

Time Monitored By Verified By


48/49

155

CORRECTIVE ACTIONS LOGProduct: ___________________________________________ Lot # ______________________

CCP Deviation/

Problem

Corrective Action

Procedures/Explain

Disposition of

Product

Responsible

Person

Date/Time

SIGNATURE: __________________________ DATE: ______________________


49/49

156

PRE-SHIPMENT REVIEW LOGDate:______________

PRODUCT LOTID

TIMERECORDSREVIEWED

BYWHOM

LOT RELEASED FOR SHIPMENT?SIGNATURE

COMMENTS *

*Monitoring frequency as per plan; Critical limits met; Certification (if applicable) as per plan; Deviations if occurred were reviewedfor appropriate corrective actions; Records complete and accurate.

HACCP Poultry Best

Documents

Transcript of HACCP Poultry Best