OpenSourceHACCP_NotCookedShelfStable_04132016.xlsx
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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
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 Meats
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1. Process Step2. Food Safety Hazard3. Reasonably Likely to Occur4. Basis of Reasonably Likely To Occur5. If Yes in Column 3, What Measures Could Be Applied to Prevent, Eliminate, or Reduce the Hazard to an Acceptable Level?6. Critical Control Point7. Sources
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1. Receiving and 6.
Storage -Packaging
Materials
Biological -Pathogen
Contamination
NoReceiving and storage SOP makes hazard unlikely.
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Chemical -Chemical contaminationNoReceived letters of guarantee from manufacturer supporting chemical hazards are unlikely.

Receiving and storage SOP makes hazard unlikely.
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Physical -Damage to packing materials; Foreign materialsNoReceiving and Storage SOP makes hazard unlikely.
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2. Receiving Raw MeatBiological -Presence of pathogen: Salmonella, Listeria, C. perfringens, C.
botulinum, S. aureus



Presence of pathogen: Trichinella
Yes







No
Raw Meat is a known source of pathogens.





Risk of acquiring human trichinosis from pork in US in the years between 2002 and 2007 was
1 in 285 million
Obtain raw meat from an inspected plant which produces using HACCP plans, SSOPs and GMP. Hazard controlled at subsequent CCPs of fermenting and drying.

Trichinella is controlled at subsequent CCPs.
Gamble, H.R.Status of
Trichinella Infection in US Commercial Pork and its Safety for International Trade in Pork and Pork Products.
2011.
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Chemical -None
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Physical -Foreign materialsNoReceiving and storage
SOP makes hazard unlikely
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3. Receiving of Restricted and
Unrestricted Non-
Meat Ingredients
Biological -Starter cultures and mold spores could die.



Presence of pathogen: Salmonella
NoCultures and mold are stored in accordance with the manufacturer’s recommendations.

Received letters of guarantee from manufacturer supporting biological hazards are unlikely.
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Chemical -none
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Physical - Foreign objectsNoReceiving and storage SOP makes hazard unlikely.
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4. Storage
(Frozen/Refrigerated)
Raw Meat
Biological -
Pathogen growth
NoCooler/Freezer SOP makes hazard unlikely.
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Chemical -None
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Physical –Foreign materialNoCooler/Freezer SOP makes hazard unlikely.
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5. Storage of Restricted and
Unrestricted Non-
Meat Ingredients
Biological-Starter cultures and mold spores could die.



Biological contamination
No





No
Cultures and mold are stored in accordance with manufacturer’s recommendations.

Receiving and storage SOP makes hazard unlikely.
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Chemical –Foreign materialNoReceiving and storage SOP makes hazard unlikely.
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Physical -None
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7. Tempering of Frozen/Raw meatBiological -
Pathogen growth
NoTempering/Thawing SOP makes hazard unlikely.
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Physical -None
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Chemical -None
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8. Weighing Restricted and Unrestricted Nonmeat IngredientsBiological - Growth of spore forming pathogens: C. botulinum, C.
perfringens.
YesInsufficient nitrite level could allow favorable conditions for growth of C. botulinum and C. perfringens.Hazard controlled at subsequent CCPs of fermenting and drying.
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Physical -None
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Chemical -Excess
Nitrite


Spice mix may contain allergens.
No



No
Pre-blended nitrite is used



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.
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9. Weighing Raw MeatBiological –Presence of Pathogens




Growth of pathogens
Yes





No
Raw meat is a known source of pathogens.




Product temperature is kept below 41°F.
Hazard controlled at subsequent CCPs of fermenting and drying.
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Physical -None
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Chemical -None
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10. Combine
Ingredients/Processing
Biological -Presence of pathogens


Growth of pathogens
Yes



No
Raw meat is a known source of pathogens.


Product temperature is kept below 41°F.
Hazard controlled at subsequent CCPs.
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Physical -None
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Chemical -Potential allergen contaminationNoOperational SSOP prevents cross-contamination of allergens.
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11. Preparing Starter
Cultures, Casings, Mold Spores
Biological -Starter Cultures and Molds may be rendered ineffectiveNoCultures and molds are prepared per the manufacturer’s recommendations.
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Physical -None
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Chemical -None
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12. Mold ApplicationBiological -
Formation of harmful molds
NoMold 600 is applied to outcompete and prevent unwanted mold growth from occurring.L Grazia et al.The
Role of Moulds in the
Ripening Process of
Salami. Food
Microbiology 1986, 3, 1925.
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Physical -None
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Chemical -None
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13. FermentingBiological -Outgrowth of Staphylococcus aureus, Clostridium botulinum and Clostridium perfringens











Outgrowth of
Salmonella, Listeria
Yes

















Yes
Temperature and pH level can allow significant growth of pathogens if not properly controlled.B-LC-007 starter culture is added, product is fermented to a pH of 5.3 within 1200 degree hours and a pH of 4.8 by the end of fermentation.

C. botulinum is inhibited by a pH below 4.8 and awbelow 0.94.

C. perfringens is inhibited by a pH below 5.0 and awbelow 0.93.

Use of Chr. Hansen BLC-007 starter culture as a bioprotective culture reducing listeria and salmonella.

Salmonella is
controlled per Option
2 inSalmonella
Compliance Guidelines.
1BGood Manufacturing
Practices for Fermented
Dry and Semi-Dry Sausage Products. American Meat Institute Foundation, 1997.

D.M. Broda and J.A. Boerema,Clostridium perfringensMicrobiological Safety of Meat.
2004, p794.

J.A. Boerema and D.M. Broda.Clostridium botulinum.Microbiological Safety of Meat.
2004, p792.

Porto-Fett A.C.S., et al.Evaluation of
Fermentation, Drying, and/or High
Pressure Processing on Viability of Listeria monocytogenes, Escherichia coli 0157:H7, Salmonella spp., and Trichinella speralis in Raw Pork and Genoa Salami.2010.

CHR Hansen.Reduce your Salmonella risk in fermented salami. B-LC-007 culture contains SM-194. *See attached

Sindelar J.J. et al.Sodium Nitrite in
Processed Meat and Poultry Meats: A Review of Curing and Examining the Risk/Benefit of its Use. 2011.

Ihnot A.M. et al.Behavior of Salmonella typhimurium DT104 during the manufacture and storage of pepperoni.
1998.
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Physical -None
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Chemical -None
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14. Drying/CuringBiological -Outgrowth of Staphylococcus aureus, Clostridium botulinum and Clostridium perfringens












Outgrowth of
Salmonella, Listeria,
Trichinae
YesTemperature and pH level can allow significant growth of pathogens if not properly controlled.End product is at or below a pH of 5.3 or below and dried to a water activity of 0.88 or below.

Each product has a salt concentration of 2% or greater.

C. botulinum is inhibited by a pH below 4.8 and awbelow 0.94.

C. perfringens is inhibited by a pH below 5.0 and awbelow 0.93.

Salmonella is controlled per Option 2 inSalmonella
Compliance Guidelines.

Trichinae is controlled per Method 6 in 9 CFR 318.10 tables 3A, 3B and 4.



Shelf-stability achieved through a combination of awand pH.
2BGood Manufacturing
Practices for Fermented
Dry and Semi-Dry Sausage Products. American Meat Institute Foundation, 1997.

Messier, S. et al.Survival of Salmonella typhimurium and Staphylococcus aureus in Genoa Salami of Varying Salt Concentrations.

D.M. Broda and J.A. Boerema,Clostridium perfringensMicrobiological Safety of Meat.
2004, p794.

J.A. Boerema and D.M. Broda.Clostridium botulinum.Microbiological Safety of Meat.
2004, p792.

Hospital X.F. et al.Effect of Reducing
Nitrate and Nitrite Added to Dry
Fermented Sausages and the Survival of Salmonella typhimurium.Food and Research International. 62.

S.C. Ingham, D.R. Buege, B.K. Dropp and J.A. Losinski.Survival of Listeria monocytogenes During Storage of Readyto-eat Meat Products Processed by Drying Fermentation, and/or Smoking.Journal of Food Protection 67:2698-2702, 2004.

Shelf Stability Predictor
(https://meathaccp.wisc.edu/ST_calc.html)
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Physical -None
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Chemical -None
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15. Determining Shelf
Stability
Biological– Outgrowth of Staphylococcus aureus and Listeria monocytogenesNoShelf stability as determined under Shelf Stability SOP makes hazard unlikely.
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Physical- None
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Chemical- None
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16. Packaging &
Labeling
Biological –
Presence/growth of
L. monocytogenes
NoLm control detailed inUnderground Meats Plan for FSIS
Listeria Compliance.
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Physical -None
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Chemical -None
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17. Storage of Finished
Product
Biological - Growth of S. aureusNoShelf stability as determined under Shelf Stability SOP makes hazard unlikely.
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Physical -None
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Chemical -None
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18. Delivery and
Shipping
Biological -None
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Physical -None
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Chemical -None
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CCP# and locationCritical LimitsMonitoring Procedures and FrequencyHACCP RecordsVerification Procedures and FrequencyCorrective Actions
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1B FermentingUsing B-LC-007 starter culture, the product is fermented at 88°F to a pH of 5.3 or below within 1200 degree hours and 4.8 or less by the end of fermentation.A pH probe will be inserted into three different pieces of product which have been identified for monitoring. The pH will be monitored during the process until a pH of 4.8 is reached. Designated staff will record pH and time at the beginning of fermentation and when the pH is below 4.8 to ensure Critical Limits are met. If the pH does not drop below 4.8 within 1200 degree hours, an intermediary pH will be logged when the pH drops below 5.3.Batch Sheet Containing:

-CCP monitoring form
-Fermentation log
-pH calibration -Degree hours calculation
-Corrective actions
Designated staff will be monitored taking a pH test at least once per week.

Designated staff will calibrate the pH meter for each lot being tested.

A review of records will be done each Week by designated staff.
Establishment will segregate all products that do not fall within the critical limits until appropriate
disposition is determined based on the nature of the deviation, time, aw, and PH of product.

Establishment will identify the cause of the deviation and prevent recurrence. If a deviation from a
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2B Drying/CuringProduct will dry in a temperature/humidity controlled environment (50°F –
60°F and 70% - 80% RH). The water activity will be
monitored and recorded until awof 0.88 or below is reached.
awwill be monitored through the use of a water activity meter throughout the drying process. 3 samples from each lot (lot size maximum 300lbs) will be taken randomly to ensure even drying across the lot until awof 0.88 or below is reached.

Drying room temperature/humidity will be monitored and recorded daily by designated staff.
Batch Sheet Containing:

-CCP monitoring form -pH log
-Water activity log
-Drying room
-Temp/humidity log
-Corrective actions
Designated staff will be monitored taking water activity at least once per week.

Designated staff will calibrate the water activity meter in accordance with the manufacturer’s recommendations.

Records will be reviewed each week by designated staff.
critical limit occurs, the establishment owner or designee is responsible for corrective action protocol as stated in 9 CFR 417.3. The cause of the deviation will be identified and eliminated. The CCP will be under control after the corrective action is taken.
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*See attached document on FSIS compliance for Lm at Underground Meats.
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Underground Meats Plan for FSIS Listeria Compliance
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To meet the requirements set forth by FSIS for Listeria, Underground Meats will use alternative 3 to control Listeria through the use of sanitation SOPs and testing.
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-All food contact surfaces in the RTE room will be sanitized using Oasis 146 Multi-Quat Sanitizer.
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-Once monthly, all FCS in the RTE room will be tested for Listeria spp. according to FSIS compliance guidelines for very small plants.
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-In the case that any FCS results in a positive reading for Listeria spp., follow-up testing following the SOP for Listeria Testing Program will be undertaken.
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Signature: ________________________________ Date: _____________
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Signature: ________________________________ Date: _____________
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