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 Agency’s 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 CCP’s, 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 CCP’s 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 establishment 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

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

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

Biological

Post process contamination due to improperly formed seams

Yes

Visual and tear-down can inspection

Yes

CCP-3

Chemical

Cleaning chemical residues and/or lubricants

Prerequisite programs

Physical

Metal fragments from closing machine after jam-ups

Prerequisite programs

Process Step/Incoming Material: Thermal Processing (Still Steam Retorts)

Biological

Non-validated process or vent schedule could result in underprocessing and survival of pathogenic bacteria

Prerequisite programs

Process Step/Incoming Material: Cooling

Biological

Post-process contamination during cooling and vacuum creation of cans due to contaminated cooling water

Yes

Use potable cooling water or control bactericide level in cooling environment to kill bacteria

Yes

CCP-5

Biological

Post process contamination due to leakage resulting from corrosion and leakage from excessive bactericide

Yes

(Canadian Food Inspection Agency 2009)

Control of each hazard identification:-

Biological Hazards

List all Biological Hazards related to Ingredients, Incoming Material, Processing, Product Flow, etc.

Identified Biological Hazards

(Bacteria, Parasites, Viruses…)

Controlled at

Incoming Materials

Mushrooms:

Could contain C. botulinumor other pathogenic bacteria, yeasts and moulds

Could contain heat-stable staphylococcal enterotoxin from improper grower handling

CCP-4

See Form 9

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

CCP-1

Dry ingredients

Could contain bacterial spores

Could contain filth from insects, animals or the environment

CCP-1

Water

Could contain pathogens

Prerequisite programs (Premises/Water Quality)

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

CCP-1

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

Prerequisite programs (Transportation &Storage, Equipment)

Prerequisite programs (Sanitation/Pest Control)

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

Prerequisite programs (Personnel)

Prerequisite programs (Sanitation/Pest Control)

Dry Ingredients Storing

Could be contaminated with filth from insects, animals or the environment

Prerequisite programs (Sanitation/Pest Control)

Depalletizing

Using incorrect cans or damaged cans could result in leakage and subsequent post-process contamination with pathogenic bacteria

Prerequisite programs (Personnel)

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

Prerequisite programs (Sanitation)

Prerequisite programs (Equipment)

Can conveying

Physical damage could cause the formation of poor double seams, which could result in post process contamination with pathogenic bacteria

Prerequisite programs (Equipment)

Slicing/Dicing

Slice thickness/clumping and percent fines could affect the heat penetration, which could result in underprocessing

Prerequisite programs (Records – verification of valid process)

Filling

Mushroom compaction during filling may result in underprocessing

Prerequisite programs (Records – verification of valid process)

Weighing

Cans not properly rejected for overweight could result in overfilled cans being underprocessed

CCP-2

Water Filling

Inadequate temperature could result in low initial temperature (IT)

CCP-4

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

CCP-3

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

Prerequisite programs (Records – verification of valid process)

CCP-4

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

CCP-5

Prerequisite programs (Personnel)

Prerequisite programs (Equipment, Personnel)

Conveying/Drying

Contaminated water from wet unclean post-process can handling equipment and general handling could contaminate product

Prerequisite programs (Sanitation)

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

Prerequisite programs (Equipment, Personnel)

Storing

Physical damage to cans could result in leakage and contamination of product

High temperatures could result in growth of thermophilic bacteria

Prerequisite programs (Personnel)

Prerequisite programs (Equipment, Transportation &Storage)

Shipping

Physical damage to cans could result in leakage and contamination of product

Prerequisite programs (Personnel)

Date: Approved by:

(Canadian Food Inspection Agency 2009)

Chemical Hazards

List all Chemical Hazards related to Ingredients, Incoming Material, Processing, Product Flow, etc.

Identified Chemical Hazards

Controlled at

Incoming Materials

Mushrooms

Could contain agricultural chemicals residues

See Form 9

Empty cans/ends

Could be contaminated with cleaning chemicals and lubricants

CCP-1

Water

Could be contaminated with dissolved heavy metals or toxic organic chemicals

Prerequisite programs (Premises/Water Quality)

Process Steps

Receiving

Empty cans/ends received from suppliers without valid contract specifications could contain cleaning chemical residues and/or lubricants

CCP-1

Empty Cans/Ends Storing

Improper storage of cleaning compounds and other chemicals could lead to empty can/end contamination

Prerequisite programs (Sanitation, Transportation &Storage)

Dry Ingredients Storing

Improper storage of cleaning compounds and other chemicals could lead to dry ingredient contamination

Prerequisite programs (Sanitation, Transportation &Storage)

Blanching

Excessive cleaning chemical residues and/or lubricants could cause product contamination

Prerequisite programs (Sanitation)

Mushroom Conveying/Inspecting

Excessive cleaning chemical residues and/or lubricants could cause product contamination

Prerequisite programs (Sanitation)

Slicing/Dicing

Excessive cleaning chemical residues and/or lubricants could cause product contamination

Prerequisite programs (Sanitation)

Filling

Excessive cleaning chemical residues and/or lubricants could cause product contamination

Prerequisite programs (Sanitation)

End Feeding/Closing/Inspecting

Excessive cleaning chemical residues and/or lubricants could cause product contamination

Prerequisite programs (Sanitation, Equipment)

Date: Approved by:

(Canadian Food Inspection Agency 2009)

Physical Hazards

List all Physical Hazards related to Ingredients, Incoming Material, Processing, Product Flow, etc.

Identified Physical Hazards

Controlled at

Incoming Materials

Mushrooms

Could be contaminated with hazardous extraneous material, eg. glass, metal, plastic, stones and wood (slivers and fragments)

Not applicable (Not likely to get through dumping, washing, blanching equipment and inspection belt)

Empty cans/ends

Could contain hazardous extraneous material

CCP-1

Dry ingredients

Could be contaminated with hazardous extraneous material

CCP-1

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

CCP-1

Raw Mushroom Storing

Inadequate protection against hazardous extraneous material could result in contamination of raw mushrooms

Prerequisite programs (Premises)

Dry Ingredients Storing

Inadequate protection against hazardous extraneous material could result in contamination of the food ingredients

Prerequisite programs (Premises, Transportation &Storage)

Can Conveying

Inappropriate design and protection against hazardous extraneous material could result in contamination of the final food product

Prerequisite programs (Equipment)

Mushroom Conveying/Inspecting

Inappropriate design and protection against hazardous extraneous material could result in contamination of the mushrooms

Prerequisite programs (Premises, Equipment, Personnel)

Slicing/Dicing

Product could become contaminated with metal fragments from plant equipment

Prerequisite programs (Equipment)

Foreign-Object Removing

Inadequate monitoring and cleaning of foreign object remover could allow foreign objects to contaminate the product

Prerequisite programs (Equipment, Personnel)

Filling

Cans of filled mushrooms could become contaminated with metal fragments from filling equipment

Prerequisite programs (Equipment)

End Feeding/Closing/Inspecting

Cans of filled mushrooms could become contaminated with metal fragments from closing machine during and after jam ups

Prerequisite programs (Equipment, Personnel)

Date: Approved by:

(Canadian Food Inspection Agency 2009)

Hazards not controlled by operator:-

Form 9

List all Biological, Chemical and Physical Hazards which are not Controlled by the Operator

Identified Hazards

Indicate the way the Hazard could be Addressed (Cooking Instructions, Public Education, Use Before Date …)

Incoming Materials

Biological

Raw mushrooms could contain heat-stable staphylococcal enterotoxin from improper grower handling

Upstream (Farm level) programs such as:

training growers on handling of raw product

ensuring growers use proper, effective refrigeration equipment

ensuring prompt delivery of raw product after picking

ensuring proper personal hygiene of workers

Chemical

Raw mushrooms could contain agricultural chemical residues

Upstream (Farm level) programs such as:

training persons who apply pesticides

purchasing registered pesticides for growers

auditing grower applications of pesticides and the records thereof

requiring periodic residue analysis reports

Date: Approved by:

(Canadian Food Inspection Agency 2009)

Preventive Measures Form:-

This from is used to review the steps listed in the Process Flow diagram and identify where significant hazards could occur and describes the preventive measures if they exist. A hazard can be Biological, Physical or Chemical that makes a food unsafe for consumption. Hazards of low risk and not likely to occur would not require further consideration. Preventive measure is a physical, chemical or other factor which can be used to control an identified health hazard.

Process Step

Hazards

Preventive Measures

Example of how a hazard is introduced

Preparation

Significant hazards are not likely to occur

Physical or chemical hazard from equipments or facilities should be prevented by routine maintenance (GMP)

Physical hazards from lack of equipment or facility maintenance

Can Cleaning

Foreign Material may remain

No significant chemical hazard. Metal poisoning likely to occur

Cleaning Operations

Foreign material present at the receiving and that may have entered the containers during the storage and handling remains in the container.

Filling

If not filled as per the processing authority’s recommendations, the thermal process may be inadequate

Operational filling controls

Sealing

No significant hazard likely to occur identified

Thermal Processing and Cooling

Improper application of the thermal process may not provide sufficient lethality to achieve shelf stability

Operational thermal processing controls

Retort temperature drops, early termination of thermal process, the retort is not vented properly, condensate accumulates in the retort, cooling water enters the retort during cooking

Labelling and Casing

No significant hazard likely to occur identified

Storage

No significant hazard likely to occur identified

Shipping

No significant hazard likely to occur identified

(United States Department of Agriculture April, 1997)

HACCP Plan Form:-

Form 10

Process Steps: Receiving

CCP/Hazard Number: CCP-1BCP

Hazard Description

Critical Limits

Monitoring

Procedures

Deviation

Procedures

Verification/ Procedures

HACCP Records

Receiving cans &ends with serious defects, damage, chemical residues or metal fragments

Receiving dry ingredients with bacterial spores, filth and hazardous extraneous material

Cans, ends and dry ingredients must be from a listed supplier having valid contract specifications

Receiver checks suppliers names and addresses against list of approved suppliers with valid contract specifications

Receiver rejects lots from suppliers not listed, notifies management and holds lot for return to supplier or for statistical sampling and evaluation

QC also does periodic checks on empty cans and ends for specifications

QC reviews closing machine operator’s records of can defects and tear-downs of the can manufacturer’s end to compare with contract specifications.

Container integrity evaluation of entire can after processing

If serious defects are found a this point, the lot is held and lots produced before and after the problem lot are statistically examined and evaluated

Supplier lists

Contract specifications

Lot receipt record

Lot reject record

Periodic check on specifications report

Container integrity evaluation report

Process Steps: Weighing

CCP/Hazard Number: CCP-2

Hazard Description

Critical Limits

Monitoring

Procedures

Deviation

Procedures

Verification/ Procedures

HACCP Records

Overfilling resulting in underprocessing and growth of pathogens

Maximum fill weight as specified in the scheduled process

On-line check-weigher ejects over &under weight cans after filler

Line operator manually adjusts weight of ejected cans by adding/taking away mushrooms

QC verifies calibration of check weighing equipment each period, checks fill weights hourly &drained weights daily

Fill Control Report

Daily Grading Report

Process Steps: End Feeding/ Closing/ Inspecting

CCP/Hazard Number: CCP-3

Hazard Description

Critical Limits

Monitoring

Procedures

Deviation

Procedures

Verification/ Procedures

HACCP Records

Post-process contamination resulting from damaged/defective ends or improper double seams on cans

Can manufacturer’s specifications

No serious defects

Continuous visual monitoring of ends by closing machine operator

Closing machine operator removes any damaged or defective ends &informs QC.

Operator holds defective ends and QC investigates

Hourly checks on visual monitoring by QC.

Container integrity evaluating before labelling

Daily Seamer Report

Double Seam Inspection Report

Container Integrity Evaluation Report

Post-process contamination resulting from damaged/defective ends or improper double seams on cans

Can manufacturer’s specifications

No serious defects

Visual examination of sealed cans (at least one sample per head) at start up, after severe jamups, after adjustments as well as every half hour &tear down examination every 4 hours on consecutive samples – one from each head by closing machine operator

Seamer mechanic adjusts closing machine &informs QC.

Operator holds all product run since last satisfactory inspection &QC investigates.

Checks on visual &tear down examination records by QC once per period.

Container integrity evaluating before labelling

Daily Seamer Report

Double Seam Inspection Report

Process Steps: Thermal Processing (Still Steam Retorts)

CCP/Hazard Number: CCP-4

Hazard Description

Critical Limits

Monitoring

Procedures

Deviation

Procedures

Verification/ Procedures

HACCP Records

Inadequate heat treatment resulting in growth of pathogens

Maximum time lapse between can closing &retort up, minimum IT, minimum time &temperature for vent &cook as specified in scheduled process. Heat sensitive indicator changes colour. Limits on any other critical factors specified by process authority

QC checks on limits to special critical factors and on time lapse between can closing &retort up (at least once per period)

Retort operator checks on it, time &temperature for vent &cook &thermograph.

Busse unloader checks heat sensitive indicator tape.

Retort operator adjusts time &temperature of cook as per authorized contingency plan &informs QC.

Operator holds all product from suspect deviation and QC investigates

Busse unloader segregates &holds product if no indicator tape or no colour change of indicator tape

Manual records &procedures are checked by QC during processing

Daily management review of retort manual records against thermograph

Container integrity evaluating before labelling

Retort Operator’s Log

Thermograph Charts.

Heat Sensitive Indicator Log

Container Integrity Inspection Report

Process Steps: Cooling———CCP/Hazard Number: CCP-5

Hazard Description

Critical Limits

Monitoring

Procedures

Deviation

Procedures

Verification/ Procedures

HACCP Records

Post-process contamination of product from contaminated cooling water

Detectable residual chlorine levels to 2.0 ppm in the cooling water

Retort operator does bactericide checks every hour at exit of cooling water

Retort operator adjusts bactericide level &informs QC.

Residual bactericide level records &bactericide consumption are checked by QC

Container integrity evaluating before labelling

Retort Operator’s Logs

Container Integrity Inspection Report

Date: Approved by:

(Canadian Food Inspection Agency 2009)

REFERNCES:-

Canadian Food Inspection Agency. (2009). “Food Safety Enhancement Program Mannual.” Retrieved 20th July, 2010, from http://www.inspection.gc.ca/english/fssa/polstrat/haccp/manue/fseppasa3e.shtml.

Canadian Food Inspection Agency. (2009). “HACCP Generic Model : Low Acid Canned Foods ” Retrieved 20th July 2010, from http://www.inspection.gc.ca/english/fssa/polstrat/haccp/muscha/muschae.shtml.

Food and Agricuture Organization (2003). Manual on the Application of the HACCP System in Mycotoxin Prevention and Control, . Rome.

International trade centre (December, 2002). An introdution to HACCP. Geneva.

United States Department of Agriculture (April, 1997). Generic HACCP Model for Thermally Processed Commercially Sterile Meat and Poultry Products

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