Generic HACCP* Model for Cooked Sausage - HACCP Alliance

1 Generic HACCP * Model forCooked Sausage *Hazard Analysisand Critical ControlPoint ( HACCP )United StatesDepartmentof AgricultureFood Safetyand InspectionServiceMarch 1994 IntroductionHACCP Generic Model for Cooked SausageHazard Analysis and Critical Control Points ( HACCP ) is a system of processcontrol. It is designed to prevent the occurrence of problems by ensuring thatcontrols are applied at any point in a food production system where hazardous orcritical situations could occur. Hazards could include microbiological, chemical, orphysical adulteration of food late May 1993, Department of Agriculture (USDA) Secretary Mike Espydirected USDA's Food Safety and Inspection Service (FSIS) to provide him with aplan for implementing mandatory HACCP in the nation's meat and poultryestablishments. The Secretary recognized that such a system, which has been understudy by FSIS, was a necessary building block of the inspection system of the workshops held in 1991 and 1992, five Generic HACCP models were developedand are being published for public information.

2 The models should be useful forcompanies developing individualized five Generic HACCP models are: Refrigerated Foods Cooked Sausage Poultry Slaughter Fresh Ground Beef Swine SlaughterThe workshop for Cooked Sausage was held in Fort Worth, Texas, from May 21-23,1991. Over 40 technical and subject matter experts from industry and governmentcollaborated in the Generic Model development. Participants identified 9 criticalcontrol points (CCP's) for Cooked Sausage , including: receiving, meat preparation,non-meat ingredient compounding, pre-blend/formulation/staging(re-work),c ooking/smoking, chilling/storage, peeling, packaging, and storage. This is thegeneric HACCP Model for Cooked SausageInformation on the other four workshops follows:The Workshop for Refrigerated Foods was held in Baltimore, Maryland, fromFebruary 26-28, 1991.

3 Over 40 technical and subject matter experts from industryand government collaborated in the Generic Model development. Participantsidentified 14 critical control points (CCP's) for refrigerated foods, including:preparation, cooking chilling, assembling components into packages, flushing withgas atmosphere, package inspection, labeling and code dating, chilling, and is the Generic HACCP Model for Refrigerated workshop for Poultry Slaughter was held in Atlanta, Georgia, from August 27-29, 1991. Over 40 technical and subject matter experts from industry andgovernment collaborated in the Generic Model development. Participants identified10 critical control points (CCP's) for poultry slaughter, including: receiving scalding,venting/opening/eviscerating, off-line procedures, neck and giblet chilling, final wash,carcass chilling, packaging/ labeling, and storage/distribution.

4 This is the genericHACCP Model for Poultry workshop for Fresh Ground Beef was held in Phoenix, Arizona, from December3-5, 1991. Over 40 technical and subject matter experts from industry andgovernment collaborated in the Generic Model development. Participants identified10 critical control points (CCP's) for fresh ground beef, including: sanitation,receiving, storage, assembly/pre-weigh/pre-grind (re-work), final grind,packaging/labeling, storage, and shipping. This is the Generic HACCP Model forFresh Ground workshop for Pork Slaughter (Market Hogs) was held in Minneapolis,Minnesota, from March 31-April 2, 1992. Over 40 technical and subject matterexperts from industry and government collaborated in the Generic modeldevelopment. Participants identified 10 critical control points (CCP's) for porkslaughter, including: receiving/holding, scalding, dehairing, trimming, neckbreaker/head dropping/brisket opening, splitting, trim rail/final rail inspection fortrimming, cooler, operational sanitation, and pre-op sanitation.

5 This is the genericHACCP Model for Pork Slaughter (Market Hogs)PRODUCT CATEGORY DESCRIPTIONPRODUCT CATEGORY: Cooked Sausage (FRANKFURTER)WORKSHOP LOCATION:FT. WORTH, TXTHE FOLLOWING QUESTIONS NEED TO BE ANSWERED WHEN DEVELOPINGTHE PRODUCT CATEGORY NAME?FRANKS/HOT DOGS; WEINERS; IS IT TO BE USED?HEAT AND EAT; READY-TO-EAT; OF PACKAGE?ATMOSPHERIC PACKED, VACUUMPACKED; MODIFIED OF SHELF LIFE, AT VACUUM PACKED-40 TO 60 DAYS;WHAT TEMPERATURE?MODIFIED ATMOSPHERIC PACKED-30TO 50 DAYS; ATMOSPHERIC PACKED-12TO 20 DAYS AT 40-50 WILL IT BE SOLD?RETAIL; INSTRUCTIONS?KEEP REFRIGERATED; FULLY- Cooked ;CODE-DATE; SPECIAL DISTRIBUTIONKEEP REFRIGERATED AT OR BELOWCONTROL NEEDED?40 DEGREES;PROCESS FLOW DIAGRAM PRODUCT CATEGORY: Cooked Sausage (FRANKFURTER)WORKSHOP LOCATION:FT. WORTH, TX_____RECEIVINGRECEIVINGRECEIVINGCCP1 CMEAT/POULTRYNON-MEATSUPPLIESINGREDIENTS STORAGESTORAGESTORAGEMEAT PREPARATIONCCP NON-MEAT INGREDIENTCCP(TEMPERING, GRINDING,2 PCOMPOUNDING3M, CFLAKING, DUMPING,ETC.)

6 PRE-BLEND, CCPFORMULATION,4M, CSTAGING(RE-WORK)CHOP AND/OR BLEND,EMULSIFYSTUFFINGSHOWERINGCOOK/SMOK ECCP5 MCHILL/STORAGECCP6 MPEELCCP7 MPACKAGINGCCP8M, C, PSTORAGECCP9 MSHIPPING/DISTRIBUTIONLIST PRODUCT CATEGORIES AND INGREDIENTSPRODUCT CATEGORY : Cooked Sausage (FRANKFURTER)WORKSHOP LOCATION : FT. WORTH, TXMEAT AND MEATBYPRODUCTSNONMEAT FOODINGREDIENTSBINDERS/EXTENDERSMEAT AND POULTRYRE-WORKSALTSUGARDEXTROSECORN SYRUPNON-FAT DRY MILKISOLATED SOY PROTEINSPICES/FLAVORINGSRESTRICTEDINGRED IENTSPRESERVATIVES/ACIDIFIERSLIQUID SMOKEPAPRIKAPROTEIN FLAVORSMUSTARDSPICE EXTRACTIVESONIONGARLICNATURAL SPICESSODIUM LACTATESODIUM NITRITEPHOSPHATESODIUM ASCORBATE AND CITRIC ACIDSODIUM CITRATEOTHERWATER/ICEDRY ICECARBON DIOXIDENITROGENINDUSTRY HACCP WORKSHOPFINISHED PRODUCT/INGREDIENT HAZARD ANALYSIS/RISK ASSIGNMENTPRODUCT CATEGORY : Cooked Sausage (FRANKFURTER)WORKSHOP LOCATION : FT.

7 WORTH, TXPRODUCT HAZARD : MICROBIOLOGICALHAZARD CHARACTERISTICS ASSOCIATEDWITH THE FINISHED PRODUCT AND + = A HAZARD EXISTS 0 = NO HAZARD EXISTSABCDEF(1) FINISHED PRODUCT (FRANKFURTER)*+0+++IV(2) INGREDIENTSMEAT AND MEAT BYPRODUCT (MEAT &POULTRY)*+++++VNON-MEAT FOOD INGREDIENTS (SALT)*0000+IBINDERS/EXTENDERS (NON-FAT DRYMILK)*+0+0+IIISPICES/FLAVORINGS (NATURAL SPICES)*+++0+IVRESTRICTED INGREDIENTS (SODIUMNITRITE)*0000+IPRESERVATIVES/ACID IFIERS*OTHER (CITY WATER)*+000+IIOTHER (RE-WORK*+++++V**HAZARD CHARACTERISTIC A N/A for industry Generic workshop HACCP doing Finished Product hazard analysis risk assignment, consider all ingredients and processes used in the establishment to produce the Finished doing hazard analysis and risk assessment on ingredients, consider only those processes taking place prior to product arriving at the receiving dock of the consuming HACCP WORKSHOPFINISHED PRODUCT/INGREDIENT HAZARD ANALYSIS/RISK ASSIGNMENTPRODUCT CATEGORY : Cooked Sausage (FRANKFURTER)WORKSHOP LOCATION : FT.)

8 WORTH, TXPRODUCT HAZARD : PHYSICALHAZARD CHARACTERISTICS ASSOCIATEDWITH THE FINISHED PRODUCT AND + = A HAZARD EXISTS 0 = NO HAZARD EXISTSABCDEF(1) FINISHED PRODUCT (FRANKFURTER)*+++0+IV(2) INGREDIENTSMEAT AND MEAT BYPRODUCT (MEAT &POULTRY)*+++0+IVNON-MEAT FOOD INGREDIENTS (SALT)*000000 BINDERS/EXTENDERS (NON-FAT DRYMILK)*000000 SPICES/FLAVORINGS (NATURAL SPICES)*000000 RESTRICTED INGREDIENTS (SODIUMNITRITE)*000000 PRESERVATIVES/ACIDIFIERS*OTHER (CITY WATER)*000000 OTHER (RE-WORK)*+++0+IV**HAZARD CHARACTERISTIC A N/A for industry Generic workshop HACCP doing Finished Product hazard analysis risk assignment, consider all ingredients and processes used in the establishment to produce the Finished doing hazard analysis and risk assessment on ingredients, consider only those processes taking place prior to product arriving at the receiving dock of the consuming HACCP WORKSHOPFINISHED PRODUCT/INGREDIENT HAZARD ANALYSIS/RISK ASSIGNMENTPRODUCT CATEGORY : Cooked Sausage (FRANKFURTER)WORKSHOP LOCATION : FT.

9 WORTH, TXPRODUCT HAZARD : CHEMICALHAZARD CHARACTERISTICS ASSOCIATEDWITH THE FINISHED PRODUCT AND + = A HAZARD EXISTS 0 = NO HAZARD EXISTSABCDEF(1) FINISHED PRODUCT (FRANKFURTER)*+000+II(2) INGREDIENTSMEAT AND MEAT BYPRODUCT (MEAT &POULTRY)*0+000 INON-MEAT FOOD INGREDIENTS (SALT)*000000 BINDERS/EXTENDERS (NON-FAT DRYMILK)*0+000 ISPICES/FLAVORINGS (NATURAL SPICES)*0+000 IRESTRICTED INGREDIENTS (SODIUMNITRITE)*++000 IIPRESERVATIVES/ACIDIFIERS*OTHER (CITY WATER)*000000 OTHER (RE-WORK*0+000I**HAZARD CHARACTERISTIC A N/A for industry Generic workshop HACCP doing Finished Product hazard analysis risk assignment, consider all ingredients and processes used in the establishment to produce the Finished doing hazard analysis and risk assessment on ingredients, consider only those processes taking place prior to product arriving at the receiving dock of the consuming WORKSHOP HACCP Model (SUBMITTED BY STEERING COMMITTEE 9/05/91)PRODUCT CATEGORY: Cooked Sausage (FRANKFURTER)WORKSHOP LOCATION: FT.)

10 WORTH, TXPROCESSSTEP/CCPCCP/HAZARDNUMBERCCPDESC RIPTIONCRITICALLIMITSESTABLISHMENTMONITO RINGCORRECTIVE/PREVENTIVEACTIONHACCPRECO RDSHACCP SYSTEMVERIFICATIONRECEIVINGNON-MEATSUPPL IESCCP 1 CFOOD GRADEMATERIALSCONTINUINGLETTER OFGUARANTEEVERIFY AND MAINTAINON FILE ACONTINUING LETTEROF GUARANTEEWHICH MAY INCLUDEA CERTIFICATE OFANALYSIS,CONDITIONS OF USEAND NOTIFICATIONOF PRODUCTPROCESS CHANGESWHICH IMPACT FOODSAFETYPLACE PRODUCT ON HOLD ANDEVALUATE SIGNIFICANCE OF THEDEVIATIONDISPOSITION BASED ONPREVIOUSLY APPROVEDGUIDELINES FROM QUALITYASSURANCE OR PROCESSAUTHORITYEVALUATE CAUSE OF DEVIATIONAND TAKE ACTION TO PREVENTRECURRENCESMAINTAIN COPYRECORD ONAPPROPRIATEESTABLISHMENTFORMS (COMPUTEROR HARD COPY)COMPLETED BYAPPROPRIATEPERSON, RECORDEDAT CCP SITE ON ATIMELY BASISRECORDS TO BEMAINTAINED FORAPPROPRIATE TIMEPERIODPERIODICOBSERVATION AND/ORMEASUREMENTAUDIT OF RELEVANTRECORDS, CONSUMERCONTACTS AND/ORPRODUCTS TODETERMINE IFMONITORING ISSUFFICIENT ANDCRITICAL LIMITS AREADEQUATE FORSAFETYPERFORM ONGOINGREVIEW OF HACCPPLAN IN RESPONSE TODEVIATIONS AND/ORSYSTEM AND PRODUCTMODIFICATIONRECEIVINGAND/ORPREPAR ATIONOF MEAT RAWMATERIALSCCP 2 PFOREIGNMATERIALSVENDORSPECIFICATIONSAND /ORPURCHASINGSPECIFICATIONSCOMPLIANCE WITHSPECIFICATIONSINCLUDING SPOTCHECKS.