Meat and Poultry Products HACCP

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TABLE OF CONTENTS

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Section I - Overview of Biological, Chemical, and Physical Hazards . . . . . . . . . . . . . . . . . . . D-2

Biological Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2


Table 1 - Characteristics of Growth for Nine
Pathogens Associated with Meat and Poultry Products . . . . . . . . . . . . . . . . D-4
Chemical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6
Table 2 - Types of Chemical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7
Physical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-8
Table 3 - Types of Physical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-8

Section II - Controls and Critical Limits for Biological, Chemical, and Physical Hazards . . . . D-9
Table 4 - Examples of Preventive Measures for Biological Hazards . . . . . . . . . . . . . D-10
Table 5 - Examples of Preventive Measures for Chemical Hazards . . . . . . . . . . . . . . D-11
Table 6 - Examples of Preventive Measures for Physical Hazards . . . . . . . . . . . . . . . D-12
Table 7 - Some Examples of Regulatory Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-13

Section III - Red Meat (Beef) Slaughter Hazards and Controls . . . . . . . . . . . . . . . . . . . . . . D-14
Table 8 - Red Meat Slaughter: Beef . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-15

Section IV - Red Meat (Swine) Slaughter Hazards and Controls . . . . . . . . . . . . . . . . . . . . . D-17


Table 9 - Red Meat Slaughter: Swine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-18

Section V - Poultry Slaughter Hazards and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-20


Table 10 - Poultry Slaughter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-21

Section VI - Ingredient Hazards and Ingredient - Related Hazards . . . . . . . . . . . . . . . . . . . . D-29


Table 11 - Ingredient and Ingredient - Related . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-30

Section VII - Processing Hazards and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-45


Table 12 - Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-46

Section VIII - References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-58


Hazard Analysis Critical Control Point Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-58
Foodborne Illnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-59
Biological, Chemical, and Physical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-59
Internet Home Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-60

i
PREFACE

This Guide is designed to help a plant’s HACCP team conduct a hazard analysis (HACCP
Principle 1) by providing both general and detailed information on hazards associated with meat
and poultry products and by listing some of the controls that can be used to prevent or manage
those hazards. When using this Guide, it is very important to remember that it is not all-inclusive:
there may be other hazards associated with ingredients or processes and there may be other
control measures. The examples assembled here are to help plant HACCP teams think through all
the hazards that could affect their product and know about various controls that can be used.

Section I describes some of the biological (including microbiological), chemical, and physical
hazards generally recognized and associated with meat and poultry products. This section can
serve as a resource when the HACCP team begins the hazard analysis. It is probably useful to
read through this general information early in the process of developing the HACCP plan. This
will help the team form an idea of what is meant by a given hazard.

Section II provides information on generally recognized preventive measures used in the meat and
poultry industry to control biological, chemical, and physical hazards. This section also has
examples of regulatory critical limits associated with some preventive measures.

Sections III, IV, and V list processing steps, hazards, and controls for beef, swine, and poultry
slaughter. This section should be used with the process flow diagram developed by the HACCP
team.

Section VI presents hazards and controls organized according to ingredients, including both meat
and poultry ingredients and other ingredients used in meat and poultry production. This section
should be used with the list of ingredients developed by the HACCP team.

Section VII contains a set of tables identifying potential hazards at various processing steps used
to produce meat and poultry products. This section should be used with the process flow diagram
developed by the plant’s HACCP team.

Section VIII contains a list of valuable references that will help the plant’s HACCP team further
develop the HACCP plan.

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SECTION I

OVERVIEW OF BIOLOGICAL, CHEMICAL, AND PHYSICAL HAZARDS

In a HACCP system, a hazard is defined as a biological, chemical, or physical property that may
cause a food to be unsafe for human consumption. This guide is a reference for plant HACCP
teams to use in their hazard identification and analysis. It is not intended to be totally inclusive;
the team may have other information or may rely on additional references.

BIOLOGICAL HAZARDS

Biological hazards, mainly bacterial, can cause either foodborne infections or intoxications. A
foodborne infection is caused by a person ingesting a number of pathogenic microorganisms
sufficient to cause infection as a result of their multiplication, e.g., salmonellosis. A foodborne
intoxication is caused by the ingestion of preformed toxins produced by some bacteria when they
multiply and release toxin into the food product, e.g., staphylococcal enterotoxin.

Nine pathogenic bacteria are frequently implicated in foodborne illness and should be considered
in assessing hazards to human health from the consumption of meat and poultry products. The
following identifies and discusses the nine pathogenic microorganisms of concern.

Bacillus cereus

B. cereus causes foodborne illness. There are two types of toxins - diarrheal and emetic
(vomiting).

Foods associated with illness include: boiled and fried rice, custards, cereal products, meats,
vegetables, and fish; food mixtures such as sauces, puddings, soups, casseroles, pastries, and
salads.

Campylobacter jejuni

Campylobacteriosis is the illness caused by C. jejuni. It is also often known as campylobacter


enteritis or gastroenteritis.

Food associated with illness include: raw and undercooked chicken, and raw milk.

Clostridium botulinum

Foodborne botulism (as distinct from wound botulism and infant botulism) is a severe foodborne
disease caused by the ingestion of foods containing the potent neurotoxin formed during growth
of the organism. Botulism has a high mortality rate if not treated immediately and properly.

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Foods associated with disease include: meat products, such as sausages, seafood products,
improperly canned foods, and vegetable products.

Clostridium perfringens

Perfringens foodborne illness is the term used to describe the common foodborne disease caused
by the release of enterotoxin during sporulation of C. perfringens in the gut.

Foods associated with illness include: meat and poultry products and gravy.

Escherichia coli O157:H7

Hemorrhagic colitis is the name of the acute disease caused by E. coli O157:H7.

Foods associated with illness include: undercooked or raw hamburger (ground beef); in sporadic
cases, other meat products and raw milk.

Listeria monocytogenes

Listeriosis is the name of the general group of disorders caused by L. monocytogenes.

Foods associated with illness include: cole slaw, cooked poultry, cooked meat, and raw milk,
supposedly pasteurized fluid milk, and cheeses (particularly soft-ripened varieties). Its ability to
grow at temperatures as low as 3oC permits multiplication in refrigerated foods.

Salmonella spp.

S. typhi and the paratyphoid bacteria are normally septicemic and produce typhoid or typhoid-like
fever in humans and are predominantly human bacteria. Other forms of salmonellosis generally
produce milder symptoms. Salmonella spp. are found in the intestinal tracts of warm blood
animals.

Foods associated with illness include: raw and cooked meats, poultry, eggs (and exterior of egg
shells), raw milk and dairy products, fish, shrimp, frog legs, yeast, sauces and salad dressing, etc.

Staphylococcus aureus

Staphylococcal food borne illness (staphylococcal enterotoxicosis; staphylococcal enterotoxemia)


is the name of the condition caused by the enterotoxins that some strains of S. aureus produce and
release into the food product.

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Foods associated with illness include: meat and meat products; poultry and egg products; egg,
tuna, ham, chicken, potato, and macaroni salads; sandwich fillings; milk and dairy products; etc.

Yersinia enterocolitica

Yersiniosis is the name of the disease caused by pathogenic species in the genus Yersinia. The
disease is a gastroenteritis with diarrhea and/or vomiting, fever, and abdominal pain.

Foods associated with illness include: meats, oysters, fish, milk, and chitterlings.

TABLE 1
Characteristics of Growth
for Nine Pathogens Associated with Meat and Poultry Products

Pathogens Temperature for pH Minimum


Growth Aw

Bacillus cereus 10-48 4.9-9.3 0.95


Campylobacter jejuni 30-47 6.5-7.5 ---
Clostridium botulinum >4.6 0.94
Group I (Toxin types A,B,F) 10-48
Group II (Toxin types B,E,F) 3.3-45
Clostridium perfringens 15-50 5.5-8.0 0.95
Escherichia coli O157:H7 10-42 4.5-9.0 ---
Listeria monocytogenes 2.5-44 5.2-9.6 ---
Salmonella 5-46
Staphylococcus aureus 6.5-46 5.2-9 0.86
Yersinia enterocolitica 2-45 4.6-9.6 ---

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Zoonotic agents are biological hazards that cause disease in animals and can be transmitted and
cause disease in humans. The following lists some zoonotic hazards:

Trichinella spiralis is a nematode parasite whose larval form encysts primarily in the striated
muscle of pigs, horses, rats, bears, and other mammals. Infection in humans results in “flu-like
symptoms” (diarrhea, fever, stiffness, muscle pain, respiratory distress, etc.). Heavy infection may
lead to death.

Foods associated with illness include: raw and undercooked pork, bear, and equine meat.

Taenia saginata is a human tapeworm whose larval form (Cysticercus bovis) encysts in the tissues
of cattle.

Foods associated with illness include: raw or undercooked beef.

Taenia solium is a human tapeworm whose larval form (Cysticercus cellulosae) encysts in the
tissues of pigs, dogs, and humans. Cysts in humans are most common in the subcutaneous
tissues, eye, and brain.

Foods associated with illness include: raw or undercooked pork.

Toxoplasma gondii is a protozoan parasite that encysts in the tissues of a variety of mammalian
hosts including pigs. Human infection may result in “flu like” symptoms in adults, late term
abortions in pregnant women, or serious congenial infections in children.

Foods associated with illness include: raw or undercooked pork.

Balantidium coli is a protozoal organism found primarily in swine and less commonly in other
animals. Human illness in debilitated patients may cause bloody dysentery, severe dehydration
and, rarely, death.

Foods associated with illness include: raw or undercooked pork (fecal contamination).

Cryptosporidium spp. is a protozoan parasite which infects epithelial cells of man and large
mammals (particularly cattle and sheep). Human illness has been described as a diarrheal,
cholera-like illness prolonged and often severe in immunodeficient humans.

Foods associated with the illness include: raw milk and fecally contaminated product.

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CHEMICAL HAZARDS

While biological hazards are of great concern because contaminated foods can cause widespread
illness outbreaks, chemical hazards may also cause foodborne illnesses, although generally
affecting fewer people.

Chemical hazards can originate from four general sources:

1. Unintentionally added chemicals

a) Agriculture chemicals: pesticides, herbicides, animal drugs, fertilizers, etc.

b) Plant chemicals: cleaners, sanitizers, oils, lubricants, paints, pesticides, etc.

c) Environmental contaminants: lead, cadmium, mercury, arsenic, PCBs.

2. Naturally-occurring chemical hazards: products of plant, animal, or microbial


metabolisms such as aflatoxins, etc.

3. Intentionally Added Chemicals: preservatives, acids, food additives, sulfiting agents,


processing aids, etc.

For many years the Food Safety and Inspection Service has conducted a National Residue
Program to monitor the occurrence of residues from hazardous chemicals in meat and poultry
products. Under a HACCP regime, frontline responsibility for control of residues from animal
drugs or environmental contaminants will move from the government to the industry, although the
agency will continue to verify that these controls and preventive measures are effective.
Companies that slaughter livestock and poultry will probably find the FSIS National Residue
Program Plan to be a useful document. The plan contains lists of compounds that might leave
residues in the tissues of animals or birds, and provides some information on their relative risk
through the rankings in the Compound Evaluation System. It provides information on which
compounds FSIS has included in its annual testing program. It also provides information on the
methods that are used to test for the compounds. Another FSIS document, the Domestic Residue
Data Book, presents the results of FSIS testing. These data can help a HACCP team understand
the overall hazards presented by various residues, although each company should gather
information about the residue control performance of its own suppliers.

Another useful reference about hazardous chemicals is the FSIS List of Proprietary Substances
and Nonfood Compounds. This publication lists substances used in the preparation of product
and nonfood compounds used in the plant environment that have been authorized by FSIS.

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Table 2 identifies some additional sources of chemical hazards. References listed in Section VIII
can be used by the HACCP team in evaluating the potential chemical hazards associated with their
product or process.

TABLE 2
Types of Chemical Hazards

Location Hazard

Raw Materials Pesticides, antibiotics, hormones, toxins, fertilizers,


fungicides, heavy metals, PCBs
Color additives, inks, indirect additives, packaging
materials
Processing Direct food additives - preservatives (e.g.,nitrite), flavor
enhancers, color additives
Indirect food additives - boiler water additives, peeling
aids, defoaming agents
Building and Equipment Lubricants, paints, coatings
Maintenance
Sanitation Pesticides, cleaners, sanitizers
Storage and Shipping All types of chemicals, cross contamination

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PHYSICAL HAZARDS

Physical hazards include a variety of materials referred to as extraneous materials or foreign


particles or objects. A physical hazard can be defined as any physical material not normally found
in a food that can cause illness or injury to a person consuming the product.

Physical hazards in finished products can arise from several sources, such as contaminated raw
materials, poorly designed or maintained facilities and equipment, faulty procedures during
processing, and improper employee training and practices. Table 3 identifies some common
physical hazards and their causes or sources.

TABLE 3
Types of Physical Hazards

Hazard Source or Cause

Glass Bottles, jars, light fixtures, utensils, gauge covers, thermometers


Metal Nuts, bolts, screws, steel wool, wire, meat hooks
Stones Raw materials
Plastics Packaging materials, raw materials
Bone Raw materials, improper plant processing
Bullet/BB Animals shot in field, hypodermic needles used for injections
Shot/Needles

D-8
SECTION II

CONTROLS AND CRITICAL LIMITS FOR BIOLOGICAL, CHEMICAL, AND


PHYSICAL HAZARDS

When all significant biological, chemical, and physical hazards are identified along with their
points of occurrence, the next task is to identify measures to prevent the hazards from
compromising the safety of the finished product.

Preventive measures or controls can be defined as physical, chemical, or other factors that can be
used to remove or limit an identified hazard. When considering preventive measures or controls,
a limit must be established - this is the criterion that must be met to ensure safety. For example,
proper heat treatment will control some pathogenic bacteria, and it is thus crucial to know what
time/temperature combinations constitute proper heat treatment for various products. These
time/temperature combinations are the critical limits. Another example of a preventive measure
for a biological hazard is the chlorination of poultry chiller water to prevent cross-contamination
of carcasses with Salmonella.

Chemical hazards associated with raw materials may be controlled through the use of detailed
product specifications set for suppliers, letters of guarantee, or purchase specifications. With
identified physical hazards, the most common preventive measures may be visual examinations of
product or the use of a metal detector.

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Tables 4, 5, and 6 identify preventive measures that may be considered by the HACCP team.
Table 7 gives some examples of regulatory limits.

TABLE 4
Examples of Preventive Measures for Biological Hazards

Pathogen Preventive Measure or Control

Bacillus cereus Proper holding and cooling temperatures of foods;


thermal processing of shelf-stable canned food
Campylobacter jejuni Proper pasteurization or cooking; avoiding cross-
contamination of utensils, equipment; freezing;
atmospheric packaging
Clostridium botulinum Thermal processing of shelf-stable canned food;
addition of nitrite and salt to cured processed meats;
refrigeration of perishable vacuum packaged meats;
acidification below pH 4.6; reduction of moisture
below water activity of 0.93
Clostridium perfringens Proper holding and cooling temperatures of foods;
proper cooking times and temperatures
Escherichia coli O157:H7 Proper holding and cooling temperatures of foods;
proper cooking times and temperatures
Listeria monocytogenes Proper heat treatments; rigid environmental sanitation
program; separation of raw and ready-to-eat
production areas and/or product. This may be
included in the Sanitation SOPs
Salmonella spp. Proper heat treatment; separation of raw and cooked
product; fermentation controls; decreased water
activity; withdrawing feed from animals before
slaughter; avoiding exterior of hide from contacting
carcass during skinning; antimicrobial rinses; proper
scalding procedures; disinfecting knives
Staphylococcus aureus Proper fermentation and pH control; proper heat
treatment and post-process product handling
practices; reduced water activity
Yersinia enterocolitica Proper refrigeration; heat treatments; control of salt
and acidity; prevention of cross-contamination

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TABLE 5
Examples of Preventive Measures for Chemical Hazards
Hazard Preventive Measure
Naturally-Occurring Chemical Supplier warranty or guarantee;
Substances verification program to test each supplier’s
compliance with the warranty or guarantee *
Intentionally Added Detailed specifications for each raw material
Chemicals and ingredient; warranty or letter of guarantee
from the supplier; visiting suppliers; requirement
that supplier operates with a HACCP plan; testing
program to verify that carcasses do not have
residues *
Unintentionally Added Chemicals Identify and list all direct and indirect food
additives and color additives; check that each
chemical is approved; check that each chemical is
properly used; record the use of any restricted
ingredients *

* These may often be considered a prerequisite to HACCP and included in a plant’s GMPs or
general SOPs and should be verified by the plant.

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Table 6
Examples of Preventive Measures for Physical Hazards
Hazard Preventive Measure
Foreign objects in raw materials Supplier’s HACCP plan; use of specifications, letters of
guarantee; vendor inspections and certification;* in-line
magnets; screens, traps, and filters; in-house inspections of
raw materials
Foreign objects in packaging Supplier’s HACCP plan; use of specifications, letters of
materials, cleaning compounds, guarantee; vendor inspections and certification;* in-house
etc. inspections of materials
Foreign objects introduced by In-line metal detectors; visual product examinations; proper
processing operations or maintenance of equipment; frequent equipment inspections
employee practices

* These may often be considered a prerequisite to HACCP and included in a plant’s GMPs or
general SOPs, though these activities should still be verified by the plant.

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Table 7
Some Examples of Regulatory Limits

Hazard Regulatory Limit Regulatory


Citation
Biological: All poultry must be chilled immediately 9 CFR
Microbial growth due to temperature abuse- after processing to a temperature of 40 381.66
Poultry Chilling or less.
Chemical: Chemicals used are approved for the 9 CFR
Excess chemicals contact product intended use and at appropriate amounts 318.7
Chemical: Edible products must be packaged in 9 CFR
Chemical hazard from packaging materials container that will not adulterate product or 317.24
be injurious to health;
Packaging materials must be covered by a
letter of guaranty
Biological: Products containing pork muscle tissue 9 CFR
Trichinae in pork must be effectively heated, refrigerated, or 318.10
cured to destroy any possible live trichinae
Biological: For destruction of pathogens that may 9 CFR 318.17
Pathogens in ready to eat products survive a dry heat process.
one of the time/temperature combinations
for cooked beef, roast beef, and cooked
corned beef; e.g., 143
minimum temperature at minimum time of
6 minutes
Physical: Metal contamination >1/32" must be FSIS
Metal contamination in meat/poultry removed from product Directive
products. 7310.4
Rev. 2

D-13
SECTION III

TABLE 8
RED MEAT (Beef) SLAUGHTER HAZARDS AND CONTROLS

USE OF INFORMATION

This section contains examples of common process steps in beef slaughter. With each processing
step, shown in the first column, you will find an “X” in the next three columns to tell you if there
is a Biological hazard in column 2, a Chemical hazard in column 3, or a Physical hazard in
column 4. Column 5 describes the hazard(s), and the last column lists some relevant controls or
preventive measures. This table should be used in conjunction with the process flow diagram
developed by your HACCP team for your plant’s beef slaughter process.

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TABLE 8: RED MEAT SLAUGHTER: BEEF

RED MEAT SLAUGHTER- B C P DESCRIPTION OF CONTROLS OR


BEEF: BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
EXAMPLES OF PHYSICAL
PROCESSING STEPS HAZARDS FOR THE
PROCESS STEPS

Receiving & Holding X -residues present in -Residue certification


edible tissues above presented for live
tolerances animal(s)
Skinning X -micro contamination of -Skinning procedures
carcass surface due to are accomplished
contaminated outside without hair or visible
hide surface fecal contamination of
-contamination of the carcass
carcass from floor -Careful employee
-cross-contamination by practices
equipment/utensils -Udder and pizzle
-contamination by removal are
employee handling accomplished without
contamination of
edible product
Evisceration X -cross-contamination -Esophagus is tied to
from broken viscera prevent escape of
stomach contents
-Bung is dropped with
sanitized knife and
bagged to prevent
escape of feces
-Viscera are removed
intact

Cleaning Systems X potential for residual -Cleaning System


Implemented Prior to Carcass contamination contamination
Wash removed as soon as
possible after
occurrence to control
microbial attachment

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RED MEAT SLAUGHTER- B C P DESCRIPTION OF CONTROLS OR
BEEF: BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
EXAMPLES OF PHYSICAL
PROCESSING STEPS HAZARDS FOR THE
PROCESS STEPS

Final Wash X -growth of pathogens -Final wash:


through insufficient Temperature: 90 -
wash 100
2070 kpa (50 - 300
psi)
-Steam Pasteurization:
Temperature: 195
or greater at surface
Dwell time: 5 - 15
seconds in cabinet
Chilling X -growth of pathogens -Surface temperature

possible
-Carcasses spaced a
minimum of 1 inch
apart
Packaging of Primals X -contamination from -Letters of guarantee
deleterious chemicals on file for all
present in the packaging packaging
materials materials/non-meat
supplies used by the
establishment
-Vendor certification
-Use of approved
materials
Storage-Non-Beef Supplies X -contamination of stored -Examine to ensure no
packing visible foreign material
materials/supplies from on/in non-meat
foreign material supplies or packaging
materials

D-16
SECTION IV

TABLE 9
RED MEAT (Swine) SLAUGHTER
HAZARDS AND CONTROLS

USE OF INFORMATION

This section contains examples of common process steps in swine slaughter. With each
processing step, shown in the first column, you will find an “X” in the next three columns to tell
you if there is a Biological hazard in column 2, a Chemical hazard in column 3, or a Physical
hazard in column 4. Column 5 describes the hazard(s) and the last column lists some relevant
controls or preventive measures. This table should be used in conjunction with the process flow
diagram developed by your HACCP team for your plant’s swine slaughter process.

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TABLE 9 RED MEAT SLAUGHTER: SWINE

RED MEAT B C P DESCRIPTION OF CONTROLS OR


SLAUGHTER-SWINE: BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
EXAMPLES OF PHYSICAL HAZARDS
PROCESSING STEPS FOR THE PROCESS
STEPS

Animal Receiving X -pathogens-parasites; -This could be covered


sanitation of receiving as part of a plant's
holding areas. GMPs
X -residues-antibiotics
X -foreign material-needles,
buckshot, etc.
Scalding X X -contamination from scalding -Plant time/temperature
medium limits for scalding (e.g.,
although it may vary
with facilities, a
temperature of 138 to
140
satisfactory)
-Equipment design and
proper adjustment
X -contamination with -USDA/FDA approved
chemicals via stick wound chemical concentration
not to exceed
manufacturer's
recommendations
Dehairing X -contamination and growth -Time/temperature
of microorganisms due to determined by plant-
breaking of the skin from specific testing results to
overexposure to the dehairer remove visible hair to an
acceptable level without
breaking skin
-Equipment design and
proper adjustment
Pre-evisceration Wash and X -high bacterial loads on the -Hot water and/or
Antibacterial Intervention surface of the carcass due to organic rinse, steam, or
dehairing & polishing other approved
antibacterial intervention

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PROCESSING STEPS FOR THE PROCESS
STEPS

Evisceration X -cross-contamination from -Remove all viscera


equipment/utensils intact
-contamination from -Contaminated
stomach, intestines, and/or equipment will be clean
bladder contents and sanitized before
-contamination from being used again *
employee handling -Training program for all
employees, to include
personal hygiene,
product handling
procedures, and sanitary
dressing procedures *

Trimming X -stick wound has not been -Remove all visible


removed stick-wound related
defects
Chilling X - growth of pathogens -Cool surface
temperature to 40
soon as possible
Receiving-Packaging X -contamination from -Letters of guarantee are
Materials and Non-Swine deleterious chemicals present on file for all packaging
Supplies in the packaging materials materials/non-poultry
supplies used by the
establishment
Storage-Non-Swine Supplies X -contamination of stored -Examine to ensure no
packing materials/supplies visible foreign material
from foreign material on/in non-poultry
supplies or packaging
materials
* Some of these activities are more appropriately covered in the Sanitation SOPs or plant
GMPs.

SECTION V

TABLE 10
POULTRY SLAUGHTER HAZARDS AND CONTROLS

USE OF INFORMATION

This section contains examples of common process steps in poultry slaughter. With each
processing step, shown in the first column, you will find an “X” in the next three columns to tell
you if there is a Biological hazard in column 2, a Chemical hazard in column 3, or a Physical
hazard in column 4. Column 5 describes the hazard(s) and the last column lists some relevant
controls or preventive measures. This table should be used in conjunction with the process flow

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diagram developed by your HACCP team for your plant’s poultry slaughter process.

D-20
TABLE 10 POULTRY SLAUGHTER

POULTRY SLAUGHTER: B C P DESCRIPTION OF CONTROLS OR


BIOLOGICAL, PREVENTIVE
EXAMPLES OF CHEMICAL, OR MEASURES
PROCESSING STEPS PHYSICAL
HAZARDS FOR
THE PROCESS
STEPS
Scalding X -contamination from -Fresh water input
scalding medium to achieve a
-cross-contamination minimum of 1 quart
from pathogens per bird.
-Temperature of the
scald water
maintained at
appropriate levels
(e.g., > 126°F)
-Maintain
counterflow
scalding unit
function
-Post scald wash
has sufficient
pressure and
volume to cover
carcass with fresh
(potable) water
spray
-Overflow volumes
are at required
amounts

D-21
POULTRY SLAUGHTER: B C P DESCRIPTION OF CONTROLS OR
BIOLOGICAL, PREVENTIVE
EXAMPLES OF CHEMICAL, OR MEASURES
PROCESSING STEPS PHYSICAL
HAZARDS FOR
THE PROCESS
STEPS

Transfer/Rehang X -cross-contamination -Follow approved


from intestinal offline plant
contents/exudate procedures for
-bird to bird handling
contamination airsacculitis salvage
and reprocessing
for contamination
(e.g., an air sac
salvage program
that transfers the
carcasses to
another station
where the thigh,
drumstick, wing tip,
and first wing
section are salvaged
and washed with
chlorinated water).
Minimize product
accumulation
Venting/Opening/Evisceration X -pathogenic cross- -Proper equipment
contamination due to adjustment. Proper
gut breakage training and
execution by
employees (turkey)
POULTRY SLAUGHTER: B C P DESCRIPTION OF CONTROLS OR
BIOLOGICAL, PREVENTIVE
EXAMPLES OF CHEMICAL, OR MEASURES
PROCESSING STEPS PHYSICAL
HAZARDS FOR
THE PROCESS
STEPS

D-22
Final Wash X -growth of pathogens -A final water wash
with appropriate
levels of chlorinated
water (e.g. 20-50
ppm residual
chlorine in the
water)
-Sufficient water
volume and
pressure for
equipment
operation and
sufficient dwell time
in the final washer
to remove visible
contamination on
internal and
external surfaces of
the carcass

D-23
POULTRY SLAUGHTER: B C P DESCRIPTION OF CONTROLS OR
BIOLOGICAL, PREVENTIVE
EXAMPLES OF CHEMICAL, OR MEASURES
PROCESSING STEPS PHYSICAL
HAZARDS FOR
THE PROCESS
STEPS
Chilling-Carcass X -growth of pathogens -Deep breast
-cross contamination muscle temperature
of carcass <40°F
within the specified
time from slaughter
for the class of
poultry
-maintain an
adequate chlorine
level in the
overflow water of
in-line immersion
chillers (e.g., 20-50
ppm residual
chlorine in the
incoming water)
-Maintain proper
water flow rates
(input/overflow) for
continuous chillers
per USDA
requirements (not
less than ½ gallon
of fresh water per
frying chicken with
continuous
overflow)
-No visible fecal
contamination
-Approved
antimicrobial
interventions

D-24
POULTRY SLAUGHTER: B C P DESCRIPTION OF CONTROLS OR
BIOLOGICAL, PREVENTIVE
EXAMPLES OF CHEMICAL, OR MEASURES
PROCESSING STEPS PHYSICAL
HAZARDS FOR
THE PROCESS
STEPS
Chilling-Carcass (continued) X -contamination from -Product entering
foreign material (prechill) and
exiting (postchill)
the chiller system
meets the criteria
for public health-
related
contamination per
USDA
requirements (e.g.
the limits are not
exceeded for the
number and size of
extraneous
materials found
during the postchill
examination -
9 CFR 381.76

D-25
POULTRY SLAUGHTER: B C P DESCRIPTION OF CONTROLS OR
BIOLOGICAL, PREVENTIVE
EXAMPLES OF CHEMICAL, OR MEASURES
PROCESSING STEPS PHYSICAL
HAZARDS FOR
THE PROCESS
STEPS
Chilling-Giblet/Neck X -growth of pathogens -Temperature and
-cross contamination fresh water input
sufficient to meet
USDA
requirements for
giblets and necks
-Chlorination of
giblet chiller water
at appropriate
levels for giblets
and necks (e.g.,
giblets must be
chilled to 40°F
within 2 hours
from removal from
other viscera/fresh
water intake not
less than 1 gallon
per 40 frying
chickens processed
- 9 CFR
381.66(c)(5)
-Other approved
antimicrobial
interventions

D-26
POULTRY SLAUGHTER: B C P DESCRIPTION OF CONTROLS OR
BIOLOGICAL, PREVENTIVE
EXAMPLES OF CHEMICAL, OR MEASURES
PROCESSING STEPS PHYSICAL
HAZARDS FOR
THE PROCESS
STEPS
Chilling-Giblet/Neck X -contamination from -Visually free of
(cont.) foreign material hazardous foreign
material
-Public health
related defects on
poultry giblet and
necks meet USDA
requirements (e.g.,
each carcass must
be observed for
conformance
against pre and post
chill criteria,
including
unidentified foreign
materials - 9 CFR
381.76

D-27
POULTRY SLAUGHTER: B C P DESCRIPTION OF CONTROLS OR
BIOLOGICAL, PREVENTIVE
EXAMPLES OF CHEMICAL, OR MEASURES
PROCESSING STEPS PHYSICAL
HAZARDS FOR
THE PROCESS
STEPS
Cut-Up/Boning/Packaging/ X -growth of pathogens -Temperature of
Labeling product does not
exceed 55° F during
further or second
processing
-Movement of
product through
these areas and into
the cooler is timely
and efficient
-A mid-shift
cleanup of the
area(s) is performed
if the room
temperature is not
maintained at or
below 50°F
-Packaging/labeling
materials that come
into direct contact
with product are
intact
Receiving-Packaging Materials X -contamination from -Letters of
and Non-Poultry Supplies deleterious chemicals guarantee are on
present in the file for all
packaging materials packaging
materials/non-
poultry supplies
used by the
establishment
Storage-Non-Poultry Supplies X -contamination by -Proper use and
chemicals stored or rinsing of chemicals
being used of product -Employee training
or product contact -Control with GMP
surface

D-28
SECTION VI

TABLE 11
INGREDIENT AND INGREDIENT-RELATED HAZARDS

USE OF INFORMATION

This section contains an alphabetical list of ingredients commonly used in making meat and
poultry products. For each entry, you will find the name of the ingredient in the first column, and
an “X” in the next three columns to tell you if there is a Biological hazard in column 2,
Chemical hazard in column 3, or Physical hazard in column 4. Column 5 describes the
hazard(s) and the last column lists some relevant controls or preventive measures. This table
should be used in conjunction with the list of ingredients developed by your HACCP team for the
products produced in the process under consideration.

The HACCP team may find that a particular ingredient does not present the hazard identified in
these tables. This can be based on a number of factors. The presence or absence of a hazard can
be influenced by the ingredient source and/or supplier. Also, Ingredient Specifications, provided
by the supplier to the establishment, may give details on the material/ingredient being sold,
including statements that the materials/ingredients are food grade and are free of harmful
components. For example, the ingredient specifications for dried legumes might state that there
will be fewer than 5 small rocks or stones per 10 pound bag and that no harmful pesticides were
used in the growing process.

The determination as to whether a hazard will exist that is significant and/or likely to occur will
also be based on the amount and type of ingredient, chemical, and/or packaging material used and
the conditions that they are used under. The following tables are examples, and are not meant to
imply the specific amount or condition that will result in a significant hazard in a particular
product, process, or operation. The toxicological results referred to as hazards, if limits are
exceeded, should be part of the determination performed during the hazard analysis. This will aid
in selecting appropriate hazards and neither under nor over estimate the significance of the hazard.

D-29
TABLE 11 INGREDIENTS AND INGREDIENT-RELATED

EXAMPLES OF B C P DESCRIPTION OF CONTROLS OR


INGREDIENTS BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
PHYSICAL HAZARD
FOR THE
INGREDIENT

Acidifiers X -toxicological effects if -Ingredients purchased


limits are exceeded under a Letter of
Guarantee
-Ingredients purchased
based on producer/
provider ingredient
specifications
Anticoagulants X -toxicological effect if -Ingredients purchased
limits are exceeded under a Letter of
Guarantee
-Ingredients purchased
based on producer/
provider ingredient
specifications
Antifoaming Agents X -toxicological effect if -Ingredients purchased
limits are exceeded under a Letter of
Guarantee
-Ingredients purchased
based on producer/
provider ingredient
specifications
Antioxidants X -toxicological effect if -Ingredients purchased
limits are exceeded under a Letter of
Guarantee
-Ingredients purchased
based on producer/
provider ingredient
specifications

D-30
EXAMPLES OF B C P DESCRIPTION OF CONTROLS OR
INGREDIENTS BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
PHYSICAL HAZARD
FOR THE
INGREDIENT

Batter/Breading X X -growth of mold due to -Temperature controls


improper storage and for storage
handling -Ingredient
-hazardous foreign specification sheet
material identifying the
required parameters
the ingredient must
meet
-Where applicable,
ingredients must be
pathogen-free
Beef (fresh, frozen) X -growth of pathogens due -Product temperature
to improper storage, must be sufficient to
handling, and/or transport preclude excess
microbial growth
-Product must meet
establishment purchase
specifications. This
may be included as
part of a plant's GMPs
-Product must be
produced under a
HACCP plan
Binders/Extenders X X -hazardous foreign -Ingredients purchased
material under a Letter of
Guarantee. This may
be included as part of
a plant's GMPs
-Ingredients purchased
based on producer/
provider ingredient
specifications. This
may be included as
part of a plant's GMPs

D-31
EXAMPLES OF B C P DESCRIPTION OF CONTROLS OR
INGREDIENTS BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
PHYSICAL HAZARD
FOR THE
INGREDIENT

Bleaching Agents X -toxicological effect if -Ingredients purchased


limits exceeded under a Letter of
Guarantee. This may
be included as part of
a plant's GMPs
-Ingredients purchased
based on producer/
provider ingredient
specifications

Blood X -growth of pathogens -Ingredient


from improper handling specification sheet
and storage, and/or identifying the
transport required parameters
the ingredient must
meet
- Where applicable,
ingredients must be
pathogen-free
-Meet appropriate
temp.

D-32
EXAMPLES OF B C P DESCRIPTION OF CONTROLS OR
INGREDIENTS BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
PHYSICAL HAZARD
FOR THE
INGREDIENT

Boneless Beef X X -growth of pathogens due -Product temperature


to improper handling must be at a level
storage, and/or transport sufficient to preclude
-foreign particle excess bacterial
contamination, e.g., metal growth at receiving
fragments or bone -Product must meet
establishment purchase
specifications
-Product must be
produced under a
HACCP plan
-Visual examination of
product for foreign
materials
Cooked Beef X X -growth of pathogens due -Frozen or refrigerated
to improper handling and receiving temperature
storage, and/or transport of product must be at
-foreign particle a level sufficient to
contamination, e.g., metal preclude excess
fragments or bone bacterial growth
particles in boneless beef - Product must be
received from an
approved supplier who
produces the product
under a HACCP plan
-Visual examination of
product for foreign
materials

D-33
EXAMPLES OF B C P DESCRIPTION OF CONTROLS OR
INGREDIENTS BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
PHYSICAL HAZARD
FOR THE
INGREDIENT

Cooked Poultry X X -growth of pathogens due -Frozen or refrigerated


to improper handling receiving temperature
storage, and/or transport of product must be at
-foreign particle a level sufficient to
contamination, e.g., bone preclude bacterial
particles in boneless growth
poultry -Product must be
received from an
approved supplier who
produces the product
under a HACCP plan.
-Visual examination of
product for hazardous
foreign materials
Cooked Pork X X -growth of pathogens due -Frozen or refrigerated
to improper handling and receiving temperature
storage, and/or transport of product must be at
-foreign particle a level sufficient to
contamination, e.g., bone preclude bacterial
particles in boneless pork growth
-Product must be
received from an
approved supplier who
produces the product
under a HACCP plan
Coloring Agents (natural) X -toxicological effect -Ingredients purchased
possible if limits exceeded under a Letter of
Guarantee
-Ingredients purchased
based on producer/
provider ingredient
specifications. This
may be included as
part of a plant's GMPs

D-34
EXAMPLES OF B C P DESCRIPTION OF CONTROLS OR
INGREDIENTS BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
PHYSICAL HAZARD
FOR THE
INGREDIENT

Coloring Agents (artificial) X -toxicological effect if -Ingredients purchased


limits exceeded under a Letter of
Guarantee
-Ingredients purchased
based on producer/
provider ingredient
specifications. This
may be included as
part of a plant's GMPs
Curing Agents X -toxicological effect if -Ingredients purchased
limits exceeded under a Letter of
Guarantee
-Ingredients purchased
based on producer/
provider ingredient
specifications. This
may be included as
part of a plant's GMPs
Curing Accelerators X -toxicological effect if -Ingredients purchased
limits are exceeded under a Letter of
Guarantee
-Ingredients purchased
based on producer/
provider ingredient
specifications. This
may be included as
part of a plant's GMPs

D-35
EXAMPLES OF B C P DESCRIPTION OF CONTROLS OR
INGREDIENTS BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
PHYSICAL HAZARD
FOR THE
INGREDIENT

Dairy Products X X -growth of pathogens due -Temperature control


to improper handling and -Ingredient
storage, and/or transport specification sheet
-hazardous foreign identifying the
material required parameters
the ingredient must
meet
-Where applicable,
ingredients must be
pathogen-free
Eggs or Egg Products X X -growth of pathogens due -Temperature control
to improper handling and -Ingredient
storage, and/or transport specification sheet
-foreign particle identifying the
contamination, e.g., shell required parameters
particles in broken eggs the ingredient must
meet
- Where applicable,
ingredients must be
pasteurized or treated
in order to assure
pathogen control
Emulsifying Agents X -toxicological effects if -Ingredients purchased
limits exceeded under a Letter of
Guarantee
-Ingredients purchased
based on producer/
provider ingredient
specifications. This
may be included as
part of a plant's GMPs

D-36
EXAMPLES OF B C P DESCRIPTION OF CONTROLS OR
INGREDIENTS BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
PHYSICAL HAZARD
FOR THE
INGREDIENT

Flavoring Agents X -toxicological effects if -Ingredients purchased


limits exceeded under a Letter of
Guarantee
-Ingredients purchased
based on producer/
provider ingredient
specifications. This
may be included as
part of a plant's GMPs
Fruits X X -contamination from -Ingredient
agricultural chemicals specification sheet
-foreign material identifying the
required food safety
parameters the
ingredient must meet

Honey X X -contamination from -Ingredient


inherent microorganisms - specification sheet
foreign particle identifying the
contamination, e.g., dirt, required food safety
insect parts parameters the
ingredient must meet

Legumes (dry) X -foreign particle -Ingredient


contamination, e.g., rocks specification sheet
identifying the
required parameters
the ingredient must
meet

D-37
EXAMPLES OF B C P DESCRIPTION OF CONTROLS OR
INGREDIENTS BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
PHYSICAL HAZARD
FOR THE
INGREDIENT

Mechanically Deboned X X -growth of pathogens due -Product temperature


Product to improper handling and must be at a level
storage sufficient to preclude
-foreign particle excess microbial
contamination, e.g., bone growth
particles -Product must meet
establishment purchase
specifications
-Product must be
produced under a
HACCP plan

Mold Inhibitors X -toxicological effect if -Ingredient


improper amounts used specification sheet
identifying the
required parameters
the ingredient must
meet

Mushrooms X X X -contamination from -Ingredient


inherent microorganisms specification sheet
-contamination from identifying the
agricultural chemicals required parameters
-foreign material the ingredient must
meet. This may be
included as part of a
plant's GMPs
-Where applicable,
ingredients must be
treated to control
pathogens

D-38
EXAMPLES OF B C P DESCRIPTION OF CONTROLS OR
INGREDIENTS BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
PHYSICAL HAZARD
FOR THE
INGREDIENT

Nuts X X X -contamination from -Ingredient


inherent microorganisms specification sheet
-contamination from identifying the
agricultural chemicals required parameters
-foreign particle the ingredient must
contamination, e.g., meet. This may be
broken shells included as part of an
establishment's GMPs

Packaging Materials X X -toxicological effects -Use only FDA


approved packaging
materials
-Each lot of packaging
material must be
accompanied by a
Letter of Guarantee in
which the
manufacturer attests to
compliance with FDA
requirements. This
may be included as
part of an
establishment's GMPs
Phosphates X -toxicological effect if -Ingredients purchased
limits are exceeded under a Letter of
Guarantee. This may
be included as part of
an establishment's
GMPs
-Ingredients purchased
based on producer/
provider ingredient
specifications

D-39
EXAMPLES OF B C P DESCRIPTION OF CONTROLS OR
INGREDIENTS BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
PHYSICAL HAZARD
FOR THE
INGREDIENT

Poultry (fresh, frozen) X -growth of pathogens due -Product temperature


to improper handling and must preclude
storage microbial growth
-Product must meet
establishment purchase
specifications. This
may be included as
part of an
establishment's GMPs
-Product must be
produced under a
HACCP plan
Pork (fresh, frozen) X -growth of pathogens due - Product temperature
to improper handling and must preclude
storage microbial growth
-Product must meet
establishment purchase
specifications
-Product must be
produced under a
HACCP plan
Proteolytic enzymes X -toxicological effects -Ingredients purchased
Aspergillus oryzae possible if limits exceeded under a Letter of
Aspergillus flavus Guarantee
oryzze group -Ingredients purchased
Bromelin based on producer/
Ficin provider ingredient
Papain specifications. This
may be included in a
plant's GMPs

D-40
EXAMPLES OF B C P DESCRIPTION OF CONTROLS OR
INGREDIENTS BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
PHYSICAL HAZARD
FOR THE
INGREDIENT

Partially Defatted Products X X -growth of pathogens due -Product temperature


to improper handling and must preclude
storage microbial growth
-foreign particle -Product must meet
contamination, e.g., metal, establishment purchase
plastic specifications
-Product must be
produced under a
HACCP plan
Seafood (fresh, frozen) X X X -growth of pathogens due -Product temperature
to improper handling and must preclude
storage microbial growth
-environmental -Product must meet
contamination establishment purchase
specifications. This
may be included in a
plant's GMPs
-Product must be
produced under a
HACCP plan
Spices/Herbs X X X -contamination from -Ingredient
Sterilized microorganisms inherent specification sheet
Unsterilized to the ingredient identifying the
-contamination from required parameters
agricultural chemicals the ingredient must
-foreign material meet

Sweeteners X -toxicological effects -Ingredients purchased


Saccharin possible if limits exceeded under a Letter of
Citric acid Guarantee
Malic acid -Ingredients purchased
Monoisopropyl citrate based on producer/
Phosphoric acid provider ingredient
Monoglyceride citrate specifications

D-41
EXAMPLES OF B C P DESCRIPTION OF CONTROLS OR
INGREDIENTS BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
PHYSICAL HAZARD
FOR THE
INGREDIENT

Tenderizing Agents X -toxicological effects -Ingredients purchased


possible if limits exceeded under a Letter of
Guarantee. This may
be included as part of
a plant's GMPs
-Ingredients purchased
based on producer/
provider ingredient
specifications. This
may be included as
part of a plant's GMPs
Variety Meats X -growth of pathogens due -Product temperature
to improper handling, must preclude
storage, or cleaning microbial growth
-Product must meet
establishment purchase
specifications
-Product must be
produced under a
HACCP plan
Vegetables X X X -growth of pathogens due -Ingredient
to improper handling and specification sheet
storage identifying the
-contamination from required parameters
agricultural chemicals the ingredient must
-foreign material meet
-Control storage
temperatures to
preclude microbial
growth

D-42
SECTION VII

TABLE 12
PROCESSING HAZARDS AND CONTROLS

USE OF INFORMATION

This section contains a list of processing hazards and controls commonly used in making meat and
poultry products. They are listed in alphabetical order. For each processing step, shown in the 1st
column, you will find an “X” in the next three columns to tell you if there is a Biological hazard in
column 2, Chemical hazard in column 3, or Physical hazard in column 4. Column 5 describes the
hazard(s) and the last column lists some relevant controls or preventive measures. This table should be
used in conjunction with the process flow diagram developed for your plant processes and considered
when conducting a hazard analysis.

D-43
TABLE 12 PROCESSING

PROCESSING: B C P DESCRIPTION OF CONTROLS OR


BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
EXAMPLES OF PHYSICAL HAZARDS
PROCESSING FOR THE PROCESS
STEPS STEPS

Acidifying (also see Pickling, X -survival of pathogens due to -Shelf-stable, non-heat


Brining) final pH > 4.6 treated acidified product
must obtain a pH of 4.6
or lower

Aging (Meats) X -growth/survival of pathogens -Temperature of the


from inappropriate storage aging room must
temperatures and humidity preclude growth of
(inadequate product water pathogenic
activity (aw)) microorganisms
-growth of pathogens due to -Product temperature
rise in the pH due to must preclude microbial
development of surface molds growth throughout the
aging process
-The aging process will
not exceed seven days

D-44
PROCESSING: B C P DESCRIPTION OF CONTROLS OR
BIOLOGICAL, PREVENTIVE
EXAMPLES OF CHEMICAL, OR MEASURES
PROCESSING PHYSICAL HAZARDS
STEPS FOR THE PROCESS
STEPS

Boning X -contamination by pathogens in -Careful employee


product accumulations (e.g., practices to make sure that
cutting boards, conveyor belts, there is no contamination
utensils and other equipment) of the product *
-cross-contamination of product -Equipment and utensils
by equipment/utensils are washed and sanitized
contaminated with pathogens immediately, when
when cutting through a non- contaminated, and each
apparent lesion (e.g., abscesses) time the employee leaves
the working station *
-All hot water sanitizers
are maintained at 180
degrees Fahrenheit
-Processing room
temperature is maintained
at 50 degrees Fahrenheit
or a midshift cleanup is
performed within five
hours after operations
begin *
X -contamination from bones, -A boneless beef re-
cartilage/extraneous material inspection procedure
established by the plant

* This may be included as part of a plant's SSOPs.

D-45
PROCESSING: B C P DESCRIPTION OF CONTROLS OR
BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
EXAMPLES OF PHYSICAL
PROCESSING HAZARDS
STEPS FOR THE PROCESS
STEPS

Cooling X -growth of pathogens -Cooked product will


due to improper be cooled according to
temperatures established procedures
-germination of spore- by a processing
forming pathogens due authority, scientific
to slow chilling (e.g., C. studies, and/or
perfringens) regulatory requirements

Cooking X -survival of pathogens -Time/Temperature


due to improper combinations are
procedures adequate to destroy the
pathogens of concern

D-46
PROCESSING: B C P DESCRIPTION OF CONTROLS OR
BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
EXAMPLES OF PHYSICAL HAZARDS
PROCESSING FOR THE PROCESS
STEPS STEPS

Drying (Meat) X -bacterial growth due to -A water activity will be


inadequate control over time, specified that in
temperature and humidity conjunction with other
barriers will inhibit
growth of pathogenic
microorganisms e.g., for
shelf stable sausage Aw
of 0.91 and a pH of 4.6
Filling X -recontamination by pathogens -Product will be
in product accumulations protected from
-growth of pathogens due to contamination during
temperature abuse the filling process, and
product temperature/
time will be maintained
at or below the
maximum determined to
inhibit growth of
pathogenic
microorganisms

X -contamination from lubricants -No lubricants or other


chemical contaminants
will be allowed in or on
the product *

* This may be included as part of a plant's GMPs.

D-47
PROCESSING: B C P DESCRIPTION OF CONTROLS OR
BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
EXAMPLES OF PHYSICAL HAZARDS
PROCESSING FOR THE PROCESS
STEPS STEPS

Formulation X -contamination by employee -Careful employee


handling practices used at all
-incorrect formulation times to make sure
-contamination through that there is no
damaged packages contamination of
product. This may
be included as part of
a plant's SSOPs or
GMPs
-Ingredient packages
will be clean and
intact
-Ingredients will be
added to product
according to
requirements
outlined 9 CFR
318.7
X -excessive addition of -Restricted
restricted ingredients/ ingredients will be
additives could be toxic to the added to product
consumer according to
requirements
outlined in the 9
CFR 317.8

Freezing (Meats) X -survival of parasites due to -Rapid cooling and


improper time/temperature freezing
application
-growth of pathogens due to
temperature abuse

D-48
PROCESSING: B C P DESCRIPTION OF CONTROLS OR
BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
EXAMPLES OF PHYSICAL HAZARDS
PROCESSING FOR THE PROCESS
STEPS STEPS

Grinding X -contamination by employee -Careful employee


handling practices to make
-recontamination by sure that there is no
pathogens in product contamination of
accumulations product. This may be
included as part of a
plant's SSOPs or
GMPs
-Product will not be
allowed to
accumulate at the
end of the grinder
-The temperature of
the grinding room
will be maintained at
50 degrees
Fahrenheit

Grinding X -contamination from -Food grade


lubricants lubricants will be
used on areas of the
machinery where a
potential for product
contamination exists.
This may be included
as part of a plant's
GMPs
X -contamination from -All boneless product
extraneous material will be re-inspected
before being loaded
into the grinder

D-49
PROCESSING: B C P DESCRIPTION OF CONTROLS OR
BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
EXAMPLES OF PHYSICAL HAZARDS
PROCESSING FOR THE PROCESS
STEPS STEPS

Handling and Inspecting of X X X -recontamination through -Packaging materials


Empty Containers and damaged or soiled and empty containers
Packaging Materials containers/packaging material will be protected
from contamination
during their storage
and handling
-No materials or
containers that
appear to be
contaminated with
foreign material will
be used
Mechanical Separating X -growth of pathogens -Product holding and
cooling requirements
outlined in 9 CFR
318.18 will be
followed

X -contamination from bone, -The finished


cartilage fragments product will meet the
-contamination from standards outlined in
extraneous material 9 CFR 319.5 for
bone particles
Packaging (also see Modified X X -contamination from -Closure and/or
Atmospheric Packaging, packaging material machine
Vacuum Packaging Seaming, -contamination through specifications
Sealing) damaged containers sufficient to ensure
adequate barrier
formation

D-50
PROCESSING: B C P DESCRIPTION OF CONTROLS OR
BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
EXAMPLES OF PHYSICAL HAZARDS
PROCESSING FOR THE PROCESS
STEPS STEPS

Packaging cont. X -contamination from metal -No detectable


clips or other foreign material foreign material will
resulting from the packaging be allowed in or on
process or equipment the product or
operation immediate product
containers

D-51
PROCESSING: B C P DESCRIPTION OF CONTROLS OR
BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
EXAMPLES OF PHYSICAL HAZARDS
PROCESSING FOR THE PROCESS
STEPS STEPS

Peeling X -contamination by pathogens -Careful employee


in product accumulations practices to make sure
-contamination from that there is no
employee handling contamination of product
*
-Product will not be
allowed to accumulate
in/on peeling equipment
X -contamination from -Peeling equipment will be
extraneous material maintained in a proper
operating condition **
-No foreign material in the
finished product

* This may be included as part of a plant's SSOPs.

** This may be included as part of a plant's GMPs.

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PROCESSING: B C P DESCRIPTION OF CONTROLS OR
BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
EXAMPLES OF PHYSICAL HAZARDS
PROCESSING FOR THE PROCESS
STEPS STEPS

Receiving X -contamination through -Product must be received


damaged containers in sound containers and at
-growth of pathogens due to temperatures appropriate
inappropriate storage for the type of product
conditions (temperature,
humidity)
-growth of pathogens due to
temperature abuse
-contamination from
receiving equipment (pumps,
hoses)
X -cross-contamination from -Product must be received
non-food chemicals in sound containers and be
accompanied by a letter of
guarantee from the supplier
if such letter is not on file.
This may be included in the
plant's GMPs
X -contamination from -Product must be received
extraneous material (wood, in sound containers. This
nails from pallets, plastic may be included in the
pieces) plant's GMPs
Retorting X -inadequate application of -A thermal process specific
scheduled process to the product, container
type and size, and retorting
system must be in use. The
initial product temperature
and any critical factors
specified for the thermal
process must also be
controlled. Specified retort
come up procedures will be
followed

D-53
PROCESSING: B C P DESCRIPTION OF CONTROLS OR
BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
EXAMPLES OF PHYSICAL HAZARDS
PROCESSING FOR THE PROCESS
STEPS STEPS

Reworking X -contamination by employee -Careful employee


handling practices to make sure that
-contamination from there is no contamination
pathogen accumulations in of product *
product improperly stored, -Temperature of storage
rework product, or emulsion coolers will preclude
microbial growth in and/or
on product

X -contamination from foreign -Careful employee


material practices to make sure that
there is no contamination
of product *

* This may be included in a plant's SSOPs.

D-54
PROCESSING: B C P DESCRIPTION OF CONTROLS OR
BIOLOGICAL, PREVENTIVE
CHEMICAL, OR MEASURES
PHYSICAL
EXAMPLES OF HAZARDS FOR
PROCESSING THE PROCESS
STEPS STEPS

Shipping X -growth due to -Product will not be


shipping temperatures shipped unless it is at a
inadequate to prevent temperature that precludes
excess microbial microbial growth
growth -Product will not be loaded
into transport vehicles if
the vehicles' temperature
does not preclude microbial
growth
X -contamination from -All product packages will
extraneous material be intact before shipping
introduced through -All transport vehicles will
damaged packages be cleaned after each use
and before loading of
product
Thawing X -growth of pathogens -Thawing Room
due to improper temperature will not exceed
temperatures 50 degrees Fahrenheit

D-55
SECTION VIII

REFERENCES

HAZARD ANALYSIS CRITICAL CONTROL POINT SYSTEMS

Agriculture Canada. 19--. Food Safety Enhancement Program - Implementation Manual. Nepean,
Ontario, Canada.

HACCP: The Hazard Analysis and Critical Control Point System in the Meat and Poultry Industry. 1994.
American Meat Institute Foundation. Washington, D.C.

International Commission on Microbiological Specification for Foods. 1989. “Microorganisms in Foods


4. Application of hazard analysis and critical control point (HACCP) system to ensure microbiological
safety and quality.” Blackwell Scientific Publications, Boston.

National Advisory Committee on Microbiological Criteria for Foods (NACMCF).


March 20, 1992 - Hazard Analysis and Critical Control Point System. Int. J. Food Micr. 16: 1-23.

National Advisory Committee on Microbiological Criteria for Foods NACMCF). June 1993 - Report on
Generic HACCP for Raw Beef. Food Micr. 10: 449-488.

Pierson, M.D. and Corlett, D A., Jr. ed. 1992. “HACCP/Principles and Applications.” Van Nostrand
Reinhold.

Stevenson, K.E. ed. 1993. “HACCP-Establishing Hazard Analysis Critical Control Point Programs.” A
Workshop Manual. The Food Processors Institute. Washington, D.C.

Tompkin, R.B. 1990. The Use of HACCP in the Production of Meat and Poultry Products. J. of Food
Protect. 53(9): 795-803.

Tompkin, R.B. 1995. The use of HACCP for producing and distributing processed meat and poultry
products. In Advances in Meat Research. Volume 10. Hazard Analysis Critical Control Point (HACCP)
in Meat, Poultry and Seafoods. Chapman & Hall (In Press).

D-56
FOODBORNE ILLNESSES

Bean, N.H. and Griffin, P.M. 1990. Foodborne disease outbreaks in the United States, 1973-1987:
Pathogens, vehicles, and trends. J. Food Protect. 53: 804-817.

Bean, N.H. and Griffin, P.M. 1990. Foodborne disease outbreaks, 5-year summary, 1983- 1987. J.
Food Protect. 53: 711.

Council for Agricultural Science and Technology. February, 1993. “Risks Associated with Foodborne
Pathogens.”.

Oblinger, J.L., ed. 1988. Bacteria Associated with Foodborne Illnesses, A Scientific Status Summary by
the Institute of Food Technologists Expert Panel on Food Safety and Nutrition. Food Technol. 42(4).

Padhye, N.V.; Doyle, M.P. 1992. E. Coli O157:H7 Epidemiology, pathogenesis, and methods for
detection in food. J. Food Prot. 55:55-565.

Schuchat, A., Swaminathan, B. and Broome, C.V. 1991. Epidemiology of human listeriosis. Clin.
Microbiol. Rev. 4: 169-183.

Tauxe, R.V., “Epidemiology of Campylobacter jejuni infections in the United States and other
Industrialized Nations,” In Nachamkin, Blaser, Tompkins, ed. Campylobacter jejuni: Current Status and
Future Trends, 1994, chapter 2, pages 9-19.

Tauxe, R.V., Hargett-Bean, N., Patton, C.M. and Wachsmuth, I.K. 1988. Campylobacter isolates in
the United States, 1982-1986. In, CDC Surveilance Summaries, June 1988. MMWR 37 (No. SS-2) : 1-
13.

Todd, E. 1990. Epidemiology of Foodborne Illness: North America. The Lancet 336:788.

BIOLOGICAL, CHEMICAL, AND PHYSICAL HAZARDS

Corlett, D.A., Jr. and R.F. Steir. 1991. Risk assessment within the HACCP system. Food Control 2:71-
72.

Enviromental Protection Agency. Tolerances for Pesticides in Foods. Title 40, Code of Federal
Regulations, Part 185. U.S. Government Printing Office, Washington, DC.

FDA. 1989. The Food Defect Action Levels. FDA/CFSAN. Washington, DC.

D-57
FDA. 1994. Fish and Fishery Products Hazards and Control Guide - Get Hooked on Seafood Safety.
Office of Seafood, Washington, DC.

HACCP: The Hazard Analysis and Critical Control Point System in the Meat and Poultry Industry. 1994.
American Meat Institute Foundation. Washington, D.C.

International Commission on Microbiological Specification for Foods. 1989. “Microorganisms in Foods


4. Application of hazard analysis and critical control point (HACCP) system to ensure microbiological
safety and quality.” Blackwell Scientific Publications, Boston.

Pierson, M.D. and Corlett, D A., Jr. ed. 1992. “HACCP/ Principles and Applications.” Van Nostrand
Reinhold.

Stevenson, K.E. ed. 1993. “HACCP-Establishing Hazard Analysis Critical Control Point Programs.” A
Workshop Manual. The Food Processors Institute. Washington, D.C.

USDA, Domestic Residue Data Book. USDA, FSIS, Washington, D.C.

USDA, Miscellaneous Publication #1419: "List of Propriety Substances and Nonfood Compounds
Authorized for Use under USDA Inspection and Grading Programs". USDA, FSIS, Washington, D.C.

USDA, National Residue Program Plan. USDA, FSIS, Washington, D.C.

INTERNET HOME PAGES

Agriculture Canada/http://aceis.agr.ca

Food Law Sites/http://www.fsci.umn.edu/FoodLaw/foodlaw.html

HACCP95/http://www.cvm.uiuc.edu/announcements/haccp95/
haccp95.html

Center for Disease Control/http://fftp.cdc.gov/pub/mmwr/MMWRweekly

Material Safety Data Sheets/http://listeria.nwfsc.noaa.gov/msds.html

U.S. Food and Drug Administration/http://vm.cfsan.fda.gov/list.html


Bad Bug Book

U.S. Department of Agriculture/http://www.usda.gov

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