Generic HACCP Model for Thermally Processed Commercial

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HACCP PLAN PROCESS CATEGORY : THERMALLY PROCESSED COMMERCIALLY STERILE PRODUCT EXAMPLE : PASTA SAUCE WITH MEAT PROCESS STEP RECEIVING - PACKAGING MATERIALS HAZARD DESCRIPTION BIOLOGICAL(B) CHEMICAL(C) PHYSICAL (P) CCP CLEANING, JARS P - Foreign Material Remains. CRITICAL LIMITS P-Foreign Material 3P No visible hazardous foreign non-food material (i.e. glass, plastic); no metal contamination þ1/32 inch.** 4 P No visible hazardous foreign non-food or food material (i.e. glass, or food); no metal contamination þ1/32 inch MONITORING PROCEDURES/FREQUENCY/ PERSON RESPONSIBLE Receiver will check source of materials; lots from approved sources will be examined for shipping damage. Receiver will date and include time of action. Washer operator will continually visually examine jars leaving washer to ensure that the unit is operating properly and the jars are being properly cleaned. Washer operator will include date, sign and record results and time of action. CORRECTIVE/PREVENTIVE ACTION/PERSON RESPONSIBLE Receiver will ensure that glass jars in damaged shippers are 100% examined for suitability. Broken/cracked jars will be discarded; Intact jars containing glass or other foreign materials will be hand cleaned before entering jar washer. Jar closures in damaged packaging will be examined and cleaned in necessary. Jar washer operator will remove any unclean jars and notify the production foreman or plant designee if the washer is not operating properly. When proper functioning is restored , jars removed will be recycled thru washer. Corrective/preventive operator signs, dates, and records time of action. HACCP RECORDS VERIFICATION PROCEDURE/PERSON RESPONSIBLE Receiving log An individual who did not produce the record(s) and who has successfully completed a course of instructions in HACCP or the responsible establishment official will verify source of accepted packaging materials and will certify the acceptability of all reconditioned jars and closures. Records all results, corrective, and preventive action(s) in jarwasher log. Sign, date, and record time of observation. An individual who did not produce the record(s) and who has successfully completed a course of instructions in HACCP or the responsible establishment official will review the log and check the washer and exiting jars every 30 minutes to ensure that the washer is operating properly and only clean jars reach the filler.
FORMULATION (Example: if included as a CCP where pH is determining factor for safety and/or specifics of 9CFR 318.300-311 or 9CFR 381.300-311.) THERMAL PROCESSING B -If not as authorized by the processing authority, the thermal process may be inadequate. B - Improper application of the thermal process may not provide sufficient lethality to achieve safety. 1 B As specified in formulation specified by the processing authority. 2 B As specified by processing authority. Head formulation cook will check ingredient characteristics quantities, and conformance with specified formulation procedure for each batch prepared. Q.A. personnel will sample each finished batch within 24 hours of processing and check sauce and internal particle pH. Head formulation cook or Q.A. personnel will date and include time of action. Steam tunnel operator will monitor and record thermal processing conditions at sufficient frequencies to ensure that the process schedule is properly applied. Steam tunnel operator will date and include time of action. Head formulation cook will not release any batch that has not been formulated correctly. If the pH of a finished product batch exceeds 4.5, the product must be cooled to refrigeration temperatures unless reworked, reprocessed as a low-acid canned food or destroyed within 48 hours of initial process. If a process deviation occurs, the production foreman will have the affected production isolated for rework or destruction based on an analysis of the deviation. *This is a Control Point, however the Thermal Processing step is the Critical Control Point in this Plant. Formulation log. Finished pH log. Corrective and preventive action log. Sign, date, and record time of observation, corrective/ preventive action. Daily process log and temperature recorder charts. Corrective/ preventive action log. Sign, date, and record time of observation and/or corrective/ preventive action. On a daily basis, An individual who did not produce the record(s) and who has successfully completed a course of instructions in HACCP or the responsible establishment official will review the logs and verify pH meter accuracy to ensure batches are properly formulated. Calibration of pH meters daily. An individual who did not produce the record(s) and who has successfully completed a course of instructions in HACCP or the responsible establishment official will review all log entries and charts within one working day after the thermal process.
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Table of Contents Introduction. ...
Page 4 and 5:
Incidents of Foodborne Illnesses fr
Page 6 and 7:
Principle No. 6: Establish effectiv
Page 8 and 9:
1 following the production steps in
Page 10 and 11: The generic models use examples of
Page 12 and 13: are: If so, proceed to the categori
Page 14 and 15: e prevented, and actions to be take
Page 16 and 17: Preparing Your HACCP Plan Assemble
Page 18 and 19: PROCESS DESCRIPTION PROCESS CATEGOR
Page 20 and 21: LIST PRODUCT(S) AND INGREDIENTS PRO
Page 23 and 24: Hazard Analysis/Preventive Measures
Page 25 and 26: HAZARD ANALYSIS/PREVENTIVE MEASURES
Page 27 and 28: CCP DETERMINATION (A CRITICAL CONTR
Page 31 and 32: HACCP Plan Form The HACCP Plan Form
Page 33 and 34: HACCP PLAN PROCESS CATEGORY : THERM
Page 43 and 44: PROCESS CATEGORY DESCRIPTION PROCES
Page 45 and 46: LIST PRODUCT(S) AND INGREDIENTS PRO
Page 48 and 49: Hazard Analysis/Preventive Measures
Page 50 and 51: HAZARD ANALYSIS/PREVENTIVE MEASURES
Page 52 and 53: CCP Determination Form The Critical
Page 58 and 59: critical limits, records for the ha
Page 62: Appendix 1 - List of Process Models
Page 65 and 66: Appendix 4 Hazard Analysis: Thermal
Page 67 and 68: Incidents of Foodborne Illnesses fr
Page 69: increase during storage. Osherhoff,
Page 72 and 73: of low-acid canned foods by mesophi
Page 74 and 75: control in foods. Food Control 3(3)
Page 76 and 77: Physical and Chemical Contamination
Page 78 and 79: samples of meat or sea-food, none e
Page 80 and 81: Sources for Epidemiology of Foodbor
Page 82 and 83: Physical and Chemical Contamination
Page 84 and 85: 1. Is the food commercially sterile
Page 86: 1. Can employee health or personal
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Generic HACCP Model for Thermally Processed Commercial

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