United States
Department of
Agriculture
Food Safety
and Inspection
Service
September 1999
HACCP-5
Generic HACCP
Model for
Poultry
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
Poultry Slaughter Model
Table of Contents
Introduction……………………………………………………………………………..…,3
Using This Generic Model……………………………………………………………..….,5
Process Flow Diagram and Product Description………………………………………..…,6
Hazard Analysis………………………………………………………………….…………7
Developing Your HACCP Plan……………………………………………………..…….,9
Identifying CCPs………………………………………………………………..…………,11
Appendix A
References for HACCP Teams………………………………….…………………..17
References for Poultry Slaughter (Broiler Carcass & Turkey Carcass)..…...………
19
Appendix B
Process Flow Diagram (Figure 1)…………………………………………………,23
Product Description Form (Figure 2)……………………………………………… 24
Hazard Analysis Form (Figure 3)…………………………………………………,25
HACCP Plan Form (Figure 4)…………………………………………………..… 30
Reprocessing Inspection Log……………………………………………………… 35
Chilling Log……………………………………………………………………….,36
Thermometer Calibration Log…………………………………………………….,37
Generic Establishment X,Room Temperature Log ………………………………,38
Antimicrobial Intervention Monitoring Log ………………………………………,39
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Poultry Slaughter Model
Corrective Actions Log……………………………………………………………,40
Pre-Shipment Review Log………………………………………………………… 41
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Poultry Slaughter Model
GENERIC HACCP MODEL
FOR
POULTRY 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
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Poultry Slaughter Model
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,
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,
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Poultry Slaughter Model
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,
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 young chickens,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
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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,
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,
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Poultry Slaughter Model
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 young chicken 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,
Figure 1 is an example of a PROCESS FLOW DIAGRAM for the young chicken slaughter
process in generic establishment X,Figure 2 is an example of a PRODUCT DESCRIPTION
for the young chickens 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 young chickens and your process includes steps not included in this
example,such as pre-evisceration spray or bacterial 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,
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(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,
(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 to address this hazard,
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 – Nonmeat Ingredients/Packaging Materials” on the first page
of the six column form; the HACCP team has determined that chemical and physical hazards
may be associated with the nonmeat ingredients or packaging materials when they are received,
but it put a,No” in the third column,Column four explains the basis for the team’s
determination,
You will notice that on our generic hazard analysis for poultry slaughter,there are four instances
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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 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 poultry
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,
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Poultry Slaughter Model
(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
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 young chicken 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,
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Poultry Slaughter Model
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 the hazard analysis form identified four points at which food safety
hazards were reasonably likely to occur,physical contamination with fecal material and potential
pathogen contamination at evisceration/presentation,pathogen contamination at reprocessing,
pathogen cross-contamination and proliferation at chilling,and pathogen proliferation at finished
products storage (cold),The establishment HACCP team has chosen to have four CCPs to
address these four hazards,proper evisceration/presentation,proper reprocessing,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 some regulatory requirements for chilling (§381.66),and realized that if the proper
chiller procedures were not followed pathogen proliferation was possible,The HACCP team
knew that the chilling process should start as soon as possible,so they set the critical limit for the
temperature of product to reach 40° F or less within four hours from the stunning/killing step,
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 do a product temperature check
at the end of the chilling procedure every hour of production,At the chilling step the carcass
chiller and neck/giblet chiller temperatures are 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,
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(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 Chilling Log
once per shift,The team also had the maintenance supervisor verify the accuracy of the carcass
chiller and necks/giblets chiller 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
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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
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 product
handling step,
The Temperature Recording Chart 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,
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
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),
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§ 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 3
1. QA will reject or hold product until temperature is achieved dependent on time and
temperature deviation,For example,the ARS cooling program can be used to make a
determination,
2. QA will identify the cause of the deviation and prevent reoccurrence by reassessment of the
HACCP plan and review of the cause of the deviation,Monitoring will be more frequent to
assure the process is in control,
3,QA will assure that no adulterated product has been shipped,
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),
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(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 clean-up,While the midshift
clean-up 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
necessary to meet regulatory requirements for a Hazard Analysis and a HACCP Plan for their
poultry 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,
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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
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
18
Poultry Slaughter Model
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,
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 Poultry
Products,In Advances in Meat Research,Vol,10,Hazard Analysis Critical Control Point in
Meat,Poultry and Seafoods,Chapman & Hall,1995,
References for Poultry Slaughter (Broiler Carcass & Turkey Carcass)
1. Baily,J,Stan,Control of Salmonella and Campylobacter in Poultry Production,A
Summary of Work at Russell Research Center,Poult,Sci,72,1169–1173,1993,
2. Benedict,R.C.,et al,Attachment and Removal of Salmonella spp,On Meat and Poultry
Tissues,J,Food Safety,11,135–148,1991,
3. Blank,Greg,et al,Microbiological and Hydraulic Evaluation of Immersion Chilling for
Poultry,J,Food Protect,58,1386–1388,1995,
4. Carpenter,Sandra L.,et al,Survival of Listeria monocytogenes on Processed Poultry,J,
Food Sci,54,556–557,1989,
5. Cherrington,Christina A.,et al,Persistence of Escherichia coli in a Poultry Processing
Plant,Letters Appl,Microbiol,7,141–143,1988,
6. Clouser,C.S.,et al,The Role of Defeathering in the Contamination of Turkey Skin by
Salmonella species and Listeria monocytogenes,Poult,Sci,74,723–731,1995,
19
Poultry Slaughter Model
7. Clouser,C.S,et al,Effect of Type of Defeathering System on Salmonella Cross-
Contamination During Commercial Processing,Poult,Sci,74,732–741,1995,
8. Dickens,J.A.,et al,The Effect of Air-Scrubbing on Moisture Pickup,Aerobic Plate Counts,
Enterobacteriaceae,and the Incidence of Salmonella on Artificially Inoculated Broiler
Carcasses,Poult,Sci,71,560–564,1992,
9. Franco,C.M.,et al,Determination of the Principal Sources of Listeria spp,Contamination
in Poultry Meat and Poultry Processing Plant,J,Food Protect,58,1320–1325,1995,
10,Genigeorgis,Constantin A.,et al,Prevalence of Listeria spp,in Poultry Meat at the
Supermarket and Slaughterhouse Level,J,Food Protect,52,618–624,1989,
11,Izat,A.L.,et al,Incidence and Level of Campylobacter jejuni in Broiler Processing,Poult,
Sci,67,1568–1572,1988,
12,James,William O,et al,Cost-Effective Techniques to Control Human Enteropathogens on
Fresh Poultry,Poult,Sci,72,1174–1176,1993,
13,James,William O.,et al,Profile of Selected Bacterial Counts and Salmonella Prevalence on
Raw Poultry in a Poultry Slaughter Establishment,J,Am,Vet,Med,Assoc,200,57–59,
1992,
14,Kim,Jeong–Weon,et al,Attachment of Salmonella typhimurium to Skins of Turkey that had
been Defeathered through Three Different Systems,Scanning Electron Microscopic
Examination,J,Food Protect,56,395–400,1993,
15,Kotula,Kathryn L.,et al,Bacterial Contamination of Broiler Chickens before Scalding,J,
Food Protect,58,1386–1388,1995,
16,Lawrence,Lorna M.,et al,Incidence of Listeria spp,and Listeria monocytogens in a Poultry
Processing Environment and in Poultry Products and Their Rapid Confirmation by
Multiplex PCR.,Appl,Environ,Microbiol,4600– 4604,December 1994,
17,Lawrence,Lorna M.,et al,Characterization of Listeria monocytogenes Isolated from Poultry
Products and from the Poultry-Processing Environment by Random amplification of
Polymorphic DNA and Multilocus Enzyme Electrophoresis,Appl,Environ,Microbiol,
2139–2144,June 1995,
18,Li,Yanbin,et al,Electrical Treatment of Poultry Chiller Water to Destroy Campylobacter
jejuni,J,Food Protect,58,1330–1334,1995,
20
Poultry Slaughter Model
19,Lillard,H.S,Factors Affecting the Persistence of Salmonella during the Processing of
Poultry,J,Food Protect,52,829–832,1989,
20,Lillard,H.S,Incidence and Recovery of Salmonella and Other Bacteria from Commercially
Processed Poultry Carcasses at Selected Pre- and Post-Evisceration Steps,J,Food Protect,
52,88–91,1989,
21,Mead G.C.,et al,Microbiological Survey of Five Poultry Processing Plants in the UK,Brit,
Poult,Sci,34,497–503,1993,
22,Mead,G.C.,et al,Use of a marker organism in poultry processing to identify sites of cross-
contamination and evaluate possible control measures,Brit,Poult,Sci,35,354,1994,
23,Moye,C.J.,et al,Poultry Processing,An Innovative Technology for Salmonella Control and
Shelf Life Extension,Food Aust,43,246–249,1991,
24,Raj,Mohan,Poultry Slaughter,Meat Focus International,Marck 1995:113-118,1995,
25,Renwick,Shane A.,et al,Variability and Determinants of Carcass Bacterial Load at a
Poultry Abattoir,J,Food Protect,56,694-699,1993,
26,Russell,S,M,The Effect of Refrigerated and Frozen Storage on Populations of Mesophilic
and Coliform Bacteria on Fresh Broiler Chicken Carcasses,Poultry Sci,75,2057-2060,
1996,
27,Russell,S,M.,et al,Spoilage Bacteria of Fresh Broiler Chicken Carcasses,Poultry Sci,
75:2041-2047,1996,
28,Thayer,Stephan G.,et al,Evaluation of Cross-Contamination on Automatic Viscera
Removal Equipment,Poult,Sci,72:741-746,1993,
29,Tokumaru,Masakazu,et al,Rates of Detection of Salmonella and Campylobacter in Meats
in Response to the Sample Size and the Infection Level of each Species,Int,J,Food
Microbiol,13,41-46,1990,
30,Villarreal,Mario E.,et al,The Incidence of Salmonella on Poultry Carcasses Following the
Use of Slow Release Chlorine Dioxide (Alcide),J,Food Protect,53,465–467,1990,
31,Waldroup,A.L,Summary of Work to Control Pathogens in Poultry Processing,Poult,Sci,
72,1177–1179,1993,
21
Poultry Slaughter Model
APPENDIX B
22
Poultry Slaughter Model
PROCESS FLOW DIAGRAM Figure 1
PROCESS CATEGORY,SLAUGHTER
PRODUCT,YOUNG CHICKEN
RECEIVING
PACKAGING
MATERIALS
RECEIVING/HOLDING
LIVE POULTRY
UNLOADING/HANGING/STUNNING/KILLING/BLEEDING
SCALDING/PICKING/HEAD REMOVAL/ SINGEING/
WASHING/HOCK CUTTER/TRANSFER/REHANG/PINNING
OIL GLAND REMOVAL/NECK BREAKING/VENTING/OPENING
EVISCERATION/PRESENTATION
LUNG/CROP REMOVAL
HOUSE INSPECTION/TRIM
FINAL WASH*
REPROCESSING* SALVAGE*
CHILLING – CARCASS/NECK/GIBLETS*
PACKAGING/LABELING*
STORAGE
LIVER/HEART HARVEST
GIZZARD HARVEST/PEEL
NECK REMOVAL/HARVEST
* Steps in the process w
PACKAGING
MATERIALS
FINISHED PRODUCT
STORAGE (COLD)
SHIPPING
here nonmeat ingredients (e.g.,antimicrobials) are added to or comes in contact with product,
23
Poultry Slaughter Model
PRODUCT DESCRIPTION Figure 2
PROCESS CATEGORY,SLAUGHTER
PRODUCT,YOUNG CHICKEN
1,COMMON NAME? CHICKEN
2,HOW IS IT TO BE USED? READY TO COOK
CARCASSES/PARTS
3,TYPE OF PACKAGE? CARCASSES – VACUUM
PACKAGED INDIVIDUALLY;
PARTS – VACUUM PACKAGED,
TRAY PACKS
4,LENGTH OF SHELF LIFE,3-6 MONTHS AT 0° F OR
AT WHAT TEMPERATURE? BELOW;7 DAYS AT 40° F
5,WHERE WILL IT BE SOLD? WHOLESALE TO DISTRIBUTORS;
CONSUMERS? RETAIL TO CONSUMERS
INTENDED USE?
6,LABELING INSTRUCTIONS? SAFE FOOD HANDLING LABELS;
KEEP REFRIGERATED OR KEEP
FROZEN; COOKING LABEL
7,IS SPECIAL DISTRIBUTION KEEP REFRIGERATED OR KEEP
CONTROL NEEDED? FROZEN
24
Poultry Slaughter Model
HAZARD ANALYSIS – YOUNG CHICKEN 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/Holding –
Live Poultry
Biological – None
Chemical – None
Physical – None
Receiving – Packaging
Materials
Biological – None
Chemical – Not
acceptable for
intended use
No Letters of guaranty are
received from all suppliers
and packaging materials,
Physical – Foreign
materials
No Plant records demonstrate
that foreign material
contamination has not
occurred during the past
several years,
Storage– Nonmeat
Ingredients/Packaging
Materials
Biological – None
Chemical – None
Physical – None
Figure 3
25
Poultry Slaughter Model
HAZARD ANALYSIS – YOUNG CHICKEN 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
Unloading/Hanging/
Stunning/Killing/
Bleeding
Biological – None
Chemical – None
Physical – None
Scalding/Picking/Head
Removal/Singeing/
Washing/Hock cutter
/Transfer/Rehang /
Pinning
Biological – None
Chemical – None
Physical – None
Oil Gland Removal/Neck
Breaking/Venting/
Opening
Biological – None
Chemical – None
Physical – None
Evisceration/
Presentation
Biological
Salmonella
Yes Significant contamination
can occur from leakage of
gut material,which may be
associated with pathogens,
Proper adjustment of
evisceration equipment and
presentation training of
employees will reduce the level
of contamination,Visual
inspection of carcasses for
fecal contamination,
1B
Chemical – None
Physical - Fecal
contamination from gut
breakage,
Yes
Figure 3
26
Poultry Slaughter Model
HAZARD ANALYSIS – YOUNG CHICKEN 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
Lung/Crop Removal
Neck Removal/Harvest
Biological – None
Chemical – None
Physical – None
House Inspection/Trim Biological – None
Chemical – None
Physical – None
Reprocessing Biological – Pathogens
Salmonella
Generic E.coli
Yes Potential for contamination
and pathogen proliferation,
Subsequent chilling will
help reduce the risk of
pathogen growth,
Proper washing (use of an
antimicrobial),trimming,
and temperature control
will reduce the numbers
and limit the growth of
pathogens,
2B
Chemical – None
Physical – None
Figure 3
27
Poultry Slaughter Model
HAZARD ANALYSIS – YOUNG CHICKEN 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
Salvage Biological – Sep/Tox No Young chickens historically
have a low incidence of
sep/tox the only poultry
disease of public health
significance,
Chemical – None
Physical – None
Final Wash Biological – None
Chemical – None
Physical – None
Liver/Heart Harvest
Gizzard Harvest/Peel
Biological – None
Chemical – None
Physical – None
Chilling –
Carcass/Necks/Giblets
Biological
cross-contamination
Salmonella
Yes Product to product contact,
Literature indicates that
improperly controlled chill-
ing systems can result in
higher prevalence of pathog-
ens in the final product,FSIS
performance standard for
Salmonella can be met using
an antimicrobial intervention
at this process step,
Product will be chilled
properly to prevent pathogen
growth,
Chlorine dioxide use can
prevent further growth of
Salmonella,
3B
Chemical – None
Physical - None
Figure 3
28
Poultry Slaughter Model
HAZARD ANALYSIS – YOUNG CHICKEN 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
Packaging/Labeling Biological – None
Chemical – None
Physical – None
Finished Product
Storage (Cold)
Biological – Pathogens 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,
4B
Chemical – None
Physical – None
Shipping Biological - None
Chemical – None
Physical – None
Figure 3
29
Poultry Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,YOUNG CHICKEN
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
1P/B
Evisceration/
Presentation
Zero visible
fecal
contamina
tion after
processing;
equipment
kept properly
adjusted; no
gut breakage
due to
improper
equipment
adjustment;
range of 20-
50 ppm
chlorine or
other
approved
antimicrobial
rinse on
equipment
and product,
Visible check (at
least once per hour
of production);
check chlorine or
other approved
antimicrobial rinse
at start up and
every 2 hours using
documented
random sampling
procedures to
demonstrate
control,Designated
Quality Assurance
employee will
record results in
appropriate Log,
Equipment
adjustment will be
checked at start of
each shift,
Plant Finished
Product Standards
Form
Antimicrobial Log
Equipment
Maintenance Log
Corrective Action
Log
Once per shift the QA supervisor
will review the Plant Antimicrobial
Log and observe chlorine level
testing,
Twice per shift Maintenance
Supervisor will review Equipment
Maintenance Log
QA will reject or hold product until zero
fecal tolerance is achieved,
Equipment will be properly adjusted to
assure contamination is not occurring after
line is stopped,All suspect product will be
visually examined between evisceration
and after final wash,Contaminated
product will be condemned or
reconditioned,Equipment maintenance
and adjustments will be reviewed and
compared to flock size and manufacturers
specs,
QA will identify the cause of the deviation
and prevent reoccurrence,
Signature,__________________________________ Date,__________________________ Figure 4
30
Poultry Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,YOUNG CHICKEN
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
2P/B
Reprocessing
Zero visible
fecal
contamina
tion after re-
processing;
equipment
kept properly
adjusted;
range of 20-
50 ppm
chlorine or
other
approved
antimicrobial
rinse on
equipment
and product,
Visible check on
each lot (at least
once per hour of
production);
check chlorine or
other approved
antimicrobial
rinse at start up
and every 2 hours
using documented
random sampling
procedures to
demonstrate
control,
Designated
Quality Assurance
employee will
record results in
appropriate Log,
Reprocessing Log
(using Plant
Finished Product
Standards)
Antimicrobial Log
Equipment
Maintenance Log
Corrective Action
Log
Once per shift the QA supervisor
will review the Reprocessing Log
and Antimicrobial Log,
Twice per shift Maintenance
Supervisor will review Equipment
Maintenance Log
QA will reject or hold product until zero
fecal tolerance is achieved,
Product will be reworked and reinspected
by QA for fecal contamination,
Any equipment adjustments will be made,
Frequency of monitoring will be reassessed
and CCP will be monitored once per hour
to assure it is under control,
QA will identify the cause of the deviation
and prevent reoccurrence,
Signature,__________________________________ Date,__________________________ Figure 4
31
Poultry Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,YOUNG CHICKEN
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
3B
Chilling (All
Products)
Temperature
of 40° F or
less will be
reached
within 4
hours on all
product,
Chlorine
dioxide level
in chiller will
be maintained
at > 20 ppm,
Product
temperature check
monitored by QA
technician at end of
chilling procedure
(every hour of
production),
Chill water will be
tested for Chlorine
level every 2 hours
by QA,
Chilling Log
Carcass Chiller
Recording Chart
Neck/Giblet Chiller
Recording Chart
Thermometer
Calibration Log
Corrective Action
Log
Antimicrobial Log
Once per shift the QA supervisor
will review the Chilling Log,Plant
Post Chill Product Standards Form,
and Antimicrobial Log,
Maintenance supervisor will verify
accuracy of the carcass chiller and
neck/giblet chiller temperature
recording charts once per shift,
QA will verify the chlorine
concentration in the chiller once per
week,
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,temperature and or antimicrobial
level deviation,
QA will identify the cause of the deviation
and prevent reoccurrence,
Maintenance will check chiller circulation
and water exchange rate and make
adjustments as required,Any necessary
repairs will be made,
QA will monitor temperature and
antimicrobial level in chiller every 2 hours
until assured that process step is under
control,
Signature,__________________________________ Date,__________________________ Figure 4
32
Poultry Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,YOUNG CHICKEN
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
4B
Finished
Product
Storage
(Cold)
(Continued
on next
page.)
Finished
product will
not exceed
40° F,
Maintenance
personnel will
check product
temperature on
carcasses every
two hours,
Chilling Log
Thermometer
Calibration Log
Corrective Action
Log
Maintenance supervisor will verify
the accuracy of the product
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
33
Poultry Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,YOUNG CHICKEN
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
4B
Finished
Product
Storage
(Cold)
4,If product temperature exceeds the
critical limit,the processing authority
will evaluate the product
time/temperature deviation before
release for shipment,If
time/temperature is not sufficient,
product will be cooked in the
establishment to ensure destruction of
pathogens or condemned,
Signature,__________________________________ Date,__________________________ Figure 4
34
Poultry Slaughter Model
REPROCESSING INSPECTION LOG
Date,_________________ Critical Limit,No visible fecal contamination entering
chiller
Time Product ID Results of Inspection Monitor
Initials
Verification
Initials
Corrective Actions and/or Comments
Reviewed by,__________________________________ Date,______________________
35
Poultry Slaughter Model
CHILLING LOG
Date,_________________ Critical Limit,Internal temperature of ≤40
0
F when product exits chiller
Time Product ID Internal
Temperature
Monitor
Initials
Verification
Initials
Corrective Actions and/or Comments
Reviewed by,__________________________________ Date,______________________
36
Poultry 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,_______________________
37
Poultry Slaughter Model
GENERIC ESTABLISHMENT X,
ROOM:__________ DATE:_________
TIME TEMP Deviation from
CL?
yes)
If Yes,
Action?
Monitored by,Verified by,
ROOM TEMPERATURE LOG
(Check if
38
Poultry Slaughter Model
ESTABLISHMENT X,
Date Lot # Time Solution
Concentration
Pressure Corrective Actions Monitored
by,
Verified
by,
Intervention Monitoring Log Antimicrobial
39
Poultry Slaughter Model
CORRECTIVE ACTIONS LOG
Product,___________________________________________ Lot # ______________________
CCP Deviation/
Problem
Corrective Action
Procedures/Explain
Disposition of
Product
Responsible
Person
Date/Time
SIGNATURE,__________________________ DATE,______________________
40
Poultry 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,
41
Department of
Agriculture
Food Safety
and Inspection
Service
September 1999
HACCP-5
Generic HACCP
Model for
Poultry
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
Poultry Slaughter Model
Table of Contents
Introduction……………………………………………………………………………..…,3
Using This Generic Model……………………………………………………………..….,5
Process Flow Diagram and Product Description………………………………………..…,6
Hazard Analysis………………………………………………………………….…………7
Developing Your HACCP Plan……………………………………………………..…….,9
Identifying CCPs………………………………………………………………..…………,11
Appendix A
References for HACCP Teams………………………………….…………………..17
References for Poultry Slaughter (Broiler Carcass & Turkey Carcass)..…...………
19
Appendix B
Process Flow Diagram (Figure 1)…………………………………………………,23
Product Description Form (Figure 2)……………………………………………… 24
Hazard Analysis Form (Figure 3)…………………………………………………,25
HACCP Plan Form (Figure 4)…………………………………………………..… 30
Reprocessing Inspection Log……………………………………………………… 35
Chilling Log……………………………………………………………………….,36
Thermometer Calibration Log…………………………………………………….,37
Generic Establishment X,Room Temperature Log ………………………………,38
Antimicrobial Intervention Monitoring Log ………………………………………,39
1
Poultry Slaughter Model
Corrective Actions Log……………………………………………………………,40
Pre-Shipment Review Log………………………………………………………… 41
2
Poultry Slaughter Model
GENERIC HACCP MODEL
FOR
POULTRY 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
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Poultry Slaughter Model
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,
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,
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Poultry Slaughter Model
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,
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 young chickens,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
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Poultry Slaughter Model
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,
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,
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Poultry Slaughter Model
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 young chicken 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,
Figure 1 is an example of a PROCESS FLOW DIAGRAM for the young chicken slaughter
process in generic establishment X,Figure 2 is an example of a PRODUCT DESCRIPTION
for the young chickens 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 young chickens and your process includes steps not included in this
example,such as pre-evisceration spray or bacterial 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,
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Poultry Slaughter Model
(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,
(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 to address this hazard,
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 – Nonmeat Ingredients/Packaging Materials” on the first page
of the six column form; the HACCP team has determined that chemical and physical hazards
may be associated with the nonmeat ingredients or packaging materials when they are received,
but it put a,No” in the third column,Column four explains the basis for the team’s
determination,
You will notice that on our generic hazard analysis for poultry slaughter,there are four instances
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Poultry Slaughter Model
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 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 poultry
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,
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Poultry Slaughter Model
(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
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 young chicken 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,
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Poultry Slaughter Model
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 the hazard analysis form identified four points at which food safety
hazards were reasonably likely to occur,physical contamination with fecal material and potential
pathogen contamination at evisceration/presentation,pathogen contamination at reprocessing,
pathogen cross-contamination and proliferation at chilling,and pathogen proliferation at finished
products storage (cold),The establishment HACCP team has chosen to have four CCPs to
address these four hazards,proper evisceration/presentation,proper reprocessing,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 some regulatory requirements for chilling (§381.66),and realized that if the proper
chiller procedures were not followed pathogen proliferation was possible,The HACCP team
knew that the chilling process should start as soon as possible,so they set the critical limit for the
temperature of product to reach 40° F or less within four hours from the stunning/killing step,
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 do a product temperature check
at the end of the chilling procedure every hour of production,At the chilling step the carcass
chiller and neck/giblet chiller temperatures are 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,
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Poultry Slaughter Model
(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 Chilling Log
once per shift,The team also had the maintenance supervisor verify the accuracy of the carcass
chiller and necks/giblets chiller 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
12
Poultry Slaughter Model
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
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 product
handling step,
The Temperature Recording Chart 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,
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
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),
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Poultry Slaughter Model
§ 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 3
1. QA will reject or hold product until temperature is achieved dependent on time and
temperature deviation,For example,the ARS cooling program can be used to make a
determination,
2. QA will identify the cause of the deviation and prevent reoccurrence by reassessment of the
HACCP plan and review of the cause of the deviation,Monitoring will be more frequent to
assure the process is in control,
3,QA will assure that no adulterated product has been shipped,
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),
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Poultry Slaughter Model
(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 clean-up,While the midshift
clean-up 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
necessary to meet regulatory requirements for a Hazard Analysis and a HACCP Plan for their
poultry 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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Poultry Slaughter Model
APPENDIX A
16
Poultry 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,
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Poultry Slaughter Model
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
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
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Poultry Slaughter Model
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,
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 Poultry
Products,In Advances in Meat Research,Vol,10,Hazard Analysis Critical Control Point in
Meat,Poultry and Seafoods,Chapman & Hall,1995,
References for Poultry Slaughter (Broiler Carcass & Turkey Carcass)
1. Baily,J,Stan,Control of Salmonella and Campylobacter in Poultry Production,A
Summary of Work at Russell Research Center,Poult,Sci,72,1169–1173,1993,
2. Benedict,R.C.,et al,Attachment and Removal of Salmonella spp,On Meat and Poultry
Tissues,J,Food Safety,11,135–148,1991,
3. Blank,Greg,et al,Microbiological and Hydraulic Evaluation of Immersion Chilling for
Poultry,J,Food Protect,58,1386–1388,1995,
4. Carpenter,Sandra L.,et al,Survival of Listeria monocytogenes on Processed Poultry,J,
Food Sci,54,556–557,1989,
5. Cherrington,Christina A.,et al,Persistence of Escherichia coli in a Poultry Processing
Plant,Letters Appl,Microbiol,7,141–143,1988,
6. Clouser,C.S.,et al,The Role of Defeathering in the Contamination of Turkey Skin by
Salmonella species and Listeria monocytogenes,Poult,Sci,74,723–731,1995,
19
Poultry Slaughter Model
7. Clouser,C.S,et al,Effect of Type of Defeathering System on Salmonella Cross-
Contamination During Commercial Processing,Poult,Sci,74,732–741,1995,
8. Dickens,J.A.,et al,The Effect of Air-Scrubbing on Moisture Pickup,Aerobic Plate Counts,
Enterobacteriaceae,and the Incidence of Salmonella on Artificially Inoculated Broiler
Carcasses,Poult,Sci,71,560–564,1992,
9. Franco,C.M.,et al,Determination of the Principal Sources of Listeria spp,Contamination
in Poultry Meat and Poultry Processing Plant,J,Food Protect,58,1320–1325,1995,
10,Genigeorgis,Constantin A.,et al,Prevalence of Listeria spp,in Poultry Meat at the
Supermarket and Slaughterhouse Level,J,Food Protect,52,618–624,1989,
11,Izat,A.L.,et al,Incidence and Level of Campylobacter jejuni in Broiler Processing,Poult,
Sci,67,1568–1572,1988,
12,James,William O,et al,Cost-Effective Techniques to Control Human Enteropathogens on
Fresh Poultry,Poult,Sci,72,1174–1176,1993,
13,James,William O.,et al,Profile of Selected Bacterial Counts and Salmonella Prevalence on
Raw Poultry in a Poultry Slaughter Establishment,J,Am,Vet,Med,Assoc,200,57–59,
1992,
14,Kim,Jeong–Weon,et al,Attachment of Salmonella typhimurium to Skins of Turkey that had
been Defeathered through Three Different Systems,Scanning Electron Microscopic
Examination,J,Food Protect,56,395–400,1993,
15,Kotula,Kathryn L.,et al,Bacterial Contamination of Broiler Chickens before Scalding,J,
Food Protect,58,1386–1388,1995,
16,Lawrence,Lorna M.,et al,Incidence of Listeria spp,and Listeria monocytogens in a Poultry
Processing Environment and in Poultry Products and Their Rapid Confirmation by
Multiplex PCR.,Appl,Environ,Microbiol,4600– 4604,December 1994,
17,Lawrence,Lorna M.,et al,Characterization of Listeria monocytogenes Isolated from Poultry
Products and from the Poultry-Processing Environment by Random amplification of
Polymorphic DNA and Multilocus Enzyme Electrophoresis,Appl,Environ,Microbiol,
2139–2144,June 1995,
18,Li,Yanbin,et al,Electrical Treatment of Poultry Chiller Water to Destroy Campylobacter
jejuni,J,Food Protect,58,1330–1334,1995,
20
Poultry Slaughter Model
19,Lillard,H.S,Factors Affecting the Persistence of Salmonella during the Processing of
Poultry,J,Food Protect,52,829–832,1989,
20,Lillard,H.S,Incidence and Recovery of Salmonella and Other Bacteria from Commercially
Processed Poultry Carcasses at Selected Pre- and Post-Evisceration Steps,J,Food Protect,
52,88–91,1989,
21,Mead G.C.,et al,Microbiological Survey of Five Poultry Processing Plants in the UK,Brit,
Poult,Sci,34,497–503,1993,
22,Mead,G.C.,et al,Use of a marker organism in poultry processing to identify sites of cross-
contamination and evaluate possible control measures,Brit,Poult,Sci,35,354,1994,
23,Moye,C.J.,et al,Poultry Processing,An Innovative Technology for Salmonella Control and
Shelf Life Extension,Food Aust,43,246–249,1991,
24,Raj,Mohan,Poultry Slaughter,Meat Focus International,Marck 1995:113-118,1995,
25,Renwick,Shane A.,et al,Variability and Determinants of Carcass Bacterial Load at a
Poultry Abattoir,J,Food Protect,56,694-699,1993,
26,Russell,S,M,The Effect of Refrigerated and Frozen Storage on Populations of Mesophilic
and Coliform Bacteria on Fresh Broiler Chicken Carcasses,Poultry Sci,75,2057-2060,
1996,
27,Russell,S,M.,et al,Spoilage Bacteria of Fresh Broiler Chicken Carcasses,Poultry Sci,
75:2041-2047,1996,
28,Thayer,Stephan G.,et al,Evaluation of Cross-Contamination on Automatic Viscera
Removal Equipment,Poult,Sci,72:741-746,1993,
29,Tokumaru,Masakazu,et al,Rates of Detection of Salmonella and Campylobacter in Meats
in Response to the Sample Size and the Infection Level of each Species,Int,J,Food
Microbiol,13,41-46,1990,
30,Villarreal,Mario E.,et al,The Incidence of Salmonella on Poultry Carcasses Following the
Use of Slow Release Chlorine Dioxide (Alcide),J,Food Protect,53,465–467,1990,
31,Waldroup,A.L,Summary of Work to Control Pathogens in Poultry Processing,Poult,Sci,
72,1177–1179,1993,
21
Poultry Slaughter Model
APPENDIX B
22
Poultry Slaughter Model
PROCESS FLOW DIAGRAM Figure 1
PROCESS CATEGORY,SLAUGHTER
PRODUCT,YOUNG CHICKEN
RECEIVING
PACKAGING
MATERIALS
RECEIVING/HOLDING
LIVE POULTRY
UNLOADING/HANGING/STUNNING/KILLING/BLEEDING
SCALDING/PICKING/HEAD REMOVAL/ SINGEING/
WASHING/HOCK CUTTER/TRANSFER/REHANG/PINNING
OIL GLAND REMOVAL/NECK BREAKING/VENTING/OPENING
EVISCERATION/PRESENTATION
LUNG/CROP REMOVAL
HOUSE INSPECTION/TRIM
FINAL WASH*
REPROCESSING* SALVAGE*
CHILLING – CARCASS/NECK/GIBLETS*
PACKAGING/LABELING*
STORAGE
LIVER/HEART HARVEST
GIZZARD HARVEST/PEEL
NECK REMOVAL/HARVEST
* Steps in the process w
PACKAGING
MATERIALS
FINISHED PRODUCT
STORAGE (COLD)
SHIPPING
here nonmeat ingredients (e.g.,antimicrobials) are added to or comes in contact with product,
23
Poultry Slaughter Model
PRODUCT DESCRIPTION Figure 2
PROCESS CATEGORY,SLAUGHTER
PRODUCT,YOUNG CHICKEN
1,COMMON NAME? CHICKEN
2,HOW IS IT TO BE USED? READY TO COOK
CARCASSES/PARTS
3,TYPE OF PACKAGE? CARCASSES – VACUUM
PACKAGED INDIVIDUALLY;
PARTS – VACUUM PACKAGED,
TRAY PACKS
4,LENGTH OF SHELF LIFE,3-6 MONTHS AT 0° F OR
AT WHAT TEMPERATURE? BELOW;7 DAYS AT 40° F
5,WHERE WILL IT BE SOLD? WHOLESALE TO DISTRIBUTORS;
CONSUMERS? RETAIL TO CONSUMERS
INTENDED USE?
6,LABELING INSTRUCTIONS? SAFE FOOD HANDLING LABELS;
KEEP REFRIGERATED OR KEEP
FROZEN; COOKING LABEL
7,IS SPECIAL DISTRIBUTION KEEP REFRIGERATED OR KEEP
CONTROL NEEDED? FROZEN
24
Poultry Slaughter Model
HAZARD ANALYSIS – YOUNG CHICKEN 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/Holding –
Live Poultry
Biological – None
Chemical – None
Physical – None
Receiving – Packaging
Materials
Biological – None
Chemical – Not
acceptable for
intended use
No Letters of guaranty are
received from all suppliers
and packaging materials,
Physical – Foreign
materials
No Plant records demonstrate
that foreign material
contamination has not
occurred during the past
several years,
Storage– Nonmeat
Ingredients/Packaging
Materials
Biological – None
Chemical – None
Physical – None
Figure 3
25
Poultry Slaughter Model
HAZARD ANALYSIS – YOUNG CHICKEN 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
Unloading/Hanging/
Stunning/Killing/
Bleeding
Biological – None
Chemical – None
Physical – None
Scalding/Picking/Head
Removal/Singeing/
Washing/Hock cutter
/Transfer/Rehang /
Pinning
Biological – None
Chemical – None
Physical – None
Oil Gland Removal/Neck
Breaking/Venting/
Opening
Biological – None
Chemical – None
Physical – None
Evisceration/
Presentation
Biological
Salmonella
Yes Significant contamination
can occur from leakage of
gut material,which may be
associated with pathogens,
Proper adjustment of
evisceration equipment and
presentation training of
employees will reduce the level
of contamination,Visual
inspection of carcasses for
fecal contamination,
1B
Chemical – None
Physical - Fecal
contamination from gut
breakage,
Yes
Figure 3
26
Poultry Slaughter Model
HAZARD ANALYSIS – YOUNG CHICKEN 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
Lung/Crop Removal
Neck Removal/Harvest
Biological – None
Chemical – None
Physical – None
House Inspection/Trim Biological – None
Chemical – None
Physical – None
Reprocessing Biological – Pathogens
Salmonella
Generic E.coli
Yes Potential for contamination
and pathogen proliferation,
Subsequent chilling will
help reduce the risk of
pathogen growth,
Proper washing (use of an
antimicrobial),trimming,
and temperature control
will reduce the numbers
and limit the growth of
pathogens,
2B
Chemical – None
Physical – None
Figure 3
27
Poultry Slaughter Model
HAZARD ANALYSIS – YOUNG CHICKEN 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
Salvage Biological – Sep/Tox No Young chickens historically
have a low incidence of
sep/tox the only poultry
disease of public health
significance,
Chemical – None
Physical – None
Final Wash Biological – None
Chemical – None
Physical – None
Liver/Heart Harvest
Gizzard Harvest/Peel
Biological – None
Chemical – None
Physical – None
Chilling –
Carcass/Necks/Giblets
Biological
cross-contamination
Salmonella
Yes Product to product contact,
Literature indicates that
improperly controlled chill-
ing systems can result in
higher prevalence of pathog-
ens in the final product,FSIS
performance standard for
Salmonella can be met using
an antimicrobial intervention
at this process step,
Product will be chilled
properly to prevent pathogen
growth,
Chlorine dioxide use can
prevent further growth of
Salmonella,
3B
Chemical – None
Physical - None
Figure 3
28
Poultry Slaughter Model
HAZARD ANALYSIS – YOUNG CHICKEN 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
Packaging/Labeling Biological – None
Chemical – None
Physical – None
Finished Product
Storage (Cold)
Biological – Pathogens 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,
4B
Chemical – None
Physical – None
Shipping Biological - None
Chemical – None
Physical – None
Figure 3
29
Poultry Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,YOUNG CHICKEN
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
1P/B
Evisceration/
Presentation
Zero visible
fecal
contamina
tion after
processing;
equipment
kept properly
adjusted; no
gut breakage
due to
improper
equipment
adjustment;
range of 20-
50 ppm
chlorine or
other
approved
antimicrobial
rinse on
equipment
and product,
Visible check (at
least once per hour
of production);
check chlorine or
other approved
antimicrobial rinse
at start up and
every 2 hours using
documented
random sampling
procedures to
demonstrate
control,Designated
Quality Assurance
employee will
record results in
appropriate Log,
Equipment
adjustment will be
checked at start of
each shift,
Plant Finished
Product Standards
Form
Antimicrobial Log
Equipment
Maintenance Log
Corrective Action
Log
Once per shift the QA supervisor
will review the Plant Antimicrobial
Log and observe chlorine level
testing,
Twice per shift Maintenance
Supervisor will review Equipment
Maintenance Log
QA will reject or hold product until zero
fecal tolerance is achieved,
Equipment will be properly adjusted to
assure contamination is not occurring after
line is stopped,All suspect product will be
visually examined between evisceration
and after final wash,Contaminated
product will be condemned or
reconditioned,Equipment maintenance
and adjustments will be reviewed and
compared to flock size and manufacturers
specs,
QA will identify the cause of the deviation
and prevent reoccurrence,
Signature,__________________________________ Date,__________________________ Figure 4
30
Poultry Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,YOUNG CHICKEN
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
2P/B
Reprocessing
Zero visible
fecal
contamina
tion after re-
processing;
equipment
kept properly
adjusted;
range of 20-
50 ppm
chlorine or
other
approved
antimicrobial
rinse on
equipment
and product,
Visible check on
each lot (at least
once per hour of
production);
check chlorine or
other approved
antimicrobial
rinse at start up
and every 2 hours
using documented
random sampling
procedures to
demonstrate
control,
Designated
Quality Assurance
employee will
record results in
appropriate Log,
Reprocessing Log
(using Plant
Finished Product
Standards)
Antimicrobial Log
Equipment
Maintenance Log
Corrective Action
Log
Once per shift the QA supervisor
will review the Reprocessing Log
and Antimicrobial Log,
Twice per shift Maintenance
Supervisor will review Equipment
Maintenance Log
QA will reject or hold product until zero
fecal tolerance is achieved,
Product will be reworked and reinspected
by QA for fecal contamination,
Any equipment adjustments will be made,
Frequency of monitoring will be reassessed
and CCP will be monitored once per hour
to assure it is under control,
QA will identify the cause of the deviation
and prevent reoccurrence,
Signature,__________________________________ Date,__________________________ Figure 4
31
Poultry Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,YOUNG CHICKEN
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
3B
Chilling (All
Products)
Temperature
of 40° F or
less will be
reached
within 4
hours on all
product,
Chlorine
dioxide level
in chiller will
be maintained
at > 20 ppm,
Product
temperature check
monitored by QA
technician at end of
chilling procedure
(every hour of
production),
Chill water will be
tested for Chlorine
level every 2 hours
by QA,
Chilling Log
Carcass Chiller
Recording Chart
Neck/Giblet Chiller
Recording Chart
Thermometer
Calibration Log
Corrective Action
Log
Antimicrobial Log
Once per shift the QA supervisor
will review the Chilling Log,Plant
Post Chill Product Standards Form,
and Antimicrobial Log,
Maintenance supervisor will verify
accuracy of the carcass chiller and
neck/giblet chiller temperature
recording charts once per shift,
QA will verify the chlorine
concentration in the chiller once per
week,
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,temperature and or antimicrobial
level deviation,
QA will identify the cause of the deviation
and prevent reoccurrence,
Maintenance will check chiller circulation
and water exchange rate and make
adjustments as required,Any necessary
repairs will be made,
QA will monitor temperature and
antimicrobial level in chiller every 2 hours
until assured that process step is under
control,
Signature,__________________________________ Date,__________________________ Figure 4
32
Poultry Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,YOUNG CHICKEN
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
4B
Finished
Product
Storage
(Cold)
(Continued
on next
page.)
Finished
product will
not exceed
40° F,
Maintenance
personnel will
check product
temperature on
carcasses every
two hours,
Chilling Log
Thermometer
Calibration Log
Corrective Action
Log
Maintenance supervisor will verify
the accuracy of the product
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
33
Poultry Slaughter Model
HACCP PLAN
PROCESS CATEGORY,SLAUGHTER
PRODUCT EXAMPLE,YOUNG CHICKEN
CCP# and
Location
Critical
Limits
Monitoring
Procedures and
Frequency
HACCP Records Verification Procedures and
Frequency
Corrective Actions
4B
Finished
Product
Storage
(Cold)
4,If product temperature exceeds the
critical limit,the processing authority
will evaluate the product
time/temperature deviation before
release for shipment,If
time/temperature is not sufficient,
product will be cooked in the
establishment to ensure destruction of
pathogens or condemned,
Signature,__________________________________ Date,__________________________ Figure 4
34
Poultry Slaughter Model
REPROCESSING INSPECTION LOG
Date,_________________ Critical Limit,No visible fecal contamination entering
chiller
Time Product ID Results of Inspection Monitor
Initials
Verification
Initials
Corrective Actions and/or Comments
Reviewed by,__________________________________ Date,______________________
35
Poultry Slaughter Model
CHILLING LOG
Date,_________________ Critical Limit,Internal temperature of ≤40
0
F when product exits chiller
Time Product ID Internal
Temperature
Monitor
Initials
Verification
Initials
Corrective Actions and/or Comments
Reviewed by,__________________________________ Date,______________________
36
Poultry 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,_______________________
37
Poultry Slaughter Model
GENERIC ESTABLISHMENT X,
ROOM:__________ DATE:_________
TIME TEMP Deviation from
CL?
yes)
If Yes,
Action?
Monitored by,Verified by,
ROOM TEMPERATURE LOG
(Check if
38
Poultry Slaughter Model
ESTABLISHMENT X,
Date Lot # Time Solution
Concentration
Pressure Corrective Actions Monitored
by,
Verified
by,
Intervention Monitoring Log Antimicrobial
39
Poultry Slaughter Model
CORRECTIVE ACTIONS LOG
Product,___________________________________________ Lot # ______________________
CCP Deviation/
Problem
Corrective Action
Procedures/Explain
Disposition of
Product
Responsible
Person
Date/Time
SIGNATURE,__________________________ DATE,______________________
40
Poultry 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,
41
