Not Cooked, Shelf Stable Whole Muscle
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Open Source Food Safety Initiative
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Visit our Website: opensourcefoodsafety.org
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HACCP Plan: Not Cooked, Shelf Stable Whole Muscle
Add a comment using the “Comments” button at the top of this page. All comments will be visible on the document and on this website. We will review edits and release revised versions of HACCP plans monthly.
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Purveyor: Underground MeatsFebruary 13, 2017
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PROCESS STEPS
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Process StepPotential Hzards (B) Biological, (C) Chemical, (P) PhysicalReasonably Likely to Occur?Justification of DecisionPreventative MeasuresCCPSources
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(1) Receiving and (6) Storage of Packaging Materials (B) Pathogen contamination
(C) Chemical contamination
(P) Damage to packing materials: Foreign materials
NoReceiving and storage SOP makes hazard unlikely.
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(2) Receiving Raw Meat(B) Presence of SalmonellaYesRaw meat is a known source of Pathogens.Obtain raw meat from an inspected plant, which produces using HACCP plans, SSOP's, and GMP practices. Letter of Guarantee from meat supplier. Hazard contolled at subsequent CCP of Drying.Gamble, H.R., 2011. Status of Trichinella Infection in US Commercial Pork and its Safety for International Trade in Pork and Pork Products.
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(B) Presence of TrichinellaYesWhile the risk is low, raw meat can be a source of pathogen.Obtain raw meat from an inspected plant, which produces using HACCP plans, SSOP's, and GMP practices. Letter of Guarantee from meat supplier. Hazard contolled at subsequent CCP of Drying.Wilson, N.O., 2015. MMWR, Trichinellosis Surveillance - United States, 2008-2012. Jan 2015 / 64 (SS01); 1-8.
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(C) NoneNoNot likely to occur. Obtain meat from USDA unspected plant(s), thus regulatory programs in animal production reduce risk of contamination.
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(P) Foreign Material.NoReceiving and Storage SOP makes hazard unlikely.
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(3) Receiving of Restricted and Unrestricted Non-Meat Ingredients(B) Starter cultures and mold spores could dieNoCultures and mold are stored in accordance with the manufacturers recommendations; use of food grade quality product(s).
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(C) Allergen; NitrateNoSee GMP for allergen control. Use of approved food grade quality products.
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(P) Foreign Material.NoReceiving and Storage SOP makes hazard unlikely.
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(4) Storage (Frozen/Refrigerated) Raw Meat(B) Outgrowth of SalmonellaNoProduct temperature is maintained at or below a level sufficient to preclude their growth. Product is stored at or below 41F and cooler temps are recorded daily during production.see Tompkin Paper and Storage Temperatures from askFSIS
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(5) Storage of Restricted and Unrestricted Non-Meat IngredientsB) Starter Cultures and Mold Spores could dieNoCultures and mold are stored in accordance with the manufacturers recommendations; use of food grade quality product(s). Storage of non-meat items in GMP make hazard not likely to occur.
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(C) NitrateNoStored in accordance with the manufacturers recommendations; use of food grade quality product(s). Storage of non-meat items in GMP make hazard not likely to occur.
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(P) Foreign Material.NoPackaged materials not likely to introduce/enhance hazards during storage. Storage of non-meat items in GMP make hazard not likely to occur.
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(7) Tempering of Frozen/Raw Meat(B) Presence of SalmonellaNoPathogen growth is unlikely to occur because tempering/thawing is done in a cooler at temperatures at or below 40F. Tempering/Thawing of Frozen Material addressed in GMP makes hazard not likely to occur. No water tempering is allowed.
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(8) Weighing Restricted and Unrestricted Non-meat Ingredients(B) Growth of spore forming pathogens: C. botulinum, C. perfringens.YesInsufficient nitrate level could allow favorable conditions for growth of spore forming pathogens.Hazard controlled at subsequent CCP of drying.
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(C) Excess Nitrate



(C) Sprice mix may contain allergens.
No


No
Pre-blended nitrate/nitrite is used. Nitrate and Nitrite not to exceed 2,187 and 625 ppm, respectively.

Operational SSOP prevents cross-contamination of allergens.
Borchert, L.L. and R.G. Cassens, Chemical Hazard Analysis for Sodium Nitrite in Meat Curing. American Meat Institute Foundation Paper, 1998.

FSIS Processing Inspectors' Calculations Handbook
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(9) Trimming(B) Presence of Pathogens

(B) Growth of Pathogens
Yes

No
Raw meat is a known source of pathogens.

Hazard unlikely. Product temperature is kept below 41°F. Raw product pH taken and recorded as determined under Pathogen Growth Inhibition SOP
Hazard controlled at subsequent CCP's of Drying.Tompkin Report
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(C) Sanitizers and cleanersNoOperational SSOP makes hazard unlikely to occur.
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(10) Combine Ingredients/Processing(B) Presence of Pathogens

(B) Growth of Pathogens
Yes

No
Raw meat is a known source of pathogens.

Salt/spice application is conducted while maintaining a product temperature below 41°F.
Hazard controlled at subsequent CCP's of Drying.
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(11) Vacuum Sealing(B) Presence of Pathogens

(B) Growth of Pathogens
Yes

No
Raw meat is a known source of pathogens.

Vacuum sealing is conducted while maintaining a product temperature below 41°F.
Hazard controlled at subsequent CCP of Drying/Aging.
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(12) Salting and Salt Equalization(B) Presence of Pathogens

(B) Growth of Pathogens
Yes

No
Raw meat is a known source of pathogens.

Hazard unlikely. Salt equalization is conducted at temperatures below 41°F. Intermediate water activity taken and recorded as determined under Pathogen Growth Inhibition SOP.
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(P) Foreign Material.NoSOP makes hazard unlikely.
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(13) Rinsing(B) Presence of PathogensYes

No
Raw meat is a known source of pathogens.Hazard controlled at subsequent CCP of Drying/Aging.
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(14) Drying/Aging(B) Growth of pathogens: C. botulinumYesPotential growth and subsequent toxigenesis with the failure of the drying process.The product is dried to a water activity of 0.91 or below in a controlled environment.1BReynolds et al.. 2001. Validation of Dry Cured Ham Process for Control of Pathogens.. Journal of Food Science.
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(15) Packaging and Labeling(B) Presence and growth of L. monocytogenes.NoLm control detailed in Underground Meats Plan for FSIS Listeria Compliance.
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(16) Storage of Finished Product(B) Growth of S. aureusNoShelf stability as determined under Shelf Stability SOP makes hazard unlikely.
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CCP
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[1] Critical Control Point[2] Hazard Description[3] Critical LimitsMonitoring[8] Corrective Action[9] Verification Activities[10] Record-keeping Procedures
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[4] What[5] How[6] Frequency[7] Who
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1B Drying/AgingPathogensWater activity (aw) below 0.91Water activity (aw)Use of water activity (aw) meterAt least once per product lotDesignated employeeContinue drying until water activity of 0.91 is reached.Whole Muscle HACCP log is reviewed once per week by designated employee.

Water activity reading is observed at least once per month by designated employee.
Whole Muscle HACCP log

Water activity calibration log
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Sign and date at initial acceptance, modification or annual reassessment.
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