HACCP Plan For Fresh Canned Mushrooms

HACCP Plan For Fresh Canned Mushrooms This project is based on the development of a generic model of a HACCP plan for fresh canned mushrooms by the usage of Canadian Food Inspection Agencys Food Safety Enhancement Program. The goal of this program is to indicate bare minimum requirements for an effective food safety management system. It is based on the principles of the Hazard Analysis and Critical Control Point (HACCP) system developed by the Codex Alimentarius Commission. FSEP has created 10 specific forms that can be used for the documentation of a HACCP plan. The 10 FSEP-HACCP Plan forms are: HACCP is an acronym for the Hazard Analysis Critical Control Point system, which is identical with food safety management. Basically it is a system which identifies, evaluates, and controls hazards which are significant for food safety. It gives confidence that food safety is being administered efficiently. The method looks for hazards, or anything that could go wrong regarding product safety, and implements controls subsequently to ensure that the product will not cause harm to the consumer. HACCP was developed originally as a microbiological safety system in the early days (1960s) of the US manned space programme, as it was vital to ensure the safety of food for astronauts. The Pillsbury Company working alongside the National Aeronautics and Space Administration (NASA) of the United States and the US Army Laboratories developed the original system (International trade centre December, 2002). PRINCIPLES OF HACCP:- There are seven discrete activities that are necessary to establish, implement and maintain a HACCP plan, and these are referred to as the seven principles in the Codex Guideline (1997). The seven principles are: Principle 1:- Conduct a hazard analysis. Identify hazards and assess the risks associated with them at each step in the commodity system. Describe possible control measures. Principle 2:- Determine the Critical Control Points (CCPs) A critical control point is a step at which control can be applied and is essential to prevent or eliminate a food safety hazard, or reduce it to an acceptable level. The determination of a CCP can be facilitated by the application of a decision tree, such as the one given in Appendix IV. Principle 3:- Establish critical limits. Each control measure associated with a CCP must have an associated critical limit which separates the acceptable from the unacceptable control parameter. Principle 4:- Establish a monitoring system Monitoring is the scheduled measurement or observation at a CCP to assess whether the step is under control, i.e. within the critical limit(s) specified in Principle 3. Principle 5:- Establish a procedure for corrective action, when monitoring at a CCP indicates a deviation from an established critical limit. Principle 6:- Establish procedures for verification to confirm the effectiveness of the HACCP plan. Such procedures include auditing of the HACCP plan to review deviations and product dispositions, and random sampling and checking to validate the whole plan. Principle 7:- Establish documentation concerning all procedures and records appropriate to these principles and their application (Food and Agricuture Organization 2003) BASIC TERMINOLOGY INVOLVED IN HACCP:- Corrective Action: Detection and eradication of the causes of a problem, thus preventing their recurrence. Critical Control Point: A point, step, or procedure at which control can be applied and as a result, a food safety hazard can be prevented, eliminated, or reduced to acceptable levels. Critical Limits:- The maximum or minimum value to which a physical biological, or chemical hazard must be controlled at a critical control point to prevent, eliminate, or reduce to an acceptable level the occurrence of the identified food safety hazard. Deviation: Failure to meet a critical limit. HACCP Plan: The written document that is based upon the principles of HACCP and delineates the procedures to be followed to ensure the control of a specific process or procedure. HACCP System: The HACCP plan in operation, including the HACCP plans itself. Hazard: Any biological, chemical, or physical property that may cause a food to be unsafe for human consumption. Hazard Analysis:- The identification of any hazardous biological, chemical, or physical properties in raw materials and processing steps, and an assessment of their likely occurrence and potential to cause food to be unsafe for consumption. Preventive Measure: Physical, chemical, or other means that can be used to control an identified food health hazard. Process:- A method consisting of any number of separate, distinct, and ordered operations that are directly under control of the establishment employed in the manufacture of a specific product, or a group of two or more products wherein all CCPs, such as packaging, may be applied to one or more of those products within the group. DEVELOPMENT OF PLANT SPECIFIC HACCP PLAN:- Some preliminary steps are required before development of a plant specific HACCP plan. These includes assembling of HACCP team, describing the food and its method of distribution, identifying the intended use and the consumers of the food, developing the flow diagram that describes the process and finally verifying the flow diagram. The following steps are all a part of developing your plant-specific plan. Description of the Product: The primary step in the development of the model for your process. To help you to progress through the remainder of your model development, it will assist you in describing your product. Process Flow Diagram: After completing product description, this form should be completed. This step consists of the course of the process as the product moves from receiving to finished products shipping. It is helpful to complete this portion of your plan while actually walking through your plant and following the production steps involved in the particular product or process. Hazard Analysis: This is a crucial step in the development of a plant specific HACCP plan. This portion must take into consideration the risk or likelihood of incident, and the rigorousness of each hazard. In order to be considered, an identified hazard must be of such a nature that its prevention, elimination, or reduction to an acceptable level is essential to the production of a safe food. Hazards that are not significant or not likely to occur will not require further consideration. According to its frequency, risk, and severity, the potential significance of each hazard should be assessed. Risk is an estimate of the likely occurrence of a hazard. The estimate of risk is usually based on a combination of experience, epidemiological data, and information in the technical literature. Pathogenic microorganisms of public health significance should be identified as a biological hazard with preventive measures to preclude their growth and propagation. In your hazard analysis there are three categories of hazards to considered: chemical, biological, and physical. Each process step will be evaluated to determine if significant hazards from one or more of these categories are present. The hazards will be listed at each process step along with the specific preventive measures that can control the hazard. Identify the processing steps that present significant hazards and any preventive measures on the Hazard Analysis/Preventive Measures Form. These will be derived from the process steps on your flow diagram. Critical Control Point (CCP) Determination: Detection and explanation of the CCP for each identified hazard is the next step in plan development. For the completion of this form we need the CCP determination and the information and data you recorded on the Hazard Analysis/Preventive Measures form. HACCP Plan Development: To ensure that your process is under control and adequate to produce a safe product, this portion of the plan development will be used to delegate the specific activities, frequencies, critical limits, and corrective actions. In addition, the HACCP plan will include specification of critical limits. These limits will be specified after the identification of the CCPs for the process and will be listed in the HACCP Plan. The critical limit must, at a minimum, meet the regulatory requirement for that specific process step if one exists. An equivalent limit based on a process or technology proven to render the product unadulterated may also be used. The following will be identified or described in the HACCP plan: the establishment monitoring procedure or device to be used; the corrective action to be taken if the limit is exceeded; the individual responsible for taking corrective action; the records that will be generated and maintained for each CCP; and the estab lishment verification activities and the frequency at which they will be conducted. (United States Department of Agriculture April, 1997) MODEL PLAN FOR FRESH CANNED MUSHROOMS:- Hazard Analysis: The foremost critical step in the effective development and implementation of the plant specific HACCP plan is conducting an analysis of the physical, chemical, and biological hazards associated with a process. The information gathered for the biological, chemical, or physical hazard will aid in determining where a hazard might happen in the process, what may possibly cause the hazard, how it can be prevented, and actions to be taken if conditions which could result in a hazard occur. Information on physical hazards may be more general and may consist simply of items found in foods that are injurious to human health such as glass, metal, broken needles, etc. The evaluation of physical hazards should include the suppliers utilized and their ability to provide products, ingredients, or materials that meet the food safety requirements of the plant. Past incidents of physical contamination occurring in the plant should also be a consideration when determining the significance of a hazard and the likely occurrence of a similar or related deviation. If specific chemical hazards exist that are associated with the process, these should also be considered at this point. Contamination from chemicals used for cleaning, equipment maintenance or upkeep is also of concern (United States Department of Agriculture April, 1997). Critical Control Point Decision Tree:- (http://www.fda.gov/ucm/groups/fdagov-public/documents/image/ucm054476.gif). PREPARING YOUR HACCP PLAN:- Assemble the HACCP team: Your HACCP team should be composed of a HACCP trained individual and/or other member(s) who are familiar with the product and the process as it is conducted in your plant. There is no set number of participants. This will be determined by each individual establishment. All team members should receive at least a basic introduction to HACCP. Training can be formal classroom training, correspondence, on-the-job training, information from college courses, and/or books or manuals. Product Description Form:- Form 1 Product Name(s) Canned mushrooms Important Product Characteristics (aw, pH, Salt, Preservatives,) pH 4.6 to 6.5 (low-acid) aw >0.85 (high moisture) How it is to be used Normally heated before serving or sometimes served unheated (salads, appetizers, etc) and can also be used for dressing Pizza etc. Packaging Hermetically sealed metal container Shelf Life Exactly Two years plus from the date of purchase, at normal retail shelf temperatures Where it will be sold Retail outlets, institutions, food service, and general public Labeling Instructions As per the ingredients added. Special Distribution Control No physical damage, excess humidity or temperature extremes Date: Approved by: (Canadian Food Inspection Agency 2009) List of Product Ingredient and Incoming Material:- This form is only needed if there is more than one ingredient. Form 2 Raw Material Mushrooms Packaging Materials Cans Ends Dry Ingredients Salt Ascorbic acid Citric acid Other Water Date: Approved by: (Canadian Food Inspection Agency 2009) Process Flow Diagram:- Plant Schematic:- A plant schematic should be prepared for the products or process groups covered by the HACCP plan. Plant schematic provides a basis for calculating prospective regions of cross-contamination. Plant schematic shall be clear, accurate and sufficiently detailed. Plant schematic shall at least include: the flow of raw products, ingredients and finished products, flow of packaging materials, employee traffic pattern throughout the establishment including change rooms, washrooms and lunchrooms, flow of the waste, inedible products and other non-food products that could cause cross-contamination and finally the hand/boot washing and sanitizing installations. The overall evaluation of potential areas of cross-contamination at the establishment should include any other plant schematic from other HACCP plans. The HACCP team shall verify the accuracy and completeness of the plant schematic by on-site checking. (Canadian Food Inspection Agency 2009). Biological Hazard Identification:- Form 5 Biological Hazards List all Biological Hazards related to Ingredients, Incoming Material, Processing, Product Flow, etc. Identified Biological Hazards (Bacteria, Parasites, Viruses) Incoming Materials Mushrooms: Could contain C. botulinum or other pathogenic bacteria, yeasts and moulds Could contain heat-stable staphylococcal enterotoxin from improper grower handling Empty cans/ends Cans could arrive with serious double seam, side seam, metal plate defects or physical damage which could result in leakage causing post-process contamination Ends could arrive with compound skips, metal plate defects, or damage, which could result in leakage causing post-process contamination Dry ingredients Could contain bacterial spores Could contain filth from insects, animals or the environment Water Could contain pathogens Process Steps Receiving Empty cans/ends received from suppliers without valid contract specifications could have serious defects or damage Dry ingredients received from suppliers without valid contract specifications could be contaminated with bacterial spores or filth from insects, animals or the environment Mushrooms (Raw) Storing Improper storage temperature humidity could result in an increased bacterial load Could be contaminated with filth from insects, animals or the environment Empty Cans/Ends Storing Physical damage could cause the formation of poor double seams, which could result in post process contamination with pathogenic bacteria Could be contaminated with filth from insects, animals or the environment Dry Ingredients Storing Could be contaminated with filth from insects, animals or the environment Depalletizing Using incorrect cans or damaged cans could result in leakage and subsequent post-process contamination with pathogenic bacteria Blanching Improper cleaning of blancher could result in the growth of thermophilic bacteria in mushroom accumulations Inadequate removal of gases could cause stressed double seams and leakage, which could result in post-process contamination with pathogenic bacteria Can conveying Physical damage could cause the formation of poor double seams, which could result in post process contamination with pathogenic bacteria Slicing/Dicing (If required) Slice thickness/clumping and percent fines could affect the heat penetration, which could result in underprocessing Filling Mushroom compaction during filling may result in underprocessing Weighing Cans not properly rejected for overweight could result in overfilled cans being underprocessed Water Filling Inadequate temperature could result in low initial temperature (IT) End Feeding/Closing/Inspecting Ends with damaged curls, compound skips or other serious defects could result in leakage and contamination with pathogenic bacteria Improperly formed double seams could result in leakage and contamination with pathogenic bacteria Thermal Processing (Still Steam Retorts) Non-validated process or vent schedule could result in underprocessing and survival of pathogenic bacteria Improper product flow procedures in retort area could result in retort baskets missing the retort allowing the survival and growth of pathogenic bacteria Excessive time lapse between closing and retorting could result in excessive build up of bacteria, some of which could survive the thermal process Lack of adherence to time, temperature and other critical factors of the scheduled process or vent schedule could result in inadequate heat treatment allowing the survival of pathogenic bacteria Cooling Insufficient bactericide in cooling water could result in contamination of product during vacuum creation in cans Excess bactericide in cooling water could eventually result in corrosion and subsequent leakage and contamination of product Insufficient contact time between the bactericide and water could result in contamination of product during vacuum creation in cans Insufficient cooling could result in thermophilic spoilage Excessive cooling could result in post-process contamination due to leakage of corroded cans Conveying/Drying Contaminated water from wet unclean post-process can handling equipment and general handling could contaminate product Container Integrity Evaluating/Labelling Failure to statistically sample and/or dud detect lots and reject and evaluate containers with no/low vacuum or serious defects could result in defective product going to market Physical damage to cans could result in leakage and contamination of product Storing Physical damage to cans could result in leakage and contamination of product High temperatures could result in growth of thermophilic bacteria Shipping Physical damage to cans could result in leakage and contamination of product Date: Approved by: (Canadian Food Inspection Agency 2009) Chemical Hazard Identification:- Form 6 Chemical Hazards List all Chemical Hazards Related to Ingredients, Incoming Material, Processing, Product Flow, etc. Identified Chemical Hazards Incoming Materials Mushrooms Could contain agricultural chemicals residues Empty cans/ends Could be contaminated with cleaning chemicals and lubricants Water Could be contaminated with dissolved heavy metals or toxic organic chemicals Process Steps Receiving Empty cans/ends received from suppliers without valid contract specifications could contain cleaning chemical residues and/or lubricants Empty Cans/Ends Storing Improper storage of cleaning compounds and other chemicals could lead to empty can/end contamination Dry Ingredients Storing Improper storage of cleaning compounds and other chemicals could lead to dry ingredient contamination Blanching Excessive cleaning chemical residues and/or lubricants could cause product contamination Mushroom Conveying/Inspecting Excessive cleaning chemical residues and/or lubricants could cause product contamination Slicing/Dicing (If required) Excessive cleaning chemical residues and/or lubricants could cause product contamination Filling Excessive cleaning chemical residues and/or lubricants could cause product contamination End Feeding/Closing/Inspecting Excessive cleaning chemical residues and/or lubricants could cause product contamination Date: Approved by: (Canadian Food Inspection Agency 2009) Physical Hazard Identification- Form 7 Physical Hazards with Controls List all Physical Hazards Related to Ingredients, Incoming Material, Processing, Product Flow, etc. Identified Physical Hazards Incoming Materials Mushrooms Could be contaminated with hazardous extraneous material, eg. glass, metal, plastic, stones and wood (slivers and fragments) Empty cans/ends Could contain hazardous extraneous material Dry ingredients Could be contaminated with hazardous extraneous material Process Steps Receiving Cans received from suppliers without valid contract specifications could contain hazardous extraneous material Dry ingredients received from suppliers without valid contract specifications could contain hazardous extraneous material Raw Mushroom Storing Inadequate protection against hazardous extraneous material could result in contamination of raw mushrooms Dry Ingredients Storing Inadequate protection against hazardous extraneous material could result in contamination of the food ingredients Can Conveying Inappropriate design and protection against hazardous extraneous material could result in contamination of the final food product Mushroom Conveying/Inspecting Inappropriate design and protection against hazardous extraneous material could result in contamination of the mushrooms Slicing/Dicing (If required) Product could become contaminated with metal fragments from plant equipment Foreign-Object Removing Inadequate monitoring and cleaning of foreign object remover could allow foreign objects to contaminate the product Filling Cans of filled mushrooms could become contaminated with metal fragments from filling equipment End Feeding/Closing/Inspecting Cans of filled mushrooms could become contaminated with metal fragments from closing machine during and after jam ups Date: Approved by: (Canadian Food Inspection Agency 2009) Critical Control Point Determination:- Form 8 Category and Identified Hazard Determine if fully controlled by Prerequisite Program(s) If YES, indicate Prerequisite Program and proceed to next identified hazard. If NO, proceed to question 1 (Q1) Q1. Could a control measure(s) be used by the operator at any process step? If NO = not a CCP + identification on how this hazard will be controlled before and after the process + proceed to the next identified hazard If YES = description + next question (Q2) Q2. Is it likely that contamination with the identified hazard could occur in excess of the acceptable level or could increase to an unacceptable level? If NO = not a CCP + proceed to the next identified hazard If YES = next question (Q3) Q3. Is this process step specifically designed to eliminate/reduce the likely occurrence of the identified hazard to an acceptable level? If NO = next question (Q4) If YES = CCP + go to last column Q4. Will a subsequent step eliminate the identified hazard or reduce likely occurrence to an acceptable level? If NO = CCP + go to last column If YES = not a CCP + identify subsequent step + proceed to the next identified hazard CCP Number + proceed to next identified hazard Process Step/Incoming Material: Mushrooms as delivered Biological Pathogens Yes Heat treatment Yes N/A Yes Thermal Processing Biological Heat stable toxins No Upstream programs (farms) Chemical Agricultural chemicals No Upstream programs (farms) Physical Hazardous extraneous material Yes Visual inspection Plant equipment No Process Step/Incoming Material: Empty cans/ends as delivered Biological Post process contamination from serious can defects and damage Yes Contract specifications Visual and can tear-down inspection Yes N/A Yes Receiving Biological Post process contamination from compound skips, plate defects and end damage Yes Contract specifications Visual end inspection Yes N/A Yes Receiving Chemical Cleaning chemical contaminants and lubricants Yes Contract specifications Yes N/A Yes Receiving Physical Hazardous extraneous material Yes Contract specifications Yes N/A Yes Receiving Process Step/Incoming Material: Dry ingredients as delivered Biological Bacterial spores Yes Contract specifications Yes N/A Yes Receiving Biological Filth Yes Contract specifications Yes N/A Yes Receiving Physical Hazardous extraneous material Yes Contract specifications Yes N/A Yes Receiving Process Step/Incoming Material: Water at intake Biological Pathogens Prerequisite programs Chemical Heavy metals other toxic chemicals Prerequisite programs Process Step Process Step/Incoming Material: Receiving Biological Empty cans/ends received from suppliers without contract specifications may contain serious defects, or damage Yes Contract specifications Yes Yes CCP-1 Biological Dry ingredients received from suppliers without contract specifications may contain bacterial spores or filth Yes Contract specifications Yes Yes CCP-1 Chemical Empty cans/ends received from suppliers without contract specifications may contain chemical residues or lubricants Yes Contract specifications Yes Yes CCP-1 Physical Empty cans/ends and dry ingredients received from suppliers without contract specifications may contain hazardous extraneous material Yes Contract specifications Yes Yes CCP-1 Process Step/Incoming Material: Mushrooms Refrigerated storing Biological Increased bacterial load Prerequisite programs Biological Filth Prerequisite Program Physical Hazardous extraneous material Prerequisite programs Process Step/Incoming Material: Cans/Ends Storing Biological Post process contamination due to cans/ends damaged during storage Prerequisite programs Biological Filth Prerequisite programs Chemical Cleaning chemical contamination Prerequisite programs Process Step/Incoming Material: Dry Ingredients Storing Biological Filth Prerequisite programs Chemical Cleaning chemical contamination Prerequisite programs Physical Hazardous extraneous material from storeroom Prerequisite programs Process Step/Incoming Material: Can Depalletizing Biological Post-process contamination due to incorrect or damaged cans Prerequisite programs Process Step/Incoming Material: Blanching Biological Growth of thermophiles Prerequisite programs Biological Inadequate removal of gases Prerequisite programs Chemical Cleaning chemical residues and/or lubricants Prerequisite programs Process Step/Incoming Material: Can Conveying Biological Post-process contamination due to damaged cans Prerequisite programs Physical Hazardous extraneous material from plant environment Prerequisite programs Process Step/Incoming Material: Mushroom / Conveying / Inspecting Chemical Cleaning chemical residues and/or lubricants Prerequisite programs Physical Hazardous extraneous material Prerequisite programs Process Step/Incoming Material: Slicing/Dicing (If required) Biological Improper slice thickness / clumping, and percent fines could result in under-processing Prerequisite programs Chemical Cleaning chemical residues and/or lubricants Prerequisite programs Physical Metal fragments from equipment Prerequisite programs Process Step/Incoming Material: Foreign Object Removing Physical Failure to remove foreign objects Prerequisite programs Process Step/Incoming Material: Filling Biological Mushroom compaction during filling resulting in under processing Prerequisite programs Chemical Cleaning chemical residues and/or lubricants Prerequisite programs Physical Metal fragments from equipment Prerequisite programs Process Step/Incoming Material: Weighing Biological Product heavier than maximum fill weight in scheduled process could result in under-processing Yes Weighing Yes Yes CCP-2 Process Step/Incoming Material: Water filling Biological Inadequate temperature resulting in low it Yes Take it just prior to thermal process Yes No Yes Thermal Processing Process Step/Incoming Material: End Feeding/Closing/ Inspecting Biological Post-process contamination due to damaged ends, compound ski