Safe Food Guidelines For Small Meat And Poultry Processors .
PuRDuE ExTEnSiOnSafe food guidelines for small meat and poultry processorsFS-20-WOverview of HACCPHazard Analysis Critical Control PointIntroductionKevin Keener, Ph.D., P.E.Food process engineer, Extensionspecialist, and associate professorof food scienceOutline1.2.3.4.5.6.Brief background of HACCPWhat is HACCP?Prerequisite programs and HACCPDeveloping a HACCP programMeeting state and federal regulationsAction steps for the processorThe Purdue Department ofFood Science has long been aleader in training students towork in the food processingindustry. For many years, foodscience Extension specialistshave provided food safety andHACCP training to the foodindustry. For small meatprocessing plants, an effectiveHACCP program requirestrained and highly motivatedindividuals. Each meatprocessing plant’s HACCP planis unique. A successful HACCPplan identifies and controls allfood safety hazards found in thefood processing operation.Federal regulations, phased in from1998 until 2000, require all large, small,and very small meat and poultryprocessors to implement a HACCPplan. For a small or very small processor,sorting all of the vast information onHACCP can seem overwhelming,especially when time and resourcesare limited. This fact sheet explainsthe benefits of HACCP, presents anoverview of HACCP principles, andlooks at the big picture. It answers thequestions: “Why is HACCP important?”and “Where does sanitation fit intoHACCP?” This fact sheet alsoprovides steps the small processor cantake to implement a HACCP system.1. Brief background of HACCPSince the Federal Meat InspectionAct of 1906 and the Poultry ProductInspection Act of 1957, meat andpoultry manufacturers have beendirectly charged with producing safe,wholesome, and unadulterated foods.As a whole, the U.S. food industry hasdone an excellent job of maintainingthe safety of its products. Unfortunately,over the years, foodborne illnesses haveresulted in thousands of sicknessesand many deaths. Investigators havealways tried to trace foodborne illnessoutbreaks back to the food processor,determine what went wrong, and thenrequire them to fix the problem. Overtime, it became clear that takingaction after the fact was inadequateto protect consumers from foodborneillness.
Overview of HACCP (FS-20-W)In response to consumer concerns, the U.S.Department of Agriculture (www.usda.gov) and theFood and Drug Administration (www.fda.gov) haverequired plants to implement a food safety programcalled Hazard Analysis Critical Control Point. Thisprogram was developed by the Pillsbury Co. for NASAin the late 1960s to ensure the complete safety of foodfor space missions. The program provides a proactiveapproach to food safety by requiring plants to identifyall potential avenues of contamination (hazards) anddetermine how to control, reduce, and/or prevent themto ensure that safe food will be produced.The timeframe to implement a HACCP programwas based on the size of the processing plant, startingwith the very largest. However, all meat and poultryplants were required to phase in a working HACCPplan by January 2000. The very small plants were thelast required to implement a HACCP program inJanuary 2000. Many very small meat processors havehad difficulty developing, writing, and implementinga HACCP plan because of limited expertise andresources. This fact sheet provides backgroundinformation on HACCP requirements, steps a smallprocessor can take to develop a HACCP plan, and alist of available resources.On July 25, 1996, the Food Safety and InspectionService (www.fsis.usda.gov) of the USDA publisheda final rule on Pathogen Reduction: Hazard AnalysisCritical Control Point Systems. The PR/HACCP rulerequires all meat and poultry plants to takeresponsibility for identifying and controlling, reducing,or eliminating chemical, physical, and biologicalhazards (including pathogenic bacteria). The HACCPrequirements that all plants must meet are describedin Title 9, Part 417, of the Code of Federal Regulations(www.access.gpo.gov/nara/cfr/waisidx 02/9cfr41702.html). (As part of complying with HACCP,processing plants must also develop a writtensanitation program (9 CFR 416, www.access.gpo.gov/nara/cfr/waisidx 02/9cfr416 02.html).2. What is HACCP?HACCP stands for Hazard Analysis CriticalControl Point. HACCP is a systematic approach tothe identification, evaluation, and control of foodsafety hazards. It is a proactive strategy where hazardsare identified and assessed, and control measures aredeveloped to prevent, reduce, or eliminate a hazard.For example, one identified hazard in ready-to-eatturkey (deli meat) is the presence of Salmonellabacteria. To eliminate Salmonella, one control measureis a cooking process where a minimum internalproduct temperature of 165 F for 15 seconds isachieved and documented.2
Overview of HACCP (FS-20-W)There are seven fundamental HACCP principles:Principle 1 — Conduct a hazard analysis.Principle 2 — Determine the critical control points.Principle 3 — Establish critical limits.Principle 4 — Establish monitoring procedures.Principle 5 — Establish corrective actions.Principle 6 — Establish record-keeping anddocumentation procedures.Principle 7 — Establish verification procedures.be trained in food safety practices and that wholesomemeat and poultry products are produced under sanitaryconditions. The minimum allowable sanitary conditionsfor the equipment and facilities are identified asSanitation Standard Operating Procedures. SSOPsconsist of written cleaning and sanitizing procedures,validation procedures, and records regarding sanitaryconditions both pre-processing and during processing.The SSOP verifications by USDA-FSIS are frequentlyperformed on a daily basis.Because of management challenges, many plantshave chosen to subdivide the Sanitation programrequirements into separate programs. Also, someplants have determined additional prerequisiteprograms are needed to ensure food and worker safety.Examples of these are shown in Table 2, along with therelevant portion of the Sanitation regulations. It isimportant to note that when FSIS verifies the regulatoryrequirements, it will only examine those recordsrequired by 9 CFR 416.3. Prerequisite programs and HACCPBefore developing the HACCP program, oneprerequisite program is required: Sanitation (9 CFR416). This prerequisite program requires that employeesHACCP is a systematic approach tothe identification, evaluation, andcontrol of food safety hazards.Examples of common prerequisite programs (Sanitation – 9 CFR 416 citations provided where appropriate)Maintenance416.1–3. 416.6Equipment is designed and constructed with sanitary practices inmind. Preventive maintenance and calibration schedulesestablished and documented.Personal Hygiene 416.1, 416.5All employees and other persons who enter and work in themanufacturing plant must follow the proper hygienic practices.Pre-operationalSSOPs 416.1, 416.11–17 This program documents that food is produced using sanitarySanitationpractices in a sanitary facility using sanitary equipment prior to thestart of daily operations.OperationalSSOPs 416.1, 416.11–17 This program documents that sanitary practices are maintainedSanitationduring processing.Pest Control416.2Effective pest control programs should be in place and monitored.Storage and416.1–416.4All raw materials and products should be stored under sanitaryShippingconditions and proper environmental conditions to assure theirsafety.Traceability and Requirement of theAll raw material and finished products should be lot-coded and aRecall†Bioterrorism Act ofrecall system in place so that rapid and complete traces and recalls2002, Section 306can be done when a product retrieval is necessary.Supplier ControlFacility should ensure that supplier has in place effective GoodManagement Practices and food safety programs.Personal SafetyThis program discusses all nonfood safety issues including(not part ofrepetitive stress injuries, general health, MSDS (Material SafetyHACCP)Data Sheets), etc. Inspections performed by Occupational Safetyand Health Administration.3
Overview of HACCP (FS-20-W)Figure 1Pro-activePlant Food SafetyFood Safety PyramidifiVerSafety and SuitabilityTraceability& gMaintenancenSupplierControlSanitation StandardOperating Procedures (SSOP’s)ioatcatiolidVanHACCPPlanbased on 7 PrinciplesPersonalHygienePestControlShaded programs are viewed by USDA as the Sanitation Program (9 CFR 416).The HACCP plan is a proactive, continual assessmentof ongoing food safety during the processing of thefood. For the HACCP plan to be successful, all of theunderlying programs must be working properly.Further details on Sanitation and other prerequisiteprograms, along with the HACCP principles, arecovered in other fact sheets in this series. It isimportant to note that from USDA’s perspective, onlythose activities indicated in 9 CFR 416 are considered“Sanitation” and will be verified as appropriate. USDAwill review other prerequisite programs only to theextent they support decisions made in the hazardanalysis (HACCP Principle 1) when developing theHACCP plan.In the pyramid, the prerequisite programs andwritten Sanitation program uphold the HACCP planas the critical food safety system.4. Developing a HACCP programOnce a Sanitation program and necessaryprerequisite programs are implemented, a HACCPplan can be developed. Several tasks are required priorto HACCP program development. Those preliminarytasks include:The underlying Sanitation and prerequisite programsprevent the introduction of food safety hazards into theplant, and thus are a foundation for the HACCP plan.For example, not having an equipment maintenanceprogram may lead to the physical hazard of brokenmachinery parts contaminating a ground product. Oneway of looking at the HACCP requirement is to thinkof the HACCP plan as a pyramid (Figure 1). TheHACCP program is built upon the sanitation programand other prerequisite programs. These programsaddress the suitability and food safety of the process. Assemble the HACCP team — The team consistsof individuals who have specific knowledge andexpertise appropriate to the product and process.Other team members include the person(s)responsible for plan maintenance. One person onthe HACCP team must be HACCP-trained. Ateam can be as few as one or two people.4
Overview of HACCP (FS-20-W) Describe the food and its distribution —This provides information on the ingredients,processing methods, and distribution methods(frozen, refrigerated, or at ambient temperature).Classification of the product into a USDA processallows the processor to focus on likely hazardsassociated with this type of product. Describe the intended use and consumers ofthe food — These may be the general public or asegment of the population such as infants, elderly,military, hospital patients, etc. Develop a flow diagram describing the process —This diagram provides a clear, simple outlineof the steps involved in the making the product.A block flow diagram is usually sufficient. Verify the flow diagram — The HACCP teamshould perform an on-site review of the operationto verify the accuracy and completeness of the flowdiagram. Perform a walk-through of the process tomake sure all process steps are covered.Once those preliminary tasks are completed, ameat processor can develop the actual HACCP planby taking the following steps.3. Establish critical limits — Provides a maximum orminimum value to which the biological, chemical, orphysical hazard must be controlled at a CCP toprevent, eliminate, or reduce to an acceptable levelthe occurrence of a food safety hazard. The criticallimit distinguishes between safe and unsafe operatingconditions at a CCP. Each control measure has one ormore critical limits, and they must be scientificallybased. For example, if a chilling step is selected as aCCP for controlling bacterial growth, a certain timeand rate would be specified (e.g. product temperaturemust be reduced from 140 F to 40 F in six hours).4. Establish monitoring procedures — These are aplanned sequence of observations or measurements(e.g. collection of data) to assess whether a CCP isunder control, and to produce an accurate recordfor future use in verification. Monitoring facilitatestracking of an operation, shows if there is a loss ofcontrol at a CCP, and provides writtendocumentation for use in verification. For example,if the chilling step as indicated above was used as aCCP, then you may want to monitor and recordtemperatures every half hour.5. Establish corrective actions — This part of theHACCP program specifies what is done when adeviation occurs: Who is responsible forimplementing the corrective actions? What happensto the product? What caused the deviation? Howcan it be prevented from reoccurring? Producersmust generate a record documenting these decisions.1. Conduct a hazard analysis — First, the HACCPteam reviews the ingredients used, activities at eachprocessing step, and method of storage anddistribution of final product, including intendeduse by consumers. Then the team makes a list offood safety hazards that are reasonably likely tocause injury or illness if not controlled. Next, eachhazard is evaluated and its likelihood of occurrenceis determined. The hazards are categorized aschemical, physical, and biological. Supportingdocumentation is needed to justify all decisionsabout whether or not something is a hazard. Forexample, a physical hazard of metal shavings fromgrinding may not be a hazard likely to occur if yourmaintenance program (and its records) documentsthat periodic checks of the grinder are performedand worn parts are replaced.2. Determine critical control points (CCPs) — Thisidentifies a step in the process at which control mustbe applied to prevent, eliminate, or reduce to anacceptable level a food safety hazard. Examples ofCCPs may include cooking times and temperatures,chilling times and temperatures, or pH control.5
Overview of HACCP (FS-20-W)7. Establish verification procedures — Verificationconsists of those activities that determine thevalidity of the HACCP plan and show that thesystem is operating according to the plan. Part ofverification is validation. Validation is the scientificinformation, in-plant data, or expert opinionsdocumenting that the existing process(es) — andtheir respective critical control points, critical limits,and monitoring procedures — produce a safe foodproduct. A validation example might be thedocumentation used to select a cook step to controlsalmonella in a ready-to-eat product, the minimumtime and temperature needed to cook the product,and the frequency of temperature monitoring toensure safety. The second part of verification is to“verify” that the validated plan is being followedcorrectly. Examples of “verifying” include: calibrationof process monitoring instruments, direct observationof monitoring activities and corrective actions, andreview of records generated and maintained inaccordance with 9 CFR 417.5(a)(3) 0800/edocket.access.gpo.gov/cfr 2002/janqtr/9cfr417.5.htm).Verification procedures are the most difficult part ofdeveloping a HACCP plan for small and very smallprocessors. A separate fact sheet in this series dealsspecifically with those issues.5. Meeting state and federal regulationsTwo laws directly pertain to meat and poultryprocessing food safety: the Federal Meat InspectionAct and the Poultry Products Inspection Act. In orderto process meat or poultry, processors must complywith the regulations developed to assure that these lawsare obeyed. These regulations are maintained in theCode of Federal Regulations in Title 9. Requirementsfor a sanitation program are contained in 9 CFR 416.Regulations mandating a written HACCP plan arecontained in 9 CFR 417. At least one employee or theirrepresentative at a meat or poultry slaughter orprocessing plant must meet minimum HACCPtraining requirements (9 CFR 417.7). HACCP trainingis offered through many university Extension programs,private food consulting firms, the Food ProductsAssociation, and numerous trade organizations.6. Establish record-keeping and documentationprocedures — These records should include thefollowing: Sanitation program records — SSOPs and othersrequired in 9 CFR 416. Prerequisite program records — USDA-FSISwill view prerequisite program records that areidentified in HACCP plan. Hazard analysis and decision-makinginformation — these records should include therationale for identifying hazards and selectingcritical control points. HACCP records — monitoring, pre-shipmentreview, corrective actions, verification, annualHACCP reassessment.6
Overview of HACCP (FS-20-W)Purdue Extension6. Action steps for the processor Look up, print, and read the sanitation regulationfor meat and poultry processing in the Code ofFederal Regulations Title 9, Part 416.} www.access.gpo.gov/nara/cfr/waisidx02/9cfr416 02.html Select the person(s) who will make up the HACCPteam. Look up, print, and read the HACCPregulations for meat and poultry processing inthe Code of Federal Regulations Title 9, Part 417.} www.access.gpo.gov/nara/cfr/waisidx02/9cfr417 02.html Enroll in an introductory HACCP course throughthe Purdue Department of Food Science(www.foodsci.purdue.edu) or another provider.Other publications in this seriesFS-21-W, Small Meat Processing Plants: SSOP andGMP Practices and Programs (Sanitation StandardOperating Procedures and Good ManufacturingPractices)} www.ces.purdue.edu/extmedia/FS/FS-21-W.pdfFS-22-W, Small Meat Processing Plants: A PestControl Program} www.ces.purdue.edu/extmedia/FS/FS-22-W.pdfFS-23-W, Small Meat Processing Plants: A Recalland Traceability Program} al resourcesPurdue Department of Food Science,} www.foodsci.purdue.edu/outreachFood Safety and Inspection Service of the USDA,} www.fsis.usda.govFSIS food safety resources for the small andvery small plants,} www.fsis.usda.gov/science/HACCP ResourcesBrochure/index.aspAcknowledgementThe author would like to acknowledge the financialsupport of the United States Department ofAgriculture/Food Safety Inspection Service/StrategicInitiatives, Partnerships, and Outreach Office indeveloping this fact sheet. This fact sheet was developedwith a portion of the funds provided from cooperativeagreement FSIS-C-30-2003.For additional informationKevin KeenerAssociate professor, food process engineer, andExtension specialistDirector, Food Technology Development LaboratoryPurdue Department of Food ScienceWest Lafayette, IN 47907-2009Phone: (765) 494-6648kkeener@purdue.eduFS-24-W, Small Meat Processing Plants: VerificationPrograms} www.ces.purdue.edu/extmedia/FS/FS-24-W.pdfFS-25-W, Small Meat Processing Plants: Selection andMaintenance of Temperature Measurement Devices} www.ces.purdue.edu/extmedia/FS/FS-25-W.pdfNew 9/07You can order or download materials on this and othertopics at the Purdue Extension Education Store.www.ces.purdue.edu/newIn accordance with Purdue policies, all persons have equalopportunity and access to Purdue University’s educationalprograms, services, activities, and facilities without regard torace, religion, color, sex, age, national origin or ancestry, maritalstatus, parental status, sexual orientation, disability or status asa veteran. Purdue University is an Affirmative Action institution.This material may be available in alternative formats.
processing plants, an effective HACCP program requires trained and highly motivated individuals. Each meat processing plant’s HACCP plan is unique. A successful HACCP plan identifies and controls all food safety hazards found in the food processing operation. Overview of HACCP Hazard
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