HACCP Plan For Fresh Canned Mushrooms

HACCP Plan For Fresh nominatened cullsThis project is based on the maturation of a generic model of a HACCP plan for fresh basened mushroom clouds by the usage of Canadian food for thought Inspection potencys food Safety Enhancement Program. The goal of this program is to indicate bargon negligible requirements for an effective food safety device management governance. It is based on the principles of the act Analysis and exact agree take (HACCP) system developed by the Codex Alimentarius Commission. FSEP has created 10 specific melodic phrases that apprize be use for the documentation of a HACCP plan. The 10 FSEP-HACCP Plan forms areHACCP is an acronym for the Hazard Analysis Critical Control Point system, which is identical with food safety management. Basic whollyy it is a system which identifies, evaluates, and moderate conditions feigns which are significant for food safety. It gives pledge that food safety is being administered efficiently. The method looks for hazards, or anything that could go wrong regarding produce safety, and implements controls subsequently to hold in that the harvest-feast depart non causation harm to the consumer. HACCP was developed originally as a microbiological safety system in the early days (1960s) of the US manned space programme, as it was vital to match the safety of food for astronauts. The Pillsbury Company working alongside the National Aeronautics and Space Administration (NASA) of the joined States and the US Army Laboratories developed the original system (International trade centre December, 2002).PRINCIPLES OF HACCP-There are seven discrete activities that are necessary to establish, implement and maintain a HACCP plan, and these are referred to as the seven principles in the Codex Guideline (1997). The seven principles are article of faith 1- Conduct a hazard analysis. send hazards and assess the risks associated with them at apiece tincture in the commodity system. Describe possibl e control measures. prescript 2- Determine the Critical Control Points (CCPs)A captious control smirch is a dance trample at which control can be applied and is essential to prevent or eliminate a food safety hazard, or flash back it to an grateful level. The determination of a CCP can be facilitated by the coat of a decision tree, such as the one given in Appendix IV.Principle 3- Establish critical frontiers.Each control measure associated with a CCP must have an associated critical limit which separates the acceptable from the unacceptable control parameter.Principle 4- Establish a monitoring systemMonitoring is the scheduled measurement or observation at a CCP to assess whether the step is on a small-scaleer floor control, i.e. within the critical limit(s) specified in Principle 3.Principle 5- Establish a routine for disciplinary action, when monitoring at a CCP indicates a deviation from an established critical limit.Principle 6- Establish procedures for verification to confirm the effectiveness of the HACCP plan.Such procedures include auditing of the HACCP plan to review deviations and harvest-time dispositions, and stochastic sampling and checking to validate the whole plan.Principle 7- Establish documentation concerning all procedures and records appropriate to these principles and their application(Food and Agricuture Organization 2003)BASIC TERMINOLOGY INVOLVED IN HACCP-Corrective Action Detection and eradication of the causes of a problem, thus preventing their recurrence.Critical Control Point A point, step, or procedure at which control can be applied and as a entrust, a food safety hazard can be prevented, eliminated, or reduced to acceptable levels.Critical Limits- The maximum or minimum value to which a strong-arm biological, or chemical substance hazard must be controlled at a critical control point to prevent, eliminate, or reduce to an acceptable level the incident of the identified food safety hazard.Deviation ill luck to meet a critical limit.HACCP Plan The written document that is based upon the principles of HACCP and delineates the procedures to be followed to ensure the control of a specific process or procedure.HACCP System The HACCP plan in operation, including the HACCP plans itself.Hazard Any biological, chemical, or physical property that may cause a food to be unsafe for homosexual consumption.Hazard Analysis- The identification of any hazardous biological, chemical, or physical properties in raw tangibles and processing move, and an judicial decision of their likely occurrence and potential to cause food to be unsafe for consumption.Preventive Measure corporeal, chemical, or other means that can be used to control an identified food health hazard. work- A method consisting of any number of separate, distinct, and ordered operations that are directly under control of the establishment employed in the manufacture of a specific product, or a group of twain or more products wher ein all CCPs, such as packaging, may be applied to one or more of those products within the group.DEVELOPMENT OF PLANT SPECIFIC HACCP PLAN-Some preliminary steps are required before development of a fix specific HACCP plan. These includes assembling of HACCP police squad, describing the food and its method of distribution, identifying the intend use and the consumers of the food, developing the flow diagram that describes the process and finally verifying the flow diagram. The following steps are all a part of developing your bring-specific plan.Description of the Product The primary step in the development of the model for your process. To help you to progress through the remainder of your model development, it lead assist you in describing your product. extremity Flow Diagram After completing product comment, this form should be completed. This step consists of the raceway of the process as the product moves from receiving to finished products shipping. It is helpful to comp lete this portion of your plan while actually walking through your vegetation and following the production steps involved in the particular product or process.Hazard Analysis This is a crucial step in the development of a sic specific HACCP plan. This portion must take into consideration the risk or likelihood of incident, and the rigorousness of each hazard. In order to be considered, an identified hazard must be of such a temperament that its prevention, elimination, or reduction to an acceptable level is essential to the production of a safe food. Hazards that are not significant or not likely to occur will not require further consideration. accord to its frequency, risk, and severity, the potential significance of each hazard should be assessed. Risk is an estimate of the likely occurrence of a hazard. The estimate of risk is usually based on a combination of experience, epidemiological data, and information in the technical literature. Pathogenic microorganisms of public h ealth significance should be identified as a biological hazard with disturbance measures to preclude their growth and propagation. In your hazard analysis there are trine categories of hazards to considered chemical, biological, and physical. Each process step will be evaluated to determine if significant hazards from one or more of these categories are present. The hazards will be listed at each process step along with the specific preventive measures that can control the hazard. Identify the processing steps that present significant hazards and any preventive measures on the Hazard Analysis/Preventive Measures Form. These will be derived from the process steps on your flow diagram.Critical Control Point (CCP) Determination Detection and explanation of the CCP for each identified hazard is the coterminous step in plan development. For the completion of this form we need the CCP determination and the information and data you recorded on the Hazard Analysis/Preventive Measures for m.HACCP Plan Development To ensure that your process is under control and commensurate to produce a safe product, this portion of the plan development will be used to indicate the specific activities, frequencies, critical limits, and corrective actions. In addition, the HACCP plan will include specification of critical limits. These limits will be specified after the identification of the CCPs for the process and will be listed in the HACCP Plan. The critical limit must, at a minimum, meet the regulatory requirement for that specific process step if one exists. An tantamount(predicate) limit based on a process or technology proven to render the product unadulterated may also be used. The following will be identified or exposit in the HACCP plan the establishment monitoring procedure or device to be used the corrective action to be taken if the limit is exceeded the individual responsible for taking corrective action the records that will be generated and maintained for each CCP and the establishment verification activities and the frequency at which they will be conducted.(United States part of factory farm April, 1997)MODEL PLAN FOR FRESH CANNED MUSHROOMS-Hazard Analysis The foremost critical step in the effective development and implementation of the whole kit and caboodle specific HACCP plan is conducting an analysis of the physical, chemical, and biological hazards associated with a process. The information gathered for the biological, chemical, or physical hazard will aid in determining where a hazard might happen in the process, what may possibly cause the hazard, how it can be prevented, and actions to be taken if conditions which could result in a hazard occur. Information on physical hazards may be more general and may consist simply of items found in foods that are injurious to human health such as glass, metal, broken needles, etc. The evaluation of physical hazards should include the suppliers utilized and their world power to provide pro ducts, ingredients, or poppycocks that meet the food safety requirements of the plant. Past incidents of physical taint occurring in the plant should also be a consideration when determining the significance of a hazard and the likely occurrence of a similar or related deviation. If specific chemical hazards exist that are associated with the process, these should also be considered at this point. Contamination from chemicals used for cleaning, equipment maintenance or upkeep is also of concern(United States Department of Agriculture April, 1997).Critical Control Point Decision Tree-(http//www.fda.gov/ucm/groups/fdagov-public/documents/image/ucm054476.gif).PREPARING YOUR HACCP PLAN-Assemble the HACCP team Your HACCP team should be composed of a HACCP trained individual and/or other member(s) who are familiar with the product and the process as it is conducted in your plant. There is no set number of participants. This will be obdurate by each individual establishment. All team me mbers should receive at least a prefatorial introduction to HACCP. Training can be formal classroom training, correspondence, on-the-job training, information from college courses, and/or books or manuals.Product Description Form-Form 1Product Name(s) Canned mushroomsImportant Product Characteristics (aw, pH, Salt, Preservatives,) pH 4.6 to 6.5 (low-acid)aw 0.85 (high moisture)How it is to be used Normally heated before serving or sometimes served unheated (salads, appetizers, etc) and can also be used for dressing Pizza etc. packaging Hermetically sealed metal nurseerShelf Life Exactly Two years plus from the date of purchase, at normal retail shelf temperaturesWhere it will be sold Retail outlets, institutions, food service, and general publicLabeling Instructions As per the ingredients added.Special Distribution Control No physical defile, excess humidity or temperature extremesDate sanctioned by(Canadian Food Inspection Agency 2009) identify of Product Ingredient and inpouri ng Material-This form is only needed if there is more than one ingredient.Form 2Raw Material picksPackaging Materials Cans Ends alter Ingredients Salt Ascorbic acid Citric acidOther WaterDate Approved by(Canadian Food Inspection Agency 2009)Process Flow Diagram-Plant Schematic-A plant conventional should be prepared for the products or process groups covered by the HACCP plan. Plant schematic provides a basis for calculating prospective regions of cross- befoulment. Plant schematic shall be clear, accurate and sufficiently detailed. Plant schematic shall at least include the flow of raw products, ingredients and finished products, flow of packaging substantials, employee traffic manikin throughout the establishment including change rooms, washrooms and lunchrooms, flow of the waste, inedible products and other non-food products that could cause cross-contamination and finally the hand/ complaint washing and sanitizing installations. The overall evaluation of potential areas of c ross-contamination at the establishment should include any other plant schematic from other HACCP plans. The HACCP team shall verify the accuracy and completeness of the plant schematic by on-site checking.(Canadian Food Inspection Agency 2009). biologic Hazard Identification-Form 5 biologic HazardsList all Biological Hazards related to Ingredients, entranceway Material, bear upon, Product Flow, etc.identify Biological Hazards (Bacteria, Parasites, Viruses) unveiling Materials picksCould look at C. botulinus or other pathogenic bacteria, yeasts and mouldsCould contain heat-stable staphylococcal enterotoxin from improper grower handlingEmpty cans/endsCans could issue forth with thoughtful double seam, side seam, metal plate defects or physical damage which could result in fountain causing post-process contaminationEnds could arrive with raise skips, metal plate defects, or damage, which could result in leakage causing post-process contaminationDry ingredientsCould contain ba cterial sporesCould contain brand from insects, animals or the environmentWaterCould contain pathogensProcess tintsReceivingEmpty cans/ends received from suppliers without valid contract specifications could have serious defects or damageDry ingredients received from suppliers without valid contract specifications could be contaminated with bacterial spores or filth from insects, animals or the environment mushroom clouds (Raw) StoringImproper storage temperature humidity could result in an increased bacterial incubusCould be contaminated with filth from insects, animals or the environmentEmpty Cans/Ends StoringPhysical damage could cause the formation of poor double seams, which could result in post process contamination with pathogenic bacteriaCould be contaminated with filth from insects, animals or the environmentDry Ingredients StoringCould be contaminated with filth from insects, animals or the environmentDepalletizingUsing incorrect cans or modify cans could result in l eakage and subsequent post-process contamination with pathogenic bacteriaBlanchingImproper cleaning of blancher could result in the growth of thermophilic bacteria in mushroom accumulations pitiable removal of gases could cause stressed double seams and leakage, which could result in post-process contamination with pathogenic bacteriaCan conveyingPhysical damage could cause the formation of poor double seams, which could result in post process contamination with pathogenic bacteriaSlicing/Dicing (If required)Slice ponderousness/clumping and percent fines could scratch the heat penetration, which could result in underprocessing plectronMushroom compaction during filling may result in underprocessing advisementCans not properly rejected for overweight could result in overfilled cans being underprocessedWater pickaxeInadequate temperature could result in low initial temperature (IT)End Feeding/Closing/InspectingEnds with dishonored curls, sharpen skips or other serious defects cou ld result in leakage and contamination with pathogenic bacteriaimproperly formed double seams could result in leakage and contamination with pathogenic bacteriaThermal Processing (Still Steam Retorts)Non-validated process or vent schedule could result in underprocessing and survival of pathogenic bacteriaImproper product flow procedures in retort area could result in retort baskets wanting(p) the retort allowing the survival and growth of pathogenic bacteria overmuchive time lapse between terminal and retorting could result in excessive build up of bacteria, some of which could survive the thermal process deprivation of adherence to time, temperature and other critical factors of the scheduled process or vent schedule could result in inadequate heat treatment allowing the survival of pathogenic bacteriaCoolingInsufficient bactericide in cooling water could result in contamination of product during vacuum creation in cansExcess bactericide in cooling water could eventually result i n corrosion and subsequent leakage and contamination of productInsufficient contact time between the bactericide and water could result in contamination of product during vacuum creation in cansInsufficient cooling could result in thermophilic despoliation lush cooling could result in post-process contamination due to leakage of corroded cansConveying/Drying colly water from wet unclean post-process can handling equipment and general handling could contaminate productContainer faithfulness Evaluating/Labelling chastening to statistically sample and/or dud detect lots and reject and evaluate containers with no/low vacuum or serious defects could result in defective product going to marketPhysical damage to cans could result in leakage and contamination of productStoringPhysical damage to cans could result in leakage and contamination of productHigh temperatures could result in growth of thermophilic bacteria cargo shipsPhysical damage to cans could result in leakage and contaminat ion of productDate Approved by(Canadian Food Inspection Agency 2009)Chemical Hazard Identification-Form 6 Chemical HazardsList all Chemical Hazards Related to Ingredients, Incoming Material, Processing, Product Flow, etc.Identified Chemical HazardsIncoming MaterialsMushroomsCould contain agricultural chemicals residuesEmpty cans/endsCould be contaminated with cleaning chemicals and lubricantsWaterCould be contaminated with dissolved lumbering metals or toxic organic chemicalsProcess gradesReceivingEmpty cans/ends received from suppliers without valid contract specifications could contain cleaning chemical residues and/or lubricantsEmpty Cans/Ends StoringImproper storage of cleaning compounds and other chemicals could lead to revoke can/end contaminationDry Ingredients StoringImproper storage of cleaning compounds and other chemicals could lead to run dry ingredient contaminationBlanchingExcessive cleaning chemical residues and/or lubricants could cause product contaminationMush room Conveying/InspectingExcessive cleaning chemical residues and/or lubricants could cause product contaminationSlicing/Dicing (If required)Excessive cleaning chemical residues and/or lubricants could cause product contaminationFillingExcessive cleaning chemical residues and/or lubricants could cause product contaminationEnd Feeding/Closing/InspectingExcessive cleaning chemical residues and/or lubricants could cause product contamination Date Approved by(Canadian Food Inspection Agency 2009)Physical Hazard Identification-Form 7 Physical Hazards with ControlsList all Physical Hazards Related to Ingredients, Incoming Material, Processing, Product Flow, etc.Identified Physical HazardsIncoming MaterialsMushroomsCould be contaminated with hazardous out-of-door material, eg. glass, metal, plastic, stones and woods (slivers and fragments)Empty cans/endsCould contain hazardous strange materialDry ingredientsCould be contaminated with hazardous extraneous materialProcess StepsReceivingC ans received from suppliers without valid contract specifications could contain hazardous extraneous materialDry ingredients received from suppliers without valid contract specifications could contain hazardous extraneous materialRaw Mushroom StoringInadequate protection against hazardous extraneous material could result in contamination of raw mushroomsDry Ingredients StoringInadequate protection against hazardous extraneous material could result in contamination of the food ingredientsCan ConveyingInappropriate design and protection against hazardous extraneous material could result in contamination of the final food productMushroom Conveying/InspectingInappropriate design and protection against hazardous extraneous material could result in contamination of the mushroomsSlicing/Dicing (If required)Product could perish contaminated with metal fragments from plant equipmentForeign-Object RemovingInadequate monitoring and cleaning of foreign object remover could allow foreign object s to contaminate the productFillingCans of filled mushrooms could become contaminated with metal fragments from filling equipmentEnd Feeding/Closing/InspectingCans of filled mushrooms could become contaminated with metal fragments from closing machine during and after jam upsDate Approved by(Canadian Food Inspection Agency 2009)Critical Control Point Determination-Form 8Category and Identified HazardDetermine if fully controlled by demand Program(s)If YES, indicate necessary Program and break to future(a) identified hazard.If NO, proceed to question 1 (Q1)Q1. Could a control measure(s) be used by the instrument at any process step?If NO = not a CCP + identification on how this hazard will be controlled before and after the process+ proceed to the next identified hazardIf YES = description + next question (Q2)Q2. Is it likely that contamination with the identified hazard could occur in excess of the acceptable level or could increase to an unacceptable level?If NO = not a CCP + proceed to the next identified hazardIf YES = next question (Q3)Q3. Is this process step specifically designed to eliminate/reduce the likely occurrence of the identified hazard to an acceptable level?If NO = next question (Q4)If YES = CCP + go to last columnQ4. Will a subsequent step eliminate the identified hazard or reduce likely occurrence to an acceptable level?If NO = CCP + go to last columnIf YES = not a CCP + identify subsequent step + proceed to the next identified hazardCCP Number+ proceed to next identified hazardProcess Step/Incoming Material Mushrooms as deliveredBiologicalPathogensYes hot pants treatmentYesN/AYesThermal ProcessingBiologicalHeat stable toxinsNoupstream programs (farms)ChemicalAgricultural chemicalsNoUpstream programs (farms)Physical speculative extraneous materialYesVisual reappraisalPlant equipmentNoProcess Step/Incoming Material Empty cans/ends as deliveredBiological stand process contamination from serious can defects and damageYes take aim specific ationsVisual and can tear-down inspectionYesN/AYesReceivingBiologicalPost process contamination from compound skips, plate defects and end damageYes find specificationsVisual end inspectionYesN/AYesReceivingChemical killing chemical contaminants and lubricantsYesContract specificationsYesN/AYesReceivingPhysicalHazardous extraneous materialYesContract specificationsYesN/AYesReceivingProcess Step/Incoming Material Dry ingredients as deliveredBiologicalBacterial sporesYesContract specificationsYesN/AYesReceivingBiologicalFilthYesContract specificationsYesN/AYesReceivingPhysicalHazardous extraneous materialYesContract specificationsYesN/AYesReceivingProcess Step/Incoming Material Water at intakeBiologicalPathogensnecessity programsChemicalHeavy metals other toxic chemicalsPrerequisite programsProcess StepProcess Step/Incoming Material ReceivingBiologicalEmpty cans/ends received from suppliers without contract specifications may contain serious defects, or damageYesContract specification sYesYesCCP-1BiologicalDry ingredients received from suppliers without contract specifications may contain bacterial spores or filthYesContract specificationsYesYesCCP-1ChemicalEmpty cans/ends received from suppliers without contract specifications may contain chemical residues or lubricantsYesContract specificationsYesYesCCP-1PhysicalEmpty cans/ends and dry ingredients received from suppliers without contract specifications may contain hazardous extraneous materialYesContract specificationsYesYesCCP-1Process Step/Incoming Material Mushrooms Refrigerated storingBiologicalIncreased bacterial loadPrerequisite programsBiologicalFilthPrerequisite ProgramPhysicalHazardous extraneous materialPrerequisite programsProcess Step/Incoming Material Cans/Ends StoringBiologicalPost process contamination due to cans/ends damaged during storagePrerequisite programsBiologicalFilthPrerequisite programsChemicalCleaning chemical contaminationPrerequisite programsProcess Step/Incoming Material Dry Ingred ients StoringBiologicalFilthPrerequisite programsChemicalCleaning chemical contaminationPrerequisite programsPhysicalHazardous extraneous material from storeroomPrerequisite programsProcess Step/Incoming Material Can DepalletizingBiologicalPost-process contamination due to incorrect or damaged cansPrerequisite programsProcess Step/Incoming Material BlanchingBiologicalGrowth of thermophilesPrerequisite programsBiologicalInadequate removal of gasesPrerequisite programsChemicalCleaning chemical residues and/or lubricantsPrerequisite programsProcess Step/Incoming Material Can ConveyingBiologicalPost-process contamination due to damaged cansPrerequisite programsPhysicalHazardous extraneous material from plant environmentPrerequisite programsProcess Step/Incoming Material Mushroom / Conveying / InspectingChemicalCleaning chemical residues and/or lubricantsPrerequisite programsPhysicalHazardous extraneous materialPrerequisite programsProcess Step/Incoming Material Slicing/Dicing (If requir ed)BiologicalImproper slice thickness / clumping, and percent fines could result in under-processingPrerequisite programsChemicalCleaning chemical residues and/or lubricantsPrerequisite programsPhysicalMetal fragments from equipmentPrerequisite programsProcess Step/Incoming Material Foreign Object RemovingPhysicalFailure to remove foreign objectsPrerequisite programsProcess Step/Incoming Material FillingBiologicalMushroom compaction during filling resulting in under processingPrerequisite programsChemicalCleaning chemical residues and/or lubricantsPrerequisite programsPhysicalMetal fragments from equipmentPrerequisite programsProcess Step/Incoming Material WeighingBiologicalProduct heavier than maximum fill weight in scheduled process could result in under-processingYesWeighingYesYesCCP-2Process Step/Incoming Material Water fillingBiologicalInadequate temperature resulting in low itYesTake it just prior to thermal processYesNoYesThermal ProcessingProcess Step/Incoming Material End F eeding/Closing/ InspectingBiologicalPost-process contamination due to damaged ends, compound ski