HACCP in Meat, Poultry, and Fish Processing

The RACCP (hazard analysis critical control point) concept for food products was an outgrowth of the US space program with the demand for a safe food supply for manned space flights by the National Aeronautics and Space Administration (NASA). The original work was carried out by the Pillsbury Company under the direction of Roward E. Bauman, who as the author of chapter 1 describes the evolution of the RACCP system and its adaptation to foods. The second chapter discusses the adoption of RACCP principles and explains how they fit into the USDA and FDA meat, poultry and seafood inspection systems. The next chapter discusses how RACCP principles can be extended to production of meat, poultry and seafoods, a most important area involved in producing a safe food supply. Chapter 4 deals with the use of RACCP in controlling hazards encountered in slaughtering and distribution of fresh meat and poultry, while chapter 5 discusses the problem - both spoilage and hazards - involved in processing and distribution of meat, poultry and seafood products. Chapter 6 covers the entire area of fish and seafoods, including both fresh and processed products from the standpoints of spoilage and hazards.

1 The origin and concept of HACCP.- 1.1 Introduction.- 1.2 Development of the HACCP concept.- 1.2.1 HACCP — A new approach.- 1.2.2 HACCP — A preventative system.- 1.3 Acceptance of HACCP by the food industry.- 1.3.1 Establishment of HACCP by other companies.- 1.3.2 Role of various agencies.- 1.4 Summary.- References.- 2 The HACCP system and how it fits into FSIS programs.- 2.1 Introduction.- 2.1.1 FSIS background.- 2.1.2 Industrial responsibility and HACCP.- 2.1.3 FSIS and HACCP.- 2.2 HACCP study.- 2.2.1 Background.- 2.2.2 Consultations and public hearings.- 2.2.3 Workshops.- 2.3 Critical control points for various models.- 2.3.1 Refrigerated foods (cooked and assembled) critical control points.- 2.3.2 Raw beef pattie critical control points.- 2.3.3 Whole young chickens critical control points.- 2.3.4 Cooked sausage critical control points.- 2.3.5 Pork slaughter market hogs critical control points.- 2.4 In-plant testing of HACCP models.- 2.4.1 Background.- 2.4.2 Plant specific plan.- 2.4.3 Inspection during phases II and III.- 2.4.4 Phase II: Implementation.- 2.4.5 Phase III: Operational.- 2.5 Evaluation.- 2.5.1 Background.- 2.5.2 Limitations.- 2.5.3 HACCP model checklist.- 2.5.4 National profiles.- 2.5.5 Quantitative plant data.- 2.5.6 Qualitative plant data.- 2.5.7 Inspector and plant personnel survey.- 2.5.8 Workshop evaluation.- 2.5.9 Training.- 2.5.10 In-plant changes.- 2.6 Current HACCP issues.- 2.6.1 Voluntary/mandatory.- 2.6.2 Review of HACCP plans.- 2.6.3 Transition period.- 2.6.4 Plan approval.- 2.6.5 Critical limits.- 2.6.6 Generic models.- 2.6.7 Training.- 2.6.8 Plan failure.- 2.6.9 Safety/economic.- 2.6.10 Other quality systems.- 2.6.11 Scientific validity.- 2.7 Quadrilateral discussions on food safety.- 2.7.1 Introduction.- 2.7.2 HACCP working group.- 2.7.3 HACCP working group report.- 2.8 Summary.- References.- 3 Implementation of HACCP program on farms and ranches.- 3.1 Introduction.- 3.2 Livestock quality assurance programs.- 3.3 Implementing HACCP on livestock units.- 3.3.1 Initiating on-farm HACCP preventive medicine programs.- 3.3.2 Hazard identification.- 3.3.3 Flow diagrams.- 3.4 Conclusion.- References.- 4 Implementation of the HACCP program by meat and poultry slaughterers.- 4.1 Introduction.- 4.2 Purpose of HACCP.- 4.2.1 Selection of team members.- 4.2.2 Training of HACCP team.- 4.3 Development of the HACCP program.- 4.3.1 Selection of the HACCP team coordinator.- 4.3.2 Development of the master HACCP program.- 4.4 Implementation of the HACCP program.- 4.4.1 Support of management.- 4.4.2 Fitting HACCP plan into operations.- 4.4.3 Focusing attention on hazards.- 4.4.4 Product specific HACCP programs.- 4.5 Summary.- References.- 5 The use of HACCP for producing and distributing processed meat and poultry products.- 5.1 Introduction.- 5.2 Reasons for using HACCP.- 5.3 Developing HACCP plans.- 5.4 Hazard analysis and risk assessment.- 5.4.1 Product recalls.- 5.4.2 Epidemiological data.- 5.4.3 Chemical hazards.- 5.4.4 Physical hazards.- 5.4.5 Biological hazards.- 5.5 Critical control points and critical limits.- 5.5.1 Formulating.- 5.5.2 Cooking.- 5.5.3 Cooling.- 5.5.4 Holding.- 5.5.5 Packaging.- 5.5.6 Preventing recontamination.- 5.5.7 Storing and distributing.- 5.6 Monitoring.- 5.7 Corrective action.- 5.8 Record keeping.- 5.9 Verification.- 5.10 Should HACCP be mandatory?.- 5.11 Summary.- References.- Addendum — Guideline for writing operating instructions/HACCP plans for processed meat and poultry products.- A.1 Headings.- A.2 Critical Control Point (CCP).- A.3 Control Point (CP).- 6 Implementation of the HACCP program by the fresh and processed seafood industry.- 6.1 Introduction.- 6.2 Significance of the seafood industry.- 6.2.1 Resources.- 6.2.2 Fishery habitats.- 6.2.3 US imports of fishery products.- 6.2.4 US exports of fishery products.- 6.2.5 Challenges facing the US seafood industry.- 6.2.6 Food safety in the US fishery system.- 6.3 HACCP in the seafood industry.- 6.3.1 Background.- 6.3.2 Benefits of HACCP.- 6.3.3 History of HACCP in the seafood industry.- 6.4 HACCP and seafood safety.- 6.4.1 CDC seafood safety data.- 6.5 Seafood industry workshops.- 6.5.1 Purpose of workshops.- 6.5.2 Outcome of workshops.- 6.6 NMFS HACCP program.- 6.6.1 Program components.- 6.6.2 Substantial and low risk products.- 6.6.3 Difference between NMFS and FDA programs.- 6.7 FDA’s HACCP program.- 6.7.1 HACCP-based system.- 6.7.2 Seven or five principles?.- 6.7.3 Mandatory training.- 6.7.4 Records access.- 6.7.5 Obligations of importers.- 6.7.6 General sanitation control procedures.- 6.8 Impact of FDA’s proposed HACCP regulation — an example.- 6.9 Summary.- References.- 7 Risk analysis, HACCP and microbial criteria in meat and poultry systems.- 7.1 Introduction.- 7.2 Risk analysis.- 7.2.1 Risk assessment.- 7.2.2 Risk management.- 7.2.3 Risk communication.- 7.3 How risk analysis and HACCP contribute to food safety.- 7.3.1 Interventions are required to reduce risk.- 7.3.2 Appropriate use of interventions.- 7.4 HACCP versus end-product microbial testing.- 7.5 The role of microbiological criteria.- 7.5.1 Microbiological standards.- 7.5.2 Microbiological guidelines.- 7.5.3 Microbiological specifications.- 7.5.4 Microbiological criteria and safety.- 7.5.5 Sampling procedures.- 7.5.6 Disposition of product.- 7.5.7 Establishment and implementation.- 7.5.8 Cost of implementation.- 7.5.9 Application to raw meat and poultry.- 7.5.10 Application to cooked meat and poultry.- 7.6 Statistical process control.- 7.6.1 Statistical process control measures critical control points.- 7.6.2 Control charts.- 7.6.3 Types of control charts.- 7.6.4 Capability.- 7.7 Summary.- Acknowledgements.- References.- 8 Relationship of the HACCP system to Total Quality Management.- 8.1 The importance of quality.- 8.1.1 What do we mean by quality?.- 8.1.2 The need for a culture change.- 8.2 Total Quality Management (TQM): the key to continuous quality improvement.- 8.2.1 TQM defined.- 8.2.2 TQM as a vehicle for corporate quality innovation.- 8.3 The Hazard Analysis Critical Control Point (HACCP) system.- 8.4 Modern quality management: striving for continuous quality improvement.- 8.4.1 Steps for successful transition: philosophies of quality management leaders.- 8.4.2 Quality leadership for the future.- 8.5 The economics of quality.- 8.5.1 The impact of quality on company finances.- 8.5.2 Quality audits.- 8.6 Implementation of TQM and HACCP.- 8.6.1 Phases of TQM implementation.- 8.6.2 Crosby’s Quality Improvement Process (QIP).- 8.6.3 Quality circles.- 8.6.4 HACCP implementation in a TQM company.- 8.6.5 Application of a HACCP system in a TQM meat processing company.- 8.7 ISO 9000.- 8.8 The National Quality Award.- 8.9 Summary.- Acknowledgements.- References.- 9 HACCP for delicatessens and meat, poultry and seafood retailers.- 9.1 Introduction.- 9.2 Potential hazards.- 9.2.1 Raw materials and ingredients.- 9.2.2 Handling and storage practices.- 9.3 Hazard controls.- 9.3.1 Food sources.- 9.3.2 Specifications for receiving.- 9.3.3 Controls at receiving.- 9.3.4 Controls for storage.- 9.3.5 Controls for food preparation.- 9.3.6 Controls for thawing frozen foods.- 9.3.7 Controls for cooking.- 9.3.8 Controls for cooling.- 9.3.9 Controls for reheating.- 9.3.10 Controls for display.- 9.3.11 Controls for sanitation.- 9.4 Monitoring.- 9.5 Corrective actions.- 9.6 Records.- 9.7 Verification.- 9.8 A deli HACCP plan.- 9.8.1 Recipe review.- 9.8.2 Flowcharts.- 9.8.3 Hazard analysis.- 9.8.4 Receiving.- 9.8.5 Preparation, storage and display.- 9.9 Example HACCP plans.- 9.10 Summary.- References.- 10 HACCP-TQM for retail and food service operations.- 10.1 Introduction.- 10.2 What is quality?.- 10.2.1 The safety assurance component of quality.- 10.3 HACCP principles for food production.- 10.4 Food science HACCP principles.- 10.4.1 The unit as a food process system.- 10.5 The HACCP-based TQM process.- 10.5.1 The system for HACCP-based food safety TQM.- 10.5.2 Hazards in the food system.- 10.5.3 Risk clientele.- 10.5.4 What constitutes a hazard?.- 10.5.5 Government microbiological standards for raw and pasteurized food.- 10.5.6 Foodborne illness: Annual estimated cases and deaths in the USA.- 10.6 Food operations hazard analysis.- 10.6.1 Pasteurized—chilled food process hazard control flow diagram.- 10.6.2 The seven recipe processes.- 10.6.3 Recipe flow charting.- 10.6.4 Quality-assured HACCP recipe procedures, the critical hazard control document.- 10.6.5 Components of an effective HACCP program.- 10.6.6 Food safety through Quality Assurance: policies, procedures and standards manual.- 10.7 Summary.- References.- 11 The HACCP program and the consumer.- 11.1 Introduction.- 11.2 The HACCP program.- 11.2.1 The Hazard Analysis Critical Control Point (HACCP) system.- 11.2.2 The goal of HACCP.- 11.2.3 Application of HACCP principles by consumers.- 11.3 HACCP and consumers.- 11.3.1 Defining the elusive customer.- 11.3.2 Target populations for HACCP application.- 11.4 HACCP incorporation into everyday life.- 11.4.1 Education and training of consumers in HACCP.- 11.4.2 Effective modes of communication and training.- 11.4.3 Base line knowledge of consumers on food safety.- 11.5 Application of HACCP principles for consumers.- 11.5.1 HACCP implementation.- 11.5.2 Pilot community.- 11.5.3 Consumer practices.- 11.5.4 HACCP principles applied by the consumer.- 11.5.5 Formation of a HACCP plan for households.- 11.6 Conclusions.- References.- 12 Organization and management of HACCP programs.- 12.1 Introduction.- 12.2 Documentation of HACCP systems.- 12.3 Phases of HACCP system implementation and management requirements.- 12.3.1 Design and introduction.- 12.3.2 Integrating the HACCP system into total operation.- 12.3.3 Operations of the HACCP program.- 12.4 Producing the framework/structure to ensure that the HACCP program is a success.- 12.4.1 Role of personnel to success of HACCP programs.- 12.4.2 A few painful lessons and helpful hints.- 12.5 Summary.- References.- 13 Predictive microbiology and HACCP.- 13.1 Introduction.- 13.2 Predictive microbiology.- 13.2.1 Relationship of predictive modelling to HACCP.- 13.2.2 History of predictive microbiology.- 13.2.3 Modelling approaches.- 13.2.4 Quantitative microbiology?.- 13.3 Predictive modelling and and HACCP.- 13.3.1 Sources of models.- 13.3.2 Principle 1. Risk and hazard assessment.- 13.3.3 Principle 2. Determination of CCPs.- 13.3.4 Principle 3. Establishing critical limits.- 13.3.5 Principle 5. Corrective action specification.- 13.4 Examples of the application of predictive models in HACCP systems.- 13.4.1 Use of the HACCP approach.- 13.4.2 Variability of responses.- 13.5 Conclusions.- References.- 14 National and international cooperation on governmental regulations for meat, poultry and fish inspection.- 14.1 Overview.- 14.2 Agencies and functions.- 14.2.1 Main agencies.- 14.2.2 Other agencies.- 14.3 Domestic interests and cooperation.- 14.3.1 Common interests, philosophies and mechanisms.- 14.3.2 Rulemaking.- 14.3.3 FSIS and FDA inspection techniques.- 14.3.4 Use of Hazard Analysis and Critical Control Point system by the federal agencies.- 14.3.5 Cooperation in developing policies and regulations.- 14.4 International interests and cooperation.- 14.4.1 Bilateral agreements with an individual country, or multilateral with a small group of countries.- 14.4.2 International agreements.- 14.4.3 Codex Alimentarius Commission (CAC).- 14.5 Opportunities to increase cooperation.- 14.5.1 Domestic.- 14.5.2 International.- 14.6 Summary.- References.