HACCP Plan – Fully Cooked, Not Shelf-stable; Soup Product .

HACCP Plan – Fully cooked, not shelf-stable; Soup1. Process Step10. Assembly ofingredients2. Food SafetyHazardChemical –cleaning/sanitizingchemical residuesPhysical – NoneBiological - Presence orgrowth of pathogens(see list in step 3above)Chemical – Cheese,flour, thickeners, gravycontain potentialallergens;cleaning/sanitizingchemical residues3.4. Basis ofReasonably Reasonably likelylikely toto occuroccurNoNoYes(Presence)No(Growth)No12/15/05 version. Supersedes all previous versions.5. If Yes in Column 3,What Measures Could beApplied to Prevent,Eliminate, or Reduce theHazard to an AcceptableLevel?Pre-operationalSSOP makes hazardunlikely to occur.Rawmeat/poultry/vegetables are a knownsources ofpathogens.Assembly is donerapidly enough toprevent pathogengrowth.Application ofcorrect labelprevents inadvertentconsumption ofallergen byconsumer.Operational SSOPprevents crosscontamination ofallergenic agents.Pre-op SSOP makesHazard will be controlled bylater CCP’s of cooking (destroysvegetative cells) andcooling/freezing (preventsgermination and growth ofclostridial spores).6. CriticalControl Point

HACCP Plan – Fully cooked, not shelf-stable; Soup1. Process Step2. Food SafetyHazard3.4. Basis ofReasonably Reasonably likelylikely toto occuroccur5. If Yes in Column 3,What Measures Could beApplied to Prevent,Eliminate, or Reduce theHazard to an AcceptableLevel?6. CriticalControl Pointpresence of chemicalresidues unlikely tooccur.11. Cooking13. Cooling/FreezingPhysical – NoneBiological – Survival orgrowth of pathogens(see lists in steps 2and 3 above);NoYes(Presence)No(Growth)Chemical – NonePhysical - NoneBiological –Growth ofClostridiumperfringens orClostridium botulinum.Pathogen contaminationvia equipment on)12/15/05 version. Supersedes all previous versions.Rawmeat/poultry/vegetables are knownsources ofpathogens. Cooking isdone rapidly enoughto prevent pathogengrowth.Hazard will be controlled byexposing pathogens (if present)to sufficiently hightemperatures for a long enoughtime to ensure destruction ofvegetative pathogens.1BSpores survivecooking and cangerminate and growif cooling is done tooslowly.Product is cooled rapidly enoughto prevent growth of Clostridiumperfringens ( 1 log) orClostridium perfringens.2BSSOP makescontamination viaequipment andworkers unlikely tooccur.

HACCP Plan – Fully cooked, not shelf-stable; Soup1. Process Step12 and 14. Packaging2. Food SafetyHazardChemical – NonePhysical - NoneBiological – Growth ofClostridiumperfringens orClostridium botulinum;Presence or growth ofListeria monocytogenesand other pathogenslisted in steps 2 and 3above (post-cookcontaminants).3.4. Basis ofReasonably Reasonably likelylikely toto )No(L.m. Growth)15. Finished productstorage, shippingChemical – NonePhysical - NoneBiological – NoneNoNoNo12/15/05 version. Supersedes all previous versions.Product is properlycooled/frozen eitherbefore or afterpackaging(prevents/limitspathogen growth).Packaging is donerapidly enough sothat clostridialgrowth does notoccur.Listeria controlmeasures, includingtesting program,make hazardunlikely. Pre-op andoperational SSOPsmake contaminationunlikely.Product is handledaccording to SOP for5. If Yes in Column 3,What Measures Could beApplied to Prevent,Eliminate, or Reduce theHazard to an AcceptableLevel?6. CriticalControl Point

HACCP Plan – Fully cooked, not shelf-stable; Soup1. Process Step2. Food SafetyHazard3.4. Basis ofReasonably Reasonably likelylikely toto occuroccurand/or retailChemical – NoneNoPhysical - NoneNo12/15/05 version. Supersedes all previous versions.Finished ProductStorageProduct is handledaccording to SOP forFinished ProductStorageProduct is handledaccording to SOP forFinished ProductStorage5. If Yes in Column 3,What Measures Could beApplied to Prevent,Eliminate, or Reduce theHazard to an AcceptableLevel?6. CriticalControl Point

HACCP Plan – Fully cooked, not shelf-stable; SoupDirections for Using the HACCP Plan Form1. Examine your Hazard Analysis form to determine which steps are CCP’s and what type of hazard(Biological, Chemical, or Physical) each CCP controls.2. Check to see whether each CCP is already listed on the HACCP Plan Form. If a CCP is notalready listed, enter the CCP number and step in the column labeled “CCP # and Location”.3. For CCP’s already listed on the model form, examine the Critical Limits listed. In the HACCPPlan Form for some HACCP categories there will be several options for Critical Limits. If this isthe case, choose the Critical Limits that will work best in your plant and cross out, white out, ordelete the other Critical Limits and the Monitoring Procedures that go with them. It may behelpful to check the “Monitoring Procedures and Frequency” column during your decisionmaking. For CCP’s already on the model form, supporting scientific documentation is alreadyincluded in your manual.4. If you are adding a new CCP, you will need to determine the scientifically valid Critical Limits tobe used with the CCP. You must also obtain scientific information supporting your choice ofCritical Limits. Consult your inspector or university extension specialists for help.5. Examine the “Monitoring Procedures and Frequency” column for each CCP. If you wish tochange the procedure and/or the frequency, check with your inspector or a university extensionspecialist for help. If a change is OK, you will need to write down your reasoning for making thechange and include this reasoning in your HACCP manual.6. Examine the “HACCP Records” column. If you are using different forms for record-keeping inthis HACCP Plan, please put the correct form title(s) in the “HACCP Records” column.7. The verification activities listed in the “Verification Procedures and Frequency” column arerequired by the regulation. However, you may choose to do additional activities; for example, forverification, beef jerky samples may be sent to the lab each quarter for water activity and Moisture: Protein Ratio testing. If you do any additional verification activities, enter them in the“Verification Procedures and Frequency” column. If you choose to use a frequency for therequired verification activities that is different than the frequency shown, you must provide writtenjustification for the different frequency. Consult your inspector or university extension specialistsfor help.8. We suggest that you make no changes in the “Corrective Actions” column. Be sure to have a formfor documenting corrective actions that you take. A corrective action form is included in thismodel.12/15/05 version. Supersedes all previous versions.

HACCP Plan – Fully cooked, not shelf-stable; SoupHACCP PLANPROCESS CATEGORY: Fully cooked, not shelf stableProduct example: SoupCCP# andLocation1B CookingCritical LimitsSoup internaltemperature is heldat a pre-determinedtemperature andtime listed inAppendix A asresulting in a 6.5 loglethality forSalmonella. Notethat no timemeasurement isnecessary if thesoup internaltemperature reaches158ºF or higher. Forpoultry products,the Appendix Atreatment (160ºFinternal temperaturefor uncuredproducts or 155ºFinternal temperaturefor cured products)or one of the newpoultry “safeharbors” treatments(based on % fat inproduct) will beMonitoring Procedures andFrequencyThe plant manager ordesignee will use acalibrated thermometerand a clock (if necessary)to determine the internaltemperature over time inthe coldest part of thesoup batch. Thisprocedure will be followedfor every lot.12/15/05 version. Supersedes all previous tion LogThermometerCalibrationLogVerification Procedures andFrequencyEstablishment owner ordesignee will review the CCPMonitoring Form, CorrectiveAction Log, and ThermometerCalibration Log once per week.Establishment owner ordesignee will calibrate allthermometers to a knownstandard monthly.Thermometers will becalibrated to 2 F or takenout of operation as stated inthe SOP. Calibration actionsare recorded in theThermometer Calibration Log.Establishment owner ordesignee will observemonitoring of temperature atleast once per month.Corrective ActionsIf a deviation from acritical limit occurs, theestablishment owner ordesignee is responsiblefor corrective actionprotocol as stated in 9CFR 417.31.2.3.The cause of thedeviation will beidentified andeliminated.The CCP will beunder control afterthe correctiveaction is taken.Measures toprevent recurrenceare established.4. No product that isinjurious to healthor otherwiseadulterated as aresult of thedeviation will bepermitted to entercommerce.

HACCP Plan – Fully cooked, not shelf-stable; SoupHACCP PLANPROCESS CATEGORY: Fully cooked, not shelf stableProduct example: SoupCCP# andLocationCritical LimitsMonitoring Procedures andFrequencyHACCPRecordsVerification Procedures andFrequencyCorrective ActionsThe plant manager ordesignee will use acalibrated thermometerand a clock to determinethe internal temperatureand time for the soupafter cooking is done.About one hour later, thisprocedure will berepeated. The procedurewill be repeated about 4.5hours after the 2ndtemperature measurement.This procedure will beperformed for every lot.CCPMonitoringFormEstablishment owner ordesignee will review the CCPMonitoring Form, CorrectiveAction Log, and ThermometerCalibration Log once per week.If a deviation from acritical limit occurs, theestablishment owner ordesignee is responsiblefor corrective actionprotocol as stated in 9CFR, 417.3followed.2BCooling/FreezingAppendix B limitsfor uncuredproducts: internaltemperature fallsfrom 130ºF to 80ºFin no more than 1.5hours, and from80ºF to 40ºF in nomore than anadditional 5 hours.CorrectiveAction LogThermometerCalibrationLogEstablishment owner ordesignee will calibrate allthermometers to a knownstandard monthly.Thermometers will becalibrated to 2 F or takenout of operation as stated inthe SOP. Calibration actionsare recorded in theThermometer Calibration Log.Establishment owner ordesignee will observemonitoring of temperature atleast once per month.Sign and date at initial acceptance, modification, and annual ate12/15/05 version. Supersedes all previous versions.1. The cause of thedeviation will be identifiedand eliminated.2.The CCP will be undercontrol after thecorrective action is taken.3.Measures to preventrecurrence areestablished.4.No product that isinjurious to health orotherwise adulterated as aresult of the deviation willbe permitted to entercommerce.

HACCP Plan – Fully cooked, not shelf-stable; SoupDateLotIDCCP Monitoring Form: Critical Limits are cold-point (cooking) or hot-point (cooling) product temperatures and timesCookingInitialsCooling Temperature/Time\\ Critical InitialsDevn.Pre-shipment / pre-use reviewTemperature/Limits: 130 to 80ºF in 1.5 h or less,fromSignature/DateTime80 to 40ºF in 5 h or lessCriticalLimit?(Y yes, N no)1st2nd1st2nd3rdelapsed time since end of cooking0h1h5.5 hVerification Activities (for up to three weeks) associated with these batches. Indicate Type of activity: DOT Direct Observation of Temperature monitoring (monthly), DOL Direct Observation of Labeling monitoring(monthly), CAL thermometer calibration, or RR Records Review (weekly).Type of activity:Type of activity:Type of activity:Result (9 Acceptable):Result (9 Acceptable):Result (9 :Initials:Initials:12/15/05 version. Supersedes all previous versions.

HACCP Plan – Fully cooked, not shelf-stable; SoupFully Cooked, Not Shelf Stable, Soup ModelCorrective Action LogProduct:Date / Time:Deviation:Lot ID:Responsible Person:Cause of Deviation:Cause of DeviationEliminated By:CCP Under ControlAfter CorrectiveActions Taken:Preventative Measures:Product Disposition:Verification (Records Review) by and Date:12/15/05 version. Supersedes all previous versions.

HACCP Plan – Fully cooked, not shelf-stable; SoupThermometer Calibration LogDateTimeTest ReferenceTherm. Therm.ID#ReadingTestTherm.ReadingAdjustments Required(yes/no)CommentsInitialsThermometers intended for measuring higher temperature items, such as cooked product, will be calibrated in hotwater, while those used for taking lower temperatures will be calibrated in ice water. All thermometers will becalibrated within or – 2 degrees F. Thermometers taken out of service , document in the “comments” column.12/15/05 version. Supersedes all previous versions.

HACCP Plan – Fully cooked, not shelf-stable; SoupSOP for Calibration of ThermometerProcessor or designee will calibrate the thermometers prior to use by following thespecifications of the manufacturer of the equipment (this will vary) or the followingprocedures.Each thermometer will be assigned an ID number.Thermometers intended for measuring higher temperature items, such as cooked product,will be calibrated in hot water, while those used for taking lower temperatures will becalibrated in ice water. All thermometers will be calibrated within or – 2 degrees F.Thermometers in use will be checked against a certified thermometer during calibration, ifavailable. Otherwise, all thermometers will be calibrated either against each other, oragainst a thermometer that is used only during calibration. The latter methods wouldrequire at least three thermometers for accuracy. Dial thermometers will only becalibrated (and used!) on one end of the range of use, e.g. either the hot end or the coldend. This practice is followed to assure accuracy.Calibration with ice water:1. Add crushed ice and water to a clean container to form a watery slush.2. Place thermometer probe into slush for at least one minute, taking care to not letthe probe contact the container.3. If the thermometer does not read between 30 degrees and 34 degrees F., adjustto 32 degrees. Nonadjustable thermometers will be removed from use until theyhave been professionally serviced. Thermometers that have been adjusted for 3consecutive months will be replaced.4. Record the results, using actual values, on the thermometer calibration log, alongwith the date and initials of the person performing the calibration procedure.Calibration with hot water:1. Heat a clean container of water to a temperature in the range of cookedproducts. Running clean water through the coffee maker gives a watertemperature of approximately 145 degrees F. Another option is to bring a cleancontainer of water to a rolling boil.2. Place the thermometer probe into the hot water, along with the certifiedthermometer and/or reference thermometer, or at least two other12/15/05 version. Supersedes all previous versions.

HACCP Plan – Fully cooked, not shelf-stable; Soupthermometers, for at least one minute, taking care not to let the probe contactthe container.3. If the test thermometer does not read within or – 2 degrees of the referencethermometer, adjust accordingly. If three thermometers are used and onethermometer differs from the other two by more than 2 F, that thermometershall be adjusted or removed from use. If all three thermometers differ fromeach other by more than 2 F, a reference thermometer must be used or eachthermometer must be calibrated against vigorously boiling water (212 F).Nonadjustable thermometers will be removed from use until they have beenprofessionally serviced. Thermometers that have been adjusted for 3consecutive months will be replaced.4. Record the results, using actual values, on the thermometer calibration log, alongwith the date and initials of the person performing the calibration procedure.Thermometers that cannot be easily calibrated through direct immersion in either icewater or hot water can be calibrated by comparing readings with another calibratedthermometer. Thermometers that may be calibrated in this way include smokehouseprobes and room temperature thermometers. When doing this, a recently calibratedthermometer will be used as the reference. Room temperature thermometers that areoutside the or – 2 degree F range will be replaced. Smokehouse probes that are outsidethe or – 2 degree F. range will be professionally serviced. Results will be recorded, usingactual values, on the thermometer calibration log, along with the date and initials of theperson performing the calibration procedure.Thermometers will be calibrated at a frequency dependent on production volumes, and useof monitoring CCP values or SOP values. Any thermometer that has been dropped orabused will be taken out of service until it has been recalibrated. Any “loose”thermometers, or thermometers that have been out of calibration for 3 consecutivemonths, shall be discarded.Thermometers in use will be checked against a certified thermometer during calibration, ifavailable. Otherwise, all thermometers will be calibrated either against each other, oragainst a thermometer that is used only during calibration. These methods would require aminimum of three thermometers for accuracy. Dial thermometers will not be calibrated onboth the high and low ends on the range it is intended to read to assure accuracy.Thermometers that cannot be easily calibrated through direct immersion in either icewater or hot water can be calibrated by comparing readings with another calibrated12/15/05 version. Supersedes all previous versions.

HACCP Plan – Fully cooked, not shelf-stable; Soupthermometer. Thermometers that may be calibrated in this way include room temperaturethermometers. When doing this, a recently calibrated thermometer will be used as thereference. Room temperature thermometers that are outside the or – 2 degree F. rangewill be replaced. Results will be recorded, using actual values, on the thermometercalibration log, along with the date and initials of the person performing the calibrationprocedure.Thermometers will be calibrated at a frequency dependent on production volumes, and useof monitoring CCP values or SOP values. Any thermometer that has been dropped orabused will be taken out of service until it has been recalibrated. Any “loose”thermometers, or thermometers that have been out of calibration for 3 consecutivemonths, shall be disposed of.12/15/05 version. Supersedes all previous versions.

HACCP Plan – Fully cooked, not shelf-stable; SoupSOP for Receiving and StorageRaw Meat/Poultry and Natural Casings We will only accept product from an approved source. All containers will be inspected for visible evidence of contamination or damage thatmay allow contamination. All contaminated or damaged product will be reje

HACCP Plan – Fully cooked, not shelf-stable; Soup Directions for Use of the Process Flow Diagram 1. Examine the model Process Flow Diagram and determine which steps you actually use in your process. Cross out, white out, or delete all steps that are NOT part