Canadian Saltfish Company

Heavy Salted Cod, Hake, Pollock and Cusk

Example QMP Plan

Saltfish Processing

Canadian Food Inspection Agency

 TABLE OF CONTENTS

1 Introduction 2

2 Management Roles and Responsibilities 3

3 Process and Product Background Information

4 Table 1 - Product Description 5

5 Chart 1- Process Flow 6

6 Prerequisite Programs

7 Plant Environment Program 7

8 Product Recall Program 9

Regulatory Action Point (RAP) Plan 10

9 HACCP

10 Hazard Analysis 14

11 Appendix A - QMP Supporting Documentation 19

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 1. Introduction

The following QMP plan was developed using the information gathered during the
seafood processing industry consultation sessions on the re-engineering of the Quality
Management Program. The basis for the development of this example plan is a fictitious
saltfish operation for which process flow descriptions and product descriptions had been
created. The example QMP plan was developed based on this information during a three
day workshop in which industry participants applied the concepts and principles of the re-
engineered QMP. The QMP Re-engineering Taskforce has edited the plan to standardize
the terminology and format. This example plan is a tool to assist industry in developing
their own product and process specific QMP Plan. It is intended as a general guideline
only and does not contain information specific to an actual saltfish operation.

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Canadian Food Inspection Agency
2. Management Roles and Responsibilities

The successful implementation of a quality system, including the QMP, is dependent on the
commitment of management to the program. It is essential that management understand
and endorse the contents of their quality plan. Management may communicate and
demonstrate their commitment to the plan through a description of the roles and
responsibilities of management. It is recommended that a company’s QMP Plan include
such a section for the following reasons:

1. To communicate management commitment to all employees;

2. To clarify how the program is delivered and how it is maintained;

3. To identify the tools required to properly implement the program;

4. To specify responsibilities for program delivery;

5. To enhance understanding and commitment to the program;

6. To enhance communication between all levels of management and workers;

7. To facilitate communication and co-operation between production and QMP

managers;

8. To facilitate the commitment of all employees to program;

9. To instil confidence in the decision making process based on the goals outlined in the
program.

There are many different ways that the management’s roles and responsibilities can be
described in the plan. The following are some examples that were proposed during the
workshops:

1. providing an organizational chart that shows the reporting structure of the company;

2. describing, in writing, the role of each manager;

3. describing, in writing, the accountability of each manager;

4. clarifying the relationship between production and QMP and the mechanism to resolve
problems ;

5. developing a mission or vision statement that identifies the importance of the QMP;
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Canadian Food Inspection Agency
6. developing a schedule and plan for internal audits of the QMP Plan;

7. accurate and complete documentation of corrective actions and preventative actions

initiated to avoid re-occurrence of problems;

8. documenting a management statement of commitment;

9. developing for each component of QMP written procedures that describe the roles and
responsibilities of management in the delivery and maintenance of that QMP
component;

10. a description of management’s commitment to training and identification of the

training that will be provided to employees based on their job and duties;

11. the planning and scheduling of QMP meetings focusing on the effectiveness of QMP
and identifying ways to improve the program.

It is not suggested that plant management perform all of these activities to demonstrate
their roles and responsibilities for their QMP Plan. The purpose of the list is to indicate
ways that management can demonstrate their commitment to the QMP Plan and identify
their roles and responsibilities in the management of the plan. This list is also considered
not to be all inclusive.

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 3. Process and Product Background Information

3.1- Table 1: Product Description

1. Product name(s) Heavy Salted Cod, Hake Pollock & Cusk

2. Source of Raw Material Locally caught fish

3. Important final product characteristics Salt Content: min 33% dry weight

Moisture content: Dried - max. 54%

Wet - max. 65%
4. Ingredients Salt

5. Packaging 25 kg waxed Cardboard Carton

1 lb cello bags
6. How the end product is to be used Soaked in fresh water - 8-10 hr

Cooked before consumption

7. Shelf life 1 year

8. Where the product will be sold Domestic Retail

International Markets
9. Special labelling instructions as per Fish Inspection Regulations, Food &
Drug Regulations & International
specifications

10. Special distribution control Maintain low humidity

Avoid excessive temperatures

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3.2 - Chart 1: Process Flow - Salted Fish

1. Receiving Input
3. Receiving (head-on, gutted) Materials

4. Cutting (heading, splitting) 2. Storage of 2. Storage of

salt packaging

5. Washing

6. Salting

7. Washing

8. Press piling

9. Drying

10. Grading

11. Packaging

12. Storage

13. Shipping
 4. Prerequisite Programs
4.1 Plant Environment Program

Standard Control Measure Monitoring Procedure Corrective Action

What How Frequency Who

FIR Sch. I - Plant 1. Inspection of construction 1. Construction 1. Inspect 1. Pre-season 1. QMP 1. Record all
Construction & and equipment. and superv deficiencies
Equipment equipme isor on
nt of the corrective
FIR Sch II - Plant 2. Continuous monitoring of plant 2. Monitoring 2. Ongoing action
Sanitation & plant environment by 2. Overall plant 2. Production report when
Hygiene trained personnel on FIR condition Manag the
requirements. s er deficiency
is
3. Inspection of construction 3. Inspect 3. Monthly identified.
and equipment.
3. Construction 3. QMP 2. QMP
and Superv Supervisor
equipme isor will sign
4. Perform preventative nt of the 4. n/a 4. n/a and date
maintenance on plant the
construction and corrective
equipment. 4. n/a 4. n/a action
5. Visual 5. Prior to report.
5. Inspection of Plant sanitation observation daily
start- 3. The plant
5. Effectiveness up 5. QC Staff manager will
of 6. Testing for verify that the
6. Verification of processing cleaning residual 6. Each shift appropriate
water treatment system. procedur chlorine at corrective
es end of line 6. QC Staff action was
taken.
7. SOPs for the following and 6. Effectiveness 7. monitoring 7. daily
applied by trained of
Standard Control Measure Monitoring Procedure Corrective Action

What How Frequency Who

employees: chlorinat 7. QMP
8. SOP for clean-up and or superv
sanitation. isor
9. SOP for employee hygiene.
10. SOP for Pest Control. 7. Application
of SOPs
11. Only cleaners, sanitizers, 8. monitoring 8. once per
and lubricants approved week
for use in food
processing facilities will 8. QMP
be used . superv
9. Inspect 9. Upon isor
12. SOP for the inspection and 8. Approved receipt
storage of cleaning cleaners,
agents, sanitizers, and sanitizer
lubricants. s, and 9. QMP staff
lubricant
s

9. Application
of SOPs
4.2 Product Recall

The Canadian Saltfish Company Recall Program

The Canadian Saltfish Company will maintain a system of control that permits a complete
and rapid recall of any lot of fish product. The written recall procedure includes the
following:

1. Documentation pertaining to the product coding system. All product is identified with
a production date or code identifying each lot.

2. Finished product distribution records are maintained for a period of 5 years which
exceeds the normal shelf life our product.

The Company will notify the local Inspection Office, CFIA, of all initiated recalls of a food
for health and safety reasons and will provide all necessary information.
 10

5. Regulatory Action Point (RAP) Plan

Regulatory Regulatory Control Measure Monitoring Procedure Corrective Action

Action Point Compliance
(RAP)

What How Frequency Who

1. Minimum Quality Standards

RAP 1 The production of fish that
Incoming Fish is not tainted, decomposed
or unwholesome and meets
all other regulatory
requirements. FIR Sec
6(1).
Final Product
1. Do not accept fish which will
result in a tainted, decomposed
or unwholesome final product
2. Train production personnel to
immediately recognize fish
which are tainted, decomposed
or unwholesome.
1. Incoming Conduct incoming fish 1. Each lot. QC staff 1. If the lot sampled does not
fish inspection meet company specifications
then refuse receipt and
Conduct on-line record cull and record in
inspection Corrective Action Log Book.
2. Final product 2. The QC Manager
Conduct final product determines the type and
inspection and grading time frame of the corrective
action
Use receiving records 3. Record the corrective action
to reflect inspections taken with signature and
and necessary actions date action taken.
4. QC Manage r to verify that
the corrective action was
taken.
5. Determine the source of the
problem and take action to
prevent reoccurrence.
6. Retrain employees if
necessary.

10
 Regulatory Regulatory Control Measure Monitoring Procedure Corrective Action
Action Point Compliance
(RAP)

What How Frequency Who

RAP 2 Use an adequate quantity of SOP for salting Application of Observe salting Each lot. QC staff 1. Change the amount of salt
Salting salt to obtain the desired SOP. procedure added.
percent salt in the final
product as described in the 2. Retrain personnel.
Saltfish standards.
Salting χ33% salt by dry
weight in the final product.

2. Input Materials
RAP 3 Use of only approved and Use only packaging materials, Packaging Inspection of Upon receipt. QC staff 1. Unacceptable input
Receiving Input acceptable products for use ingredients and chemicals approved materials, and packaging materials materials will be rejected upon
Materials in food processing. for use in food processing plants. salt upon and ingredients to receipt and rejection will be
• Packaging receipt. determine their recorded in the corrective
Obtain documents from supplier to condition and ensure action log.
Materials
indicate their acceptability. that packaging
• Salt materials are clean, 2. Identification of the nature
• Labels Apply SOP for receiving and new and solid. of and time frames for
storage of packaging materials and corrective action by the QC
ingredients. Observation of the manager
storage area and of
Ensure conformity of labels with SOP. 3. Corrective action entered in
applicable regulatory provisions by Labels upon a report with signature and
forwarding proof to the DFO receipt. Ensure that labels date of implementation
inspection office for review and received from the
comment prior to printing. supplier are those that 4. Audit of corrective action by
Training of QC staff were ordered. QC manager

5. Identifying the source of the

problem and taking steps to
avoid any recurrence.

6. Providing new training to

employees if necessary

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Canadian Food Inspection Agency
 12

Regulatory Regulatory Control Measure Monitoring Procedure Corrective Action

Action Point Compliance
(RAP)

What How Frequency Who

RAP 4 1. Unacceptable input
Storage of Input Use of only approved and SOP for Receipt and Storage of Application of Inspect all incoming Once per shift. QC Staff. materials will be rejected prior
Materials acceptable products for use Packaging Materials and SOP input materials. to entering storage and this
• Packaging in food processing by Ingredients. rejection will be recorded in
controlling storage. Inspect all input the corrective action log.
Materials
materials in storage
• Salt and prior to use. 2. Identification of the nature
• Labels of the time frames for
corrective action by the QC
manager.

3. Corrective action entered in

a report with signature and
date of implementation.

4. Audit of corrective action by

QC manager.

5. Identifying the source of the

problem and taking steps to
avoid any recurrence.

6. Providing new training to

employees if necessary

3. Labelling
RAP 5
Receipt of Input Labels meet all applicable 1. Verify labels meet Regulations 1. Label proof. 1. Checklist prior to 1. Per new label. 1. QC Staff 1. Correct proof before
Materials Regulations before printing. ordering. printing.
• Labels 2. Labels 2. Per Shipment.
2. Verify labels upon receipt. received. 2. Verify against order. 2. QC Staff 2. Isolate non-conforming
labels and return to printer.

12
 Regulatory Regulatory Control Measure Monitoring Procedure Corrective Action
Action Point Compliance
(RAP)

What How Frequency Who

RAP 6
Packaging Labels meet all applicable Verify that the correct label is Labels applied. Verify that label Per lot QC Staff Stop labelling.
Regulations applied. matches product. Apply correct labels.
Isolate mislabelled product
Final Product and re-label.
Each unit to be individually Inspect one unit for Once per hour. QC Personnel
weighed on calibrated scales. each size of product. If the final product does not
meet the net weight
specifications then put product
on hold since last monitoring
and sample as per Codes AQL
6.5.
RAP 7 The fish meets classification If lot is to be classified, evaluate to The lots after Sample as per Codex Each lot. QC staff If the lot does not meet
Grading and identification standards. saltfish standard. grading. AQL 6.5 and conduct classification and identification
As per the Fish Inspection sensory evaluation to standards then isolate the lot
Regulation. determine if the fish and reclassify it.
meets the classification
and identification
standards.

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6.1 Hazard Analysis
*Note - no significant hazards identified.
Ingredient/Processing Potential Hazard Introduced
Step or Controlled
1. Receipt of Input Materials Biological
- Packaging Materials Potential for incoming materials to
- Salt be contaminated during
manufacture or transportation.
Chemical
Potential for incoming materials to
be contaminated during
manufacture or transportation.
Physical
Potential for incoming materials to
be contaminated during
manufacture or transportation.
2. Storage of Input Materials Biological
- Packaging Materials Potential for materials to become
- Salt contaminated during storage.
Chemical
Potential for materials to become
contaminated during storage.
Physical
Potential for materials to become
contaminated during storage.
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6. HACCP
Is the Potential Justification for Inclusion or Preventative Measures
Hazard Exclusion as a Significant Hazard of the Significant
Significant Hazards
No Not reasonably likely to occur; controlled by
RAPs, SOP - Receipt and Storage of
Packaging Materials and Ingredients.
No Not reasonably likely to occur; controlled by
RAPs, SOP - Receipt and Storage of
Packaging Materials and Ingredients.
No Not reasonably likely to occur; controlled by
RAPs, SOP - Receipt and Storage of
Packaging Materials and Ingredients.
No Not reasonably likely to occur; controlled by
RAPs, SOP - Receipt and Storage of
Packaging Materials and Ingredients.
No Not reasonably likely to occur; controlled by
RAPs, SOP - Receipt and Storage of
Packaging Materials and Ingredients.
No Not reasonably likely to occur; controlled by
RAPs, SOP - Receipt and Storage of
Packaging Materials and Ingredients.
14
 Ingredient/Processing Potential Hazard Introduced Is the Potential Justification for Inclusion or Preventative Measures
Step or Controlled Hazard Exclusion as a Significant Hazard of the Significant
Significant Hazards
3. Receiving Fish (head-on, Biological
gutted) Pathogens No The presence or growth of pathogens or
parasites on the raw product is not considered
Parasites significant for three reasons. The product is
customarily cooked prior to consumption.,
due to competition from dominant
microflora and the continuous nature of the
process.

4. Cutting (Heading,
Splitting)
Chemical
Petroleum products. No Not reasonably likely to occur. Raw material
may be contaminated with petroleum
products during postharvest handling.
However, contaminated raw material will be
rejected at RAP 1.
Physical
Foreign matter. No During harvesting and on-board handling,
the raw material may become contaminated
with pieces of plastic from nets or other
materials from the vessel. However, the
presence of this material is not considered
significant as it will be removed through
normal processing operations RAP 1.
Biological
None Identified n/a
Chemical
None Identified n/a
Physical
None Identified n/a

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 Ingredient/Processing Potential Hazard Introduced Is the Potential Justification for Inclusion or Preventative Measures
Step or Controlled Hazard Exclusion as a Significant Hazard of the Significant
Significant Hazards
5. Washing Biological
Water contaminated with pathogens No Not reasonably likely to occur; water quality
controlled by prerequisite programs.
Chemical
Contaminants in water No Not reasonably likely to occur; water quality
controlled by prerequisite programs.
Physical
None Identified n/a
6. Salting Biological
None Identified n/a
Chemical
None Identified n/a
Physical
None Identified n/a
7. Washing Biological
Water contaminated with pathogens No Not reasonably likely to occur; water quality
controlled by prerequisite programs.
Chemical
Contaminants in water No Not reasonably likely to occur; water quality
controlled by prerequisite programs.
Physical
None Identified n/a
8. Press Piling Biological
None Identified n/a
Chemical
None Identified n/a
Physical
None Identified n/a

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Canadian Food Inspection Agency
 Ingredient/Processing Potential Hazard Introduced Is the Potential Justification for Inclusion or Preventative Measures
Step or Controlled Hazard Exclusion as a Significant Hazard of the Significant
Significant Hazards
9. Drying Biological
None Identified n/a
Chemical
None Identified n/a
Physical
None Identified n/a
10. Grading Biological
None Identified n/a
Chemical
None Identified n/a
Physical
None Identified n/a
11. Packaging Biological
None Identified n/a
Chemical
None Identified n/a
Physical
None Identified n/a
12. Storage Biological
None Identified n/a
Chemical
None Identified n/a
Physical
None Identified n/a

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 Ingredient/Processing Potential Hazard Introduced Is the Potential Justification for Inclusion or Preventative Measures
Step or Controlled Hazard Exclusion as a Significant Hazard of the Significant
Significant Hazards
13. Shipping Biological
None Identified n/a
Chemical
None Identified n/a
Physical
None Identified n/a

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 7. QMP Supporting Documents
(to be supplied by company)
Standard Operating Procedures
1. Sanitation Program
1) SOP Clean-up and Sanitation
2) SOP Employee Hygiene
3) SOP Pest Control
2. SOP for Inspection and Storage of Cleaning Agents, Sanitizers, and Lubricants
3. SOP Salting
4. SOP for Receipt and Storage of Packaging Materials and Ingredients

Forms
1. Construction and Equipment Inspection checklist
2. Plant Sanitation Checklist

Other Documents
1. Copies of Standards to be used if not CFIA Standard