Ex. Haccp Plan For Canning Corned Beef PDF

# MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group Amendment 3: August 1998
# A Guide to HACCP Systems in the Meat Industry

# Appendix X.3: Canning Page: X.3.1
Appendix X.3: Generic HACCP Plan for Canning (Corned Beef)
1. Prerequisite Requirements
The following are documented prerequisite programmes/sanitation standard operating procedures

(SSOPs):
sanitary design;
C potable water quality (including cooling water requirements);
C sanitation and cleanup procedures for edible areas and food contact surfaces
(preoperational and operational);
C personal hygiene (protective clothing requirements, personal equipment and use of
amenities);
C training (including specific requirements as per IS 6, Section 8.6.2)
C hygienic processing (processing techniques and procedures, damaged carton procedures,
dropped meat, post-retort can handling);
C food contact materials (specifications, handling and storage, including can receipt and
maintenance, can sterilisation);
C food additives/ingredients (specifications, handling and storage);
C calibration, installation and maintenance of heat processing equipment and instruments;
C repairs and maintenance of equipment;
C control of chemicals;
C vermin control;
C waste disposal;
C refrigeration management (raw material);
C recall procedures;
C heat penetration trials/F0 value determination/deviation trials.
2. Scope of HACCP Plan
HACCP application: Food safety
Product: Canned corned beef
Process: Canning of corned beef from decartoning of tempered beef, heat

processing in a non-agitating retort, through to dispatch of canned
product.
3. Product Description and Intended Use
Form 1: Product description and intended use
1. Product name(s) Canned corned beef
2. Important product characteristics Commercially sterile product in a can produced in

accordance with New Zealand Food Regulations 1984,
Meat Regulations 1969 and IS 6.
3. How is it to be used:
a. By a further processor or retailer a. Not applicable
b. By the consumer. b. Ready to eat
4. Intended consumer General public ("high-risk" groups not specified for this
plan)
5. Packaging Company/regulatory specification
6. Shelf life and storage requirements Indefinite when stored at ambient temperatures
7. Where it will be sold

a. Export market List countries, if applicable
b. Local market
8. Labelling instructions Company/regulatory specification
9. Special distribution controls required Handle cans with care (GMP)

4. Initial Food Safety Objectives
(To be confirmed after hazard identification and determination of hazard responsibilities. See
Section 8 for confirmed objectives).
To ensure commercial sterility of product by destruction of all viable microorganisms of public

health significance as well as those capable of reproducing under non-refrigerated conditions of
storage and distribution.
To ensure that no post-processing contamination occurs.
To ensure that the sodium nitrite content of the product is within acceptable safety limits.
To ensure that the product is free from container integrity defects which compromise the hermetic
seal.
To ensure that the product is free from any physical hazards that pose a food safety risk to the
consumer.
5. Process Flow Diagram
Form 2: Raw materials/other inputs
Product name: Canned corned beef
Raw material/ other inputs Description / specification
Raw material
Packed beef, frozen (polylined in cartons) and tempered Slaughtered , dressed and processed under a HACCP
plan.
Other inputs1
Water/cooling water Potable as per MAF specifications (including cooling water

requirements given in IS 6 Section 8.6.4)
Flaked frozen beef As per raw material. May be subject to a separate hazard
analysis. Allowable limit: < 5%. Regulation 61(9) of the,
Food Regulations 1984
Salt2 Food grade salt (as per Regulation 196 of the Food
Regulations 1984) and written company specification
Sodium nitrite2 Prepared as per written company specification. Maximum
of 50 ppm in finished product (as per Regulation 61 of the
Food Regulations 1984)
Cans and ends2 As per written company specification and in accordance
with IS 6
1. These inputs and their hazards must be addressed by a prerequisite programme/SSOP, or specifically
considered during hazard identification within the HACCP plan.
2. Specifications and hygienic handling of these materials are covered by specific premises prerequisite
programmes.
Form 3: Process flow diagram
Process: Canning of corned beef
Inputs Process steps Edible outputs
Packed beef, frozen and tempered< 1. Decartoning

?
2. Slicing
Potable water < ?
Flaked frozen beef < 3. Parboiling < Broth
? < Fat
Additives < 4. Mixing with additives
(water, salt, sodium nitrite) ?
5. Mincing
?
Sterilised cans < 6. Can filling
?
7. Weight checking
?
Can ends < 8. Seaming under vacuum
?
9. Washing cans
?
10. Basket stacking cans
?
Cooling water with 5 ppm free < 11. Heat processing and cooling
residual chlorine (FRC)1 ?
12. Drying
?
13. Labelling
?
14. Packing
?
15. Storage
?
16. Dispatch < Canned corned beef
1. Note exemptions to this requirement in IS 6, Section 8.6.4.

6. Job Descriptions
Form 4 must be completed and confirmed for each step in the particular process.
Form 4: Template for job description
Job description
Process step no:
Summary list of food safety responsibilities of operator: (confirm after HACCP plan completed)
Reference:
7. Hazard Analysis and CCP Determination
7.1 Raw material hazard identification
Form 5a: Hazard identification for packed beef 1
Raw material Biological hazard Chemical hazard Physical hazard3
Packed beef (frozen and B4/B5 % Microbiological C22% Chemical hazards None
tempered) hazards associated with associated with unidentified
contamination from faeces, chemical residues, e.g.
ingesta, hide, e.g. anthelmintics, antibiotics,
Salmonella spp., E. coli environmental
O157:H7, Campylobacter contaminants
jejuni, Clostridium spp.
1. Hazards listed are those that have been identified in the Generic HACCP Plan for Cooling and Boning of
Beef as food safety hazards that may reasonably be associated with frozen packed beef. Further information
on hazards associated with beef are discussed in the Annex to Appendix IX.1: Background Information to the
Generic HACCP Plan for Slaughter and Dressing of Cattle, and Annex to Appendix X.1: Background
Information to the Generic HACCP Plan for Cooling and Boning of Beef.
The following codes have been used in the generic HACCP plans:
B % Biological B1 % Microbiological hazards associated with grossly-detectable abnormalities, i.e. fever,

abscesses
B2 % Microbiological hazards not grossly detectable (not applicable for this plan)
B3 % Visible parasites
B4 % Microbiological hazards associated with faeces and ingesta from the gastrointestinal
tract
B5 % Microbiological hazards associated with the hide
B6 % Microbiological hazards associated with other inputs
B7 % Microbiological hazards associated with mastitic milk
B8 – Microbiological hazards associated with contamination due to a process step
requirement not being met (sporadic occurrence)
C % Chemical C1 % Chemical hazards associated with identified chemical residues

C2 % Chemical hazards associated with unidentified chemical residues
C3 % Chemical hazards associated with other inputs
P % Physical P1 % Physical hazards associated with raw materials

P2 % Physical hazards associated with a process step requirement not being met (sporadic
occurrence)
P3 % Physical hazards associated with other inputs
2. If a supplier has controls for these hazards (e.g. producer guarantees accompanying livestock receipt) in their
HACCP plan, then C2 will not appear in this raw material hazard identification.
3. When customising this HACCP plan, individual premises may wish to include metal and bone fragments if
these hazards are reasonably likely to occur in their raw material.
7.2 Hazard analysis and CCP determination (raw material, other inputs and process steps)
Hazard analysis may result in changes to the initial food safety objectives set in Section 4. See Section 8 for confirmed objectives.
Form 5b: Hazard analysis and CCP determination (raw material, other inputs and process steps)
Process step Inputs (i) Process Q1. Could the hazard be Q2. Is there a Q3. Is there a CCP
step hazards present in or on the product1 at control measure control measure No.
unacceptable levels2 at this at this step that available at a
(ii) Potential step? would prevent previous step?
Raw material Other inputs impact of unacceptable
process step If yes, answer Q2 and Q3. levels of the If yes,
on existing hazard? retrospectively
hazards assign the previous
If yes, this step is
Component Hazards Component Hazards Yes/No Justification step as a CCP.
a CCP.
If no, not a CCP.
1. Boneless B4/B5. Enteric Yes Any microorganism No No

Decartoning beef pathogens will be unacceptable
in relation to FSO 1.
Refer to IS 6 Section
8.6
C2. No3
Unidentified
chemical
residues
(i) P2. Plastic Yes Reported incidences Yes. Removal of No 1

of unacceptable entrapped plastic
plastic found (e.g. by airgun
entrapped in frozen application)
blocks. Customer
complaints
2. Slicing Boneless B4/B5. Yes Any microorganism No No

beef Enteric will be unacceptable
pathogens in relation to FSO 1.
8.6
a CCP.
If no, not a CCP.
3. Parboiling Beef slices B4/B5. Yes Any microorganism No No

Enteric will be unacceptable
8.6
Water None
Flaked B4/B5. Yes Any microorganism No No

frozen beef Enteric will be unacceptable
8.6
C2. No3
Unident-
ified
chemical
residues
4. Mixing Beef slices B4/B5. Yes Any microorganism No No

8.6
Nitrite C3. Yes Incorrect amount may Yes % addition of No 2

Excess cause nitrite defined amount of
Nitrite poisoning. nitrite per mix.
Salt None
a CCP.
If no, not a CCP.
5. Mincing Corned beef B4/B5. Yes Any microorganism No No

8.6.
6. Can filling Corned beef B4/B5. Yes Any microorganism No No

8.6.
Sterilised None
cans
7. Weight Corned beef B4/B5. Yes Any microorganism No No

checking Enteric will be unacceptable
8.6.
8. Seaming Corned beef B4/B5. Yes Any microorganism No No

under Enteric will be unacceptable
vacuum pathogens in relation to FSO 1.
8.6.
a CCP.
If no, not a CCP.
(i) B8. Yes Seam inadequacies Yes % can seam No 3

Pathogen reported as cause of check
contamination sterilisation failures. R1
due to seam Refer to Canned
failure Foods: Principles of
Thermal Process
Control, Acidification
and Container
Closure Evaluation.
Can ends None
9. Washing Canned B4/B5. Yes Any microorganism No No

cans corned beef Enteric will be unacceptable
8.6.
10. Basket Canned B4/B5. Yes Any microorganism No No

stacking cans corned beef Enteric will be unacceptable
8.6.
11. Heat Canned B4/B5. Yes Any microorganism Yes % heat Yes % IT can 4
processing corned beef Enteric will be unacceptable processing as per selection at step 8
and cooling pathogens in relation to FSO 1. defined schedule. (CCP R1).
Refer to IS 6 Section Refer to IS 6 Yes % seam check
8.6. Section 8.6.3. at step 8 (CCP 3).
a CCP.
If no, not a CCP.
(ii) B4/B5. Yes Potential growth of Yes % cooling as No 4

Growth of thermophilic per defined
thermophilic organisms due to schedule. Refer
bacteria due to inadequate cooling to IS 6 Section
inadequate Refer to IS 6 Section 8.6.4.5.
cooling 8.6.
Cooling None
water
12. Drying Sterilised,

canned
corned beef
13. Labelling Sterilised,

canned
corned beef
14. Packing Sterilised,

canned
corned beef
15. Storage Sterilised,

canned
corned beef
16. Dispatch Sterilised,

canned
corned beef
1. Product is defined as the edible component of final product.
2. Unacceptable % as demonstrated by data (scientific literature, applied research or on-site experience) associated with achieving the FSOs established for the process. In
the determination of unacceptability, hazards should be considered in terms of:
C level;
C frequency;
C transfer and redistribution;
C severity of effect on consumer.
3. Sporadic chemical residues at some level will always occur. However, results from the National Residue Monitoring Programme indicate that residue levels are in
compliance with national requirements. The level of this hazard will not change during processing (i.e. no growth or increase in the hazard level). Therefore, it will not
be considered at subsequent steps.
8. Confirmed Food Safety Objectives (FSOs)
FSO 1: To ensure commercial sterility of product by destruction of all viable microorganisms

of public health significance as well as those capable of reproducing under non-refrigerated
conditions of storage and distribution.
FSO 2: To ensure that no post-processing contamination occurs.
FSO 3: To ensure that the product shall not contain sodium nitrite at a level which may represent
a hazard to human health.
FSO 4: To ensure that the product is free from container integrity defects which compromise the
hermetic seal.
FSO 5: To ensure that the product is free from any physical hazards that pose a food safety risk
to the consumer.
9. Completion of the HACCP Plan
Full documentation is required for the remaining elements of the HACCP plan:
C critical limit setting;

C monitoring procedures;
C corrective action procedures;
C verification procedures including validation;
C documentation and recordkeeping procedures.
Refer to Sections 9-13 of the Template for Establishing a HACCP Plan for Further Processing
of Meat and Meat Products for detailed requirements.
Form 6 provides a summary of the plan. References to documented procedures located elsewhere
should be shown on this form.
10. Verification of the HACCP Plan
10.1 Validation of the HACCP plan
Validation of the HACCP plan involves the initial confirmation that the HACCP plan is complete
and will achieve each of the food safety objectives. Identified CCPs should be evaluated to
ensure that the control measure applied at that particular process step will achieve or contribute
to the achievement of the relevant food safety objective (FSO).
Validation of a HACCP plan for canning may include validation of the associated process
schedule or, alternatively, the use of an already-validated process schedule. In this latter case,
further validation would only be needed for chemical and physical hazards.
FSO 1: To ensure commercial sterility of product by eliminating microorganisms capable

of growth under normal conditions of product storage and distribution.
The first FSO is expected to be achieved by providing adequate control measures at CCP3, CCP
R1 (seaming under vacuum) and CCP4 (heat processing and cooling), in conjunction with
effective prerequisite programmes (e.g. sanitation and cleanup procedures, personal hygiene,
hygienic processing). Prerequisite programmes are to be validated in accordance with
requirements in IS 8.
(a) CCP3 (seaming under vacuum)
The use of visual inspection and physical measurements (tear downs) are appropriate for
validation of this CCP. Historical data in conjunction with the can manufacturer’s specifications
may be used. The measurement components and frequency of measurement may be influenced
by market access requirements.
(b) CCP R1 (seaming under vacuum)
Collection of the coldest can is an integral part of the heat processing schedule. Validation of this
procedure will occur when the processing schedule is established.
(c) CCP4 (heat processing and cooling)
The use of historical data from the heat penetration tests/establishment of F0, and the etablishment
of the process schedule, will provide validation for this CCP. Refer to information in IS 6,
Section 8.6.3. Can incubation tests are included in this validation process (IS 6 Section 8.6.5).
FSO2: To ensure that no post processing contamination occurs
FSO2 is expected to be achieved by providing adequate control measures as per FSO1, in

conjunction with effective perequisite programmes, e.g. can handling and hygienic processing.
Prerequisite programmes are to be validated in accordance with requirements in IS 8.
FSO3: To ensure that the product shall not contain sodium nitrite at a level which may
represent a hazard to human health.
FSO3 is expected to be achieved by providing adequate control measures at CCP2 (mixing). The
control measure reflects a regulatory requirement in the New Zealand Food Regulations 1984.
It is therefore expected that premises will already have historical data under GMP to show that
procedures in place are adequate to achieve the regulatory standard and therefore the FSO. Initial
product trial results also should be available to validate this FSO.
FSO4: To ensure that the product is free from container integrity defects which compromise
the hermetic seal.
FSO4 is expected to be achieved by effective application of controls at CCP 3 (see also FSO1)
and some key prerequisite programmes such as can specifications, receipt and storage, can
handling and processing hygiene. The prerequisite programmes are expected to be validated
according to IS 8.
FSO5: To ensure that the product is free from any physical hazards (i.e. plastic) that pose
a food safety risk to the consumer.
FSO5 is expected to be achieved by visual inspection at CCP1(decartoning). Guidance on

establishing sampling regimes for validation using visual observations at this step may be
obtained from publications on statistical process control.
10.2 Ongoing verification
On-going verification activities confirm whether the HACCP plan is operating effectively and
according to documented procedures. Examples of these activities are internal and extrinsic
audits, HACCP review, and a product testing programme.
10.3 Revalidation
A revalidation of the HACCP plan is required, whenever changes are made (e.g. changes to
premises, product, process, intended use of the product) or process failure which may
compromise product safety, occurs.
Form 6: HACCP plan summary spreadsheet for canning (corned beef)
Process Step Hazard ID CCP no: Critical limits Monitoring procedures/tools Corrective action Verification HACCP records3
(consider who, what, when, procedures1 procedures2
how)
1. Decartoning Plastic 1 Operator technique % Observation every 2 hours of (a) Talk to operator FSO validation Validation record
100% compliance with operator removing entrapped (b) Increase supervision
food safety component of plastic and inspecting meat and/or monitoring Internal audit Daily monitoring
job description block (c) Retrain or remove record
operator Extrinsic audit
All meat blocks free of Visual check of random Corrective action
plastic selection of blocks for Customer complaints report
entrapped plastic
HACCP review Internal audit report
Extrinsic audit report
Customer
complaints file
HACCP review
record
2. Slicing
3. Parboiling
Process Hazard ID CCP no: Critical limits Monitoring procedures/tools Corrective action Verification HACCP records3
Step (consider who, what, when, procedures1 procedures2
how)
4. Mixing Excess 2 Predetermined and Individual batch lots identified Detain product and test FSO validation Validation record
sodium prepared amount to be for nitrite
nitrite added per batch size. Visual check on amount per Finished product Nitrite monitoring record
Amount to result in # 50 batch evaluation resulting in
ppm nitrite in final # 50 ppm nitrite in final Corrective action report
product. product
Product evaluation
Internal audit records
Extrinsic audit Internal audit report
HACCP review Extrinsic audit report
HACCP review record
5. Mincing
6. Can filling
7. Weight
checking
how)
8. Seaming Pathogen 3 As per manufacturer’s Visual examination for double Stop production FSO validation Validation record
under contamina specifications for seam and other container
vacuum tion due to particular can defects at least every 30 Check on vacuum Daily monitoring record
seam minutes of continuous headspace after
failure operation cooling Visual examination and
teardown records
Double seam teardown Adjust seamer Calibration of vacuum
examination at intervals of Isolate defective stock gauge every 12 Calibration and
sufficient frequency to ensure and detain months maintenance records
proper closure. Interval not to
exceed 4 operating hours (e.g. Internal audit Corrective action report
every 2 hours)
Extrinsic audit Internal audit report
Additional visual and teardown Isolate defective stock
examinations to be made at the and detain HACCP review Extrinsic audit report
start of production,
immediately after a seamer HACCP review record
jam, machine adjustment or a
prolonged shutdown
Regular supervisor checks of

operator performance
R1 Select, mark and set Talk to operator
aside coldest can for each
retort load Advise retort operator
to take appropriate
action associated with
deviation from process
schedule
9. Washing
cans
10. Stacking
how)
11. Heat Enteric 4 All cans heat processed Monitor and record critical Refer to IS 6 Section FSO validation Validation record
processing pathogens using a validated parameters as per 8.6.9.5
and cooling and process schedule that requirements given in the Internal audit Retort log
thermophiles will achieve a 12D process schedule
reduction in Clostridium Extrinsic audit Corrective action report
botulinum spores.
HACCP review Calibration and
Thermal process maintenance records
parameters (e.g. product Sterility tests
initial temperature, Internal audit report
process time Incubation results
/temperature) and other Extrinsic audit report
critical factors that may Calibration of
affect the attainment of time/temp devices HACCP review record
commercial sterility to every 6 months
be established for each Product evaluation
process schedule. records
8.6.3
12. Drying
13. Labelling
how)
14. Packing
15. Storage
16. Dispatch
1. Corrective actions should reflect an escalating response when ongoing non-compliance occurs.
2. Verification procedures apply to all aspects of the HACCP plan.
3. HACCP records apply to all aspects of the HACCP plan. Refer to IS 8 Section 4 regarding requirements for documentation and record keeping.
References
IS No. 6. (1997) Industry Standard No. 6: Processing of Edible Product. The New Zealand Meat
Industry Hygiene Council, Wellington.
National Food Processors Association. (1995) Principles of Thermal Process Control,

Acidification and Container Closure Evaluation. The Food Processors Institute, Washington D.C.
New Zealand Food Regulations (1984). New Zealand Government, Wellington.

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# MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group Amendment 3: August 1998

# A Guide to HACCP Systems in the Meat Industry

Appendix X.3: Generic HACCP Plan for Canning (Corned Beef)

The following are documented prerequisite programmes/sanitation standard operating procedures

2. Scope of HACCP Plan

HACCP application: Food safety

Product: Canned corned beef

Process: Canning of corned beef from decartoning of tempered beef, heat

3. Product Description and Intended Use

Form 1: Product description and intended use

1. Product name(s) Canned corned beef

2. Important product characteristics Commercially sterile product in a can produced in

5. Packaging Company/regulatory specification

7. Where it will be sold

8. Labelling instructions Company/regulatory specification

9. Special distribution controls required Handle cans with care (GMP)

4. Initial Food Safety Objectives

To ensure commercial sterility of product by destruction of all viable microorganisms of public

To ensure that no post-processing contamination occurs.

5. Process Flow Diagram

Form 2: Raw materials/other inputs

Product name: Canned corned beef

Raw material/ other inputs Description / specification

Water/cooling water Potable as per MAF specifications (including cooling water

Form 3: Process flow diagram

Process: Canning of corned beef

Inputs Process steps Edible outputs

Packed beef, frozen and tempered< 1. Decartoning

1. Note exemptions to this requirement in IS 6, Section 8.6.4.

Form 4: Template for job description

Process step no:

7. Hazard Analysis and CCP Determination

7.1 Raw material hazard identification

Form 5a: Hazard identification for packed beef 1

Raw material Biological hazard Chemical hazard Physical hazard3

B % Biological B1 % Microbiological hazards associated with grossly-detectable abnormalities, i.e. fever,

C % Chemical C1 % Chemical hazards associated with identified chemical residues

P % Physical P1 % Physical hazards associated with raw materials

1. Boneless B4/B5. Enteric Yes Any microorganism No No

(i) P2. Plastic Yes Reported incidences Yes. Removal of No 1

2. Slicing Boneless B4/B5. Yes Any microorganism No No

3. Parboiling Beef slices B4/B5. Yes Any microorganism No No

Flaked B4/B5. Yes Any microorganism No No

4. Mixing Beef slices B4/B5. Yes Any microorganism No No

Nitrite C3. Yes Incorrect amount may Yes % addition of No 2

5. Mincing Corned beef B4/B5. Yes Any microorganism No No

6. Can filling Corned beef B4/B5. Yes Any microorganism No No

7. Weight Corned beef B4/B5. Yes Any microorganism No No

8. Seaming Corned beef B4/B5. Yes Any microorganism No No

(i) B8. Yes Seam inadequacies Yes % can seam No 3

Can ends None

9. Washing Canned B4/B5. Yes Any microorganism No No

10. Basket Canned B4/B5. Yes Any microorganism No No

(ii) B4/B5. Yes Potential growth of Yes % cooling as No 4

12. Drying Sterilised,

13. Labelling Sterilised,

14. Packing Sterilised,

15. Storage Sterilised,

16. Dispatch Sterilised,

1. Product is defined as the edible component of final product.

8. Confirmed Food Safety Objectives (FSOs)

FSO 1: To ensure commercial sterility of product by destruction of all viable microorganisms