HACCP Generic Model-Mushrooms （Low Acid Canned Foods）.DOC

CANADA:FSEPHACCP Generic Model Mushrooms (Low Acid Canned Foods)Form 1 IntroductionThis HACCP model was designed to serve as an example or guideline for developing establishment specific HACCP plans for low-acid canned food processing plants. It was developed as a pilot project for a fresh mushroom processing cannery using Agriculture and Agri-Food Canadas (AAFC) Food Safety Enhancement Program (FSEP). Canned mushrooms were chosen for this pilot because past records indicate that this processing is associated with well-known problems. The particular canning establishment was chosen because of its size, progressive and cooperative spirit, and dedication to one product. It was felt that this product/establishment provided the environment for a good example of how to use HACCP principles to establish a food safety control program for low-acid canned products. One has to appreciate that this generic model does not present a list of all hazards related to all low-acid food canning establishments, because it was developed for a particular product in a particular establishment. Low-acid canned foods include such a wide variation of products and thermal processing equipment, no one model could represent all hazards. Also, varying conditions in and around different processing establishments sometimes affect the potential occurrence of hazards. Therefore, all critical control points will not necessarily be the same (nor will the means of monitoring and verifying them) for different establishments processing the same low-acid canned product or for different low-acid canned products being processed by the same establishment. However, all low-acid canned foods share the most serious and resistant microbiological hazard of all food products, Clostridium botulinum. Therefore, low-acid canned foods will have many common critical control points to prevent that microorganism from producing toxin in food. This generic HACCP model was developed by a team of AAFC and cannery officials using the tools and materials of AAFCs FSEP. These tools and materials consist of Volumes I and II of the FSEP Implementation Manual and the FSEP Reference Database For Hazard Identification, which were being written and modified to reflect the experience acquired during the use of these materials in the development of the generic models. This model should be used in conjunction with Volumes II and III of the FSEP Implementation Manual. FSEP encompasses Prerequisite Programs and the twelve steps (including the seven principles) of the International Codex Alimentarius HACCP System and Guidelines For Its Application. Prerequisite Programs are essential procedures that control the operational conditions within a food establishment allowing for environmental conditions that are favourable to the production of safe food. They are the foundation on which the HACCP system can be built. Also, FSEP uses ten forms to identify and analyse the hazards of a food processing establishment. Within FSEP, hazard analysis is accomplished using the Codex Alimentarius decision tree to determine the critical control points (CCPs) in the processing establishment. Then, the critical limits, the monitoring, deviation and verification procedures, as well as the records are established to control the CCPs and complete the HACCP plan. Considerable time was spent by the team members amongst themselves and with industry discussing the best mechanism for dealing with sensitive ingredients and materials. This was done to ensure that only safe ingredients and materials are the starting point for food processing in HACCP establishments and that processing establishments would not be overburdened with costly repeat testing. The ideal, of course, is to purchase all sensitive ingredients and materials from suppliers with fully implemented HACCP systems. When this is not possible, a check on the suitability of sensitive ingredients and materials is considered to be necessary before their use. Many establishments have different means of control by incoming inspections or specifications. This may range from a full analysis by QC on every incoming lot to a verification that the ingredients and materials come from a supplier with whom the establishment has a detailed ingredient/material specification contract. Establishments may choose to document their control in one of the following two ways: i. The receiver checks to make sure that the ingredients or materials come from a supplier having valid, up-to-date contract specifications approved by the establishment. This type of control is considered to be minimal and would be a critical control point requiring all the necessary documentation including deviation and verification procedures. This model incorporated a receiving CCP. ii. An inspection system detailing the sampling plans, analysis and action to be taken, etc and filled out as part of a comprehensive prerequisite program. Canned mushroom history, in the form of reports on foodborne illness, food safety complaints and recalls, shows that the two major problems associated with the canned mushrooms have been underprocessing and container leakage. Both problems could result in the production of toxin by Clostridium botulinum; therefore, most of the CCPs in this model are established to prevent those problems. This means that post-process container integrity evaluation is very important, because it can be an indicator of both problems. Can defects, poor can seams, leaking cans and swollen cans can be detected and removed by an effective container integrity evaluation step at the end of the processing line, optimally, after a suitable incubation period; usually 14 days at 20C or higher. The HACCP team considered this step not to be a CCP, but a very significant verification procedure, because it is performed on finished products, ideally after a suitable incubation period, and it is an indicator of inadequate control at one or more processing steps. There are both mechanical and manual methods of carrying out this verification. This model outlines the method and rational for the HACCP plan developed with this registered establishment. The information and cooperation received from the company officials helping with the study are greatly appreciated. The following model resulting from the pilot study has helped the Department develop an effective and practical program, which will realize many benefits for both the government and the industry. Form 2 List of Product Ingredients and Incoming MaterialProcess/Product Type Name: Mushrooms (Low Acid Canned Foods)Raw MaterialPackaging MaterialsDry IngredientsMushrooms (domestic white) BCPCans BCPEnds BCPSalt BPAscorbic acid BPCitric acid BPOtherWater (municipal) BC0Form3 Process Flow DiagramForm 4 Plant SchematicProcess/Product Type Name: Mushrooms (Low Acid Canned Foods)Plant specificProduct flow diagramandEmployees traffic pattern diagramForm 5 Hazards Identification, Biological HazardsProcess/Product Type Name: Mushrooms (Low Acid Canned Foods) List all Biological Hazards related to Ingredients, Incoming Material, Processing, Product Flow, etc. Identified Biological Hazards(Bacteria, Parasites, Viruses.) Controlled at Incoming Materials Mushrooms:- Could contain C. botulinum or other pathogenic bacteria, yeasts and moulds- Could contain heat-stable staphylococcal enterotoxin from improper grower handling Empty cans/ends- Cans could arrive with serious double seam, side seam, metal plate defects or physical damage which could result in leakage causing post-process contamination- Ends could arrive with compound skips, metal plate defects, or damage, which could result in leakage causing post-process contamination Dry ingredients- Could contain bacterial spores- Could contain filth from insects, animals or the environment Water- Could contain pathogens Process Steps #1 Receiving- Empty cans/ends received from suppliers without valid contract specifications could have serious defects or damage- Dry ingredients received from suppliers without valid contract specifications could be contaminated with bacterial spores or filth from insects, animals or the environment #2 Mushrooms (Raw) Storing- Improper storage temperature & humidity could result in an increased bacterial load- Could be contaminated with filth from insects, animals or the environment #3 Empty Cans/Ends Storing- Physical damage could cause the formation of poor double seams, which could result in post process contamination with pathogenic bacteria- Could be contaminated with filth from insects, animals or the environment #4 Dry Ingredients Storing- Could be contaminated with filth from insects, animals or the environment #6 Depalletizing- Using incorrect cans or damaged cans could result in leakage and subsequent post-process contamination with pathogenic bacteria #8 Blanching- Improper cleaning of blancher could result in the growth of thermophilic bacteria in mushroom accumulations- Inadequate removal of gases could cause stressed double seams and leakage, which could result in post-process contamination with pathogenic bacteria #9 Can conveying- Physical damage could cause the formation of poor double seams, which could result in post process contamination with pathogenic bacteria #13 Slicing/Dicing- Slice thickness/clumping and percent fines could affect the heat penetration, which could result in underprocessing #16 Filling- Mushroom compaction during filling may result in underprocessing #17 Weighing- Cans not properly rejected for overweight could result in overfilled cans being underprocessed #18 Water Filling- Inadequate temperature could result in low initial temperature (IT) #20 End Feeding/Closing/Inspecting- Ends with damaged curls, compound skips or other serious defects could result in leakage and contamination with pathogenic bacteria- Improperly formed double seams could result in leakage and contamination with pathogenic bacteria #22 Thermal Processing (Still Steam Retorts)- Non-validated process or vent schedule could result in underprocessing and survival of pathogenic bacteria- Improper product flow procedures in retort area could result in retort baskets missing the retort allowing the survival and growth of pathogenic bacteria- Excessive time lapse between closing and retorting could result in excessive build up of bacteria, some of which could survive the thermal process- Lack 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 bacteria #23 Cooling- Insufficient bactericide in cooling water could result in contamination of product during vacuum creation in cans- Excess bactericide in cooling water could eventually result in corrosion and subsequent leakage and contamination of product- Insufficient contact time between the bactericide and water could result in contamination of product during vacuum creation in cans- Insufficient cooling could result in thermophilic spoilage- Excessive cooling could result in post-process contamination due to leakage of corroded cans #24 Conveying/Drying- Contaminated water from wet unclean post-process can handling equipment and general handling could contaminate product #25 Container Integrity Evaluating/Labelling- Failure 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 market- Physical damage to cans could result in leakage and contamination of product #26 Storing- Physical damage to cans could result in leakage and contamination of product- High temperatures could result in growth of thermophilic bacteria #27 Shipping- Physical damage to cans could result in leakage and contamination of product Form 6 Hazards Identification, Chemical HazardsProcess/Product Type Name: Mushrooms (Low Acid Canned Foods) Lst all Chemical Hazards related to Ingredients, Incoming Material, Processing, Product Flow, etc. Identified Chemical Hazards Controlled at Incoming Materials Mushrooms- Could contain agricultural chemicals residues Empty cans/ends- Could be contaminated with cleaning chemicals and lubricants Water- Could be contaminated with dissolved heavy metals or toxic organic chemicals Process Steps #1 Receiving- Empty cans/ends received from suppliers without valid contract specifications could contain cleaning chemical residues and/or lubricants #3 Empty Cans/Ends Storing- Improper storage of cleaning compounds and other chemicals could lead to empty can/end contamination #4 Dry Ingredients Storing- Improper storage of cleaning compounds and other chemicals could lead to dry ingredient contamination #8 Blanching- Excessive cleaning chemical residues and/or lubricants could cause product contamination #11 Mushroom Conveying/Inspecting- Excessive cleaning chemical residues and/or lubricants could cause product contamination #13 Slicing/Dicing- Excessive cleaning chemical residues and/or lubricants could cause product contamination #16 Filling- Excessive cleaning chemical residues and/or lubricants could cause product contamination #20 End Feeding/Closing/Inspecting- Excessive cleaning chemical residues and/or lubricants could cause product contamination Form 7 Hazards Identification, Physical HazardsProcess/Product Type Name: Mushrooms (Low Acid Canned Foods) List all Physical Hazards related to Ingredients, Incoming Material, Processing, Product Flow, etc. Identified Physical Hazards Controlled at Incoming Materials Mushrooms- Could be contaminated with hazardous extraneous material, eg. glass, metal, plastic, stones and wood (slivers and fragments) Empty cans/ends- Could contain hazardous extraneous material Dry ingredients- Could be contaminated with hazardous extraneous material Process Steps #1 Receiving- Cans received from suppliers without valid contract specifications could contain hazardous extraneous material- Dry ingredients received from suppliers without valid contract specifications could contain hazardous extraneous material #2 Raw Mushroom Storing- Inadequate protection against hazardous extraneous material could result in contamination of raw mushrooms #4 Dry Ingredients Storing- Inadequate protection against hazardous extraneous material could result in contamination of the food ingredients #9 Can Conveying- Inappropriate design and protection against hazardous extraneous material could result in contamination of the final food product #11 Mushroom Conveying/Inspecting- Inappropriate design and protection against hazardous extraneous material could result in contamination of the mushrooms #13 Slicing/Dicing- Product could become contaminated with metal fragments from plant equipment #15 Foreign-Object Removing- Inadequate monitoring and cleaning of foreign object remover could allow foreign objects to contaminate the product #16 Filling- Cans of filled mushrooms could become contaminated with metal fragments from filling equipment #20 End Feeding/Closing/Inspecting- Cans of filled mushrooms could become contaminated with metal fragments from closing machine during and after jam ups Form 8 Critical Control Points (CCPs) DeterminationProcess/Product Type Name: Mushrooms (Low Acid Canned Foods) Catergory and Identified HazardDetermine if fully controlled by Prerequisite Program(s)If YES, indicate Prerequisite Program and proceed to next identified hazard.If NO, proceed to question 1 (Q1) Q1. Could a control measure(s) be used by the operator 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 unacceptabkle 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 occurence of the identified hazard to an acceptable level?If NO = next question (Q4)If YES = CCP + go to last column Q4. Will a subsequent step eliminate the identified hazard or reduce likely occurence to an acceptable level?If NO = CCP + go to last columnIf YES = not a CCP + identify subsequent step + proceed to the next identified hazard CCP Number+ proceed to next identified hazard Process Step/Incoming Material: Mushrooms as delivered Biological Pathogens YesHeat treatment Yes N/A Yes Step #22, Thermal Processing Biological Heat stable toxins No Upstream programs (farms) Chemical Agricultural chemicals No Upstream programs (farms) Physical Hazardous extraneous material YesVisual inspection Plant equipment No Process Step/Incoming Material: Empty cans/ends as delivered Biological Post process contamination from serious can defects and damage YesContract specificationsVisual and can tear-down inspection Yes N/A YesStep #1, Receiving Biological Post process contamination from compound skips, plate defects and end damage YesContract specificationsVisual end inspection