HACCP Plan – Heat Treated, Shelf Stable



Directions for Using the HACCP Plan Form

1. Examine your Hazard Analysis form to determine which steps are CCP’s and what type of hazard (Biological, Chemical, or Physical) each CCP controls.

2. Check to see whether each CCP is already listed on the HACCP Plan Form. If a CCP is not already listed, enter the CCP number and step in the column labeled “CCP # and Location”.

3. For CCP’s already listed on the model form, examine the Critical Limits listed. In the HACCP Plan Form for some HACCP categories there will be several options for Critical Limits. If this is the case, choose the Critical Limits that will work best in your plant and cross out, white out, or delete the other Critical Limits and the Monitoring Procedures that go with them. It may be helpful to check the “Monitoring Procedures and Frequency” column during your decision-making. For CCP’s already on the model form, supporting scientific documentation is already included in your manual.

4. If you are adding a new CCP, you will need to determine the scientifically valid Critical Limits to be used with the CCP. You must also obtain scientific information supporting your choice of Critical Limits. Consult your inspector or university extension specialists for help.

5. Examine the “Monitoring Procedures and Frequency” column for each CCP. If you wish to change the procedure and/or the frequency, check with your inspector or a university extension specialist for help. If a change is OK, you will need to write down your reasoning for making the change and include this reasoning in your HACCP manual.

6. Examine the “HACCP Records” column. If you are using different forms for record-keeping in this HACCP Plan, please put the correct form title(s) in the “HACCP Records” column.

7. The verification activities listed in the “Verification Procedures and Frequency” column are required by the regulation. However, you may choose to do additional activities; for example, for verification, beef jerky samples may be sent to the lab each quarter for water activity testing. Moisture:Protein Ratio (MPR) testing would not be necessary to meet HACCP requirements for jerky. However, MPR testing and/or water activity testing may be needed to meet HACCP requirements for other shelf-stable products. If you do any additional verification activities, enter them in the “Verification Procedures and Frequency” column. If you choose to use a frequency for the required verification activities that is different than the frequency shown, you must provide written justification for the different frequency. Consult your inspector or university extension specialists for help.

8. We suggest that you make no changes in the “Corrective Actions” column. Be sure to have a form for documenting corrective actions that you take. A corrective action form is included in this model.

9.

|HACCP PLAN |

|PROCESS CATEGORY: Heat treated, shelf stable |

|Product example: Snack Sticks, Summer Sausage, Jerky |

|CCP# and Location |Critical Limits |Monitoring Procedures and Frequency |HACCP Records |Verification Procedures and Frequency |Corrective Actions |

|1B |pH ≤ 5.3 – achieved within one of the | |Fermentation Log |Establishment owner or designee will |If a deviation from a |

|Fermenting (Snack |following time limits (based on a constant | | |review the Fermentation Log, Corrective |critical limit occurs, the |

|Sticks, Summer |chamber temperature). | |Corrective Action Log |Action Log, Thermometer Calibration Log, |establishment owner or |

|Sausage produced w/| | | |and pH Meter Calibration Log once per |designee is responsible for |

|a fermentation |Constant | |Thermometer Calibration Log |week. |corrective action protocol |

|step) |Chamber | | | |as stated in |

| |Temp (°F) Max Hrs | |pH Meter Calibration Log |Establishment owner or designee will |9 CFR, 417.3 |

| |75 80 | | |calibrate all thermometers to a known |The cause of the deviation |

| |80 60 | | |standard monthly. Thermometers will be |will be identified and |

| |85 48 | | |calibrated to ± 2° F or taken out of |eliminated. |

| |90 33 | | |operation as stated in the SOP. |The CCP will be under |

| |95 28 | | |Calibration actions are recorded in the |control after the corrective|

| |100 25 | | |Thermometer Calibration Log. |action is taken. |

| |105 20 | | | |Measures to prevent |

| |110 18 | | |Establishment owner or designee will check|recurrence will be |

| | | | |the pH meter used for monitoring, to |established. |

| |In addition, pH and water activity must be | | |verify accuracy before each batch of |No product that is injurious|

| |reduced to one of the following combinations: | | |product is produced. The SOP for |to health or otherwise |

| |Max. pH Max. water activity | | |calibration will be used and calibration |adulterated as a result of |

| |5.3 0.91 | | |will be accurate to ± 0.1. Calibration |the deviation will be |

| |5.2 0.91 | | |activities will be recorded in the pH |permitted to enter commerce.|

| |5.1 0.92 | | |Meter Calibration Log. | |

| |5.0 0.93 | | | | |

| |4.9 0.96 | | |Establishment owner or designee will | |

| |4.8 0.96 | | |observe monitoring of temperature and pH | |

| |4.7 0.96 | | |at least once per month. | |

|2 B |Snack Sticks to be cooked to an internal |Smokehouse operator or designee will |Smokehouse/ |Establishment owner or designee will |If a deviation from a |

|Heat Treatment |temperature of at least 150°F for at least 72 |take the internal temperature at |Product Temperature Log |review Smokehouse/Product Temperature Log,|critical limit occurs, the |

|(summer sausage, |seconds, or another pre-determined Appendix A |appropriate times using a calibrated | |Corrective Action Log, and Thermometer |establishment owner or |

|snack sticks with |temperature/time combination. Summer sausages|internal probe or thermometer and/or |Thermometer Calibration Log |Calibration Log once per week. |designee is responsible for |

|fermentn./ |to be cooked to a pre-determined Appendix A |review smokehouse chart for each lot at| | |corrective action protocol |

|acidificn. step) |temperature/time combination. Note that less |completion of cooking cycle and before |Corrective Action Log |Once per week the establishment owner or |as stated in |

| |severe temperature/time combinations have been|removal of product from smokehouse. | |designee will observe the monitoring of |9 CFR, 417.3 |

| |validated for some products with low pH: |The number of product pieces monitored | |process time and temperature. |The cause of the deviation |

| |summer sausage with pH 4.6 or lower can be |for temperature will be determined | | |will be identified and |

| |heated to an internal temperature of at least |based on lot size, product history, | |Thermometer calibration will be done in |eliminated. |

| |130°F instantaneous, summer sausage with pH |recent changes in formulation, | |accordance with the SOP for Calibration of|The CCP will be under |

| |5.0 or lower can be heated to an internal |previously observed variation, etc. | |Thermometer. |control after the corrective|

| |temperature of at least 130°F and held for at | | | |action is taken. |

| |least 30 minutes, pepperoni with pH 5.0 or | | | |Measures to prevent |

| |lower can be heated to an instantaneous | | | |recurrence are established. |

| |internal temperature of at least 145° or can | | | |No product that is injurious|

| |be heated to an internal temperature of least| | | |to health or otherwise |

| |128°F and held at least 60 minutes. | | | |adulterated as a result of |

| | | | | |the deviation will be |

| | | | | |permitted to enter commerce.|

| | | | | | |

|2 B Heat Treatment |Application of one of the processing schedules|Oven temperature will be monitored |Smokehouse/ |Smokehouse operator or designee will |If a deviation from a |

|(Jerky except |below: |using calibrated smokehouse dry-bulb |Product Temperature and Yield |verify that the wet bulb wick is clean and|critical limit occurs, the |

|Poultry) |1. Set oven dry-bulb temperature to reach |and wet-bulb thermometers. |Log |the wet-bulb water well contains the |establishment owner or |

| |170°F within 30 minutes, and then apply one of| | |appropriate amount of water prior to |designee is responsible for |

| |the following wet-bulb temperature spikes. | |Corrective Action Log |startup. |corrective action protocol |

| |a. 125°F for 60 min. | | | |as stated in |

| |b. 130°F for 60 min. | |Thermometer Calibration Log |Once per week, the establishment owner or |9 CFR, 417.3 |

| |c. 135°F for 30 min. | | |designee will review the |The cause of the deviation |

| |d. 140°F for 10 min. | | |Smokehouse/Product Temperature Log, |will be identified and |

| |Then dry to required dryness at a dry-bulb | | |Corrective Action Log, Thermometer |eliminated. |

| |temperature of at least 170 °F. | | |Calibration Log. |The CCP will be under |

| |2. Increase dry-bulb temperature to reach at | |Smokehouse/ | |control after the corrective|

| |least 170°F within 15 minutes, and then dry to| |Product Temperature and Yield |Once per month the establishment owner or |action is taken. |

| |required dryness at a dry-bulb temperature of | |Log |designee will observe the smokehouse |Measures to prevent |

| |at least 170°F. Relative humidity at the start| | |operator or designee perform the |recurrence are established. |

| |of the process must be at least 27% (wet-bulb | |Corrective Action Log |monitoring activity. |No product that is injurious|

| |temperature of at least 105°F) and relative | | | |to health or otherwise |

| |humidity after 120 minutes of processing must | |Thermometer Calibration Log |Smokehouse operator or designee will |adulterated as a result of |

| |be at least 17% (wet-bulb temperature of at | | |verify that the wet bulb wick is clean and|the deviation will be |

| |least 112°F). | | |the wet-bulb water well contains the |permitted to enter commerce.|

| | | | |appropriate amount of water prior to | |

| | | | |startup. | |

| | | | | | |

| |3. Increase dry-bulb temperature to reach at | | | | |

| |least 170°F within 90 minutes, and then dry to| | | | |

| |required dryness at a dry-bulb temperature of | | | | |

| |at least 170°F. Relative humidity at the start| | | |If a deviation from a |

| |of the process must be at least 41% (wet-bulb | | | |critical limit occurs, the |

| |temperature of at least 115°F) and relative | | | |establishment owner or |

| |humidity after 180 minutes of processing must | | |Once per week, the establishment owner or |designee is responsible for |

| |be at least 21% (wet-bulb temperature of at | | |designee will review the |corrective action protocol |

| |least 117°F). | | |Smokehouse/Product Temperature Log, |as stated in |

| | | | |Corrective Action Log, Thermometer |9 CFR, 417.3 |

| | | | |Calibration Log. |1. The cause of the |

| |4. Increase dry-bulb temperature in smokehouse| | | |deviation will be identified|

| |in 1-hour intervals to 120°F, 130°F, 140°F, | | |Once per month the establishment owner or |and eliminated. |

| |and 170°F, then dry to required dryness at |Oven temperature will be monitored | |designee will observe the smokehouse |2. The CCP will be under |

| |dry-bulb temperature of at least 170°F. |using calibrated smokehouse wet-bulb | |operator or designee perform the |control after the corrective|

| |Relative humidity at the start of the process |thermometers. | |monitoring activity. |action is taken. |

| |must be at least 43% (wet-bulb temperature of | | | |3. Measures to prevent |

| |at least 98°F) and relative humidity after 240| | | |recurrence are established. |

| |minutes of processing must be at least 15% | | | |4.No product that is |

| |(wet-bulb temperature of at least 109°F). | | | |injurious to health or |

| | | | | |otherwise adulterated as a |

| | | | | |result of the deviation will|

| | | | | |be permitted to enter |

| |Dry-bulb temperature in chamber must reach at | | | |commerce. |

| |least 165°F and be maintained for at least 210| | | | |

| |minutes. Relative humidity at the start of the| | | | |

| |process must be at least 49% (wet-bulb | | | | |

| |temperature of at least 139°F) and relative | | | | |

| |humidity after 210 minutes of processing must | | | | |

| |be at least 30% (wet-bulb temperature of at | | | | |

| |least 124°F). | | | | |

| |Dry-bulb temperature in chamber must reach at | | | | |

| |least 180°F and be maintained for at least 150| | | | |

| |minutes. Relative humidity at the start of the| | | | |

| |process must be at least 49% (wet-bulb | | | | |

| |temperature of at least 153°F) and relative | | | | |

| |humidity after 150 minutes of processing must | | | | |

| |be at least 24% (wet-bulb temperature of at | | | | |

| |least 134°F). | | | | |

|2B Heat Treatment | | | | | |

|(poultry jerky) | | | | | |

|3B Drying |Yield pre-determined to result in either: |Smokehouse operator or designee will |Smokehouse/ |Once per week, the establishment owner or |If a deviation from a |

| |jerky with MPR of 0.75 or lower and water |determine product yield (see SOP for |Product Temperature and Yield |designee will review the |critical limit occurs, the |

| |activity of not higher than 0.85 (air storage)|relating product yield to water |Log |Smokehouse/Product Temperature and Yield |establishment owner or |

| |or 0.88 (oxygen-free packaging), OR non-jerky |activity and Moisture:Protein Ratio) | |Log, Corrective Action Log,. |designee is responsible for |

| |product with pH and water activity must be |for every lot. |Corrective Action Log | |corrective action protocol |

| |reduced to one of the following combinations: | | |Once per month the establishment owner or |as stated in |

| |Max. pH Max. water activity | |Thermometer Calibration Log |designee will observe the smokehouse |9 CFR, 417.3 |

| |5.3 0.91 | | |operator or designee perform the |1. The cause of the |

| |5.2 0.91 | |Results of yield and/or water |monitoring activity. |deviation will be identified|

| |5.1 0.92 | |activity testing. May be part | |and eliminated. |

| |5.0 0.93 | |of Smokehouse/Product |Twice per year (once during warm weather, |2. The CCP will be under |

| |4.9 0.96 | |Temperature and Yield Log |once during cold weather), water activity |control after the corrective|

| |4.8 0.96 | | |and MPR will be tested to ensure that |action is taken. |

| |4.7 0.96 | | |product meets shelf-stability standards |3. Measures to prevent |

| | | | |(see SOP for Relating Product Yield to |recurrence are established. |

| | | | |Water Activity and Moisture:Protein |4.No product that is |

| | | | |Ratio)> |injurious to health or |

| | | | | |otherwise adulterated as a |

| | | | | |result of the deviation will|

| | | | | |be permitted to enter |

| | | | | |commerce. |

Sign and date at initial acceptance, modification, or annual reassessment.

Signed __________________________________ Date ___________________________

Signed __________________________________ Date ___________________________

Signed __________________________________ Date ___________________________

Signed __________________________________ Date ___________________________

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