United States
Department of
Agriculture
Food Safety
and Inspection
Service
September 1999
HACCP-13
Generic HACCP
Model for Beef
Slaughter
Additional copies of the Guidebook for the Preparation
of HACCP Plans and the Generic HACCP Models are
available from,
U.S,Department of Agriculture
Food Safety and Inspection Service (FSIS)
Office of Policy,Program Development,
and Evaluation (OPPDE)
Inspection Systems Development Division
Room 202,Cotton Annex Building
300 12
th
Street SW
Washington,D.C,20250-3700
Phone,(202) 720-3219
Fax,(202) 690-0824
This material is also available on the FSIS Homepage,
http://www.fsis.usda.gov/index.htm
Beef Slaughter Model
Table of Contents
Introduction……………………………………………………………………………..…,2
Using This Generic Model…………………………………………………………..…….,4
Process Flow Diagram and Product Description…………………………………..………,5
Hazard Analysis………………………………………………………………….…………6
Developing Your HACCP Plan………………………………………………..………….,8
Identifying CCPs……………………………………………………………………..……,10
Appendix A
References for HACCP Teams…………………………………………………… 16
References for Beef Slaughter (Steer/Heifer Carcass & Cow Carcass)…………… 18
Appendix B
Process Flow Diagram (Figure 1)…………………………………………………,21
Product Description Form (Figure 2)……………………………………………… 22
Hazard Analysis Form (Figure 3)…………………………………………………,23
HACCP Plan Form (Figure 4)..…………………………………………………… 29
Thermometer Calibration Log…………………………………………………….,36
Generic Establishment X,Room/Product Temperature Log ………………………37
Establishment X,Antimicrobial Intervention Monitoring Log ……………………38
Corrective Actions Log……………………………………………………………,39
Pre-Shipment Review Log………………………………………………………… 40
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Beef Slaughter Model
GENERIC HACCP MODEL
FOR
BEEF SLAUGHTER
Introduction
The Hazard Analysis Critical Control Point (HACCP) system is a scientific approach to process
control,It is designed to prevent the occurrence of problems by assuring that controls are
applied at any point in a food production system where hazardous or critical situations could
occur,Hazards include biological,chemical,or physical contamination of food products,
The Food Safety and Inspection Service (FSIS) published a final rule in July 1996 mandating
that HACCP be implemented as the system of process control in all inspected meat and poultry
plants,As part of its efforts to assist establishments in the preparation of plant-specific HACCP
plans,FSIS determined that a generic model for each process defined in the regulation would be
made available for use on a voluntary basis by inspected establishments,
The generic models have been revised since their initial publication and distribution as
DRAFTS,The most important change in the revised versions is to make certain that these
models are
fully consistent with the features of the final regulation,Also,other technical and editorial
improvements have been made,
Throughout this generic model,FSIS discusses a HACCP team with members from different
departments,In many very small establishments,there will not be separate departments with
different employees,But,there will be employees who perform these different functions – often
several of them,For purposes of explaining concepts,it is easier to speak as if these were
different people,even though in many cases,they may be the same person carrying out more
than one responsibility,
Each generic model can be used as a starting point for the development of plant-specific plan(s)
reflecting actual plant environments and the processes conducted,The generic model is not
intended to be used,as is” for plant specific HACCP plans,
The generic models are designed for use in conjunction with the list of process categories found
in the HACCP regulations in section 417.2(b)(1),
(b) The HACCP plan,(1) Every establishment shall develop and implement a written
HACCP plan covering each product produced by that establishment whenever a hazard
analysis reveals one or more food safety hazards that are reasonably likely to occur,
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Beef Slaughter Model
based on the hazard analysis conducted in accordance with paragraph (a) of this section,
including products in the following processing categories,
(i) Slaughter--all species,
(ii) Raw product--ground,
(iii) Raw product--not ground,
(iv) Thermally processed--commercially sterile,
(v) Not heat treated--shelf stable,
(vi) Heat treated--shelf stable,
(vii) Fully cooked--not shelf stable,
(viii) Heat treated but not fully cooked--not shelf stable,
(ix) Product with secondary inhibitors--not shelf stable,
This generic model is designed for use with the first process category,Slaughter,
The purpose of the process category listing in 417.2 is to set out the circumstances under which a
HACCP team may develop a single HACCP plan for multiple products,This may be done when
products are in the same process category,and food safety hazards,critical control points,and
other features are essentially the same,There is a generic model for each process category,plus
two for subcategories which present special issues,irradiated products and mechanically
separated products,
In order to select the model or models that will be most useful for the activities performed in any
specific plant,the following steps should be taken,
1) For slaughtering operations,select the model for the appropriate species,
2) For processed products,make a list of all products produced in the plant,
3) Examine the list and group like products,considering common processing steps and
equipment used,
4) Compare the grouped products with the list of processes in the regulations; this step should
reveal how many and which of the generic models might be useful,
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Beef Slaughter Model
Deciding on a generic model and which products can be covered by a single plan is an important
achievement,If the team does it well,it can save a lot of unnecessary effort and paperwork,
Selecting an inappropriate generic model reduces its potential benefits,However,often the
HACCP team will discover they have made this error when they develop their process flow
diagram or during their hazard analysis,These are early stages in the process when it is
relatively easy to make changes,
In any case,establishments must meet all regulatory requirements for their products,
Using This Generic Model
This generic model is designed to be used by establishments that slaughter,the first process
category,The model can be used for all establishments that slaughter,but would be most useful
to establishments that slaughter cattle,The generic model is not suitable for products that fall
into any of the other process categories,
The model will be most useful to a HACCP team that includes access to one trained individual,
as specified in 417.7(b),
(b)The individual performing the functions listed in paragraph (a) of this section shall
have successfully completed a course of instruction in the application of the seven
HACCP principles to meat or poultry product processing,including a segment on the
development of a HACCP plan for a specific product and on record review,
It would be beneficial for other team members to have reviewed any of the various guidance
materials available on how to develop a HACCP plan for your company,including several useful
videos,handbooks,or computer programs,Once the HACCP team has prepared itself as
thoroughly as possible in general HACCP principles and how to use them,this model should be
helpful,
Note,This generic model includes a number of forms that can be used to record various types of
required information,The forms themselves are samples; a company HACCP team can develop
whatever forms it finds most useful,All the forms mentioned in this document are included in
Appendix B; they appear in the order in which they are discussed in the text,
All FSIS generic models are designed to assist establishments in applying the seven HACCP
principles to their meat and poultry processing operations AND to meet the regulatory
requirements of Part 417,Therefore,the definitions used in this and all other FSIS generic
models are those found in 417.1,
§ 417.1 Definitions,
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For purposes of this part,the following shall apply,
Corrective action,Procedures to be followed when a deviation occurs,
Critical control point,A point,step,or procedure in a food process at which control can
be applied and,as a result,a food safety hazard can be prevented,eliminated,or reduced
to acceptable levels,
Critical limit,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,
Food safety hazard,Any biological,chemical,or physical property that may cause a
food to be unsafe for human consumption,
HACCP System,The HACCP plan in operation,including the HACCP plan itself,
Hazard,SEE Food Safety Hazard,
Preventive measure,Physical,chemical,or other means that can be used to control an
identified food safety hazard,
Process-monitoring instrument,An instrument or device used to indicate conditions
during processing at a critical control point,
Responsible establishment official,The individual with overall authority on-site or a
higher level official of the establishment,
Process Flow Diagram and Product Description
To begin using this model,the company's HACCP team should first describe the product(s)
which are part of this process category and covered by this HACCP plan,The product(s) should
be described in two ways,
(1) by a simple diagram which shows the steps the company uses when it produces the product,
and
(2) in a brief written description which provides key facts about the product and its use,
In this generic model,there is an example for cattle slaughter,one of the species in this process
category,FSIS has developed certain forms as part of the examples in the generic models;
company HACCP teams are not required to use these forms,
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Beef Slaughter Model
Figure 1 is an example of a PROCESS FLOW DIAGRAM for the cattle slaughter process in
generic establishment X,Figure 2 is an example of a PRODUCT DESCRIPTION for the cattle
slaughtered by generic establishment X,
Once the company HACCP team in your establishment has prepared your Process Flow
Diagram,they should verify it by walking through the establishment following the flow of
product and making sure that all the steps of the process are included in the flow diagram,The
team should also review the information provided on the Product Description to make sure all
the key facts are included,such as identifying consumers,especially those with particular health
problems or known to be at risk,
Note,If you are slaughtering cattle and your process includes steps not included in this example,
such as pre-evisceration spray,those steps should be added,Also,if your process does not
include all the steps identified in this example,those steps would be omitted when conducting
the hazard analysis,That is generally,how you use these generic model examples--just omit the
features which do not apply to your operation or if your operation includes features not included
in this example,they should be added,
By completing a Process Flow Diagram and a Product Description,you have met the
requirements of 417.2(a)(2),You can use the Process Flow Diagram in particular to help you
complete the rest of the hazard analysis,Use the flow diagram to systematically review each
step in the process and ask the question,"Is there a food safety hazard which is reasonably likely
to occur which may be introduced at this step?" In answering the question,your HACCP team
needs to consider biological (including microbiological),chemical,and physical hazards,
Hazard Analysis
Once your product(s) are accurately described through the flow diagram and product description,
the HACCP team should begin work on the HAZARD ANALYSIS,The hazard analysis is
fundamental to developing a good HACCP plan and one that meets regulatory requirements,
The regulatory requirements for a hazard analysis are found at 417.2(a),
§ 417.2 Hazard Analysis and HACCP Plan,
(a) Hazard analysis,(1) Every official establishment shall conduct,or have conducted
for it,a hazard analysis to determine the food safety hazards reasonably likely to occur
in the production process and identify the preventive measures the establishment can
apply to control those hazards,The hazard analysis shall include food safety hazards
that can occur before,during,and after entry into the establishment,A food safety
hazard that is reasonably likely to occur is one for which a prudent establishment would
establish controls because it historically has occurred,or because there is a reasonable
possibility that it will occur in the particular type of product being processed,in the
absence of those controls,
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Beef Slaughter Model
(2) A flow chart describing the steps of each process and product flow in the
establishment shall be prepared,and the intended use or consumers of the finished
product shall be identified,
Generic establishment X,which we are using for our example,is capturing these regulatory
requirements on a 6-column Hazard Analysis Form (See Figure 3),A good way to use a form
like this is to create the first column by using the Process Flow Diagram and the second by
answering the question,Once the HACCP team has considered all the steps in the flow diagram
and determined if a food safety hazard could be introduced,it needs to consider whether the
hazard is "reasonably likely to occur",using the meaning of this phrase included in 417.2(a),On
the 6-column form used by generic establishment X,the third and fourth columns address this
issue,If the establishment's HACCP team has decided that the hazard is not reasonably likely to
occur,they enter "No" in column three,explain the basis for their determination in column four,
and do not need to further consider activity at this point in the process,
If,however,the team has determined there is a "food safety hazard reasonably likely to occur"
introduced at a certain point in the process,column five is used to describe a measure which
could be applied to "prevent,eliminate,or reduce to acceptable levels" the food safety hazard
identified in column three,Column six is used when a critical control point (CCP) is identified
based upon the decision made in the hazard analysis,Each CCP has a number – the order
corresponds to steps in the process,For example 1 is the first CCP in the process flow,2 the
next,etc,The letter indicates whether the hazard is biological – B; chemical – C; or physical –
P,
Look at the entries for,Receiving – Live Cattle” on the first page of the six column form; the
HACCP team has determined that pathogens are likely to be on the animals when they are
received,but it put a,No” in the third column,Column four explains the basis for the team’s
determination,The HACCP team made sure that controls were in place to ensure that sanitary
dressing procedures will be followed during the process,
You will notice that on our generic hazard analysis for cattle slaughter,there are five food safety
hazards in which the HACCP team has identified a point in the process at which a food safety
hazard is reasonably likely to occur,For each one of these they have identified a measure which
can be used to control the hazard,
When your HACCP team has completed their hazard analysis (whether they use this format or
not),it is a good idea to review the flow diagram,the product description and the hazard analysis
itself to make sure they are complete,Part 417.2(a)(3) includes a list of sources from which food
safety hazards might be expected to arise,Reviewing that list could help the HACCP team
check for completeness,
Note,If you are using this generic model and slaughter a different species of livestock or if you
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use a different process flow,you may have different hazards which are reasonably likely to
occur,For these different hazards,there may be different measures which could be used for
control purposes,
This,and all other FSIS generic models,contains a list of references which can help your
HACCP team in making sure the hazard analysis is complete,The references for cattle slaughter
are found in Appendix A,A member of your HACCP team might want to review at least some
of the references to make sure hazards have not been omitted from the hazard analysis,
Completing the hazard analysis is a very significant and important element in developing your
HACCP system,Your HACCP team should feel a real sense of accomplishment when they get
this far; this is like completing the foundation of a house,
Developing Your HACCP Plan
The company HACCP team can now take the materials it developed while doing the hazard
analysis and use them to build the HACCP Plan,Remember that one of the important
objectives of the FSIS generic models is to provide examples which illustrate how to meet the
regulatory requirements of Part 417,as well as to correctly apply the principles of HACCP,
Part 417.2 (c) and (d) are the regulatory requirements,
(c) The contents of the HACCP plan,The HACCP plan shall,at a minimum,
(1) List the food safety hazards identified in accordance with paragraph (a) of this
section,which must be controlled for each process,
(2) List the critical control points for each of the identified food safety hazards,
including,as appropriate,
(i) Critical control points designed to control food safety hazards that could be
introduced in the establishment,and
(ii) Critical control points designed to control food safety hazards introduced outside the
establishment,including food safety hazards that occur before,during,and after entry
into the establishment;
(3) List the critical limits that must be met at each of the critical control points,Critical
limits shall,at a minimum,be designed to ensure that applicable targets or performance
standards established by FSIS,and any other requirement set forth in this chapter
pertaining to the specific process or product,are met;
(4) List the procedures,and the frequency with which those procedures will be
performed,that will be used to monitor each of the critical control points to ensure
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compliance with the critical limits;
(5) Include all corrective actions that have been developed in accordance with §417.3(a)
of this part,to be followed in response to any deviation from a critical limit at a critical
control point; and
(6) Provide for a recordkeeping system that documents the monitoring of the critical
control points,The records shall contain the actual values and observations obtained
during monitoring,
(7) List the verification procedures,and the frequency with which those procedures will
be performed,that the establishment will use in accordance with § 417.4 of this part,
(d) Signing and dating the HACCP plan,(1) The HACCP plan shall be signed and
dated by the responsible establishment individual,This signature shall signify that the
establishment accepts and will implement the HACCP plan,
(2) The HACCP plan shall be dated and signed,
(i) Upon initial acceptance;
(ii) Upon any modification; and
(iii) At least annually,upon reassessment,as required under § 417.4(a)(3) of this part,
Generic establishment X has prepared its HACCP plan for cattle slaughter on a six column form
(See Figure 4),You do not need to use this form,although some kind of a form is probably the
easiest way to present your HACCP plan,
Identifying CCPs
The first column on this particular form is used to enter information developed and contained on
the hazard analysis form,Part 417.2(c)(1) and (2) require that the food safety hazards identified
in the hazard analysis be listed on the HACCP plan and that there be a CCP for each identified
hazard,You will notice that there were five points on the hazard analysis form where food
safety hazards reasonably likely to occur were identified,pathogen contamination from the hide
at skinning,pathogen contamination from the gastrointestinal tract during evisceration,final
wash,pathogen proliferation at chilling,and pathogen proliferation at finished products storage
(cold),The establishment HACCP team has chosen to have three CCPs to address these five
hazards,final wash (antimicrobial),proper chilling of product,and proper maintenance of
finished product temperatures during storage,
After identifying its CCPs,the HACCP team proceeded to consider critical limits,monitoring
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procedures and their frequencies,and verification procedures and their frequencies,and HACCP
records,
In deciding what would be the critical limits,the HACCP team first considered whether there
were any regulatory requirements which had to be met and would function as critical limits,
They found no regulatory requirements for chilling carcasses or variety meats,but realized that if
the proper chiller procedures were not followed pathogen proliferation was possible,The
HACCP team knew that the variety meats should start the chilling process soon after they are
removed from the carcass,so they set the critical limit for chilling variety meats to start within
one hour after removal from the carcass,They set the critical limit for carcass chilling to start
within one hour after bleedout,
Once they had decided on their critical limits,they needed to identify how the monitoring
procedures would be carried out and at what frequency,
For their chilling step (variety meats),the establishment had the QA technician observe the
variety meats handling procedures to ensure the chilling process starts within an hour after
removal from the carcass,At the chilling step (carcass and variety meats) the cooler temperature
is monitored continuously with recording charts,
These decisions by the HACCP team regarding critical limits,plus monitoring procedures and
their frequencies are written up in columns two and three of the HACCP Plan,
The team then went on to consider appropriate verification procedures; the team knew that there
were different types of verification and that Part 417.4(a)(2) included specific regulatory
requirements for each,The regulatory requirements for ongoing verification are,
(2) Ongoing verification activities,Ongoing verification activities include,but are not
limited to,
(i) The calibration of process-monitoring instruments;
(ii) Direct observations of monitoring activities and corrective actions; and
(iii) The review of records generated and maintained in accordance with §417.5(a)(3) of
this part,
The HACCP team decided they could verify the chilling of variety meats and carcasses by
checking the Variety Meats Chilling Log and Carcass Chilling Log once per shift,The team
also had the maintenance supervisor verify the accuracy of the carcass cooler and variety meats
cooler temperature recording charts once per shift,
There is a regulatory requirement (Part 417.4(a)(2)(i)) for including as a verification,the
calibration of process-monitoring instruments,Each day QA checks the hand-held thermometers
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for accuracy in slush ice water and calibrates them to within 2° F accuracy,
The HACCP team described the verification procedures and their frequencies in the fifth column
of their HACCP plan,
The HACCP team for generic establishment X knew that their HACCP Plan needed to provide
for a recordkeeping system,They wanted their records to be easy to create and understand,
They wanted to be sure their records met regulatory requirements,so they reviewed part 417.5(a)
and (b),
§ 417.5 Records,
(a) The establishment shall maintain the following records documenting the
establishment's HACCP plan,
(1) The written hazard analysis prescribed in § 417.2(a) of this part,including all
supporting documentation;
(2) The written HACCP plan,including decision making documents associated with the
selection and development of CCPs and critical limits,and documents supporting both
the monitoring and verification procedures selected and the frequency of those
procedures,
(3) Records documenting the monitoring of CCPs and their critical limits,including the
recording of actual times,temperatures,or other quantifiable values,as prescribed in the
establishment's HACCP plan; the calibration of process-monitoring instruments;
corrective actions,including all actions taken in response to a deviation; verification
procedures and results; product code(s),product name or identity,or slaughter
production lot,Each of these records shall include the date the record was made,
(b) Each entry on a record maintained under the HACCP plan shall be made at the time
the specific event occurs and include the date and time recorded,and shall be signed or
initialed by the establishment employee making the entry,
The HACCP team decided that their records would be kept on some simple forms,some of
which the team itself devised,
The HACCP team decided that since QA had a form that they had been using for measuring
variety meats chilling temperatures,that they would modify that form,The form was modified
to provide spaces for all entries necessary for the monitoring and verification activities at the
variety meats handling step,
The Room/Product Temperature Recording Chart for the carcass chill was already in use and the
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team knew that they needed to do some personnel training to ensure that all recordkeeping
requirements are included on the recording chart,
QA already had a Thermometer Calibration Log and this form was modified to meet the HACCP
regulatory recordkeeping requirements,The HACCP team decided that this form could be used
by QA for more than one day because there are very limited numbers of thermometers issued for
product temperature measurements,If at any time during the shift a thermometer is dropped or if
the employee questions the accuracy of the thermometer he is to immediately take the
thermometer to the QA lab for an accuracy check,
On its HACCP Plan,generic establishment X has listed the names of the forms it will be using
for monitoring and verification records,The team also devised the antimicrobial intervention log
to record monitoring results for pressure and antimicrobial concentrations,
There is one other form included in column four,where the establishment has described its
recordkeeping system,That is the Corrective Actions Log; it is used to create the records of any
corrective actions taken because of deviations from critical limits at CCPs,Column six of the
HACCP plan references the planned corrective actions for each CCP,The HACCP team
carefully reviewed the regulatory requirements for planned corrective actions found at 417.3(a),
§ 417.3 Corrective actions,
(a) The written HACCP plan shall identify the corrective action to be followed in
response to a deviation from a critical limit,The HACCP plan shall describe the
corrective action to be taken,and assign responsibility for taking corrective action,to
ensure,
(1) The cause of the deviation is identified and eliminated;
(2) The CCP will be under control after the corrective action is taken;
(3) Measures to prevent recurrence are established; and
(4) No product that is injurious to health or otherwise adulterated as a result of the
deviation enters commerce,
The HACCP team has developed a specific corrective action plan which will be followed
whenever there is a deviation from a critical limit at a CCP; each of the planned corrective
actions meets the four regulatory requirements of 417.3(a),
Planned Corrective Actions for CCP 1,
1,QA will reject or hold product until temperature is achieved,dependent on time and
temperature deviation,
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2,QA will identify the cause of the deviation and prevent reoccurrence,
The HACCP team also develops planned corrective actions for each of the other CCPs and
attaches them to the HACCP plan,Whenever a deviation from a critical limit occurs,company
employees follow the corrective action plan and use the Corrective Action Log to create a record
of their actions,The Corrective Action Log forms are available at CCPs,so they can be used
immediately when an employee performing a monitoring check discovers and records a
deviation,All Corrective Action Logs,which have been used during the day,are turned in to the
HACCP coordinator,
There is one final verification/recordkeeping requirement which the company must perform; it is
found at 417.5(c),
(c) Prior to shipping product,the establishment shall review the records associated with
the production of that product,documented in accordance with this section,to ensure
completeness,including the determination that all critical limits were met and,if
appropriate,corrective actions were taken,including the proper disposition of product,
Where practicable,this review shall be conducted,dated,and signed by an individual
who did not produce the record(s),preferably by someone trained in accordance with §
417.7 of this part,or the responsible establishment official,
In generic establishment X,product is shipped out,often in small lots,throughout the day,This
means that pre-shipment verification checks must be as complete as possible when finished
product is in storage,so that a shipment can be made up quickly and moved into distribution
channels,
The establishment uses a half day lotting system and a midshift cleanup,While the midshift
cleanup is being performed,QA personnel or the HACCP coordinator review results of
monitoring and verification checks applied to that lot; if there were deviations from critical
limits,they review the Corrective Action Logs to make sure all appropriate planned responses
were carried out,If everything is in order and there are complete records showing that the
establishment has controlled production of this product through its HACCP system,the HACCP
coordinator will sign the pre-shipment review form which the HACCP team devised for this
purpose,
Note,It is not a regulatory requirement that a separate form be used for pre-shipment review; in
addition,FSIS has indicated that it will be very flexible in accepting a variety of arrangements
for accomplishing pre-shipment review to reflect the variety of commercial practices which it
has encountered in the industry,It is,however,important to remember that pre-shipment review
is a regulatory requirement that must be met,as it indicates that the establishment is taking full
responsibility for the product having been produced under a well-functioning HACCP system,
The HACCP team believes it has now completed preparation of the documents which are
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necessary to meet regulatory requirements for a Hazard Analysis and a HACCP Plan for their
cattle slaughter production process,They have secured a copy of FSIS Directive 5000.1,
Enforcement of Regulatory Requirements in Establishments Subject to HACCP System
Requirements,the HACCP Basic Compliance Checklist which will be used by inspection
program personnel,The HACCP team has modified the inspection form to make the statements
into positives,and now has a checklist for its own use to make sure they have not omitted
anything in their plan development and preparation,When they are confident that they have
done what is necessary,they will turn their Hazard Analysis and HACCP Plan over to the
establishment owner for decisions about implementation,
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APPENDIX A
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References for HACCP Teams
1. Agriculture Canada,Food Safety Enhancement Program – HACCP Implementation Manual,
Camelot Drive,Nepean,Ontario,Canada,1996,
2. American Meat Institute Foundation,HACCP,The Hazard Analysis and Critical Control
Point System in the Meat and Poultry Industry,Washington,D.C.,1994,
Useful sections in particular are,
Chapter 3 – microbiological hazards,pp,15-26
Chapter 4 – chemical hazards,pp,27-32
Chapter 5 – physical hazards,pp,33-35
Appendix A – NACMCF HACCP
Appendix C – Model HACCP plans
3. Baker,D.A,Application of Modeling in HACCP Plan Development,Int,J,Food Microbiol,
25:251-261,1995,
4. Corlett,D.A.,Jr,and Stier,R.F,Risk Assessment within the HACCP System,Food Control
2:71-72,1991,
5. Council for Agriculture Science and Technology,Risks Associated with Foodborne
Pathogens,February 1993,
6. Easter,M.C.,et al,The Role of HACCP in the Management of Food Safety and Quality,
J,Soc,Dairy Technol,47:42-43,1994,
7. Environmental Protection Agency,Tolerances for Pesticides in Foods,Title 40,Code of
Federal Regulations,Part 185,U.S,Government Printing Office,Washington,D.C.,1998,
8. Food and Drug Administration,The Food Defect Action Levels,FDA/CFSAN,
Washington,D.C.,1998,
9. Food and Drug Administration,Fish and Fishery Products Hazards and Control Guide --
Get Hooked on Seafood Safety,Office of Seafood,Washington,D.C.,1994,
10,International Commission on Microbiological Specification for Foods,HACCP in
Microbiological Safety and Quality,Blackwell Scientific Publications,Oxford,1988,
Useful sections in particular are,
Chapter 10 – raw meat and poultry,pp,176-193
Chapter 11 – roast beef,pp,234-238
Chapter 11 – canned ham,pp,238-242
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11,International Commission on Microbiological Specification for Foods,Microorganisms in
Foods 4,Application of Hazard Analysis and Critical Control Point (HACCP) Systems to
Ensure Microbiological Safety and Quality,Blackwell Scientific Publications,Boston,1989
12,National Advisory Committee on Microbiological Criteria for Foods,March 20,1992 --
Hazard Analysis and Critical Control Point System,Int,J,Food Microbiol,16,1-23,1993,
13,National Advisory Committee on Microbiological Criteria for Foods,Adopted August 14,
1997-- Hazard Analysis and Critical Control Point Principles and Application Guidelines,
J,Food Protect,61(9),1246-1259,1998,
14,National Advisory Committee on Microbiological Criteria for Foods,DRAFT document -
FSIS Microbiological Hazard Identification Guide for Meat and Poultry Components of
Products Produced by Very Small Plants,1-22,August 1999,
15,National Advisory Committee on Microbiological Criteria for Foods,June 1993 -- Report
on Generic HACCP for Raw Beef,Food Microbiol,10,449-488,1994,
16,National Research Council,An Evaluation of the Role of Microbiological Criteria for Foods
and Food Ingredients,National Academy Press,Washington,D.C.,1985,
Useful sections in particular are,
Chapter 4 – microbiological hazards,pp,72-103
Chapter 9 – raw meat,pp,193-199
Chapter 9 – processed meats,pp,199-216
17,Notermans,S.,et al,The HACCP Concept,Identification of Potentially Hazardous
Microorganisms,Food Microbiol,11:203-214,1994,
18,Pierson M.D,and Dutson,T,Editors,HACCP in Meat,Poultry,and Fish Processing,
Blackie Academic & Professional,Glasgow,1995,
Useful sections in particular are,
Chapter 4 – meat and poultry slaughter,pp,58-71
Chapter 5 – processed meats,pp,72-107
Chapter 7 – risk analysis,pp,134-154
Chapter 13 – predictive modeling,pp,330-354
19,Pierson,M.D,and Corlett,D.A.,Jr,Editors,HACCP Principles and Applications,Van
Nostrand Reinhold,New York,1992,
20,Stevenson,K.E,and Bernard,D.T,Editors,HACCP,Establishing Hazard Analysis Critical
Control Point Programs,A Workshop Manual,The Food Processors Institute,Washington,
17
Beef Slaughter Model
D.C.,1995,
Useful sections in particular are,
Chapter 11 – forms for hazard analysis,CCPs,critical limits,HACCP master
sheet,example HACCP for breaded chicken
21,Stevenson,K.E,and Bernard,D.T,Editors,HACCP,A Systematic Approach to Food
Safety,3
rd
Edition,The Food Processors Institute,Washington,D.C.,1999,
22,Tompkin,R.B,The Use of HACCP in the Production of Meat and Poultry Products,
J,Food Protect,53(9),795-803,1990,
23,Tompkin,R.B,The Use of HACCP for Producing and Distributing Processed Meat and
Poultry Products,In Advances in Meat Research,Volume 10,Hazard Analysis Critical
Control Point in Meat,Poultry and Seafoods,Chapman & Hall,1995,
References for Beef Slaughter (Steer/Heifer Carcass & Cow Carcass)
1. Barkate,M,L.,et al,Hot Water Decontamination of Beef Carcasses for Reduction of Initial
Bacteria Numbers,Meat Sci,35:397-401,1993,
2. Charlebois,R.,et al,Surface Contamination of Beef Carcasses by Fecal Coliforms,J,Food
Protect,54:950-956,1991,
3. Clayton,R,Paul,Carcass Sanitizing Systems,Proceedings,Meat Industry Research
Conference 2,8-24,,October 7,1992,
4. Cutter,C,N.,et al,Application of Chlorine to Reduce Populations of Escherichia coli on
Beef,J,Food Safety,15:67-75,1995,
5. Dickson,J,S,Susceptibility of Preevisceration washed beef carcasses to contamination by
Escherichia coli 0157:H7 and Salmonellae,J,Food Protect,58:1065-1068,1996,
6. Gill,C,O,Use of a temperature function integration technique to assess the hygienic
adequacy of beef carcass cooling process,Food Microbiol,8:83-94,1991,
7. Gill,C,O,Current and Emerging Approaches to Assuring the Hygienic Condition of Red
Meats,Can,J,Anim,Sci,75:1-13,1995,
8,Gill,C,O,HACCP & Beef Carcass Dressing,Meat & Poultry,21-47,May 1996,
18
Beef Slaughter Model
9. Gustavsson,Patrick,et al,Contamination of beef carcasses by psychrotrophic Pseudomonas
and Enterobacteriaceae at different stages along the processing line,Int,J,Food Microbiol,
20:67-83,1993,
10,Hardin,M,D.,et al,Comparison of Methods for Decontamination from Beef Carcass
Surfaces,J,Food Protect,58:368-374,1995,
11,Hogue,Allan T.,et al,Bacteria on Beef Briskets and Ground Beef,Correlation with
Slaughter Volume and Antemortem Condemnation,J Food Protect,56:110-113,119,1993,
12,Jericho,Klaus W,F.,et al,Visual Demerit and Microbiological Evaluation of Beef
Carcasses,Methodology,J,Food Protect,56:114-119,1993,
13,Meat Marketing & Technology,Futuristic Slaughtering System to Begin Operation in
Australia,Meat Marketing & Technology,48-50,August 1993,
14,Meat Marketing & Technology,Faster,More Sanitary Hide Removal Procedure Key to
Successful Operation,Meat Marketing & Technology,52,August 1994,
15,Meat Marketing & Technology,Early Results Positive on Steam Vacuuming,Meat
Marketing & Technology,108,August 1995,
16,NACMCF,Generic HACCP for Raw Beef,Food Microbiol,10:449-488,1994,
17,Smith,M,G,Destruction of Bacteria on Fresh Meat by Hot Water,Epidemiol,Infect,
109:491-496,1992,
18,Smith,G,C.,et al,Fecal-material Removal and Bacterial-count Reduction by Trimming
and/or Spray-washing of Beef External-fat Surfaces,1996,
19
Beef Slaughter Model
APPENDIX B
20
Beef Slaughter Model
PROCESS FLOW DIAGRAM Figure 1
PROCESS CATEGORY,SLAUGHTER
PRODUCT,BEEF
RECEIVING
PACKAGING
MATERIALS
RECEIVING LIVE CATTLE
STUNNING/BLEEDING
HEAD/SHANK
REMOVAL
SKINNING
EVISCERATION
SPLITTING
TRIM RAIL
FINAL WASH
VISCERA
PROCESSING
VARIETY
MEATS
PRODUCTION
CHILLING
PACKAGING/LABELING
FINISHED PRODUCT
STORAGE (COLD)
STORAGE
PACKAGING
MATERIALS
SHIPPING
21
Beef Slaughter Model
PRODUCT DESCRIPTION Figure 2
PROCESS CATEGORY,SLAUGHTER
PRODUCT,BEEF
1,COMMON NAME? BEEF; BEEF VARIETY MEATS
2,HOW IS IT TO BE USED? CARCASSES; VARIETY MEATS
3,TYPE OF PACKAGE? CARCASSES – NONE; VARIETY
MEATS – 50 POUND BOXES
4,LENGTH OF SHELF LIFE,7 DAYS AT 40° F
AT WHAT TEMPERATURE?
5,WHERE WILL IT BE SOLD? WHOLESALE TO DISTRIBUTORS
CONSUMERS? ONLY
INTENDED USE?
6,LABELING INSTRUCTIONS? KEEP REFRIGERATED
7,IS SPECIAL DISTRIBUTION KEEP REFRIGERATED
CONTROL NEEDED?
22
Beef Slaughter Model
HAZARD ANALYSIS – BEEF SLAUGHTER
Process Step Food Safety
Hazard
Reasonably
Likely to
Occur?
Basis If Yes in Column 3,
What Measures Could
be Applied to Prevent,
Eliminate,or Reduce
the Hazard to an
Acceptable Level?
Critical Control
Point
Receiving – Live Cattle
* Note,Since residues
can be a hazard
reasonably likely to
occur in cull cows
(dairy & beef) and bob
veal calves,plants
should make chemical
(residues) a CCP with
these animals,
Biological
Escherichia coli
O157:H7
No Sanitary dressing
procedures prevent
contamination,
Chemical – Residues No Plant/FSIS records
demonstrate residues have
not been a past problem,
Physical – Foreign
materials such as
broken needles
No Cattle are purchased from
feedlots having QA
procedures to prevent
foreign materials such as
broken needles from
remaining in animals,
Figure 3
23
Beef Slaughter Model
HAZARD ANALYSIS – BEEF SLAUGHTER
Process Step Food Safety
Hazard
Reasonably
Likely to
Occur?
Basis If Yes in Column 3,
What Measures Could
be Applied to Prevent,
Eliminate,or Reduce
the Hazard to an
Acceptable Level?
Critical Control
Point
Stunning/Bleeding
Head/Shank Removal
Biological – None
Chemical – None
Physical – None
Skinning Biological – Pathogens
- Contamination from
the Hide
- E,coli O157:H7
Yes Contamination from the
hide is a known source of
pathogens,Potential
contamination could occur
at this step,
Will be controlled at the
final wash (antimicrobial)
step,
Chemical – None
Physical – None
Figure 3
24
Beef Slaughter Model
HAZARD ANALYSIS – BEEF SLAUGHTER
Process Step Food Safety
Hazard
Reasonably
Likely to
Occur?
Basis If Yes in Column 3,
What Measures Could
be Applied to Prevent,
Eliminate,or Reduce
the Hazard to an
Acceptable Level?
Critical Control
Point
Evisceration Biological – Pathogens
-Contamination from
the Gastrointestinal
Tract
-E,coli O157:H7
Yes Potential contamination
could occur at this step,
Will be controlled at the
final wash (antimicrobial)
step,
Chemical – None
Physical – None
Splitting Biological – None
Chemical – None
Physical – None
Trim Rail Biological – Pathogens
-E,coli O157:H7
No This step in the process
used to remove incidental
contamination that might
have occurred in previous
steps,
Chemical – None
Physical – None
Figure 3
25
Beef Slaughter Model
HAZARD ANALYSIS – BEEF SLAUGHTER
Process Step Food Safety
Hazard
Reasonably
Likely to
Occur?
Basis If Yes in Column 3,
What Measures Could
be Applied to Prevent,
Eliminate,or Reduce
the Hazard to an
Acceptable Level?
Critical Control
Point
Viscera Processing Biological – Pathogens
-Contamination from
the Gastrointestinal
Tract
-E,coli O157:H7
No Contamination from the
gastrointestinal tract is a
known source of pathogens;
however,plant records
demonstrate that
contamination has not been
a problem in the past,
Chemical – None
Physical – None
Final Wash
(Antimicrobial)
Biological – Pathogens
(Contamination from
the Hide and/or
Gastrointestinal Tract)
Yes Appropriate step to reduce
pathogens,
An acceptable
antimicrobial wash (rinse)
is applied to the carcasses,
1B
Chemical – None
Physical – None
Variety Meats
Production
Biological – None
Chemical – None
Physical – None
Figure 3
26
Beef Slaughter Model
HAZARD ANALYSIS – BEEF SLAUGHTER
Process Step Food Safety
Hazard
Reasonably
Likely to
Occur?
Basis If Yes in Column 3,
What Measures Could
be Applied to Prevent,
Eliminate,or Reduce
the Hazard to an
Acceptable Level?
Critical Control
Point
Chilling (All products) Biological – Pathogens
- E,coli O157:H7
Yes Pathogens are reasonably
likely to grow if improper
chilling procedures are
used,
Proper chilling procedures
are used,
2B
Chemical – None
Physical – None
Packaging/Labeling Biological – None
Chemical – None
Physical – None
Finished Product
Storage (Cold)
Biological – Pathogens
- E,coli O157:H7
Yes Pathogens are reasonably
likely to grow if
temperature is not
maintained at or below a
level sufficient to preclude
their growth,
Maintain product
temperature at or below a
level sufficient to preclude
pathogen growth,
3B
Chemical – None
Physical – None
Figure 3
27
Beef Slaughter Model
HAZARD ANALYSIS – BEEF SLAUGHTER
Process Step Food Safety
Hazard
Reasonably
Likely to
Occur?
Basis If Yes in Column 3,
What Measures Could
be Applied to Prevent,
Eliminate,or Reduce
the Hazard to an
Acceptable Level?
Critical Control
Point
Shipping Biological - None
Chemical – None
Physical – None
Figure 3
28
Beef Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,BEEF
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
1B
Final Wash
(antimicro
bial)
Continued
on next
page
No visible
contamination
on carcasses
Antimicrobial
concentration
in sanitizing
cabinet will
be maintained
between 0.5
& 2.5%,
Solution
pressure at
nozzles in
sanitizing
cabinet will
be maintained
above 35 PSI,
Quality Assurance
monitors
washing/antimicro
bial equipment use
every 2 hours to
ensure that
distance,volume
and pressure meet
critical limit &
results are
recorded,dated and
initialed,
Quality Assurance
evaluates 25% of
carcasses for
visible fecal
contamination,
Washing Equipment
Monitoring Log
Antimicrobial
Intervention
Monitoring Log
Washing Equipment
Calibration Log
Corrective Action
Log
Once per shift the QA supervisor
will review all Logs and observe the
operation and monitoring at the
CCP,
Maintenance supervisor will verify
accuracy (calibration) of the
washing and antimicrobial
intervention equipment once per
shift,
QA will identify the cause of the deviation
and prevent reoccurrence,
If concentration is outside limits,QA will
identify the cause of deviation & make
corrections to return concentration to with-
in prescribed limits,Also,preventive
actions will be taken to reduce the likeli
hood of a recurrence,Product produced
below critical limit will be identified &
sprayed w/ a 0.2% antimicro-bial solution
in the cooler,Product produced above
critical limit will be identified,held (expo
sed to carcass spraying in the cooler),and
sampled until a representative sample
determines that the level of residual anti-
microbial on carcasses shows no significa
nt difference between carcasses sprayed
within limits and ones sprayed above the
upper limit,When there is no difference,
carcass will be released for fabrication,
Signature,__________________________________ Date,__________________________ Figure 4
29
Beef Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,BEEF
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
1B
Final Wash
(antimicro
bial)
Continued
from
previous
page
Pressures in
carcass wash
will be main
tained bet,
100-350 PSI,
Continued from previous page
If PSI drops below 100,QA will identify
cause of deviation & require corrective
action to return the pressures to within
prescribed limits,
Also,preventive actions will be taken to
reduce the likelihood of a recurrence,
Product produced outside critical limit will
be identified & subjected to carcass AQL
reinspection,If carcasses pass they will
proceed to fabrication,If the lot fails AQL,
carcasses will be reworked & reinspected
using AQL criteria,
QA will stop production when the
wash/antimicrobial intervention falls
outside critical limits,All affected
carcasses back to the last acceptable check
will be visually inspected & reworked if
visible fecal contamination is observed,
Maintenance will correct problems found
in equipment adjustment,
Signature,__________________________________ Date,__________________________ Figure 4
30
Beef Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,BEEF
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
1B
Final Wash
(antimicro
bial)
Continued
from
previous
page
Continued from previous page
** Note,Most establishments will be
washing beef carcass with a hand held at
pressure 50-75 PI,which is the pressure of
the system delivering water to the
establishment,When pressure drops
slaughter operations are stopped,The
antimicrobial application in many
small/very small plants will be a hand
operated garden sprayer containing a 2%
acid solution,Other than the concentration
there are no critical limits,
Signature,__________________________________ Date,__________________________ Figure 4
31
Beef Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,BEEF
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
2B
Chilling (All
Products)
(Continued
on next
page)
All carcasses
will begin
chilling
within 1 hour
from
bleedout,All
variety meats
will begin
chilling
within 1 hour
after removal
from carcass,
Temperature
of 40°F or
less will be
reached
within 24
hours on all
products,
QA technician will
observe chilling
handling
procedures to
ensure critical
limits are met,
Carcass and variety
meats coolers will
be monitored and
recorded
continuously on
temperature
recording charts,
QA technician will
select and check 10
carcasses and 5
samples of each
type of variety
Carcass Chilling
Log
Variety Meats
Chilling Log
Carcass Cooler
Temperature
Recording Chart
Variety Meats
Cooler Temperature
Recording Chart
Thermometer
Calibration Log
Corrective Action
Log
Once per shift the QA supervisor
will review the Carcass Chilling
Log and Variety Meats Chilling Log
and observe the taking and
recording a carcass & variety meat
temperatures and cooler temp,
Maintenance supervisor will verify
accuracy of the carcass cooler
temperature and variety meats
cooler temperature recording charts
once per shift,
QA will check all thermometers
used for monitoring and verification
for accuracy daily and calibrate to
within 2°F accuracy as necessary,
QA will reject or hold product dependent
on time and temperature deviation,Process
Authority or cooling curves will be used to
determine specific corrective action or
rejection,
QA will identify the cause of the deviation
and prevent reoccurrence,
Cooler maintenance will be adjusted to
prevent reoccurrence and repairs made if
necessary,
Signature,__________________________________ Date,__________________________ Figure 4
32
Beef Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,BEEF
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
2B
Chilling (All
Products)
meats produced
after 24 hours
chilling to ensure a
temperature of 40°
F or less has been
reached,
Carcass lots will be
monitored to assure
that 1 hour
requirement is met
by tracking 10
carcasses per lot,
All results are
recorded with the
actual value,dated
and initialed/
signed,
Signature,__________________________________ Date,__________________________ Figure 4
33
Beef Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,BEEF
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
3B
Finished
Product
Storage
(Cold)
(Continued
on next
page)
Finished
product
storage areas
will not
exceed 40° F,
Maintenance
personnel will
check finished
product storage
areas temperatures
every two hours
and record cooler
temperature in the
room temperature
log & initial &
date,
Room Temperature
Log
Thermometer
Calibration Log
Corrective Action
Log
Maintenance supervisor will verify
the accuracy of the room
temperature log once per shift,
QA will check all thermometers
used for monitoring and verification
activities for accuracy daily and
calibrate to within 2° F accuracy as
necessary,
QA will observe maintenance
personnel check finished product
storage area once per shift,
If a deviation from a critical limit occurs,
the following corrective actions will be
taken,
1,The cause of the temperature
exceeding 40° F will be identified and
eliminated,
2,The CCP will be monitored hourly
after the corrective action is taken to
ensure that it is under control,
3,When the cause of the deviation is
identified,measures will be taken to
prevent it from recurring e.g.,if the
cause is equipment failure,preventive
maintenance program will be reviewed
and revised,if necessary,
Signature,__________________________________ Date,__________________________ Figure 4
34
Beef Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,BEEF
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
3B
Finished
Product
Storage
(Cold)
If a deviation from a critical limit occurs,
the following corrective actions will be
taken,
4,If room temperature exceeds the
critical limit,the processing authority
will evaluate the product temperature
to ensure the temperature is sufficient
to preclude pathogen growth before
release for shipment,If temperature is
not sufficient to preclude pathogen
growth,product will be cooked in the
establishment to ensure destruction of
pathogens or condemned,
Signature,__________________________________ Date,__________________________ Figure 4
35
Beef Slaughter Model
THERMOMETER CALIBRATION LOG
Calibrate to 32
0
F while thermometer is in slush ice water
Date Time Department or
Area
Thermometer
ID#
Personal
Thermometer
Reading
Adjustment
Required (Yes
or No)
Initials Comments
6/15 1:00 PM Carcass Chilling 2A 32°F No HK
If a thermometer is broken or taken out of service,document this in the comment column,
Reviewed by,_______________________
Date,_______________________
36
Beef Slaughter Model
GENERIC ESTABLISHMENT X,
Time Bleed
Out
Time
Time
In
Cooler
Cooler
Location
Lot # Carcass
Temp,
Room
Temp,
Deviation
from CL?
(Check if
yes)
If Yes,
Action?
Monitored
by,
Verified
by,
ROOM / PRODUCT TEMPERATURE LOG
37
Beef Slaughter Model
ESTABLISHMENT X,
Date Lot # Time Solution
Concentration
Pressure Corrective Actions Monitored
by,
Verified
by,
Intervention Monitoring Log Antimicrobial
38
Beef Slaughter Model
CORRECTIVE ACTIONS LOG
Product,___________________________________________ Lot # ______________________
CCP Deviation/
Problem
Corrective Action
Procedures/Explain
Disposition of
Product
Responsible
Person
Date/Time
SIGNATURE,__________________________ DATE,______________________
39
Beef Slaughter Model
PRE-SHIPMENT
Date:______________
PRODUCT LOT ID TIME
RECORDS
REVIEWED
BY
WHOM
LOT RELEASED FOR
SHIPMENT?
SIGNATURE
COMMENTS *
LOG REVIEW
*Monitoring frequency as per plan; Critical limits met; Certification (if applicable) as per plan; Deviations if occurred were reviewed
for appropriate corrective actions; Records complete and accurate,
40
Department of
Agriculture
Food Safety
and Inspection
Service
September 1999
HACCP-13
Generic HACCP
Model for Beef
Slaughter
Additional copies of the Guidebook for the Preparation
of HACCP Plans and the Generic HACCP Models are
available from,
U.S,Department of Agriculture
Food Safety and Inspection Service (FSIS)
Office of Policy,Program Development,
and Evaluation (OPPDE)
Inspection Systems Development Division
Room 202,Cotton Annex Building
300 12
th
Street SW
Washington,D.C,20250-3700
Phone,(202) 720-3219
Fax,(202) 690-0824
This material is also available on the FSIS Homepage,
http://www.fsis.usda.gov/index.htm
Beef Slaughter Model
Table of Contents
Introduction……………………………………………………………………………..…,2
Using This Generic Model…………………………………………………………..…….,4
Process Flow Diagram and Product Description…………………………………..………,5
Hazard Analysis………………………………………………………………….…………6
Developing Your HACCP Plan………………………………………………..………….,8
Identifying CCPs……………………………………………………………………..……,10
Appendix A
References for HACCP Teams…………………………………………………… 16
References for Beef Slaughter (Steer/Heifer Carcass & Cow Carcass)…………… 18
Appendix B
Process Flow Diagram (Figure 1)…………………………………………………,21
Product Description Form (Figure 2)……………………………………………… 22
Hazard Analysis Form (Figure 3)…………………………………………………,23
HACCP Plan Form (Figure 4)..…………………………………………………… 29
Thermometer Calibration Log…………………………………………………….,36
Generic Establishment X,Room/Product Temperature Log ………………………37
Establishment X,Antimicrobial Intervention Monitoring Log ……………………38
Corrective Actions Log……………………………………………………………,39
Pre-Shipment Review Log………………………………………………………… 40
1
Beef Slaughter Model
GENERIC HACCP MODEL
FOR
BEEF SLAUGHTER
Introduction
The Hazard Analysis Critical Control Point (HACCP) system is a scientific approach to process
control,It is designed to prevent the occurrence of problems by assuring that controls are
applied at any point in a food production system where hazardous or critical situations could
occur,Hazards include biological,chemical,or physical contamination of food products,
The Food Safety and Inspection Service (FSIS) published a final rule in July 1996 mandating
that HACCP be implemented as the system of process control in all inspected meat and poultry
plants,As part of its efforts to assist establishments in the preparation of plant-specific HACCP
plans,FSIS determined that a generic model for each process defined in the regulation would be
made available for use on a voluntary basis by inspected establishments,
The generic models have been revised since their initial publication and distribution as
DRAFTS,The most important change in the revised versions is to make certain that these
models are
fully consistent with the features of the final regulation,Also,other technical and editorial
improvements have been made,
Throughout this generic model,FSIS discusses a HACCP team with members from different
departments,In many very small establishments,there will not be separate departments with
different employees,But,there will be employees who perform these different functions – often
several of them,For purposes of explaining concepts,it is easier to speak as if these were
different people,even though in many cases,they may be the same person carrying out more
than one responsibility,
Each generic model can be used as a starting point for the development of plant-specific plan(s)
reflecting actual plant environments and the processes conducted,The generic model is not
intended to be used,as is” for plant specific HACCP plans,
The generic models are designed for use in conjunction with the list of process categories found
in the HACCP regulations in section 417.2(b)(1),
(b) The HACCP plan,(1) Every establishment shall develop and implement a written
HACCP plan covering each product produced by that establishment whenever a hazard
analysis reveals one or more food safety hazards that are reasonably likely to occur,
2
Beef Slaughter Model
based on the hazard analysis conducted in accordance with paragraph (a) of this section,
including products in the following processing categories,
(i) Slaughter--all species,
(ii) Raw product--ground,
(iii) Raw product--not ground,
(iv) Thermally processed--commercially sterile,
(v) Not heat treated--shelf stable,
(vi) Heat treated--shelf stable,
(vii) Fully cooked--not shelf stable,
(viii) Heat treated but not fully cooked--not shelf stable,
(ix) Product with secondary inhibitors--not shelf stable,
This generic model is designed for use with the first process category,Slaughter,
The purpose of the process category listing in 417.2 is to set out the circumstances under which a
HACCP team may develop a single HACCP plan for multiple products,This may be done when
products are in the same process category,and food safety hazards,critical control points,and
other features are essentially the same,There is a generic model for each process category,plus
two for subcategories which present special issues,irradiated products and mechanically
separated products,
In order to select the model or models that will be most useful for the activities performed in any
specific plant,the following steps should be taken,
1) For slaughtering operations,select the model for the appropriate species,
2) For processed products,make a list of all products produced in the plant,
3) Examine the list and group like products,considering common processing steps and
equipment used,
4) Compare the grouped products with the list of processes in the regulations; this step should
reveal how many and which of the generic models might be useful,
3
Beef Slaughter Model
Deciding on a generic model and which products can be covered by a single plan is an important
achievement,If the team does it well,it can save a lot of unnecessary effort and paperwork,
Selecting an inappropriate generic model reduces its potential benefits,However,often the
HACCP team will discover they have made this error when they develop their process flow
diagram or during their hazard analysis,These are early stages in the process when it is
relatively easy to make changes,
In any case,establishments must meet all regulatory requirements for their products,
Using This Generic Model
This generic model is designed to be used by establishments that slaughter,the first process
category,The model can be used for all establishments that slaughter,but would be most useful
to establishments that slaughter cattle,The generic model is not suitable for products that fall
into any of the other process categories,
The model will be most useful to a HACCP team that includes access to one trained individual,
as specified in 417.7(b),
(b)The individual performing the functions listed in paragraph (a) of this section shall
have successfully completed a course of instruction in the application of the seven
HACCP principles to meat or poultry product processing,including a segment on the
development of a HACCP plan for a specific product and on record review,
It would be beneficial for other team members to have reviewed any of the various guidance
materials available on how to develop a HACCP plan for your company,including several useful
videos,handbooks,or computer programs,Once the HACCP team has prepared itself as
thoroughly as possible in general HACCP principles and how to use them,this model should be
helpful,
Note,This generic model includes a number of forms that can be used to record various types of
required information,The forms themselves are samples; a company HACCP team can develop
whatever forms it finds most useful,All the forms mentioned in this document are included in
Appendix B; they appear in the order in which they are discussed in the text,
All FSIS generic models are designed to assist establishments in applying the seven HACCP
principles to their meat and poultry processing operations AND to meet the regulatory
requirements of Part 417,Therefore,the definitions used in this and all other FSIS generic
models are those found in 417.1,
§ 417.1 Definitions,
4
Beef Slaughter Model
For purposes of this part,the following shall apply,
Corrective action,Procedures to be followed when a deviation occurs,
Critical control point,A point,step,or procedure in a food process at which control can
be applied and,as a result,a food safety hazard can be prevented,eliminated,or reduced
to acceptable levels,
Critical limit,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,
Food safety hazard,Any biological,chemical,or physical property that may cause a
food to be unsafe for human consumption,
HACCP System,The HACCP plan in operation,including the HACCP plan itself,
Hazard,SEE Food Safety Hazard,
Preventive measure,Physical,chemical,or other means that can be used to control an
identified food safety hazard,
Process-monitoring instrument,An instrument or device used to indicate conditions
during processing at a critical control point,
Responsible establishment official,The individual with overall authority on-site or a
higher level official of the establishment,
Process Flow Diagram and Product Description
To begin using this model,the company's HACCP team should first describe the product(s)
which are part of this process category and covered by this HACCP plan,The product(s) should
be described in two ways,
(1) by a simple diagram which shows the steps the company uses when it produces the product,
and
(2) in a brief written description which provides key facts about the product and its use,
In this generic model,there is an example for cattle slaughter,one of the species in this process
category,FSIS has developed certain forms as part of the examples in the generic models;
company HACCP teams are not required to use these forms,
5
Beef Slaughter Model
Figure 1 is an example of a PROCESS FLOW DIAGRAM for the cattle slaughter process in
generic establishment X,Figure 2 is an example of a PRODUCT DESCRIPTION for the cattle
slaughtered by generic establishment X,
Once the company HACCP team in your establishment has prepared your Process Flow
Diagram,they should verify it by walking through the establishment following the flow of
product and making sure that all the steps of the process are included in the flow diagram,The
team should also review the information provided on the Product Description to make sure all
the key facts are included,such as identifying consumers,especially those with particular health
problems or known to be at risk,
Note,If you are slaughtering cattle and your process includes steps not included in this example,
such as pre-evisceration spray,those steps should be added,Also,if your process does not
include all the steps identified in this example,those steps would be omitted when conducting
the hazard analysis,That is generally,how you use these generic model examples--just omit the
features which do not apply to your operation or if your operation includes features not included
in this example,they should be added,
By completing a Process Flow Diagram and a Product Description,you have met the
requirements of 417.2(a)(2),You can use the Process Flow Diagram in particular to help you
complete the rest of the hazard analysis,Use the flow diagram to systematically review each
step in the process and ask the question,"Is there a food safety hazard which is reasonably likely
to occur which may be introduced at this step?" In answering the question,your HACCP team
needs to consider biological (including microbiological),chemical,and physical hazards,
Hazard Analysis
Once your product(s) are accurately described through the flow diagram and product description,
the HACCP team should begin work on the HAZARD ANALYSIS,The hazard analysis is
fundamental to developing a good HACCP plan and one that meets regulatory requirements,
The regulatory requirements for a hazard analysis are found at 417.2(a),
§ 417.2 Hazard Analysis and HACCP Plan,
(a) Hazard analysis,(1) Every official establishment shall conduct,or have conducted
for it,a hazard analysis to determine the food safety hazards reasonably likely to occur
in the production process and identify the preventive measures the establishment can
apply to control those hazards,The hazard analysis shall include food safety hazards
that can occur before,during,and after entry into the establishment,A food safety
hazard that is reasonably likely to occur is one for which a prudent establishment would
establish controls because it historically has occurred,or because there is a reasonable
possibility that it will occur in the particular type of product being processed,in the
absence of those controls,
6
Beef Slaughter Model
(2) A flow chart describing the steps of each process and product flow in the
establishment shall be prepared,and the intended use or consumers of the finished
product shall be identified,
Generic establishment X,which we are using for our example,is capturing these regulatory
requirements on a 6-column Hazard Analysis Form (See Figure 3),A good way to use a form
like this is to create the first column by using the Process Flow Diagram and the second by
answering the question,Once the HACCP team has considered all the steps in the flow diagram
and determined if a food safety hazard could be introduced,it needs to consider whether the
hazard is "reasonably likely to occur",using the meaning of this phrase included in 417.2(a),On
the 6-column form used by generic establishment X,the third and fourth columns address this
issue,If the establishment's HACCP team has decided that the hazard is not reasonably likely to
occur,they enter "No" in column three,explain the basis for their determination in column four,
and do not need to further consider activity at this point in the process,
If,however,the team has determined there is a "food safety hazard reasonably likely to occur"
introduced at a certain point in the process,column five is used to describe a measure which
could be applied to "prevent,eliminate,or reduce to acceptable levels" the food safety hazard
identified in column three,Column six is used when a critical control point (CCP) is identified
based upon the decision made in the hazard analysis,Each CCP has a number – the order
corresponds to steps in the process,For example 1 is the first CCP in the process flow,2 the
next,etc,The letter indicates whether the hazard is biological – B; chemical – C; or physical –
P,
Look at the entries for,Receiving – Live Cattle” on the first page of the six column form; the
HACCP team has determined that pathogens are likely to be on the animals when they are
received,but it put a,No” in the third column,Column four explains the basis for the team’s
determination,The HACCP team made sure that controls were in place to ensure that sanitary
dressing procedures will be followed during the process,
You will notice that on our generic hazard analysis for cattle slaughter,there are five food safety
hazards in which the HACCP team has identified a point in the process at which a food safety
hazard is reasonably likely to occur,For each one of these they have identified a measure which
can be used to control the hazard,
When your HACCP team has completed their hazard analysis (whether they use this format or
not),it is a good idea to review the flow diagram,the product description and the hazard analysis
itself to make sure they are complete,Part 417.2(a)(3) includes a list of sources from which food
safety hazards might be expected to arise,Reviewing that list could help the HACCP team
check for completeness,
Note,If you are using this generic model and slaughter a different species of livestock or if you
7
Beef Slaughter Model
use a different process flow,you may have different hazards which are reasonably likely to
occur,For these different hazards,there may be different measures which could be used for
control purposes,
This,and all other FSIS generic models,contains a list of references which can help your
HACCP team in making sure the hazard analysis is complete,The references for cattle slaughter
are found in Appendix A,A member of your HACCP team might want to review at least some
of the references to make sure hazards have not been omitted from the hazard analysis,
Completing the hazard analysis is a very significant and important element in developing your
HACCP system,Your HACCP team should feel a real sense of accomplishment when they get
this far; this is like completing the foundation of a house,
Developing Your HACCP Plan
The company HACCP team can now take the materials it developed while doing the hazard
analysis and use them to build the HACCP Plan,Remember that one of the important
objectives of the FSIS generic models is to provide examples which illustrate how to meet the
regulatory requirements of Part 417,as well as to correctly apply the principles of HACCP,
Part 417.2 (c) and (d) are the regulatory requirements,
(c) The contents of the HACCP plan,The HACCP plan shall,at a minimum,
(1) List the food safety hazards identified in accordance with paragraph (a) of this
section,which must be controlled for each process,
(2) List the critical control points for each of the identified food safety hazards,
including,as appropriate,
(i) Critical control points designed to control food safety hazards that could be
introduced in the establishment,and
(ii) Critical control points designed to control food safety hazards introduced outside the
establishment,including food safety hazards that occur before,during,and after entry
into the establishment;
(3) List the critical limits that must be met at each of the critical control points,Critical
limits shall,at a minimum,be designed to ensure that applicable targets or performance
standards established by FSIS,and any other requirement set forth in this chapter
pertaining to the specific process or product,are met;
(4) List the procedures,and the frequency with which those procedures will be
performed,that will be used to monitor each of the critical control points to ensure
8
Beef Slaughter Model
compliance with the critical limits;
(5) Include all corrective actions that have been developed in accordance with §417.3(a)
of this part,to be followed in response to any deviation from a critical limit at a critical
control point; and
(6) Provide for a recordkeeping system that documents the monitoring of the critical
control points,The records shall contain the actual values and observations obtained
during monitoring,
(7) List the verification procedures,and the frequency with which those procedures will
be performed,that the establishment will use in accordance with § 417.4 of this part,
(d) Signing and dating the HACCP plan,(1) The HACCP plan shall be signed and
dated by the responsible establishment individual,This signature shall signify that the
establishment accepts and will implement the HACCP plan,
(2) The HACCP plan shall be dated and signed,
(i) Upon initial acceptance;
(ii) Upon any modification; and
(iii) At least annually,upon reassessment,as required under § 417.4(a)(3) of this part,
Generic establishment X has prepared its HACCP plan for cattle slaughter on a six column form
(See Figure 4),You do not need to use this form,although some kind of a form is probably the
easiest way to present your HACCP plan,
Identifying CCPs
The first column on this particular form is used to enter information developed and contained on
the hazard analysis form,Part 417.2(c)(1) and (2) require that the food safety hazards identified
in the hazard analysis be listed on the HACCP plan and that there be a CCP for each identified
hazard,You will notice that there were five points on the hazard analysis form where food
safety hazards reasonably likely to occur were identified,pathogen contamination from the hide
at skinning,pathogen contamination from the gastrointestinal tract during evisceration,final
wash,pathogen proliferation at chilling,and pathogen proliferation at finished products storage
(cold),The establishment HACCP team has chosen to have three CCPs to address these five
hazards,final wash (antimicrobial),proper chilling of product,and proper maintenance of
finished product temperatures during storage,
After identifying its CCPs,the HACCP team proceeded to consider critical limits,monitoring
9
Beef Slaughter Model
procedures and their frequencies,and verification procedures and their frequencies,and HACCP
records,
In deciding what would be the critical limits,the HACCP team first considered whether there
were any regulatory requirements which had to be met and would function as critical limits,
They found no regulatory requirements for chilling carcasses or variety meats,but realized that if
the proper chiller procedures were not followed pathogen proliferation was possible,The
HACCP team knew that the variety meats should start the chilling process soon after they are
removed from the carcass,so they set the critical limit for chilling variety meats to start within
one hour after removal from the carcass,They set the critical limit for carcass chilling to start
within one hour after bleedout,
Once they had decided on their critical limits,they needed to identify how the monitoring
procedures would be carried out and at what frequency,
For their chilling step (variety meats),the establishment had the QA technician observe the
variety meats handling procedures to ensure the chilling process starts within an hour after
removal from the carcass,At the chilling step (carcass and variety meats) the cooler temperature
is monitored continuously with recording charts,
These decisions by the HACCP team regarding critical limits,plus monitoring procedures and
their frequencies are written up in columns two and three of the HACCP Plan,
The team then went on to consider appropriate verification procedures; the team knew that there
were different types of verification and that Part 417.4(a)(2) included specific regulatory
requirements for each,The regulatory requirements for ongoing verification are,
(2) Ongoing verification activities,Ongoing verification activities include,but are not
limited to,
(i) The calibration of process-monitoring instruments;
(ii) Direct observations of monitoring activities and corrective actions; and
(iii) The review of records generated and maintained in accordance with §417.5(a)(3) of
this part,
The HACCP team decided they could verify the chilling of variety meats and carcasses by
checking the Variety Meats Chilling Log and Carcass Chilling Log once per shift,The team
also had the maintenance supervisor verify the accuracy of the carcass cooler and variety meats
cooler temperature recording charts once per shift,
There is a regulatory requirement (Part 417.4(a)(2)(i)) for including as a verification,the
calibration of process-monitoring instruments,Each day QA checks the hand-held thermometers
10
Beef Slaughter Model
for accuracy in slush ice water and calibrates them to within 2° F accuracy,
The HACCP team described the verification procedures and their frequencies in the fifth column
of their HACCP plan,
The HACCP team for generic establishment X knew that their HACCP Plan needed to provide
for a recordkeeping system,They wanted their records to be easy to create and understand,
They wanted to be sure their records met regulatory requirements,so they reviewed part 417.5(a)
and (b),
§ 417.5 Records,
(a) The establishment shall maintain the following records documenting the
establishment's HACCP plan,
(1) The written hazard analysis prescribed in § 417.2(a) of this part,including all
supporting documentation;
(2) The written HACCP plan,including decision making documents associated with the
selection and development of CCPs and critical limits,and documents supporting both
the monitoring and verification procedures selected and the frequency of those
procedures,
(3) Records documenting the monitoring of CCPs and their critical limits,including the
recording of actual times,temperatures,or other quantifiable values,as prescribed in the
establishment's HACCP plan; the calibration of process-monitoring instruments;
corrective actions,including all actions taken in response to a deviation; verification
procedures and results; product code(s),product name or identity,or slaughter
production lot,Each of these records shall include the date the record was made,
(b) Each entry on a record maintained under the HACCP plan shall be made at the time
the specific event occurs and include the date and time recorded,and shall be signed or
initialed by the establishment employee making the entry,
The HACCP team decided that their records would be kept on some simple forms,some of
which the team itself devised,
The HACCP team decided that since QA had a form that they had been using for measuring
variety meats chilling temperatures,that they would modify that form,The form was modified
to provide spaces for all entries necessary for the monitoring and verification activities at the
variety meats handling step,
The Room/Product Temperature Recording Chart for the carcass chill was already in use and the
11
Beef Slaughter Model
team knew that they needed to do some personnel training to ensure that all recordkeeping
requirements are included on the recording chart,
QA already had a Thermometer Calibration Log and this form was modified to meet the HACCP
regulatory recordkeeping requirements,The HACCP team decided that this form could be used
by QA for more than one day because there are very limited numbers of thermometers issued for
product temperature measurements,If at any time during the shift a thermometer is dropped or if
the employee questions the accuracy of the thermometer he is to immediately take the
thermometer to the QA lab for an accuracy check,
On its HACCP Plan,generic establishment X has listed the names of the forms it will be using
for monitoring and verification records,The team also devised the antimicrobial intervention log
to record monitoring results for pressure and antimicrobial concentrations,
There is one other form included in column four,where the establishment has described its
recordkeeping system,That is the Corrective Actions Log; it is used to create the records of any
corrective actions taken because of deviations from critical limits at CCPs,Column six of the
HACCP plan references the planned corrective actions for each CCP,The HACCP team
carefully reviewed the regulatory requirements for planned corrective actions found at 417.3(a),
§ 417.3 Corrective actions,
(a) The written HACCP plan shall identify the corrective action to be followed in
response to a deviation from a critical limit,The HACCP plan shall describe the
corrective action to be taken,and assign responsibility for taking corrective action,to
ensure,
(1) The cause of the deviation is identified and eliminated;
(2) The CCP will be under control after the corrective action is taken;
(3) Measures to prevent recurrence are established; and
(4) No product that is injurious to health or otherwise adulterated as a result of the
deviation enters commerce,
The HACCP team has developed a specific corrective action plan which will be followed
whenever there is a deviation from a critical limit at a CCP; each of the planned corrective
actions meets the four regulatory requirements of 417.3(a),
Planned Corrective Actions for CCP 1,
1,QA will reject or hold product until temperature is achieved,dependent on time and
temperature deviation,
12
Beef Slaughter Model
2,QA will identify the cause of the deviation and prevent reoccurrence,
The HACCP team also develops planned corrective actions for each of the other CCPs and
attaches them to the HACCP plan,Whenever a deviation from a critical limit occurs,company
employees follow the corrective action plan and use the Corrective Action Log to create a record
of their actions,The Corrective Action Log forms are available at CCPs,so they can be used
immediately when an employee performing a monitoring check discovers and records a
deviation,All Corrective Action Logs,which have been used during the day,are turned in to the
HACCP coordinator,
There is one final verification/recordkeeping requirement which the company must perform; it is
found at 417.5(c),
(c) Prior to shipping product,the establishment shall review the records associated with
the production of that product,documented in accordance with this section,to ensure
completeness,including the determination that all critical limits were met and,if
appropriate,corrective actions were taken,including the proper disposition of product,
Where practicable,this review shall be conducted,dated,and signed by an individual
who did not produce the record(s),preferably by someone trained in accordance with §
417.7 of this part,or the responsible establishment official,
In generic establishment X,product is shipped out,often in small lots,throughout the day,This
means that pre-shipment verification checks must be as complete as possible when finished
product is in storage,so that a shipment can be made up quickly and moved into distribution
channels,
The establishment uses a half day lotting system and a midshift cleanup,While the midshift
cleanup is being performed,QA personnel or the HACCP coordinator review results of
monitoring and verification checks applied to that lot; if there were deviations from critical
limits,they review the Corrective Action Logs to make sure all appropriate planned responses
were carried out,If everything is in order and there are complete records showing that the
establishment has controlled production of this product through its HACCP system,the HACCP
coordinator will sign the pre-shipment review form which the HACCP team devised for this
purpose,
Note,It is not a regulatory requirement that a separate form be used for pre-shipment review; in
addition,FSIS has indicated that it will be very flexible in accepting a variety of arrangements
for accomplishing pre-shipment review to reflect the variety of commercial practices which it
has encountered in the industry,It is,however,important to remember that pre-shipment review
is a regulatory requirement that must be met,as it indicates that the establishment is taking full
responsibility for the product having been produced under a well-functioning HACCP system,
The HACCP team believes it has now completed preparation of the documents which are
13
Beef Slaughter Model
necessary to meet regulatory requirements for a Hazard Analysis and a HACCP Plan for their
cattle slaughter production process,They have secured a copy of FSIS Directive 5000.1,
Enforcement of Regulatory Requirements in Establishments Subject to HACCP System
Requirements,the HACCP Basic Compliance Checklist which will be used by inspection
program personnel,The HACCP team has modified the inspection form to make the statements
into positives,and now has a checklist for its own use to make sure they have not omitted
anything in their plan development and preparation,When they are confident that they have
done what is necessary,they will turn their Hazard Analysis and HACCP Plan over to the
establishment owner for decisions about implementation,
14
Beef Slaughter Model
APPENDIX A
15
Beef Slaughter Model
References for HACCP Teams
1. Agriculture Canada,Food Safety Enhancement Program – HACCP Implementation Manual,
Camelot Drive,Nepean,Ontario,Canada,1996,
2. American Meat Institute Foundation,HACCP,The Hazard Analysis and Critical Control
Point System in the Meat and Poultry Industry,Washington,D.C.,1994,
Useful sections in particular are,
Chapter 3 – microbiological hazards,pp,15-26
Chapter 4 – chemical hazards,pp,27-32
Chapter 5 – physical hazards,pp,33-35
Appendix A – NACMCF HACCP
Appendix C – Model HACCP plans
3. Baker,D.A,Application of Modeling in HACCP Plan Development,Int,J,Food Microbiol,
25:251-261,1995,
4. Corlett,D.A.,Jr,and Stier,R.F,Risk Assessment within the HACCP System,Food Control
2:71-72,1991,
5. Council for Agriculture Science and Technology,Risks Associated with Foodborne
Pathogens,February 1993,
6. Easter,M.C.,et al,The Role of HACCP in the Management of Food Safety and Quality,
J,Soc,Dairy Technol,47:42-43,1994,
7. Environmental Protection Agency,Tolerances for Pesticides in Foods,Title 40,Code of
Federal Regulations,Part 185,U.S,Government Printing Office,Washington,D.C.,1998,
8. Food and Drug Administration,The Food Defect Action Levels,FDA/CFSAN,
Washington,D.C.,1998,
9. Food and Drug Administration,Fish and Fishery Products Hazards and Control Guide --
Get Hooked on Seafood Safety,Office of Seafood,Washington,D.C.,1994,
10,International Commission on Microbiological Specification for Foods,HACCP in
Microbiological Safety and Quality,Blackwell Scientific Publications,Oxford,1988,
Useful sections in particular are,
Chapter 10 – raw meat and poultry,pp,176-193
Chapter 11 – roast beef,pp,234-238
Chapter 11 – canned ham,pp,238-242
16
Beef Slaughter Model
11,International Commission on Microbiological Specification for Foods,Microorganisms in
Foods 4,Application of Hazard Analysis and Critical Control Point (HACCP) Systems to
Ensure Microbiological Safety and Quality,Blackwell Scientific Publications,Boston,1989
12,National Advisory Committee on Microbiological Criteria for Foods,March 20,1992 --
Hazard Analysis and Critical Control Point System,Int,J,Food Microbiol,16,1-23,1993,
13,National Advisory Committee on Microbiological Criteria for Foods,Adopted August 14,
1997-- Hazard Analysis and Critical Control Point Principles and Application Guidelines,
J,Food Protect,61(9),1246-1259,1998,
14,National Advisory Committee on Microbiological Criteria for Foods,DRAFT document -
FSIS Microbiological Hazard Identification Guide for Meat and Poultry Components of
Products Produced by Very Small Plants,1-22,August 1999,
15,National Advisory Committee on Microbiological Criteria for Foods,June 1993 -- Report
on Generic HACCP for Raw Beef,Food Microbiol,10,449-488,1994,
16,National Research Council,An Evaluation of the Role of Microbiological Criteria for Foods
and Food Ingredients,National Academy Press,Washington,D.C.,1985,
Useful sections in particular are,
Chapter 4 – microbiological hazards,pp,72-103
Chapter 9 – raw meat,pp,193-199
Chapter 9 – processed meats,pp,199-216
17,Notermans,S.,et al,The HACCP Concept,Identification of Potentially Hazardous
Microorganisms,Food Microbiol,11:203-214,1994,
18,Pierson M.D,and Dutson,T,Editors,HACCP in Meat,Poultry,and Fish Processing,
Blackie Academic & Professional,Glasgow,1995,
Useful sections in particular are,
Chapter 4 – meat and poultry slaughter,pp,58-71
Chapter 5 – processed meats,pp,72-107
Chapter 7 – risk analysis,pp,134-154
Chapter 13 – predictive modeling,pp,330-354
19,Pierson,M.D,and Corlett,D.A.,Jr,Editors,HACCP Principles and Applications,Van
Nostrand Reinhold,New York,1992,
20,Stevenson,K.E,and Bernard,D.T,Editors,HACCP,Establishing Hazard Analysis Critical
Control Point Programs,A Workshop Manual,The Food Processors Institute,Washington,
17
Beef Slaughter Model
D.C.,1995,
Useful sections in particular are,
Chapter 11 – forms for hazard analysis,CCPs,critical limits,HACCP master
sheet,example HACCP for breaded chicken
21,Stevenson,K.E,and Bernard,D.T,Editors,HACCP,A Systematic Approach to Food
Safety,3
rd
Edition,The Food Processors Institute,Washington,D.C.,1999,
22,Tompkin,R.B,The Use of HACCP in the Production of Meat and Poultry Products,
J,Food Protect,53(9),795-803,1990,
23,Tompkin,R.B,The Use of HACCP for Producing and Distributing Processed Meat and
Poultry Products,In Advances in Meat Research,Volume 10,Hazard Analysis Critical
Control Point in Meat,Poultry and Seafoods,Chapman & Hall,1995,
References for Beef Slaughter (Steer/Heifer Carcass & Cow Carcass)
1. Barkate,M,L.,et al,Hot Water Decontamination of Beef Carcasses for Reduction of Initial
Bacteria Numbers,Meat Sci,35:397-401,1993,
2. Charlebois,R.,et al,Surface Contamination of Beef Carcasses by Fecal Coliforms,J,Food
Protect,54:950-956,1991,
3. Clayton,R,Paul,Carcass Sanitizing Systems,Proceedings,Meat Industry Research
Conference 2,8-24,,October 7,1992,
4. Cutter,C,N.,et al,Application of Chlorine to Reduce Populations of Escherichia coli on
Beef,J,Food Safety,15:67-75,1995,
5. Dickson,J,S,Susceptibility of Preevisceration washed beef carcasses to contamination by
Escherichia coli 0157:H7 and Salmonellae,J,Food Protect,58:1065-1068,1996,
6. Gill,C,O,Use of a temperature function integration technique to assess the hygienic
adequacy of beef carcass cooling process,Food Microbiol,8:83-94,1991,
7. Gill,C,O,Current and Emerging Approaches to Assuring the Hygienic Condition of Red
Meats,Can,J,Anim,Sci,75:1-13,1995,
8,Gill,C,O,HACCP & Beef Carcass Dressing,Meat & Poultry,21-47,May 1996,
18
Beef Slaughter Model
9. Gustavsson,Patrick,et al,Contamination of beef carcasses by psychrotrophic Pseudomonas
and Enterobacteriaceae at different stages along the processing line,Int,J,Food Microbiol,
20:67-83,1993,
10,Hardin,M,D.,et al,Comparison of Methods for Decontamination from Beef Carcass
Surfaces,J,Food Protect,58:368-374,1995,
11,Hogue,Allan T.,et al,Bacteria on Beef Briskets and Ground Beef,Correlation with
Slaughter Volume and Antemortem Condemnation,J Food Protect,56:110-113,119,1993,
12,Jericho,Klaus W,F.,et al,Visual Demerit and Microbiological Evaluation of Beef
Carcasses,Methodology,J,Food Protect,56:114-119,1993,
13,Meat Marketing & Technology,Futuristic Slaughtering System to Begin Operation in
Australia,Meat Marketing & Technology,48-50,August 1993,
14,Meat Marketing & Technology,Faster,More Sanitary Hide Removal Procedure Key to
Successful Operation,Meat Marketing & Technology,52,August 1994,
15,Meat Marketing & Technology,Early Results Positive on Steam Vacuuming,Meat
Marketing & Technology,108,August 1995,
16,NACMCF,Generic HACCP for Raw Beef,Food Microbiol,10:449-488,1994,
17,Smith,M,G,Destruction of Bacteria on Fresh Meat by Hot Water,Epidemiol,Infect,
109:491-496,1992,
18,Smith,G,C.,et al,Fecal-material Removal and Bacterial-count Reduction by Trimming
and/or Spray-washing of Beef External-fat Surfaces,1996,
19
Beef Slaughter Model
APPENDIX B
20
Beef Slaughter Model
PROCESS FLOW DIAGRAM Figure 1
PROCESS CATEGORY,SLAUGHTER
PRODUCT,BEEF
RECEIVING
PACKAGING
MATERIALS
RECEIVING LIVE CATTLE
STUNNING/BLEEDING
HEAD/SHANK
REMOVAL
SKINNING
EVISCERATION
SPLITTING
TRIM RAIL
FINAL WASH
VISCERA
PROCESSING
VARIETY
MEATS
PRODUCTION
CHILLING
PACKAGING/LABELING
FINISHED PRODUCT
STORAGE (COLD)
STORAGE
PACKAGING
MATERIALS
SHIPPING
21
Beef Slaughter Model
PRODUCT DESCRIPTION Figure 2
PROCESS CATEGORY,SLAUGHTER
PRODUCT,BEEF
1,COMMON NAME? BEEF; BEEF VARIETY MEATS
2,HOW IS IT TO BE USED? CARCASSES; VARIETY MEATS
3,TYPE OF PACKAGE? CARCASSES – NONE; VARIETY
MEATS – 50 POUND BOXES
4,LENGTH OF SHELF LIFE,7 DAYS AT 40° F
AT WHAT TEMPERATURE?
5,WHERE WILL IT BE SOLD? WHOLESALE TO DISTRIBUTORS
CONSUMERS? ONLY
INTENDED USE?
6,LABELING INSTRUCTIONS? KEEP REFRIGERATED
7,IS SPECIAL DISTRIBUTION KEEP REFRIGERATED
CONTROL NEEDED?
22
Beef Slaughter Model
HAZARD ANALYSIS – BEEF SLAUGHTER
Process Step Food Safety
Hazard
Reasonably
Likely to
Occur?
Basis If Yes in Column 3,
What Measures Could
be Applied to Prevent,
Eliminate,or Reduce
the Hazard to an
Acceptable Level?
Critical Control
Point
Receiving – Live Cattle
* Note,Since residues
can be a hazard
reasonably likely to
occur in cull cows
(dairy & beef) and bob
veal calves,plants
should make chemical
(residues) a CCP with
these animals,
Biological
Escherichia coli
O157:H7
No Sanitary dressing
procedures prevent
contamination,
Chemical – Residues No Plant/FSIS records
demonstrate residues have
not been a past problem,
Physical – Foreign
materials such as
broken needles
No Cattle are purchased from
feedlots having QA
procedures to prevent
foreign materials such as
broken needles from
remaining in animals,
Figure 3
23
Beef Slaughter Model
HAZARD ANALYSIS – BEEF SLAUGHTER
Process Step Food Safety
Hazard
Reasonably
Likely to
Occur?
Basis If Yes in Column 3,
What Measures Could
be Applied to Prevent,
Eliminate,or Reduce
the Hazard to an
Acceptable Level?
Critical Control
Point
Stunning/Bleeding
Head/Shank Removal
Biological – None
Chemical – None
Physical – None
Skinning Biological – Pathogens
- Contamination from
the Hide
- E,coli O157:H7
Yes Contamination from the
hide is a known source of
pathogens,Potential
contamination could occur
at this step,
Will be controlled at the
final wash (antimicrobial)
step,
Chemical – None
Physical – None
Figure 3
24
Beef Slaughter Model
HAZARD ANALYSIS – BEEF SLAUGHTER
Process Step Food Safety
Hazard
Reasonably
Likely to
Occur?
Basis If Yes in Column 3,
What Measures Could
be Applied to Prevent,
Eliminate,or Reduce
the Hazard to an
Acceptable Level?
Critical Control
Point
Evisceration Biological – Pathogens
-Contamination from
the Gastrointestinal
Tract
-E,coli O157:H7
Yes Potential contamination
could occur at this step,
Will be controlled at the
final wash (antimicrobial)
step,
Chemical – None
Physical – None
Splitting Biological – None
Chemical – None
Physical – None
Trim Rail Biological – Pathogens
-E,coli O157:H7
No This step in the process
used to remove incidental
contamination that might
have occurred in previous
steps,
Chemical – None
Physical – None
Figure 3
25
Beef Slaughter Model
HAZARD ANALYSIS – BEEF SLAUGHTER
Process Step Food Safety
Hazard
Reasonably
Likely to
Occur?
Basis If Yes in Column 3,
What Measures Could
be Applied to Prevent,
Eliminate,or Reduce
the Hazard to an
Acceptable Level?
Critical Control
Point
Viscera Processing Biological – Pathogens
-Contamination from
the Gastrointestinal
Tract
-E,coli O157:H7
No Contamination from the
gastrointestinal tract is a
known source of pathogens;
however,plant records
demonstrate that
contamination has not been
a problem in the past,
Chemical – None
Physical – None
Final Wash
(Antimicrobial)
Biological – Pathogens
(Contamination from
the Hide and/or
Gastrointestinal Tract)
Yes Appropriate step to reduce
pathogens,
An acceptable
antimicrobial wash (rinse)
is applied to the carcasses,
1B
Chemical – None
Physical – None
Variety Meats
Production
Biological – None
Chemical – None
Physical – None
Figure 3
26
Beef Slaughter Model
HAZARD ANALYSIS – BEEF SLAUGHTER
Process Step Food Safety
Hazard
Reasonably
Likely to
Occur?
Basis If Yes in Column 3,
What Measures Could
be Applied to Prevent,
Eliminate,or Reduce
the Hazard to an
Acceptable Level?
Critical Control
Point
Chilling (All products) Biological – Pathogens
- E,coli O157:H7
Yes Pathogens are reasonably
likely to grow if improper
chilling procedures are
used,
Proper chilling procedures
are used,
2B
Chemical – None
Physical – None
Packaging/Labeling Biological – None
Chemical – None
Physical – None
Finished Product
Storage (Cold)
Biological – Pathogens
- E,coli O157:H7
Yes Pathogens are reasonably
likely to grow if
temperature is not
maintained at or below a
level sufficient to preclude
their growth,
Maintain product
temperature at or below a
level sufficient to preclude
pathogen growth,
3B
Chemical – None
Physical – None
Figure 3
27
Beef Slaughter Model
HAZARD ANALYSIS – BEEF SLAUGHTER
Process Step Food Safety
Hazard
Reasonably
Likely to
Occur?
Basis If Yes in Column 3,
What Measures Could
be Applied to Prevent,
Eliminate,or Reduce
the Hazard to an
Acceptable Level?
Critical Control
Point
Shipping Biological - None
Chemical – None
Physical – None
Figure 3
28
Beef Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,BEEF
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
1B
Final Wash
(antimicro
bial)
Continued
on next
page
No visible
contamination
on carcasses
Antimicrobial
concentration
in sanitizing
cabinet will
be maintained
between 0.5
& 2.5%,
Solution
pressure at
nozzles in
sanitizing
cabinet will
be maintained
above 35 PSI,
Quality Assurance
monitors
washing/antimicro
bial equipment use
every 2 hours to
ensure that
distance,volume
and pressure meet
critical limit &
results are
recorded,dated and
initialed,
Quality Assurance
evaluates 25% of
carcasses for
visible fecal
contamination,
Washing Equipment
Monitoring Log
Antimicrobial
Intervention
Monitoring Log
Washing Equipment
Calibration Log
Corrective Action
Log
Once per shift the QA supervisor
will review all Logs and observe the
operation and monitoring at the
CCP,
Maintenance supervisor will verify
accuracy (calibration) of the
washing and antimicrobial
intervention equipment once per
shift,
QA will identify the cause of the deviation
and prevent reoccurrence,
If concentration is outside limits,QA will
identify the cause of deviation & make
corrections to return concentration to with-
in prescribed limits,Also,preventive
actions will be taken to reduce the likeli
hood of a recurrence,Product produced
below critical limit will be identified &
sprayed w/ a 0.2% antimicro-bial solution
in the cooler,Product produced above
critical limit will be identified,held (expo
sed to carcass spraying in the cooler),and
sampled until a representative sample
determines that the level of residual anti-
microbial on carcasses shows no significa
nt difference between carcasses sprayed
within limits and ones sprayed above the
upper limit,When there is no difference,
carcass will be released for fabrication,
Signature,__________________________________ Date,__________________________ Figure 4
29
Beef Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,BEEF
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
1B
Final Wash
(antimicro
bial)
Continued
from
previous
page
Pressures in
carcass wash
will be main
tained bet,
100-350 PSI,
Continued from previous page
If PSI drops below 100,QA will identify
cause of deviation & require corrective
action to return the pressures to within
prescribed limits,
Also,preventive actions will be taken to
reduce the likelihood of a recurrence,
Product produced outside critical limit will
be identified & subjected to carcass AQL
reinspection,If carcasses pass they will
proceed to fabrication,If the lot fails AQL,
carcasses will be reworked & reinspected
using AQL criteria,
QA will stop production when the
wash/antimicrobial intervention falls
outside critical limits,All affected
carcasses back to the last acceptable check
will be visually inspected & reworked if
visible fecal contamination is observed,
Maintenance will correct problems found
in equipment adjustment,
Signature,__________________________________ Date,__________________________ Figure 4
30
Beef Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,BEEF
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
1B
Final Wash
(antimicro
bial)
Continued
from
previous
page
Continued from previous page
** Note,Most establishments will be
washing beef carcass with a hand held at
pressure 50-75 PI,which is the pressure of
the system delivering water to the
establishment,When pressure drops
slaughter operations are stopped,The
antimicrobial application in many
small/very small plants will be a hand
operated garden sprayer containing a 2%
acid solution,Other than the concentration
there are no critical limits,
Signature,__________________________________ Date,__________________________ Figure 4
31
Beef Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,BEEF
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
2B
Chilling (All
Products)
(Continued
on next
page)
All carcasses
will begin
chilling
within 1 hour
from
bleedout,All
variety meats
will begin
chilling
within 1 hour
after removal
from carcass,
Temperature
of 40°F or
less will be
reached
within 24
hours on all
products,
QA technician will
observe chilling
handling
procedures to
ensure critical
limits are met,
Carcass and variety
meats coolers will
be monitored and
recorded
continuously on
temperature
recording charts,
QA technician will
select and check 10
carcasses and 5
samples of each
type of variety
Carcass Chilling
Log
Variety Meats
Chilling Log
Carcass Cooler
Temperature
Recording Chart
Variety Meats
Cooler Temperature
Recording Chart
Thermometer
Calibration Log
Corrective Action
Log
Once per shift the QA supervisor
will review the Carcass Chilling
Log and Variety Meats Chilling Log
and observe the taking and
recording a carcass & variety meat
temperatures and cooler temp,
Maintenance supervisor will verify
accuracy of the carcass cooler
temperature and variety meats
cooler temperature recording charts
once per shift,
QA will check all thermometers
used for monitoring and verification
for accuracy daily and calibrate to
within 2°F accuracy as necessary,
QA will reject or hold product dependent
on time and temperature deviation,Process
Authority or cooling curves will be used to
determine specific corrective action or
rejection,
QA will identify the cause of the deviation
and prevent reoccurrence,
Cooler maintenance will be adjusted to
prevent reoccurrence and repairs made if
necessary,
Signature,__________________________________ Date,__________________________ Figure 4
32
Beef Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,BEEF
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
2B
Chilling (All
Products)
meats produced
after 24 hours
chilling to ensure a
temperature of 40°
F or less has been
reached,
Carcass lots will be
monitored to assure
that 1 hour
requirement is met
by tracking 10
carcasses per lot,
All results are
recorded with the
actual value,dated
and initialed/
signed,
Signature,__________________________________ Date,__________________________ Figure 4
33
Beef Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,BEEF
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
3B
Finished
Product
Storage
(Cold)
(Continued
on next
page)
Finished
product
storage areas
will not
exceed 40° F,
Maintenance
personnel will
check finished
product storage
areas temperatures
every two hours
and record cooler
temperature in the
room temperature
log & initial &
date,
Room Temperature
Log
Thermometer
Calibration Log
Corrective Action
Log
Maintenance supervisor will verify
the accuracy of the room
temperature log once per shift,
QA will check all thermometers
used for monitoring and verification
activities for accuracy daily and
calibrate to within 2° F accuracy as
necessary,
QA will observe maintenance
personnel check finished product
storage area once per shift,
If a deviation from a critical limit occurs,
the following corrective actions will be
taken,
1,The cause of the temperature
exceeding 40° F will be identified and
eliminated,
2,The CCP will be monitored hourly
after the corrective action is taken to
ensure that it is under control,
3,When the cause of the deviation is
identified,measures will be taken to
prevent it from recurring e.g.,if the
cause is equipment failure,preventive
maintenance program will be reviewed
and revised,if necessary,
Signature,__________________________________ Date,__________________________ Figure 4
34
Beef Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,BEEF
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
3B
Finished
Product
Storage
(Cold)
If a deviation from a critical limit occurs,
the following corrective actions will be
taken,
4,If room temperature exceeds the
critical limit,the processing authority
will evaluate the product temperature
to ensure the temperature is sufficient
to preclude pathogen growth before
release for shipment,If temperature is
not sufficient to preclude pathogen
growth,product will be cooked in the
establishment to ensure destruction of
pathogens or condemned,
Signature,__________________________________ Date,__________________________ Figure 4
35
Beef Slaughter Model
THERMOMETER CALIBRATION LOG
Calibrate to 32
0
F while thermometer is in slush ice water
Date Time Department or
Area
Thermometer
ID#
Personal
Thermometer
Reading
Adjustment
Required (Yes
or No)
Initials Comments
6/15 1:00 PM Carcass Chilling 2A 32°F No HK
If a thermometer is broken or taken out of service,document this in the comment column,
Reviewed by,_______________________
Date,_______________________
36
Beef Slaughter Model
GENERIC ESTABLISHMENT X,
Time Bleed
Out
Time
Time
In
Cooler
Cooler
Location
Lot # Carcass
Temp,
Room
Temp,
Deviation
from CL?
(Check if
yes)
If Yes,
Action?
Monitored
by,
Verified
by,
ROOM / PRODUCT TEMPERATURE LOG
37
Beef Slaughter Model
ESTABLISHMENT X,
Date Lot # Time Solution
Concentration
Pressure Corrective Actions Monitored
by,
Verified
by,
Intervention Monitoring Log Antimicrobial
38
Beef Slaughter Model
CORRECTIVE ACTIONS LOG
Product,___________________________________________ Lot # ______________________
CCP Deviation/
Problem
Corrective Action
Procedures/Explain
Disposition of
Product
Responsible
Person
Date/Time
SIGNATURE,__________________________ DATE,______________________
39
Beef Slaughter Model
PRE-SHIPMENT
Date:______________
PRODUCT LOT ID TIME
RECORDS
REVIEWED
BY
WHOM
LOT RELEASED FOR
SHIPMENT?
SIGNATURE
COMMENTS *
LOG REVIEW
*Monitoring frequency as per plan; Critical limits met; Certification (if applicable) as per plan; Deviations if occurred were reviewed
for appropriate corrective actions; Records complete and accurate,
40
