HACCP Meat Volume 2 : Appendix X.3: Generic HACCP …sintak.unika.ac.id/staff/blog/uploaded/5812002253/files/...Generic HACCP Plan for Slaughter and Dressing of Cattle, and Annex to

# MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group Amendment 3: August 1998# A Guide to HACCP Systems in the Meat Industry# Appendix X.3: Canning Page: X.3.1

Appendix X.3: Generic HACCP Plan for Canning (Corned Beef)

1. Prerequisite Requirements

The following are documented prerequisite programmes/sanitation standard operating procedures(SSOPs):

� sanitary design;

C potable water quality (including cooling water requirements);

C sanitation and cleanup procedures for edible areas and food contact surfaces

(preoperational and operational);

C personal hygiene (protective clothing requirements, personal equipment and use of

amenities);

C training (including specific requirements as per IS 6, Section 8.6.2)

C hygienic processing (processing techniques and procedures, damaged carton procedures,

dropped meat, post-retort can handling);

C food contact materials (specifications, handling and storage, including can receipt and

maintenance, can sterilisation);

C food additives/ingredients (specifications, handling and storage);

C calibration, installation and maintenance of heat processing equipment and instruments;

C repairs and maintenance of equipment;

C control of chemicals;

C vermin control;

C waste disposal;

C refrigeration management (raw material);

C recall procedures;

C heat penetration trials/F0 value determination/deviation trials.


2. Scope of HACCP Plan

HACCP application: Food safety

Product: Canned corned beef

Process: Canning of corned beef from decartoning of tempered beef, heatprocessing in a non-agitating retort, through to dispatch of cannedproduct.

3. Product Description and Intended Use

Form 1: Product description and intended use

1. Product name(s) Canned corned beef

2. Important product characteristics Commercially sterile product in a can produced inaccordance with New Zealand Food Regulations 1984,Meat Regulations 1969 and IS 6.

3. How is it to be used:a. By a further processor or retailerb. By the consumer.

a. Not applicableb. Ready to eat

4. Intended consumer General public ("high-risk" groups not specified for thisplan)

5. Packaging Company/regulatory specification

6. Shelf life and storage requirements Indefinite when stored at ambient temperatures

7. Where it will be solda. Export marketb. Local market

List countries, if applicable

8. Labelling instructions Company/regulatory specification

9. Special distribution controls required Handle cans with care (GMP)


4. Initial Food Safety Objectives

(To be confirmed after hazard identification and determination of hazard responsibilities. SeeSection 8 for confirmed objectives).

To ensure commercial sterility of product by destruction of all viable microorganisms of publichealth significance as well as those capable of reproducing under non-refrigerated conditions ofstorage and distribution.

To ensure that no post-processing contamination occurs.

To ensure that the sodium nitrite content of the product is within acceptable safety limits.

To ensure that the product is free from container integrity defects which compromise the hermeticseal.

To ensure that the product is free from any physical hazards that pose a food safety risk to theconsumer.

5. Process Flow Diagram

Form 2: Raw materials/other inputs

Product name: Canned corned beef

Raw material/ other inputs Description / specification

Raw material

Packed beef, frozen (polylined in cartons) and tempered

Other inputs1

Water/cooling water

Flaked frozen beef

Salt2

Sodium nitrite2

Cans and ends2

Slaughtered , dressed and processed under a HACCPplan.

Potable as per MAF specifications (including cooling waterrequirements given in IS 6 Section 8.6.4)

As per raw material. May be subject to a separate hazardanalysis. Allowable limit: < 5%. Regulation 61(9) of the,Food Regulations 1984

Food grade salt (as per Regulation 196 of the FoodRegulations 1984) and written company specification

Prepared as per written company specification. Maximumof 50 ppm in finished product (as per Regulation 61 of theFood Regulations 1984)

As per written company specification and in accordancewith IS 6

1. These inputs and their hazards must be addressed by a prerequisite programme/SSOP, or specificallyconsidered during hazard identification within the HACCP plan.

2. Specifications and hygienic handling of these materials are covered by specific premises prerequisiteprogrammes.


Form 3: Process flow diagram

Process: Canning of corned beef

Inputs Process steps Edible outputs

Packed beef, frozen and tempered<

Potable water <

Flaked frozen beef <

Additives <

(water, salt, sodium nitrite)

Sterilised cans <

Can ends <

Cooling water with 5 ppm free <

residual chlorine (FRC)1

1. Decartoning ?2. Slicing ?3. Parboiling ?4. Mixing with additives ?5. Mincing ?6. Can filling ?7. Weight checking ?8. Seaming under vacuum ?9. Washing cans ?10. Basket stacking cans ?11. Heat processing and cooling ?12. Drying ?13. Labelling ?14. Packing ?15. Storage ?16. Dispatch

< Broth< Fat

< Canned corned beef

1. Note exemptions to this requirement in IS 6, Section 8.6.4.


6. Job Descriptions

Form 4 must be completed and confirmed for each step in the particular process.

Form 4: Template for job description

Job description

Process step no:

Summary list of food safety responsibilities of operator: (confirm after HACCP plan completed)

Reference:


7. Hazard Analysis and CCP Determination

7.1 Raw material hazard identification

Form 5a: Hazard identification for packed beef 1

Raw material Biological hazard Chemical hazard Physical hazard3

Packed beef (frozen andtempered)

B4/B5 % Microbiologicalhazards associated withcontamination from faeces,ingesta, hide, e.g.Salmonella spp., E. coliO157:H7, Campylobacterjejuni, Clostridium spp.

C22% Chemical hazards

associated with unidentifiedchemical residues, e.g.anthelmintics, antibiotics,environmentalcontaminants

None

1. Hazards listed are those that have been identified in the Generic HACCP Plan for Cooling and Boning ofBeef as food safety hazards that may reasonably be associated with frozen packed beef. Further informationon hazards associated with beef are discussed in the Annex to Appendix IX.1: Background Information to theGeneric HACCP Plan for Slaughter and Dressing of Cattle, and Annex to Appendix X.1: BackgroundInformation to the Generic HACCP Plan for Cooling and Boning of Beef.

The following codes have been used in the generic HACCP plans:

B % Biological B1 % Microbiological hazards associated with grossly-detectable abnormalities, i.e. fever,abscesses

B2 % Microbiological hazards not grossly detectable (not applicable for this plan)B3 % Visible parasitesB4 % Microbiological hazards associated with faeces and ingesta from the gastrointestinal

tract B5 % Microbiological hazards associated with the hideB6 % Microbiological hazards associated with other inputsB7 % Microbiological hazards associated with mastitic milkB8 – Microbiological hazards associated with contamination due to a process step

requirement not being met (sporadic occurrence)

C % Chemical C1 % Chemical hazards associated with identified chemical residues C2 % Chemical hazards associated with unidentified chemical residues C3 % Chemical hazards associated with other inputs

P % Physical P1 % Physical hazards associated with raw materialsP2 % Physical hazards associated with a process step requirement not being met (sporadic

occurrence)P3 % Physical hazards associated with other inputs

2. If a supplier has controls for these hazards (e.g. producer guarantees accompanying livestock receipt) in their

HACCP plan, then C2 will not appear in this raw material hazard identification.

3. When customising this HACCP plan, individual premises may wish to include metal and bone fragments ifthese hazards are reasonably likely to occur in their raw material.


7.2 Hazard analysis and CCP determination (raw material, other inputs and process steps)

Hazard analysis may result in changes to the initial food safety objectives set in Section 4. See Section 8 for confirmed objectives.

Form 5b: Hazard analysis and CCP determination (raw material, other inputs and process steps)

Process step Inputs (i) Processstep hazards

(ii) Potentialimpact ofprocess stepon existinghazards

Q1. Could the hazard bepresent in or on the product1 atunacceptable levels2 at thisstep?

If yes, answer Q2 and Q3.

Q2. Is there acontrol measureat this step thatwould preventunacceptablelevels of thehazard?

If yes, this step isa CCP.

If no, not a CCP.

Q3. Is there acontrol measureavailable at aprevious step?

If yes,retrospectivelyassign the previousstep as a CCP.

CCPNo.

Raw material Other inputs

Component Hazards Component Hazards Yes/No Justification

1. Decartoning

Bonelessbeef

B4/B5. Entericpathogens

Yes Any microorganismwill be unacceptablein relation to FSO 1. Refer to IS 6 Section8.6

No No

C2.Unidentifiedchemicalresidues

No3

(i) P2. Plastic Yes Reported incidencesof unacceptableplastic foundentrapped in frozenblocks. Customercomplaints

Yes. Removal ofentrapped plastic(e.g. by airgunapplication)

No 1

2. Slicing Bonelessbeef

B4/B5.Entericpathogens


No No








If no, not a CCP.



CCPNo.



3. Parboiling Beef slices B4/B5.Entericpathogens


No No

Water None

Flakedfrozen beef



No No

C2. Unident-ifiedchemicalresidues

No3

4. Mixing Beef slices B4/B5.Entericpathogens


No No

Nitrite C3. ExcessNitrite

Yes Incorrect amount maycause nitritepoisoning.

Yes % addition ofdefined amount ofnitrite per mix.

No 2

Salt None








If no, not a CCP.



CCPNo.



5. Mincing

Corned beef B4/B5.Entericpathogens

Yes Any microorganismwill be unacceptablein relation to FSO 1. Refer to IS 6 Section8.6.

No No

6. Can filling Corned beef B4/B5.Entericpathogens


No No

Sterilisedcans

None

7. Weightchecking



No No

8. Seamingundervacuum



No No








If no, not a CCP.



CCPNo.



(i) B8. Pathogencontamination due to seamfailure

Yes Seam inadequaciesreported as cause ofsterilisation failures.Refer to CannedFoods: Principles ofThermal ProcessControl, Acidificationand ContainerClosure Evaluation.

Yes % can seamcheck

No 3

R1

Can ends None

9. Washingcans

Cannedcorned beef



No No

10. Basketstacking cans

Cannedcorned beef



No No

11. Heatprocessingand cooling

Cannedcorned beef



Yes % heatprocessing as perdefined schedule. Refer to IS 6Section 8.6.3.

Yes % IT canselection at step 8(CCP R1). Yes % seam checkat step 8 (CCP 3).

4








If no, not a CCP.



CCPNo.



(ii) B4/B5. Growth ofthermophilicbacteria due toinadequatecooling

Yes Potential growth ofthermophilicorganisms due toinadequate coolingRefer to IS 6 Section8.6.

Yes % cooling asper definedschedule. Referto IS 6 Section8.6.4.5.

No 4

Coolingwater

None

12. Drying Sterilised,cannedcorned beef

13. Labelling Sterilised,cannedcorned beef

14. Packing Sterilised,cannedcorned beef

15. Storage Sterilised,cannedcorned beef

16. Dispatch Sterilised,cannedcorned beef


1. Product is defined as the edible component of final product.

2. Unacceptable % as demonstrated by data (scientific literature, applied research or on-site experience) associated with achieving the FSOs established for the process. Inthe determination of unacceptability, hazards should be considered in terms of:

C level;C frequency;C transfer and redistribution;C severity of effect on consumer.

3. Sporadic chemical residues at some level will always occur. However, results from the National Residue Monitoring Programme indicate that residue levels are incompliance with national requirements. The level of this hazard will not change during processing (i.e. no growth or increase in the hazard level). Therefore, it will notbe considered at subsequent steps.


8. Confirmed Food Safety Objectives (FSOs)

FSO 1: To ensure commercial sterility of product by destruction of all viable microorganismsof public health significance as well as those capable of reproducing under non-refrigeratedconditions of storage and distribution.

FSO 2: To ensure that no post-processing contamination occurs.

FSO 3: To ensure that the product shall not contain sodium nitrite at a level which may representa hazard to human health.

FSO 4: To ensure that the product is free from container integrity defects which compromise thehermetic seal.

FSO 5: To ensure that the product is free from any physical hazards that pose a food safety riskto the consumer.


9. Completion of the HACCP Plan

Full documentation is required for the remaining elements of the HACCP plan:

C critical limit setting;C monitoring procedures;C corrective action procedures;C verification procedures including validation;C documentation and recordkeeping procedures.

Refer to Sections 9-13 of the Template for Establishing a HACCP Plan for Further Processingof Meat and Meat Products for detailed requirements.

Form 6 provides a summary of the plan. References to documented procedures located elsewhereshould be shown on this form.

10. Verification of the HACCP Plan

10.1 Validation of the HACCP plan

Validation of the HACCP plan involves the initial confirmation that the HACCP plan is completeand will achieve each of the food safety objectives. Identified CCPs should be evaluated toensure that the control measure applied at that particular process step will achieve or contributeto the achievement of the relevant food safety objective (FSO).

Validation of a HACCP plan for canning may include validation of the associated processschedule or, alternatively, the use of an already-validated process schedule. In this latter case,further validation would only be needed for chemical and physical hazards.

FSO 1: To ensure commercial sterility of product by eliminating microorganisms capableof growth under normal conditions of product storage and distribution.

The first FSO is expected to be achieved by providing adequate control measures at CCP3, CCPR1 (seaming under vacuum) and CCP4 (heat processing and cooling), in conjunction witheffective prerequisite programmes (e.g. sanitation and cleanup procedures, personal hygiene,hygienic processing). Prerequisite programmes are to be validated in accordance withrequirements in IS 8.

(a) CCP3 (seaming under vacuum)

The use of visual inspection and physical measurements (tear downs) are appropriate forvalidation of this CCP. Historical data in conjunction with the can manufacturer’s specificationsmay be used. The measurement components and frequency of measurement may be influencedby market access requirements.


(b) CCP R1 (seaming under vacuum)

Collection of the coldest can is an integral part of the heat processing schedule. Validation of thisprocedure will occur when the processing schedule is established.

(c) CCP4 (heat processing and cooling)

The use of historical data from the heat penetration tests/establishment of F0, and the etablishmentof the process schedule, will provide validation for this CCP. Refer to information in IS 6,Section 8.6.3. Can incubation tests are included in this validation process (IS 6 Section 8.6.5).

FSO2: To ensure that no post processing contamination occurs

FSO2 is expected to be achieved by providing adequate control measures as per FSO1, inconjunction with effective perequisite programmes, e.g. can handling and hygienic processing.Prerequisite programmes are to be validated in accordance with requirements in IS 8.

FSO3: To ensure that the product shall not contain sodium nitrite at a level which mayrepresent a hazard to human health.

FSO3 is expected to be achieved by providing adequate control measures at CCP2 (mixing). Thecontrol measure reflects a regulatory requirement in the New Zealand Food Regulations 1984.It is therefore expected that premises will already have historical data under GMP to show thatprocedures in place are adequate to achieve the regulatory standard and therefore the FSO. Initialproduct trial results also should be available to validate this FSO.

FSO4: To ensure that the product is free from container integrity defects which compromisethe hermetic seal.

FSO4 is expected to be achieved by effective application of controls at CCP 3 (see also FSO1)and some key prerequisite programmes such as can specifications, receipt and storage, canhandling and processing hygiene. The prerequisite programmes are expected to be validatedaccording to IS 8.

FSO5: To ensure that the product is free from any physical hazards (i.e. plastic) that posea food safety risk to the consumer.

FSO5 is expected to be achieved by visual inspection at CCP1(decartoning). Guidance onestablishing sampling regimes for validation using visual observations at this step may beobtained from publications on statistical process control.

10.2 Ongoing verification

On-going verification activities confirm whether the HACCP plan is operating effectively andaccording to documented procedures. Examples of these activities are internal and extrinsicaudits, HACCP review, and a product testing programme.


10.3 Revalidation

A revalidation of the HACCP plan is required, whenever changes are made (e.g. changes topremises, product, process, intended use of the product) or process failure which maycompromise product safety, occurs.


Form 6: HACCP plan summary spreadsheet for canning (corned beef)

Process Step Hazard ID CCP no: Critical limits Monitoring procedures/tools(consider who, what, when,how)

Corrective actionprocedures1

Verificationprocedures2

HACCP records3

1. Decartoning Plastic 1 Operator technique %100% compliance withfood safety component ofjob description

All meat blocks free ofplastic

Observation every 2 hours ofoperator removing entrappedplastic and inspecting meatblock

Visual check of randomselection of blocks forentrapped plastic

(a) Talk to operator(b) Increase supervisionand/or monitoring(c) Retrain or removeoperator

FSO validation

Internal audit

Extrinsic audit

Customer complaints

HACCP review

Validation record

Daily monitoringrecord

Corrective actionreport

Internal audit report

Extrinsic audit report

Customercomplaints file

HACCP reviewrecord

2. Slicing

3. Parboiling


ProcessStep

Hazard ID CCP no: Critical limits Monitoring procedures/tools(consider who, what, when,how)



HACCP records3

4. Mixing Excesssodiumnitrite

2 Predetermined andprepared amount to beadded per batch size. Amount to result in # 50ppm nitrite in finalproduct.

Individual batch lots identified Visual check on amount perbatch

Detain product and testfor nitrite

FSO validation

Finished product evaluation resulting in # 50 ppm nitrite in finalproduct

Internal audit

Extrinsic audit

HACCP review

Validation record

Nitrite monitoring record

Corrective action report

Product evaluationrecords



HACCP review record

5. Mincing

6. Can filling

7. Weightchecking


ProcessStep




HACCP records3

8. Seamingunder vacuum

Pathogencontamination due toseamfailure

3

R1

As per manufacturer’sspecifications forparticular can

Select, mark and setaside coldest can for eachretort load

Visual examination for doubleseam and other containerdefects at least every 30minutes of continuousoperation

Double seam teardownexamination at intervals ofsufficient frequency to ensureproper closure. Interval not toexceed 4 operating hours (e.g.every 2 hours)

Additional visual and teardownexaminations to be made at thestart of production, immediately after a seamerjam, machine adjustment or aprolonged shutdown

Regular supervisor checks ofoperator performance

Stop production

Adjust seamerIsolate defective stockand detain

Isolate defective stockand detain

Talk to operator

Advise retort operatorto take appropriateaction associated withdeviation from processschedule

FSO validation

Check on vacuumheadspace aftercooling

Calibration of vacuumgauge every 12months

Internal audit

Extrinsic audit

HACCP review

Validation record

Daily monitoring record

Visual examination andteardown records

Calibration andmaintenance records




HACCP review record

9. Washingcans

10. Stacking


ProcessStep




HACCP records3

11. Heatprocessingand cooling

Entericpathogensandthermophiles

4 All cans heat processedusing a validatedprocess schedule thatwill achieve a 12Dreduction in Clostridiumbotulinum spores.

Thermal processparameters (e.g. productinitial temperature,process time/temperature) and othercritical factors that mayaffect the attainment ofcommercial sterility tobe established for eachprocess schedule. Refer to IS 6 Section8.6.3

Monitor and record criticalparameters as perrequirements given in theprocess schedule

Refer to IS 6 Section8.6.9.5

FSO validation

Internal audit

Extrinsic audit

HACCP review

Sterility tests

Incubation results

Calibration oftime/temp devicesevery 6 months

Validation record

Retort log


Calibration andmaintenance records



HACCP review record

Product evaluationrecords

12. Drying

13. Labelling


ProcessStep




HACCP records3

14. Packing

15. Storage

16. Dispatch

1. Corrective actions should reflect an escalating response when ongoing non-compliance occurs.

2. Verification procedures apply to all aspects of the HACCP plan. 3. HACCP records apply to all aspects of the HACCP plan. Refer to IS 8 Section 4 regarding requirements for documentation and record keeping.


References

IS No. 6. (1997) Industry Standard No. 6: Processing of Edible Product. The New Zealand MeatIndustry Hygiene Council, Wellington.

National Food Processors Association. (1995) Principles of Thermal Process Control,Acidification and Container Closure Evaluation. The Food Processors Institute, Washington D.C.

New Zealand Food Regulations (1984). New Zealand Government, Wellington.

HACCP Meat Volume 2 : Appendix X.3: Generic HACCP …sintak.unika.ac.id/staff/blog/uploaded/5812002253/files/...Generic HACCP Plan for Slaughter and Dressing of Cattle, and Annex to

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