Poultry slaughter Model in which the HACCP team has identified a point in the process at which a food safety hazard is reasonably likely to occur. For each one of these they have identified a measure which can used to control the hazard When your hACCP team has completed their hazard analysis(whether they use this format or not), it is a good idea to review the flow diagram, the product description and the hazard analysis itself to make sure they are complete. Part 4 17. 2(a) 3 )includes a list of sources from which food safety hazards might be expected to arise. Reviewing that list could help the haCCPteam check for completeness Note: If you are using this generic model and slaughter a different species or if you use a these different hazards, there may be different measures which could be used for contour.For different process flow, you may have different hazards which are reasonably likely to oc purposes This, and all other FSiS generic models, contains a list of references which can help your HACCP team in making sure the hazard analysis is complete. The references for poultry slaughter are found in Appendix A. a member of your HACCP team might want to review at least some of the references to make sure hazards have not been omitted from the hazard Completing the hazard analysis is a very significant and important element in developing your HACCP system. Your HACCP team should feel a real sense of accomplishment when they get this far; this is like completing the foundation of a house Developing Your HACCP Plan The company HACCP team can now take the materials it developed while doing the hazard analysis and use them to build the HACCP Plan. Remember that one of the important objectives of the FSiS generic models is to provide examples which illustrate how to meet the regulatory requirements of Part 417, as well as to correctly apply the principles of HACCP Part 417 2(c)and(d)are the regulatory requirements (c) The contents of the HacCP plan. The HaccP plan shall, at a minimum ()List the food safery hazards identified in accordance with paragraph(a)of this section, which must be controlled for each proces 2) List the critical control points for each of the identified food safety hazards including, as appropriate
Poultry Slaughter Model in which the HACCP team has identified a point in the process at which a food safety hazard is reasonably likely to occur. For each one of these they have identified a measure which can be used to control the hazard. When your HACCP team has completed their hazard analysis (whether they use this format or not), it is a good idea to review the flow diagram, the product description and the hazard analysis itself to make sure they are complete. Part 417.2(a)(3) includes a list of sources from which food safety hazards might be expected to arise. Reviewing that list could help the HACCP team check for completeness. Note: If you are using this generic model and slaughter a different species or if you use a different process flow, you may have different hazards which are reasonably likely to occur. For these different hazards, there may be different measures which could be used for control purposes. This, and all other FSIS generic models, contains a list of references which can help your HACCP team in making sure the hazard analysis is complete. The references for poultry slaughter are found in Appendix A. A member of your HACCP team might want to review at least some of the references to make sure hazards have not been omitted from the hazard analysis. Completing the hazard analysis is a very significant and important element in developing your HACCP system. Your HACCP team should feel a real sense of accomplishment when they get this far; this is like completing the foundation of a house. Developing Your HACCP Plan The company HACCP team can now take the materials it developed while doing the hazard analysis and use them to build the HACCP Plan. Remember that one of the important objectives of the FSIS generic models is to provide examples which illustrate how to meet the regulatory requirements of Part 417, as well as to correctly apply the principles of HACCP. Part 417.2 (c) and (d) are the regulatory requirements: (c) The contents of the HACCP plan. The HACCP plan shall, at a minimum: (1) List the food safety hazards identified in accordance with paragraph (a) of this section, which must be controlled for each process. (2) List the critical control points for each of the identified food safety hazards, including, as appropriate: 9
Poultry slaughter Model (i) Critical control points designed to control food safety hazards that could be introduced in the establishment, and (ii) Critical control points designed to control food safety hazards introduced outside the establishment, including food safety hazards that occur before, during, and afterentry into the establisher () List the critical limits that must be met at each of the critical control points. Critical standards established by FS/S, and any other requirement set forth in this chapter limits shall, at a minimum, be designed to ensure that applicable targets or performance pertaining to the specific process or product, are met; (4List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits 7 Include all corrective actions that have been developed in accordance with 5417. 3(a) of this part, to be followed in response to any deviation from a critical limit at a critical control point; and (6 Provide for a recordkeeping system that documents the monitoring of the critical control points. The records shall contain the actual values and observations obtained during monitoring (7 List the verification procedures, and the frequency with which those procedures will be performed, that the establishment will use in accordance with$417. 4 of this part (d)Signing and dating the HaccP plan. (1 The haCCP plan shall be signed and dated by the responsible establishment individual. This signature shall signify that the establishment accepts and will implement the HaCCP plan (2) The HaCCP plan shall be dated and signed (i Upon initial acceptance (ii) Upon any modification; and (iii) At least annually, upon reassessment, as required under417.(a))of this part generic establishment X has prepared its HACCP plan for young chicken slaughter on a six column form(See Figure 4). You do not need to use this form, although some kind of a form probably the easiest way to present your HACCP plan
Poultry Slaughter Model (i) Critical control points designed to control food safety hazards that could be introduced in the establishment, and (ii) Critical control points designed to control food safety hazards introduced outside the establishment, including food safety hazards that occur before, during, and after entry into the establishment; (3) List the critical limits that must be met at each of the critical control points. Critical limits shall, at a minimum, be designed to ensure that applicable targets or performance standards established by FSIS, and any other requirement set forth in this chapter pertaining to the specific process or product, are met; (4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits; (5) Include all corrective actions that have been developed in accordance with §417.3(a) of this part, to be followed in response to any deviation from a critical limit at a critical control point; and (6) Provide for a recordkeeping system that documents the monitoring of the critical control points. The records shall contain the actual values and observations obtained during monitoring. (7) List the verification procedures, and the frequency with which those procedures will be performed, that the establishment will use in accordance with § 417.4 of this part. (d) Signing and dating the HACCP plan. (1) The HACCP plan shall be signed and dated by the responsible establishment individual. This signature shall signify that the establishment accepts and will implement the HACCP plan. (2) The HACCP plan shall be dated and signed: (i) Upon initial acceptance; (ii) Upon any modification; and (iii) At least annually, upon reassessment, as required under § 417.4(a)(3) of this part. Generic establishment X has prepared its HACCP plan for young chicken slaughter on a six column form (See Figure 4). You do not need to use this form, although some kind of a form is probably the easiest way to present your HACCP plan. 10
Poultry slaughter Model Identifying ccps The first column on this particular form is used to enter information developed and contained on the hazard analysis form. Part 417 2(c)(1)and(2)require that the food safety hazards identified in the hazard analysis be listed on the haCCP plan and that there be a CCp for each identified hazard. You will notice the hazard analysis form identified four points at which food safety hazards were reasonably likely to occur: physical contamination with fecal material and potential pathogen contamination at evisceration/presentation, pathogen contamination at reprocessing, pathogen cross-contamination and proliferation at chilling, and pathogen proliferation at finished products storage(cold ). The establishment HACCP team has chosen to have four CCPs to address these four hazards: proper evisceration/presentation, proper reprocessing, proper chilling of product, and proper maintenance of finished product temperatures during storage After identifying its CCPs, the HACCP team proceeded to consider critical limits, monitoring procedures and their frequencies, and verification procedures and their frequencies, and HACCP record In deciding what would be the critical limits. the haccp team first considered whether there were any regulatory requirements which had to be met and would function as critical limits They found some regulatory requirements for chilling($381.66), and realized that if the proper chiller procedures were not followed pathogen proliferation was possible. The HACCP team knew that the chilling process should start as soon as possible, so they set the critical limit for the temperature of product to reach 40%F or less within four hours from the stunning/killing step Once they had decided on their critical limits, they needed to identify how the monitorin procedures would be carried out and at what frequency For their chilling step, the establishment had the Qa technician do a product temperature check at the end of the chilling procedure every hour of production. At the chilling step the carcass chiller and neck/giblet chiller temperatures are monitored continuously with recording charts These decisions by the HacCP team regarding critical limits, plus monitoring procedures and their frequencies are written up in columns two and three of the HACCP Plan The team then went on to consider appropriate verification procedures; the team knew that there were different types of verification and that Part 417. 4(a)(2)included specific regulatory requirements for each. The regulatory requirements for ongoing verification are (2)Ongoing verification activities. Ongoing verification activities include, but are not limited to
Poultry Slaughter Model Identifying CCPs The first column on this particular form is used to enter information developed and contained on the hazard analysis form. Part 417.2(c)(1) and (2) require that the food safety hazards identified in the hazard analysis be listed on the HACCP plan and that there be a CCP for each identified hazard. You will notice the hazard analysis form identified four points at which food safety hazards were reasonably likely to occur: physical contamination with fecal material and potential pathogen contamination at evisceration/presentation, pathogen contamination at reprocessing, pathogen cross-contamination and proliferation at chilling, and pathogen proliferation at finished products storage (cold). The establishment HACCP team has chosen to have four CCPs to address these four hazards: proper evisceration/presentation, proper reprocessing, proper chilling of product, and proper maintenance of finished product temperatures during storage. After identifying its CCPs, the HACCP team proceeded to consider critical limits, monitoring procedures and their frequencies, and verification procedures and their frequencies, and HACCP records. In deciding what would be the critical limits, the HACCP team first considered whether there were any regulatory requirements which had to be met and would function as critical limits. They found some regulatory requirements for chilling (§381.66), and realized that if the proper chiller procedures were not followed pathogen proliferation was possible. The HACCP team knew that the chilling process should start as soon as possible, so they set the critical limit for the temperature of product to reach 40° F or less within four hours from the stunning/killing step. Once they had decided on their critical limits, they needed to identify how the monitoring procedures would be carried out and at what frequency. For their chilling step, the establishment had the QA technician do a product temperature check at the end of the chilling procedure every hour of production. At the chilling step the carcass chiller and neck/giblet chiller temperatures are monitored continuously with recording charts. These decisions by the HACCP team regarding critical limits, plus monitoring procedures and their frequencies are written up in columns two and three of the HACCP Plan. The team then went on to consider appropriate verification procedures; the team knew that there were different types of verification and that Part 417.4(a)(2) included specific regulatory requirements for each. The regulatory requirements for ongoing verification are: (2) Ongoing verification activities. Ongoing verification activities include, but are not limited to: 11
Poultry slaughter Model The calibration of process-monitoring instruments, (ii) Direct observations of monitoring activities and corrective actions; and (iii) The review of records generated and maintained in accordance with $417.5(a))of this part The HACCP team decided they could verify the chilling of product by checking the Chilling log once per shift. The team also had the maintenance supervisor verify the accuracy of the carcass chiller and necks/giblets chiller temperature recording charts once per shift There is a regulatory requirement(Part 417.4(a)(2)(i)) for including as a verification, the calibration of process-monitoring instruments. Each day Qa checks the hand-held thermometers for accuracy in slush ice water and calibrates them to within 2 Accuracy The HACCP team described the verification procedures and their frequencies in the fifth column of their haCCp plan The HACCP team for generic establishment X knew that their hacCP Plan needed to provide for a recordkeeping system. They wanted their records to be easy to create and understand They wanted to be sure their records met regulatory requirements, so they reviewed part 417. 5(a) nd(b) 8477.5 Records. (a) The establishment shall maintain the following records documenting the establishment's HAcCP plar () The written hazard analysis prescribed in 5417. 2(a)of this part, including all supporting documentation 2) The written HACCP plan, including decision making documents associated with the selection and development of CCP's and critical limits, and documents supporting both the monitoring and verification procedures selected and the frequency of those procedures () Records documenting the monitoring of CCP's and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment's HACCP plan, the calibration of process-monitoring instruments corrective actions, including all actions taken in response to a deviation; verification procedures and results, product code(s), product name or identity, or slaughte
Poultry Slaughter Model (i) The calibration of process-monitoring instruments; (ii) Direct observations of monitoring activities and corrective actions; and (iii) The review of records generated and maintained in accordance with §417.5(a)(3) of this part. The HACCP team decided they could verify the chilling of product by checking the Chilling Log once per shift. The team also had the maintenance supervisor verify the accuracy of the carcass chiller and necks/giblets chiller temperature recording charts once per shift. There is a regulatory requirement (Part 417.4(a)(2)(i)) for including as a verification, the calibration of process-monitoring instruments. Each day QA checks the hand-held thermometers for accuracy in slush ice water and calibrates them to within 2° F accuracy. The HACCP team described the verification procedures and their frequencies in the fifth column of their HACCP plan. The HACCP team for generic establishment X knew that their HACCP Plan needed to provide for a recordkeeping system. They wanted their records to be easy to create and understand. They wanted to be sure their records met regulatory requirements, so they reviewed part 417.5(a) and (b): § 417.5 Records. (a) The establishment shall maintain the following records documenting the establishment's HACCP plan: (1) The written hazard analysis prescribed in § 417.2(a) of this part, including all supporting documentation; (2) The written HACCP plan, including decision making documents associated with the selection and development of CCP's and critical limits, and documents supporting both the monitoring and verification procedures selected and the frequency of those procedures. (3) Records documenting the monitoring of CCP's and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment's HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter 12
Poultry slaughter Model production lot. Each of these records shall include the date the record was made (b) each entry on a record maintained under the haccP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry The HACCP team decided that their records would be kept on some simple forms, some of which the team itself devised The HACCP team decided that since Qa had a form that they had been using for measuring chilling temperatures, that they would modify that form. The form was modified to provide spaces for all entries necessary for the monitoring and verification activities at the product handling step The Temperature Recording Chart for the carcass chill was already in use and the team knew that they needed to do some personnel training to ensure that all recordkeeping requirements are included on the recording chart Qa already had a Thermometer Calibration Log and this form was modified to meet the HACCP regulatory recordkeeping requirements. The HACCP team decided that this form could be used by Qa for more than one day because there are very limited numbers of thermometers issued for product temperature measurements. If at any time during the shift a thermometer is dropped or if the employee questions the accuracy of the thermometer he is to immediately take the thermometer to the Qa lab for an accuracy check On its HACCP Plan, generic establishment X has listed the names of the forms it will be using for monitoring and verification records. The team also devised the antimicrobial intervention log to record monitoring results for pressure and antimicrobial concentrations There is one other form included in column four where the establishment has described its recordkeeping system. That is the Corrective Actions Log; it is used to create the records of any corrective actions taken because of deviations from critical limits at CCPs. Column six references the planned corrective actions for each CCP. The haCCP team carefully reviewed the regulatory requirements for planned corrective actions found at 417.3(a)
Poultry Slaughter Model production lot. Each of these records shall include the date the record was made. (b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry. The HACCP team decided that their records would be kept on some simple forms, some of which the team itself devised. The HACCP team decided that since QA had a form that they had been using for measuring chilling temperatures, that they would modify that form. The form was modified to provide spaces for all entries necessary for the monitoring and verification activities at the product handling step. The Temperature Recording Chart for the carcass chill was already in use and the team knew that they needed to do some personnel training to ensure that all recordkeeping requirements are included on the recording chart. QA already had a Thermometer Calibration Log and this form was modified to meet the HACCP regulatory recordkeeping requirements. The HACCP team decided that this form could be used by QA for more than one day because there are very limited numbers of thermometers issued for product temperature measurements. If at any time during the shift a thermometer is dropped or if the employee questions the accuracy of the thermometer he is to immediately take the thermometer to the QA lab for an accuracy check. On its HACCP Plan, generic establishment X has listed the names of the forms it will be using for monitoring and verification records. The team also devised the antimicrobial intervention log to record monitoring results for pressure and antimicrobial concentrations. There is one other form included in column four, where the establishment has described its recordkeeping system. That is the Corrective Actions Log; it is used to create the records of any corrective actions taken because of deviations from critical limits at CCPs. Column six references the planned corrective actions for each CCP. The HACCP team carefully reviewed the regulatory requirements for planned corrective actions found at 417.3(a): 13