Pork Slaughter model standards established by FSiS, and any other requirement set forth in this chapter e limits shall, at a minimum, be designed to ensure that applicable targets or performai 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 ( Include all corrective actions that have been developed in accordance with 5417.3(a) ofthis part, to be followed in response to anmy 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 (i)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 pork 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 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 that there were eight points on the hazard analysis form where food safety hazards reasonably likely to occur were identified: cross-contamination with pathogens at
Pork Slaughter Model 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 pork 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. 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 that there were eight points on the hazard analysis form where food safety hazards reasonably likely to occur were identified: cross-contamination with pathogens at 9
Pork Slaughter model dehairing; pathogens at the pre-evisceration wash; pathogen contamination from the gastrointestinal tract at evisceration, pluck/viscera disassembly and processing, head wash, final trim/final wash, and pluck/viscera wash; and, pathogen proliferation at chill/cold storage. The establishment haCCP team has chosen to have five CCPs to address these seven hazards an acceptable antimicrobial wash at pre-evisceration, final head wash, and pluck/viscera wash; and, 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 no regulatory requirements for chilling product, but realized that if the proper chiller procedures were not followed pathogen proliferation was possible. The HACCP team knew that the product should start the chilling process soon after bleedout, so they set the critical limit fo chilling product to start within one hour after bleedout 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 observe the chilling handling procedures to ensure the chilling process starts within an hour after bleedout. At the chilling step the cooler temperature is 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 (i The calibration of process-monitoring instruments (ii) Direct observations of monitoring activities and corrective actions; and (iii) The review ofrecords 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
Pork Slaughter Model dehairing; pathogens at the pre-evisceration wash; pathogen contamination from the gastrointestinal tract at evisceration, pluck/viscera disassembly and processing, head wash, final trim/final wash, and pluck/viscera wash; and, pathogen proliferation at chill/cold storage. The establishment HACCP team has chosen to have five CCPs to address these seven hazards: an acceptable antimicrobial wash at pre-evisceration, final head wash, and pluck/viscera wash; and, 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 no regulatory requirements for chilling product, but realized that if the proper chiller procedures were not followed pathogen proliferation was possible. The HACCP team knew that the product should start the chilling process soon after bleedout, so they set the critical limit for chilling product to start within one hour after bleedout. 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 observe the chilling handling procedures to ensure the chilling process starts within an hour after bleedout. At the chilling step the cooler temperature is 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: (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 10
Pork Slaughter model Pluck/Viscera Chilling Log and Carcass Chilling log once per shift. The team also had the maintenance supervisor verify the accuracy of the carcass cooler and pluck/viscera cooler temperature recording charts once per shift There is a regulatory requirement(Part 417.4(a)(2)()) 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) nd(b 8417.5 Records (a) The establishment shall maintain the following records documenting the establishment's HACCP plan () 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 ofCCP'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 ofactual 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 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 initialed by the establishment employee making the enty Corded, and shall be signed or the specific event occurs and include the date and time re The HACCP team decided that their records would be kept on some simple forms, some of which the team itself devised
Pork Slaughter Model Pluck/Viscera Chilling Log and Carcass Chilling Log once per shift. The team also had the maintenance supervisor verify the accuracy of the carcass cooler and pluck/viscera cooler 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 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. 11
Pork Slaughter model The HACCP team decided that since Qa had a form that they had been using for measuring ariety meats 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 variety meats handling step The Room/Product Temperature Log 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 ncluded 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. The team also devised the antimicrobial intervention log to record monitoring results for pressure and antimicrobial concentrations On its HACCP Plan, generic establishment X has listed the names of the forms it will be using for monitoring and verification records There is another 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 of the HACCP plan 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) 8417.3 Corrective actions (a) The written HACCP plan shall identify the corrective action to be followed in response to a deviation from a critical limit. The haccP plan shall describe the corrective action to be taken, and assign responsibility for taking corrective action, to ensure ( The cause of the deviation is identified and eliminated (2) The CCP will be under control after the corrective action is taken 3) Measures to prevent recurrence are established; and (4)No product that is injurious to health or othenwise adulterated as a result of the deviation enters commerce The HACCP team has developed a specific corrective action plan which will be followed
Pork Slaughter Model The HACCP team decided that since QA had a form that they had been using for measuring variety meats 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 variety meats handling step. The Room/Product Temperature Log 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. The team also devised the antimicrobial intervention log to record monitoring results for pressure and antimicrobial concentrations. On its HACCP Plan, generic establishment X has listed the names of the forms it will be using for monitoring and verification records. There is another 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 of the HACCP plan 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): § 417.3 Corrective actions. (a) The written HACCP plan shall identify the corrective action to be followed in response to a deviation from a critical limit. The HACCP plan shall describe the corrective action to be taken, and assign responsibility for taking corrective action, to ensure: (1) The cause of the deviation is identified and eliminated; (2) The CCP will be under control after the corrective action is taken; (3) Measures to prevent recurrence are established; and (4) No product that is injurious to health or otherwise adulterated as a result of the deviation enters commerce. The HACCP team has developed a specific corrective action plan which will be followed 12
Pork Slaughter model whenever there is a deviation from a critical limit at a CCP; each of the planned corrective actions meets the four regulatory requirements of 4 17.3(a) Planned Corrective Actions for CCP 4 1. QA will reject or hold product until temperature is achieved: dependent on time and temperature deviation 2. QA will identify the cause of the deviation and prevent reoccurrence The HACCP team also develops planned corrective actions for each of the other CCPs and attaches them to the HACCP plan. Whenever a deviation from a critical limit occurs, company employees follow the corrective action plan and use the Corrective Action Log to create a record of their actions. The Corrective Action Log forms are available at CCPs, so they can be used immediately when an employee performing a monitoring check discovers and records a deviation. All Corrective Action Logs, which have been used during the day, are turned in to the HACCP coordinate There is one final verification/recordkeeping requirement which the company must perform; it is found at 417.5(c) (c Prior to shipping product, the establishment shall review the records associated with the production of that product, documented in accordance with this section, to ensure completeness, including the determination that all critical limits were met and, if ppropriate, corrective actions were taken, including the proper disposition ofproduct Where practicable, this review shall be conducted, dated, and signed by an individual who did not produce the record(s), preferably by someone trained in accordance with s 417.7 this part, or the responsible establishment official. In generic establishment X, product is shipped out, often in small lots, throughout the day. Thi means that pre-shipment verification checks must be as complete as possible when finished product is in storage, so that a shipment can be made up quickly and moved into distribution channels The establishment uses a half day lotting system and a midshift cleanup. While the midshaft cleanup is being performed, QA personnel or the HACCP coordinator review results of monitoring and verification checks applied to that lot; if there were deviations from critical limits, they review the Corrective Action Logs to make sure all appropriate planned responses were carried out. If everything is in order and there are complete records showing that the establishment has controlled production of this product through its HACCP system, the HACCP coordinator will sign the pre-shipment review form which the HACCP team devised for this
Pork Slaughter Model whenever there is a deviation from a critical limit at a CCP; each of the planned corrective actions meets the four regulatory requirements of 417.3(a). Planned Corrective Actions for CCP 4 1. QA will reject or hold product until temperature is achieved: dependent on time and temperature deviation. 2. QA will identify the cause of the deviation and prevent reoccurrence. The HACCP team also develops planned corrective actions for each of the other CCPs and attaches them to the HACCP plan. Whenever a deviation from a critical limit occurs, company employees follow the corrective action plan and use the Corrective Action Log to create a record of their actions. The Corrective Action Log forms are available at CCPs, so they can be used immediately when an employee performing a monitoring check discovers and records a deviation. All Corrective Action Logs, which have been used during the day, are turned in to the HACCP coordinator. There is one final verification/recordkeeping requirement which the company must perform; it is found at 417.5(c): (c) Prior to shipping product, the establishment shall review the records associated with the production of that product, documented in accordance with this section, to ensure completeness, including the determination that all critical limits were met and, if appropriate, corrective actions were taken, including the proper disposition of product. Where practicable, this review shall be conducted, dated, and signed by an individual who did not produce the record(s), preferably by someone trained in accordance with § 417.7 of this part, or the responsible establishment official. In generic establishment X, product is shipped out, often in small lots, throughout the day. This means that pre-shipment verification checks must be as complete as possible when finished product is in storage, so that a shipment can be made up quickly and moved into distribution channels. The establishment uses a half day lotting system and a midshift cleanup. While the midshift cleanup is being performed, QA personnel or the HACCP coordinator review results of monitoring and verification checks applied to that lot; if there were deviations from critical limits, they review the Corrective Action Logs to make sure all appropriate planned responses were carried out. If everything is in order and there are complete records showing that the establishment has controlled production of this product through its HACCP system, the HACCP coordinator will sign the pre-shipment review form which the HACCP team devised for this purpose. 13