Heat Treated, Shelf-Stable: Jerky Product HACCP Plan

Rosenthal Meat Science and Technology Center

Department of Animal Science Texas A&M University College Station, Texas January 6, 2000

Signature Page

Heat Treated, Shelf-Stable: Jerky Product

Signature: _______________________________________________ _______________ Jeff W. Savell, HACCP Coordinator Date Department of Animal Science Texas A&M University College Station, Texas 77843-2471 Telephone: 409-845-3935 E-mail: j-savell@tamu.edu Web Site: http://meat.tamu.edu/

Member Dr. Gary Acuff, Professor Ivan Brigman, Graduate Student Darrell Demel, Meat Lab Foreman Mike De La Zerda, Graduate Student Dr. Davey Griffin, Associate Professor Dr. Dan Hale, Professor Dr. Kerri B. Harris Dr. Jimmy Keeton, Professor Lisa Lucia, Research Assistant Rob Maddock, Graduate Student Misty Pfeiffer, Communication Specialist Ray Riley, RMSTC Manager Dr. Jeff Savell, Professor

Telephone Number 409-845-4425 409-845-3957 409-845-5651 409-845-3957 409-845-0435 409-845-0435 409-862-3643 409-845-3936 409-845-4449 409-845-3957 409-862-2036 409-845-5651 409-845-3935

Heat Treated, Shelf Stable: Jerky Product

HACCP Plan Summary Heat Treated, Shelf-Stable: Jerky Product

Monitoring CCP CCP 1B Cold Storage Hazard Pathogens Critical Limits 45 F Product temperature What Room Temperature How Temperature Monitoring Device Frequency Daily Who Cooler operator Corrective Actions1 1. Identify and eliminate cause of deviation. 2. Bring the CCP under control after corrective action is taken. 3. Measures to prevent recurrence are established. 4. No product that is injurious to health or adulterated enters commerce. CCP 2B Heat Treatment Pathogens
Smokehouse Temperature/Time,
FSIS Directive 7110.3

Verification2 Weekly internal product temperature in cooler. Plant manager or designee will review cooler charts. Weekly calibration and/or verification of temperature monitoring device by plant manager or designee.

Records Product Temperature Verification Log Cooler Chart Deviation/ Corrective Action Log Temperature Monitoring Device Calibration and/or Verification Log

142 F 8 min. 141 F 10 min. 140 F 12 min. 139 F 15 min. 138 F 19 min. 137 F 24 min. 136 F 32 min. 135 F 37 min. 134 F 47 min. 133 F 62 min. 132 F 77 min. 131 F 97 min. 130 F 121 min.

Temperature of the Smokehouse

Temperature Monitoring Device

Continuous

Smokehouse operator

1. Identify and eliminate cause of deviation. 2. Bring the CCP under control after corrective action is taken. 3. Measures to prevent recurrence are established. 4. No product that is injurious to health or adulterated enters commerce.

Visual observation of monitoring activity by plant manager or designee. Weekly calibration and/or verification of temperature monitoring device by plant manager or designee. On days of jerky manufacturing, plant manager or designee will review records.

Temperature/Time Log Heating Chart Deviation/ Corrective Action Log Temperature Monitoring Device Calibration and/or Verification Log

Time at specified temperature

Temperature Monitoring Device

Continuous

Smokehouse operator

1 2

Plant manager or designee is responsible for performing corrective actions to ensure appropriate corrective actions are taken. Direct observation of corrective action by plant manager or designee will be conducted when a deviation is found during the pre-shipment record review. January 6, 2000 Version

PRODUCT DESCRIPTION
COMPANY NAME: Rosenthal Meat Science and Technology Center PRODUCT NAME:

PRODUCT DESCRIPTION: Cured, peppered, smoked and dried beef product

INTENDED USE OF PRODUCT? Retail sales for general public consumption

TYPE OF PACKAGE? Poly-lined boxes for bulk storage Laminated plastic bag, sealed without vacuuming, for retail

WHERE WILL IT BE SOLD? Retail sales area. LABELING INSTRUCTIONS: Not applicable DISTRIBUTION METHOD? Not applicable

January 6, 2000 Version

PRODUCTS/INGREDIENTS USED TO PRODUCE PRODUCT:

MEAT/POULTRY AND BYPRODUCTS Beef rounds

NONMEAT FOOD INGREDIENTS

BINDERS/ EXTENDERS

SPICES/FLAVORINGS

RESTRICTED INGREDIENTS Prague Powder (6.25% Sodium Nitrite)

PRESERVATIVES/ ACIDIFIERS

Pepper Salt Hydrolyzed Vegetable Protein Hickory Smoked Flavor

OTHER Potable water Packaging materials

January 6, 2000 Version

Rosenthal Meat Science and Technology Center Heat Treated, Shelf-Stable: Jerky Flow Chart
Receiving Non-meat Ingredients

Receiving Meat

Storage

Brine Mixing

Cold Storage

(CCP 1B)

Curing

Slicing

Peppering, if applicable Receiving Packaging Labels Boxing Loading Truck Heat Treatment Cutting/Sizing Packaging Storage Distribution (CCP 2B)

Storage

January 6, 2000 Version

Heat Treated, Shelf Stable: Jerky Product

Heat Treated, Shelf Stable: Jerky Product Hazard Analysis

Ingredient/ Process Step Potential hazard introduced, controlled, enhanced or reduced at this step Physical: Buckshot Plastic Receiving Meat Chemical: Antibiotic residues Pesticides Growth promotants No Unlikely to occur. USDA Residue Monitoring Program indicates that the great majority of livestock are free of violative residues when slaughtered in inspected facilities. Any animal used for research involving chemical exposure will follow protocol for proper use. Raw meat is a potential source of enteric pathogens. Eliminated by thermal destruction later in the process. No Is the potential food safety hazard significant? (Risk:Severity) No Justification for decision What control measures can be applied to prevent the significant hazard(s)? Is this step a critical control point (CCP)?

Unlikely to occur. No reported incidences of these hazards have been made at this facility from Jan. 1, 1998 to Jan. 6, 2000.

Biological: Enteric pathogens (i.e. Salmonella, Campylobacter, and verotoxigenic E. coli) and Listeria monocytogenes Physical: None identified at this time. Cold Storage of Meat

Yes

No

Unlikely to occur. No reported incidences of these hazards have been made at this facility from Jan. 1, 1998 to Jan. 6, 2000.

Chemical: None identified at this time. Biological: Potential pathogen growth. Yes Improper storage temperatures could result in pathogen growth Cold storage Yes

January 6, 2000 Version

Heat Treated, Shelf Stable: Jerky Product

Ingredient/ Process Step Potential hazard introduced, controlled, enhanced or reduced at this step Physical: Metal fragments, knife blade tips, saw blades and plastic Slicing Chemical: Sanitizers and lubricants. Biological: None identified at this time. No Unlikely to occur. SSOPs address the proper use of sanitizers and lubricants are food-grade. Is the potential food safety hazard significant? (Risk:Severity) No Justification for decision What control measures can be applied to prevent the significant hazard(s)? Is this step a critical control point (CCP)?

Unlikely to occur. No reported incidences of these hazards have been made at this facility from Jan. 1, 1998 to Jan. 6, 2000.

Physical: None identified at this time. Curing Chemical: None identified at this time. Biological: None identified at this time.

Physical: None identified at this time. Peppering Chemical: None identified at this time. Biological: None identified at this time.
January 6, 2000 Version

Heat Treated, Shelf Stable: Jerky Product

Ingredient/ Process Step Potential hazard introduced, controlled, enhanced or reduced at this step Is the potential food safety hazard significant? (Risk:Severity) Justification for decision What control measures can be applied to prevent the significant hazard(s)? Is this step a critical control point (CCP)?

Physical: None identified at this time. Loading Truck Chemical: None identified at this time. Biological: None identified at this time. Physical: None identified at this time. Heat Treatment Chemical: None identified at this time. Biological: Pathogens Physical: Saw blades Plastic Cutting / Sizing Chemical: None identified at this time. Biological: Staphylococcus aureus, Listeria monocytogenes Yes Thermal destruction of vegetative pathogens at specified temperature and time. Unlikely to occur. No reported incidences of these hazards have been made at this facility from Jan. 1, 1998 to Jan. 6, 2000. Heat treatment. Yes

No

No

Low water activity of product will control growth of pathogens to prevent increase to toxic levels.
January 6, 2000 Version

Heat Treated, Shelf Stable: Jerky Product

Ingredient/ Process Step Potential hazard introduced, controlled, enhanced or reduced at this step Physical: None identified at this time. Packaging Chemical: None identified at this time. Biological: None identified at this time. Physical: None identified at this time. Storage Chemical: None identified at this time. Biological: None identified at this time. Physical: None identified at this time. Distribution Chemical: None identified at this time. Biological: None identified at this time. Is the potential food safety hazard significant? (Risk:Severity) Justification for decision What control measures can be applied to prevent the significant hazard(s)? Is this step a critical control point (CCP)?

January 6, 2000 Version

Heat Treated, Shelf Stable: Jerky Product

Ingredient/ Process Step Potential hazard introduced, controlled, enhanced or reduced at this step Physical: Metal fragments, wood splinters, and plastic Receiving Non-meat Ingredients Chemical: Chemical contaminants in seasoning Biological: Pathogens Physical: None identified at this time. Storage of Seasonings Chemical: Pesticides Biological: None identified at this time. Physical: None identified at this time. Brine Mixing Chemical: Sodium Nitrite No Only food-grade approved pesticides are used in the facility. Is the potential food safety hazard significant? (Risk:Severity) No Justification for decision What control measures can be applied to prevent the significant hazard(s)? Is this step a critical control point (CCP)?

Unlikely to occur. No reported incidences of these hazards have been made at this facility from Jan. 1, 1998 to Jan. 6, 2000. Letters of guarantee from seasoning manufacturers on file.

No

No

Letter of guarantee for irradiation or fumigation of seasonings.

No

Brine mixing SOP in place to assure proper sodium nitrite use.

Biological: None identified at this time.

January 6, 2000 Version

Heat Treated, Shelf Stable: Jerky Product

Ingredient/ Process Step Potential hazard introduced, controlled, enhanced or reduced at this step Physical: None identified at this time. Receiving Packaging, Labels and Boxing Materials Chemical: Deleterious chemical contaminants Is the potential food safety hazard significant? (Risk:Severity) Justification for decision What control measures can be applied to prevent the significant hazard(s)? Is this step a critical control point (CCP)?

No

Only food-grade packaging materials are used. Letters of guarantee from packaging company on file.

Biological: None identified at this time. Physical: None identified at this time. Storage of Packaging, Materials Chemical: Pesticides Biological: None identified at this time.

No

Only approved pesticides are used in the facility.

January 6, 2000 Version

Heat Treated, Shelf-Stable: Jerky Product

CCP Description, Critical Limits, Monitoring Procedures, Corrective Actions

PRODUCT: Process Step Heat Treated, Shelf-Stable: Jerky Product CCP Number CCP Description Critical Limits 45 F product temperature Establishment Monitoring Procedures: (What/How/Frequency/Responsible Person) What: Room temperature How: Temperature Monitoring Device Frequency: Daily Responsible Person: Cooler Operator Corrective Actions1

Cold Storage

CCP 1B

Product temperature

1. 2. 3. 4.

Identify and eliminate cause of deviation. Bring the CCP under control after corrective action is taken. Measures to prevent recurrence are established. No product that is injurious to health or adulterated enters commerce. Identify and eliminate cause of deviation. Bring the CCP under control after corrective action is taken. Measures to prevent recurrence are established. No product that is injurious to health or adulterated enters commerce.

Heat Treatment

CCP 2B

Heat Treatment

Temperature/Time 142 F 8 minutes 141 F 10 minutes 140 F 12 minutes 139 F 15 minutes 138 F 19 minutes 137 F 24 minutes 136 F 32 minutes 135 F 37 minutes 134 F 47 minutes 133 F 62 minutes 132 F 77 minutes 131 F 97 minutes 130 F 121 minutes

What: Temperature of smokehouse How: Temperature Monitoring Device Frequency: Continuous Responsible Person: Smokehouse Operator

1. 2. 3.

What: Time at specified temperature How: Temperature Monitoring Device Frequency: Continuous Responsible Person: Smokehouse operator

4.

Unforeseen Hazards
There are chances that unforeseen hazards may occur at the Rosenthal Meat Science and Technology Center. Therefore, if an unforeseen hazard occurs, this establishment will: 1. Segregate and hold the affected product, at least until the requirements of (2) and (3) are met; 2. Perform a review to determine the acceptability of the affected product for distribution; 3. Take action, when necessary, with respect to the affected product to ensure that no product that is injurious to health or otherwise adulterated, as a result of the deviation, enters commerce; 4. Perform or obtain reassessment by an individual trained in accordance with section 417.7 of the USDA/FSIS Pathogen Reduction; Hazard Analysis and Critical Control Point (HACCP) Systems; Final Rule, to determine whether the newly identified deviation or other unforeseen hazard should be incorporated into the HACCP plan.
1

Plant manager or designee is responsible for performing corrective actions to ensure appropriate corrective actions are taken. January 6, 2000 Version

Heat Treated, Shelf Stable: Jerky Product

Heat Treated, Shelf Stable: Jerky Product Verification and Recordkeeping

PROCESS STEP/CCP CCP 1B Cold Storage VERIFICATION1 Weekly internal product temperature one time per week when product is available. Weekly calibration and/or verification of temperature monitoring device by plant manager or designee. Plant manager or designee will review cooler charts. Visual observation of monitoring activity by plant manager or designee. On days of jerky manufacturing, plant manager or designee will review records. Weekly calibration and/or verification of temperature monitoring device. RECORDS Product Temperature Verification Log Cooler Chart Deviation/Corrective Action Log Temperature Monitoring Device Calibration and/or Verification Log

CCP 2B Heat Treatment

Time/Temperature Log Heating Chart Deviation/Corrective Action Log Temperature Monitoring Device Calibration and/or Verification Log

Direct observation of corrective action by plant manager or designee will be conducted when a deviation is found during the pre-shipment record review. January 6, 2000 Version

Rosenthal Meat Science and Technology Center Texas A&M University Temperature Monitoring Device Calibration and/or Verification Log
Date Time Temperature Monitoring Device Identification Temperature Reading at: 32F 212F Action Taken Performed by

Date

Time

Location

Temperature Monitoring Device Reading F

Calibrated Thermometer Monitoring Device Reading F

Action Taken

Performed by

Holding Cooler Aging Cooler Cooked Meat Cooler Cured Meat Cooler Freezer Smokehouse Probe 1 Smokehouse Probe 2 Chill-Down Probe 1 Chill-Down Probe 2

Reviewed by:_____________________________________

Date:_____________________________

Date:_________________________

Rosenthal Meat Science and Technology Center Texas A&M University

Product Temperature Verification Log
Location Internal Temperature of Product (F) Time

Holding Cooler Aging Cooler Cooked Meat Cooler Cured Meat Cooler Freezer Performed by:

Rosenthal Meat Science and Technology Center Texas A&M University

Pre-Shipment Review Log Cold Storage
Date Cooked Cooler Cured Cooler Holding Cooler Aging Cooler Freezer Time Comments Review Signature

Temperature/Time Log
Heat Treated, Shelf-Stable: Jerky Product CCP Record
CCP 1B Cold Storage Date:

Cooler Chart

Freezer Chart

Pre-shipment Review Signature:_________________________________________ Date:___________________________

Temperature/Time Log
Heat Treated, Shelf-Stable: Jerky Product CCP Record
CCP 2B Heat Treatment Date:

CCP 2: Temperature/Time Smokehouse Temperature/Time 142 F 8 min. 141 F 10 min. 140 F 12 min. 139 F 15 min. 138 F 19 min. 137 F 24 min. 136 F 32 min. 135 F 37 min. 134 F 47 min. 133 F 62 min. 132 F 77 min. 131 F 97 min. 130 F 121 min.

Pre-shipment Review Signature:_________________________________________ Date:___________________________

Deviation/Corrective Action Record

1. 2. 3. 4. Identify and eliminate cause of deviation Bring CCP under control after corrective action is taken Measures to prevent recurrence are established No product that is injurious to health or adulterated enters commerce.
Product I.D. Deviation Corrective Action No. 1 Corrective Action No. 2 Corrective Action No. 3 Corrective Action No. 4 Performed By Time

CCP No.

Pre-shipment Review Signature:________________________________________

Approved Date:____________________

Time:_________________