Guidebook for HACCP：HACCP-11.PDF

United States
Department of
Agriculture
Food Safety
and Inspection
Service
September 1999
HACCP-14
Generic HACCP
Model for Pork
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
Pork 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 Pork Slaughter…………………………………..,….……..……… 18
Appendix B
Process Flow Diagram (Figure 1)………………………….……………………….24
Product Description Form (Figure 2)……………………….………………………25
Hazard Analysis Form (Figure 3)………………………….………………………,26
HACCP Plan Form (Figure 4)……………………………………….………….…,32
Thermometer Calibration Log……………………………………….…………….,40
Generic Establishment X,Room/Product Temperature Log ……………….……...41
Establishment X,Antimicrobial Intervention Monitoring Log……………………,42
Corrective Actions Log………………………………………………….………….43
Pre-Shipment Review Log……………………………………………….…………44
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Pork Slaughter Model
GENERIC HACCP MODEL
FOR
PORK 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
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analysis reveals one or more food safety hazards that are reasonably likely to occur,
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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Pork 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 swine,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,
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Pork Slaughter Model
§ 417.1 Definitions,
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 pork slaughter,one of the species in this process
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Pork Slaughter Model
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,
Figure 1 is an example of a PROCESS FLOW DIAGRAM for the pork slaughter process in
generic establishment X,Figure 2 is an example of a PRODUCT DESCRIPTION for the
swine 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 swine and your process includes steps not included in this example,
such as pre-slaughter 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
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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,
(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 Swine” 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 pork slaughter,there are seven 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
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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
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 pork 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
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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
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 pork 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 eight points on the hazard analysis form where food
safety hazards reasonably likely to occur were identified,cross-contamination with pathogens at
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dehairing; pathogens at the pre-evisceration wash; pathogen contamination from the
gastrointestinal tract at evisceration,pluck/viscera disassembly and processing,head wash,final
trim/final wash,and pluck/viscera wash; and,pathogen proliferation at chill/cold storage,The
establishment HACCP team has chosen to have five CCPs to address these seven hazards,an
acceptable antimicrobial wash at pre-evisceration,final head wash,and pluck/viscera wash; and,
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
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 product,but realized that if the proper chiller
procedures were not followed pathogen proliferation was possible,The HACCP team knew that
the product should start the chilling process soon after bleedout,so they set the critical limit for
chilling product 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,the establishment had the QA technician observe the chilling handling
procedures to ensure the chilling process starts within an hour after bleedout,At the chilling step
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 product by checking the
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Pluck/Viscera Chilling Log and Carcass Chilling Log once per shift,The team
also had the maintenance supervisor verify the accuracy of the carcass cooler and pluck/viscera
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
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 CCP's 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 CCP's 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,
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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 Log for the carcass chill was already in use and the 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,The team also devised the antimicrobial
intervention log to record monitoring results for pressure and antimicrobial concentrations,
On its HACCP Plan,generic establishment X has listed the names of the forms it will be using
for monitoring and verification records,
There is another 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
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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 4
1. QA will reject or hold product until temperature is achieved,dependent on time and
temperature deviation,
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,
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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
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
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Chapter 11 – roast beef,pp,234-238
Chapter 11 – canned ham,pp,238-242
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,
17
Pork Slaughter Model
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,
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 Pork Slaughter
1. Akier,A.,Mafu,R.,Nadeau,M.,Cousineau,G,The incidence of Salmonella,
Campylobacter and Yersinia enterocolitica in Swine Carcasses and the Slaughterhouse
Environment,Journal of Food Protect,52,642-645,1989,
2. Baker,D.A,Application of modeling in HACCP plan development,International Journal of
Food Microbiology 25,251-261,1995,
3. Berends,J.M.,Snijders,M.A.,van Logtestijn,J.G,Efficacy of current EC meat inspection
procedures and some proposed revisions with respect to microbiological safety,a critical
review,Veterinary Record 133,411-415,1993,
18
Pork Slaughter Model
4. Cacciarelli,M.A.,et al,Effects of Washing and Sanitizing on the Bacterial Flora of
Vacuum-Packaged Pork Loins,J,Food Protect,46,231-234,1983,
5. Cacciarelli,M.A.,Stringer,W.C.,Anderson,M.E.,Naumann,H.D,Effects of Washing and
Sanitizing on the Bacterial Flora of Vacuum-Packaged Pork Loins,Journal of Food Protect,
46,231-234,1983,
6. Coates,K.J.,Beattie,J.C.,Morgan,I.R.,Widders,P.R,The contribution of carcass
contamination and the boning process to microbial spoilage of aerobically stored pork,
Food Microbiology 12,49-54,1995,
7. Currier,M.,Singleton,M.,Lee,D.R,Salmonella in Swine at Slaughter,Incidence and
Serovar Distribution at Different Seasons,J,Food Protect,49,366-368,1986,
8. Fedorka-Cray,P.J.,Whipp S.C.,Isaacson,R.E.,Nord,N.,Lager,K,Transmission of
Salmonella typhimurium to Swine,J,Veterinary Microbiology,Article 822,1-12,1994,
9. Fraser,A.M.,Sawyer,S.A.,Andrews,S.A.,et al,A Food Classification Scheme to
Summarize Epidemiological Patterns of Food-borne Illness,Dairy,Food and Environmental
Sanitation 15-5,292-300,1995,
10,Fu,A.H.,et al,Microbial and Quality Characteristics of Pork Cuts from Carcasses Treated
with Sanitizing Sprays,J,Food Sci,59,306-309,1994,
11,Ghosh,A.C,An epidemiological study of the incidence of Salmonella in pigs,J,Hyg,Camb,
70,151-160,1972,
12,Gill,C.O.,et al,Assessment of the hygienic efficiencies of two commercial processes for
cooling pig carcass,Food Microbial,9,335-343,1992,
13,Gill,C.O.,et al,The contamination of pork with spoilage bacteria during commercial
dressing,chilling and cutting of pig carcasses,Int,J,Food Microbial,16,51-62,1992,
14,Gill,C.O.,et al,The presence of Escherichia coli,Salmonella and Campylobacter in pig
carcass dehairing equipment,Food Microbial,10,337-344,1993,
15,Gill,C.O.,et al,Decontamination of commercial,polished pig carcasses with hot water,
Food Microbial,12,143-149,1995,
19
Pork Slaughter Model
16,Gill,C.O,Current and emerging approaches to assuring the hygienic condition of red meats,
Canadian Journal of Animal Science,Contribution No,762,1995,
17,Gill,C.O.,Jones,T,The presence of Aeromonas,Listeria and Yersinia in carcass processing
equipment at two pig slaughtering plants,Food Microbiology 12,135-141,1995,
18,Gill,C.O.,Jones,T,Assessment of the hygienic efficiencies of two commercial processors
for cooling pig carcasses,Food Microbiology 9,335-343,1992,
19,Gray,J.T.,Stabel,T.J.,Fedorka-Cray,P.J,Effect of dose on the immune response and
persistence of Salmonella choleraesuis infection in swine,AJVR 57-3,313-319,1996,
20,Gray,J.T.,Fedorka-Cray,P.J.,Stabel,T.J.,Kramer,T.T,Natural Transmission of
Salmonella choleraesuis in Swine,Appl,Environ,Microbiol,62-1,141-146,1996,
21,Greer,G,G.,Dilts,BD,Lactic acid inhibition of the growth of spoilage bacteria and cold
tolerant pathogens on pork,Int,J,Food Microbiol,25,141-151,1995,
22,Kampelmacher,E.H.,Guinee,P.A.M.,Hofstra,K.,Van Keulen,A,Further Studies on
Salmonella in Slaughterhouses and in normal Slaughter Pigs,Zentbl Vet,Med,10,1-27,
1963,
23,Kapperud,G,Yersinia enterocolitica in food hygiene,Int,J,Food Microbiol,12,53-56,
1991,
24,Kindred,T.P.,Hubbert,W.T,Residue prevention strategies in the United States,J,Amer,
Vet,Med,Assoc,202-1,46-49,1993,
25,Kindred,T.P.,Patel,B.L.,Walcott,J.R,The FSIS National Residue Program,Residues of
Veterinary Drugs in Food,Proceedings of the EuroResidue III Conference,75-184,May
1996,
26,Kotula,A.W.,Emswiler-Rose,B.S,Airborne Microorganisms in a Pork Processing
Establishment,J,Food Protect,51,935-937,1988,
27,Knudston,L,M.,Hartman,P.A,Enterococci in Pork Processing,J,Food Protect,56,6-9,
1993,
20
Pork Slaughter Model
28,Linton,A.H.,Heard,T.W.,et al,Computer-based Analysis of Epidemiological Data Arising
from Salmonellosis in Pigs,Res,Vet,Sci,II,523-532,1970,
29,Mendonca,A.F.,et al,Microbiological,Chemical,and Physical Changes in Fresh,
Vacuum-Packaged Pork Treated with Organic Acids and Salts,J,Food Sci,54,18-21,1989,
30,Miller,M.F.,Carr,M.A.,Bawconry,D.W.,Ramsey,C.B.,Thompson,L.D,Microbiology of
pork carcasses from pigs with differing origins and feed withdrawal times,J,Food Protect,
1996,
31,National Pork Producers Council,Pork Quality Assurance,a program of America’s Pork
Producers Level III,1994,
32,Newell,K.W.,Williams,L.P,The Control of Salmonella Affecting Swine and Man,
J.A.V.M.A,158 (1),89-97,1971,
33,Notermans,S.,Gallhoff,G.,Zwietering,M.H,& Mead,G.C,Identification of critical
control points in the HACCP systems with a quantitative effect on the safety of food products,
Food Microbiology 12,93-98,1995,
34,Notermans,S.,Zwietering,M.H.,Mead,G.C,The HACCP concept,identification of
potentially hazardous microorganisms,Food Microbiology 11,203-214,1994,
35,Oosterom,J.,et al,Survival of Campylobacter jejuni during Poultry Processing and Pig
Slaughtering,J,Food Protect,46,702-706,1983,
36,Pensabene,J.W.,and W,Fiddler,Indole and skatole in fresh pork as possible markers of
fecal contamination,J,Food Protect,59,663-665,1996,
37,Riette,L.J.,Van Laak,M.,Johnson,J.L.,et al,Survival of Pathogenic Bacteria on Pork
Loins as Influenced by Hot Processing and Packaging,J,Food Protect,56,847-851,1993,
38,Tompkin,R.B,The Hazard Analysis Critical Control Point (HACCP) System,Presented at
the Texas A&M University’s Center for Food Safety and the International Meat & Poultry
HACCP Alliance Symposium,College Station Texas on December 2,1994,
39,USDA,FSIS,Backgrounder,Antimicrobial Sprays for Livestock Carcasses,December,
1992,
21
Pork Slaughter Model
40,Van Netten,P.,Mossel,D.A.A,Lactic acid decontamination of fresh pork carcasses,a
pilot plant study,Int,J,Food Microbiol,25,1-9,1995,
41,Weakley,D,F.,et al,Effects of Packaging and Processing Procedures on the Quality and
Shelf Life of Fresh Pork Loins,J,Food Sci,51,281-283,1986,
42,Williams,L.P.,Newell,K.W,Salmonella Excretion in Joy-Riding Pigs,Am,J,Public
Health 60(5),926-929,1970,
43,Wood,R.L.,Rose,R,Populations of Salmonella typhimurium in internal organs of
experimentally infected carrier swine,Am,J,Vet,Res,53-5,653-658,1992,
44,Wood,R.L.,Pospischil,A.,Rose,R,Distribution of persistent Salmonella typhimurium
infection in internal organs of swine,Am,J,Vet,Res,50-7,1015-1021,1989,
22
Pork Slaughter Model
APPENDIX B
23
Pork Slaughter Model
PROCESS FLOW DIAGRAM Figure 1
PROCESS CATEGORY,SLAUGHTER
PRODUCT,PORK (CARCASSES)
RECEIVING
PACKAGING
MATERIALS
RECEIVING LIVE SWINE
STUNNING/BLEEDING/SCALDING
DEHAIRING
GAMBRELLING/SINGEING/POLISHING/SHAVING
PRE-EVISCERATION WASH (ANTIMICROBIAL)
HEAD DROP/HEAD REMOVAL
BUNGING
EVISCERATION
FINAL TRIM/FINAL WASH (ANTIMICROBIAL)
CHILL/COLD STORAGE
PACKAGING/LABELING
STORAGE
PACKAGING
PLUCK/VISCERA
DISASSEMBLE &
PROCESS
WASH
(ANTIMICROBIAL)
WASH
(ANTIMICROBIAL)
DISASSEMBLE
MATERIALS
& PROCESS
SHIPPING
24
Pork Slaughter Model
PRODUCT DESCRIPTION Figure 2
PROCESS CATEGORY,SLAUGHTER
PRODUCT,PORK
1,COMMON NAME? PORK CARCASSES; HEADS (SNOUT,TONGUE,
CHEEK MEAT,EARS,PATE/FOREHEAD,
BRAINS,LIPS); PLUCK (HEART,LIVER,
KIDNEYS); VISCERA (STOMACH,SMALL &
LARGE INTESTINES,RECTUM,UTERI)
2,HOW IS IT TO BE USED? WHOLE CARCASS FABRICATION
3,TYPE OF PACKAGE? CARCASSES – NONE; HEADS,PLUCK,
VISCERA – BOXED
4,LENGTH OF SHELF LIFE,14-21 DAYS DEPENDING ON TEMPERATURE
AT WHAT TEMPERATURE? AND STORAGE CONDITIONS; HEAD,PLUCK
& VISCERA FROZEN AT –20°F AS SOON AS
POSSIBLE
5,WHERE WILL IT BE SOLD? WHOLESALE TO DISTRIBUTORS
CONSUMERS? FURTHER PROCESSORS
INTENDED USE?
6,LABELING INSTRUCTIONS? VARIETY MEATS - KEEP REFRIGERATED OR
KEEP FROZEN; CARCASSES - KEEP
REFRIGERATED
7,IS SPECIAL DISTRIBUTION VARIETY MEATS - KEEP REFRIGERATED OR
CONTROL NEEDED? KEEP FROZEN;
CARCASSES - KEEP REFRIGERATED
25
Pork Slaughter Model
HAZARD ANALYSIS – PORK 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 Swine Biological – Salmonella No Sanitary dressing
procedures prevent
contamination,
Chemical – residue No Producers all participate in
the swine certification
program and records of
residue testing indicate no
violations for the past two
years with no supplier
changes
Physical – Foreign
materials such as
broken needles
No Swine are purchased from
feedlots having QA
procedures to prevent
foreign materials such as
broken needles from
remaining in animals,
Receiving – Packaging
Materials
Biological – None
Chemical – Not
acceptable for
intended use
No Letters of guaranty are
received from all suppliers
of nonmeat ingredients and
packaging materials,
Figure 3
26
Pork Slaughter Model
HAZARD ANALYSIS – PORK 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
Physical – Foreign
materials
No Plant records demonstrate
that foreign material
contamination has not
occurred during the past
several years,
Storage – Packaging
Materials
Biological – None
Chemical – None
Physical – None
Stunning/Bleeding/
Scalding
Biological – None
Chemical – None
Physical – None
Dehairing Biological – Pathogens
Cross-contamination
Salmonella
Yes Significant cross-
contamination occurs
during dehairing
operations,
Will be controlled at the
pre-evisceration wash
(antimicrobial) step,
Chemical – None
Physical – None
Figure 3
27
Pork Slaughter Model
HAZARD ANALYSIS – PORK 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
Gambrelling/Singeing/
Polishing/Shaving
Biological – None
Chemical – None
Physical – None
Pre-Evisceration Wash
(Antimicrobial)
Biological – Pathogens Yes Dehairing is a known
source of pathogens,
Washing at this step
removes microbes prior to
attachment,
An acceptable
antimicrobial wash (rinse)
is applied to the carcasses,
1B
Chemical – None
Physical – None
Head Drop/Head
Removal
Biological – Salmonella Yes Use of antimicrobial rinse;
Sanitary dressing
procedures
Chemical – None
Physical – None
Figure 3
28
Pork Slaughter Model
HAZARD ANALYSIS – PORK 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
Bunging Biological – Pathogens No Contamination from this
source is a known source of
pathogens; however,plant
records demonstrate that
contamination has not been
a problem in the past,
Chemical – None
Physical – None
Evisceration Biological – Pathogens
(Contamination from
the gastrointestinal
tract)
Yes Potential contamination
could occur at this step,
Will be controlled at the
final trim/final wash
(antimicrobial) step,
Chemical – None
Physical – None
Pluck/Viscera
Disassemble & Process
Biological – Pathogens
(Contamination from
the gastrointestinal
tract)
Yes Potential contamination
could occur at this step,
Will be controlled at the
pluck/viscera wash
(antimicrobial) step
Chemical – None
Physical – None
Figure 3
29
Pork Slaughter Model
HAZARD ANALYSIS – PORK 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
Head Wash
(Antimicrobial)
Biological – Pathogens
Salmonella
Yes Appropriate step to reduce
pathogens
An acceptable
antimicrobial wash (rinse)
is applied to the heads,
2B
Chemical – None
Physical – None
Final Trim/Final Wash
(Antimicrobial)
Biological – Pathogens
(Contamination from
the gastrointestinal
tract)
Yes Appropriate step to reduce
pathogens,
An acceptable
antimicrobial wash (rinse)
is applied to the carcasses,
3B
Chemical – None
Physical – None
Pluck/Viscera Wash
(Antimicrobial)
Biological – Pathogens
(Contamination from
the gastrointestinal
tract)
Yes Appropriate step to reduce
pathogens,
An acceptable
antimicrobial wash (rinse)
is applied to product,
4B
Chemical – None
Physical – None
Figure 3
30
Pork Slaughter Model
HAZARD ANALYSIS – PORK 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
Head Disassemble &
Process
Biological – None
Chemical – None
Physical – None
Chill/Cold Storage (All
Products)
Biological – Pathogens
Salmonella
Yes Pathogens are reasonably
likely to grow if improper
chilling procedures are used,
Pathogens are reasonably
likely to grow if temperature
is not maintained at or below
a level sufficient to preclude
their growth,
Proper chilling procedures
are used,Maintain product
temperature at or below a
level sufficient to preclude
pathogen growth,
5B
Chemical – None
Physical – None
Packaging/Labeling Biological – None
Chemical – None
Physical – None
Shipping Biological - None
Chemical – None
Physical – None
Figure 3
31
Pork Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,PORK
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
1B
Pre-eviscera
tion Wash
(Antimicro
bial)
Continued
on next
page
No visible
contaminatio
n on
carcasses
(zero fecal
tolerance)
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
evaluates 25% of
carcasses for
visible
contaminants,
Quality Assurance
monitors washing
& antimicrobial
equipment use
every 2 hours to
ensure adjustments
are suited to
animals and
according to
manufacturing
instructions,
Concentration of
antimicrobial is
tested once per
Washing Equipment
Monitoring Log
Antimicrobial
Intervention
Monitoring Log
Washing Equipment
Calibration Log
Corrective Action
Log
Maintenance supervisor will verify
accuracy (calibration) of the
washing and antimicrobial
intervention equipment once per
shift,
Concentration of antimicrobial will
be verified weekly,
QA will stop production when the
wash/antimicrobial intervention falls
outside critical limit,Product will be
placed on QA hold,
Carcasses will be visually inspected for
fecal contamination back to last acceptable
check,
If concentration is outside limits,QA will
identify the cause of deviation & make
corrections to return concentration to
within prescribed limits,Also,preventive
actions will be taken to reduce the
likelihood of a recurrence,Product
produced below critical limit will be
identified & sprayed w/ a 0.2%
antimicrobial solution in the cooler,
Product produced above critical limit will
be identified,held (exposed to carcass
spraying in the cooler),and sampled until a
representative sample determines that the
level of residual antimicrobial on carcasses
Signature _______________________________ Date,__________________________ Figure 4
32
Pork Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,PORK
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
1B
Pre-eviscera
tion Wash
(Antimicro
bial)
Pressures in
carcass wash
will be
maintained
between 100
and 350 PSI,
shift,All results
are recorded,dated
and initialed or
signed,
shows no significant difference between
carcasses sprayed within limits and ones
sprayed above the upper limit,When there
is no difference,carcass will be released
for fabrication,
If PSI drops below 100,QA will identify
cause of deviation & require corrective
action to return the pressures to within
prescribed limits,
Once per shift the QA supervisor will
review all Logs and observe monitoring,
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,
Equipment will be adjusted if required,
maintenance schedule reviewed,and
adjustments made to antimicrobial
concentration if necessary,
Signature,__________________________________ Date,__________________________ Figure 4
33
Pork Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,PORK
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
2B
Head Wash
(Antimicro
bial)
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,
Pressures in
carcass wash
will be
maintained
between 100
and 350 PSI,
Quality Assurance
monitors
washing/antimicrob
ial equipment use
every 2 hours to
ensure adjustments
are suited to
animals and,
according to
manufacturing
instructions,
Quality Assurance
evaluates 25% of
heads for visible
fecal
contamination,
Concentration of
antimicrobial is
tested once per
shift,All results
are recorded,dated
and initialed or
signed,
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
QA monitoring for visible
contamination,
Maintenance supervisor will verify
accuracy (calibration) of the
washing and antimicrobial
intervention equipment once per
shift,
QA will stop production when the
wash/antimicrobial intervention falls
outside critical limits,Product will be
placed on QA hold,
Product produced following the deviation
will be re-evaluated by QA,Any product
with visible fecal contamination will be
reworked,
QA will identify the cause of the deviation
and prevent reoccurrence,
Follow the corrective actions same as in
CCP 1B,
Signature,__________________________________ Date,__________________________ Figure 4
34
Pork Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,PORK
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
3B
Final Trim/
Final Wash
(Antimicro
bial)
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,
Pressures in
carcass wash
will be
maintained
between 100
and 350 PSI,
Quality Assurance
monitors
washing/antimicrob
ial equipment use
every 2 hours to
ensure adjustments
are suited to
animals and,
according to
manufacturing
instructions,
Quality Assurance
evaluates 25% of
pluck/viscera for
visible
contaminants,
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
QA monitoring for visible
contamination,
Maintenance supervisor will verify
accuracy (calibration) of the
washing and antimicrobial
intervention equipment once per
shift,
QA will stop production when the
wash/antimicrobial intervention falls
outside critical limits,Product will be
placed on QA hold,
Product produced following deviation will
be re-evaluated by QA,Any product with
visible fecal contamination will be re-
worked
QA will identify the cause of the deviation
and prevent reoccurrence,
Follow the corrective actions same as in
CCP 1B,
Signature,___________________________ Date,__________________________ Figure 4
35
Pork Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,PORK
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
3B
Final Trim/
Final Wash
(Antimicro
bial)
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,
Pressures in
carcass wash
will be
maintained
between 100
and 350 PSI,
Quality Assurance
monitors
washing/antimicrob
ial equipment use
every 2 hours to
ensure adjustments
are suited to
animals and,
according to
manufacturing
instructions,
Quality Assurance
evaluates 25% of
pluck/viscera for
visible
contaminants,
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
QA monitoring for visible
contaminants,
Maintenance supervisor will verify
accuracy (calibration) of the
washing and antimicrobial
intervention equipment once per
shift,
QA will stop production when the
wash/antimicrobial intervention falls
outside critical limits,Product will be
placed on QA hold,
Product produced following deviation will
be re-evaluated by QA,Any product with
visible fecal contamination will be re-
worked
QA will identify the cause of the deviation
and prevent reoccurrence,
Follow the corrective actions same as in
CCP 1B,
Signature,__________________________________ Date,__________________________ Figure 4
36
Pork Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,PORK
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
4B
Pluck/
Viscera
Wash
(Antimicro
bial)
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,
Pressures in
carcass wash
will be
maintained
between 100
and 350 PSI,
Quality Assurance
monitors
washing/antimicrob
ial equipment use
every 2 hours to
ensure adjustments
are suited to
animals and,
according to
manufacturing
instructions,
Quality Assurance
evaluates 25% of
pluck/viscera for
visible
contaminants,
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
QA monitoring for visible
contaminants,
Maintenance supervisor will verify
accuracy (calibration) of the
washing and antimicrobial
intervention equipment once per
shift,
QA will stop production when the
wash/antimicrobial intervention falls
outside critical limits,Product will be
placed on QA hold,
Product produced following deviation will
be re-evaluated by QA,Any product with
visible fecal contamination will be re-
worked
QA will identify the cause of the deviation
and prevent reoccurrence,
No adulterated product will be released
into production or shipped,
Signature,__________________________________ Date,__________________________ Figure 4
37
Pork Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,PORK
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
5B
Chilling
/Cold
Storage (All
Products)
(Continued
on next
page.)
All products
will begin
chilling
within 1 hour
from
bleedout,
Internal
Temperature
of 40° F or
less will be
reached
within 24
hours on all
products,
Finished
product cold
storage areas
will not
exceed 40°F,
QA technician will
observe chilling
handling
procedures to
ensure critical
limits are met,
Carcass and pluck/
viscera 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 pluck &
viscera meats
produced after
Carcass Chilling
Log
Pluck/Viscera
Chilling Log
Carcass Cooler
Temperature
Recording Chart
Pluck/Viscera
Cooler Temperature
Recording Chart
Thermometer
Calibration Log
Room Temperature
Log
Corrective Action
Log
Once per shift the QA supervisor
will review the Carcass Chilling
Log and Pluck/Viscera Chilling
Log,
Maintenance supervisor will verify
accuracy of the carcass cooler and
pluck/viscera 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,
Maintenance supervisor will verify
the accuracy of the room
temperature log once per shift,and
observe monitoring procedures,
QA will reject or hold product dependent
on time and temperature deviation,
Product disposition will be determined by
the cause and impact of the deviation,
Maintenance will review cooler operation
and make repairs if required,Time for
product to reach cooler and carcass holding
procedures will be reviewed,
QA will identify the cause of the deviation
and prevent reoccurrence,
Signature,__________________________________ Date,__________________________ Figure 4
38
Pork Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,PORK
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
5B
Chilling
/Cold
Storage (All
Products)
24 hours chilling to
ensure a tempera
ture of 40°F or less
has been reached,
To determine 24
hour limit is not
exceeded,all
results,lot #,time,
temperature and,
result will be
signed/initialed and
dated at the time of
observation,
Maintenance pers
onnel will check
finished product
cold storage areas
temperatures every
two hours,and
record results,date,
time and initial/
sign log,
QA will observe maintenance
personnel check finished product
cold storage areas once per shift,
Signature,__________________________________ Date,__________________________ Figure 4
39
Pork 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,_______________________
40
Pork 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
41
Pork Slaughter Model
ESTABLISHMENT X,
Date Lot # Time Solution
Concentration
Pressure Corrective Actions Monitored
by,
Verified
by,
Intervention Monitoring Log Antimicrobial
42
Pork Slaughter Model
CORRECTIVE ACTIONS LOG
Product,___________________________________________ Lot # ______________________
CCP Deviation/
Problem
Corrective Action
Procedures/Explain
Disposition of
Product
Responsible
Person
Date/Time
SIGNATURE,__________________________ DATE,______________________
43
Pork 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,
44