#
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MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group
A Guide to HACCP Systems in the Meat Industry
Appendix X.3: Canning
Amendment 3: August 1998
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;
potable water quality (including cooling water requirements);
sanitation and cleanup procedures for edible areas and food contact surfaces
(preoperational and operational);
personal hygiene (protective clothing requirements, personal equipment and use of
amenities);
training (including specific requirements as per IS 6, Section 8.6.2)
hygienic processing (processing techniques and procedures, damaged carton procedures,
dropped meat, post-retort can handling);
food contact materials (specifications, handling and storage, including can receipt and
maintenance, can sterilisation);
food additives/ingredients (specifications, handling and storage);
calibration, installation and maintenance of heat processing equipment and instruments;
repairs and maintenance of equipment;
control of chemicals;
vermin control;
waste disposal;
refrigeration management (raw material);
recall procedures;
heat penetration trials/F0 value determination/deviation trials.
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MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group
A Guide to HACCP Systems in the Meat Industry
Appendix X.3: Canning
2.
Amendment 3: August 1998
Page: X.3.2
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
b. By the consumer.
a. Not applicable
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
b. Local market
List countries, if applicable
8.
Labelling instructions
Company/regulatory specification
9.
Special distribution controls required
Handle cans with care (GMP)
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MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group
A Guide to HACCP Systems in the Meat Industry
Appendix X.3: Canning
4.
Amendment 3: August 1998
Page: X.3.3
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.
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MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group
A Guide to HACCP Systems in the Meat Industry
Appendix X.3: Canning
Amendment 3: August 1998
Page: X.3.4
Form 3: Process flow diagram
Process: Canning of corned beef
Inputs
Process steps
Packed beef, frozen and tempered<
1.
2.
Potable water
Flaked frozen beef
<
<
3.
Additives
(water, salt, sodium nitrite)
<
4.
5.
Sterilised cans
<
6.
7.
Can ends
<
8.
9.
10.
Cooling water with 5 ppm free
residual chlorine (FRC)1
<
11.
12.
13.
14.
15.
16.
1.
Decartoning
?
Slicing
?
Parboiling
?
Mixing with additives
?
Mincing
?
Can filling
?
Weight checking
?
Seaming under vacuum
?
Washing cans
?
Basket stacking cans
?
Heat processing and cooling
?
Drying
?
Labelling
?
Packing
?
Storage
?
Dispatch
Note exemptions to this requirement in IS 6, Section 8.6.4.
Edible outputs
< Broth
< Fat
< Canned corned beef
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MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group
A Guide to HACCP Systems in the Meat Industry
Appendix X.3: Canning
6.
Amendment 3: August 1998
Page: X.3.5
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:
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MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group
A Guide to HACCP Systems in the Meat Industry
Appendix X.3: Canning
7.
Hazard Analysis and CCP Determination
7.1
Raw material hazard identification
Amendment 3: August 1998
Page: X.3.6
Form 5a: Hazard identification for packed beef 1
1.
Raw material
Biological hazard
Chemical hazard
Physical hazard3
Packed beef (frozen and
tempered)
B4/B5 % Microbiological
hazards associated with
contamination from faeces,
ingesta, hide, e.g.
Salmonella spp., E. coli
O157:H7, Campylobacter
jejuni, Clostridium spp.
C22% Chemical hazards
associated with unidentified
chemical residues, e.g.
anthelmintics, antibiotics,
environmental
contaminants
None
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.
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MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group
A Guide to HACCP Systems in the Meat Industry
Appendix X.3: Canning
7.2
Amendment 3: August 1998
Page: X.3.7
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
Raw material
Component
Hazards
(i) Process
step hazards
Other inputs
Component
(ii) Potential
impact of
process step
on existing
hazards
Hazards
Q1. Could the hazard be
present in or on the product1 at
unacceptable levels2 at this
step?
If yes, answer Q2 and Q3.
Yes/No
Justification
Q2. Is there a
control measure
at this step that
would prevent
unacceptable
levels of the
hazard?
If yes, this step is
a CCP.
Q3. Is there a
control measure
available at a
previous step?
CCP
No.
If yes,
retrospectively
assign the previous
step as a CCP.
If no, not a CCP.
1.
Decartoning
Boneless
beef
Boneless
beef
No
No
Yes
Reported incidences
of unacceptable
plastic found
entrapped in frozen
blocks. Customer
complaints
Yes. Removal of
entrapped plastic
(e.g. by airgun
application)
No
Yes
Any microorganism
will be unacceptable
in relation to FSO 1.
Refer to IS 6 Section
8.6
No
No
Yes
C2.
Unidentified
chemical
residues
No3
(i) P2. Plastic
2. Slicing
Any microorganism
will be unacceptable
in relation to FSO 1.
Refer to IS 6 Section
8.6
B4/B5. Enteric
pathogens
B4/B5.
Enteric
pathogens
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MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group
A Guide to HACCP Systems in the Meat Industry
Appendix X.3: Canning
Process step
Amendment 3: August 1998
Page: X.3.8
Inputs
(i) Process
step hazards
Raw material
Component
Hazards
Other inputs
Component
Hazards
(ii) Potential
impact of
process step
on existing
hazards
Q1. Could the hazard be
present in or on the product1 at
unacceptable levels2 at this
step?
If yes, answer Q2 and Q3.
Yes/No
Justification
Q2. Is there a
control measure
at this step that
would prevent
unacceptable
levels of the
hazard?
If yes, this step is
a CCP.
Q3. Is there a
control measure
available at a
previous step?
CCP
No.
If yes,
retrospectively
assign the previous
step as a CCP.
If no, not a CCP.
3. Parboiling
4. Mixing
Beef slices
Beef slices
B4/B5.
Enteric
pathogens
Yes
Any microorganism
will be unacceptable
in relation to FSO 1.
Refer to IS 6 Section
8.6
No
No
Any microorganism
will be unacceptable
in relation to FSO 1.
Refer to IS 6 Section
8.6
No
No
Yes
Any microorganism
will be unacceptable
in relation to FSO 1.
Refer to IS 6 Section
8.6
No
No
Yes
Incorrect amount may
cause nitrite
poisoning.
Yes % addition of
defined amount of
nitrite per mix.
No
Water
None
Flaked
frozen beef
B4/B5.
Enteric
pathogens
Yes
C2.
Unidentified
chemical
residues
No3
B4/B5.
Enteric
pathogens
Nitrite
C3.
Excess
Nitrite
Salt
None
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MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group
A Guide to HACCP Systems in the Meat Industry
Appendix X.3: Canning
Process step
Amendment 3: August 1998
Page: X.3.9
Inputs
Raw material
Component
Hazards
(i) Process
step hazards
Other inputs
Component
Hazards
(ii) Potential
impact of
process step
on existing
hazards
Q1. Could the hazard be
present in or on the product1 at
unacceptable levels2 at this
step?
If yes, answer Q2 and Q3.
Yes/No
Justification
Q2. Is there a
control measure
at this step that
would prevent
unacceptable
levels of the
hazard?
If yes, this step is
a CCP.
Q3. Is there a
control measure
available at a
previous step?
If yes,
retrospectively
assign the previous
step as a CCP.
If no, not a CCP.
5. Mincing
Corned beef
B4/B5.
Enteric
pathogens
Yes
Any microorganism
will be unacceptable
in relation to FSO 1.
Refer to IS 6 Section
8.6.
No
No
6. Can filling
Corned beef
B4/B5.
Enteric
pathogens
Yes
Any microorganism
will be unacceptable
in relation to FSO 1.
Refer to IS 6 Section
8.6.
No
No
Sterilised
cans
None
7. Weight
checking
Corned beef
B4/B5.
Enteric
pathogens
Yes
Any microorganism
will be unacceptable
in relation to FSO 1.
Refer to IS 6 Section
8.6.
No
No
8. Seaming
under
vacuum
Corned beef
B4/B5.
Enteric
pathogens
Yes
Any microorganism
will be unacceptable
in relation to FSO 1.
Refer to IS 6 Section
8.6.
No
No
CCP
No.
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MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group
A Guide to HACCP Systems in the Meat Industry
Appendix X.3: Canning
Process step
Amendment 3: August 1998
Page: X.3.10
Inputs
Raw material
Component
Hazards
(i) Process
step hazards
Other inputs
Component
(ii) Potential
impact of
process step
on existing
hazards
Hazards
Q1. Could the hazard be
present in or on the product1 at
unacceptable levels2 at this
step?
If yes, answer Q2 and Q3.
Yes/No
Justification
Q2. Is there a
control measure
at this step that
would prevent
unacceptable
levels of the
hazard?
If yes, this step is
a CCP.
Q3. Is there a
control measure
available at a
previous step?
CCP
No.
If yes,
retrospectively
assign the previous
step as a CCP.
If no, not a CCP.
(i) B8.
Pathogen
contamination
due to seam
failure
Can ends
Yes
Seam inadequacies
reported as cause of
sterilisation failures.
Refer to Canned
Foods: Principles of
Thermal Process
Control, Acidification
and Container
Closure Evaluation.
Yes % can seam
check
No
3
R1
None
9. Washing
cans
Canned
corned beef
B4/B5.
Enteric
pathogens
Yes
Any microorganism
will be unacceptable
in relation to FSO 1.
Refer to IS 6 Section
8.6.
No
No
10. Basket
stacking cans
Canned
corned beef
B4/B5.
Enteric
pathogens
Yes
Any microorganism
will be unacceptable
in relation to FSO 1.
Refer to IS 6 Section
8.6.
No
No
11. Heat
processing
and cooling
Canned
corned beef
B4/B5.
Enteric
pathogens
Yes
Any microorganism
will be unacceptable
in relation to FSO 1.
Refer to IS 6 Section
8.6.
Yes % heat
processing as per
defined schedule.
Refer to IS 6
Section 8.6.3.
Yes % IT can
selection at step 8
(CCP R1).
Yes % seam check
at step 8 (CCP 3).
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MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group
A Guide to HACCP Systems in the Meat Industry
Appendix X.3: Canning
Process step
Amendment 3: August 1998
Page: X.3.11
Inputs
Raw material
Component
Hazards
(i) Process
step hazards
Other inputs
Component
(ii) Potential
impact of
process step
on existing
hazards
Hazards
Q1. Could the hazard be
present in or on the product1 at
unacceptable levels2 at this
step?
If yes, answer Q2 and Q3.
Yes/No
Justification
Q2. Is there a
control measure
at this step that
would prevent
unacceptable
levels of the
hazard?
If yes, this step is
a CCP.
Q3. Is there a
control measure
available at a
previous step?
CCP
No.
If yes,
retrospectively
assign the previous
step as a CCP.
If no, not a CCP.
(ii) B4/B5.
Growth of
thermophilic
bacteria due to
inadequate
cooling
Cooling
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
None
Yes
Potential growth of
thermophilic
organisms due to
inadequate cooling
Refer to IS 6 Section
8.6.
Yes % cooling as
per defined
schedule. Refer
to IS 6 Section
8.6.4.5.
No
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MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group
A Guide to HACCP Systems in the Meat Industry
Appendix X.3: Canning
Amendment 3: August 1998
Page: X.3.12
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
C
C
C
3.
level;
frequency;
transfer and redistribution;
severity of effect on consumer.
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.
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MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group
A Guide to HACCP Systems in the Meat Industry
Appendix X.3: Canning
8.
Amendment 3: August 1998
Page: X.3.13
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.
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MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group
A Guide to HACCP Systems in the Meat Industry
Appendix X.3: Canning
9.
Amendment 3: August 1998
Page: X.3.14
Completion of the HACCP Plan
Full documentation is required for the remaining elements of the HACCP plan:
C
C
C
C
C
critical limit setting;
monitoring procedures;
corrective action procedures;
verification procedures including validation;
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 manufacturers specifications
may be used. The measurement components and frequency of measurement may be influenced
by market access requirements.
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MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group
A Guide to HACCP Systems in the Meat Industry
Appendix X.3: Canning
(b)
Amendment 3: August 1998
Page: X.3.15
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.
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MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group
A Guide to HACCP Systems in the Meat Industry
Appendix X.3: Canning
10.3
Amendment 3: August 1998
Page: X.3.16
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.
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MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group
A Guide to HACCP Systems in the Meat Industry
Appendix X.3: Canning
Amendment 3: August 1998
Page: X.3.17
Form 6: HACCP plan summary spreadsheet for canning (corned beef)
Process Step
Hazard ID
CCP no:
Critical limits
Monitoring procedures/tools
(consider who, what, when,
how)
Corrective action
procedures1
Verification
procedures2
HACCP records3
1. Decartoning
Plastic
Operator technique %
100% compliance with
food safety component of
job description
Observation every 2 hours of
operator removing entrapped
plastic and inspecting meat
block
(a) Talk to operator
(b) Increase supervision
and/or monitoring
(c) Retrain or remove
operator
FSO validation
Validation record
Internal audit
Daily monitoring
record
All meat blocks free of
plastic
Visual check of random
selection of blocks for
entrapped plastic
Extrinsic audit
Customer complaints
Corrective action
report
HACCP review
Internal audit report
Extrinsic audit report
Customer
complaints file
HACCP review
record
2. Slicing
3. Parboiling
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MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group
A Guide to HACCP Systems in the Meat Industry
Appendix X.3: Canning
Amendment 3: August 1998
Page: X.3.18
Process
Step
Hazard ID
CCP no:
Critical limits
Monitoring procedures/tools
(consider who, what, when,
how)
Corrective action
procedures1
Verification
procedures2
HACCP records3
4. Mixing
Excess
sodium
nitrite
Predetermined and
prepared amount to be
added per batch size.
Amount to result in # 50
ppm nitrite in final
product.
Individual batch lots identified
Detain product and test
for nitrite
FSO validation
Validation record
Finished product
evaluation resulting in
# 50 ppm nitrite in final
product
Nitrite monitoring record
Visual check on amount per
batch
Corrective action report
Internal audit
Product evaluation
records
Extrinsic audit
Internal audit report
HACCP review
Extrinsic audit report
HACCP review record
5. Mincing
6. Can filling
7. Weight
checking
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MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group
A Guide to HACCP Systems in the Meat Industry
Appendix X.3: Canning
Amendment 3: August 1998
Page: X.3.19
Process
Step
Hazard ID
CCP no:
Critical limits
Monitoring procedures/tools
(consider who, what, when,
how)
Corrective action
procedures1
Verification
procedures2
HACCP records3
8. Seaming
under
vacuum
Pathogen
contamina
tion due to
seam
failure
As per manufacturers
specifications for
particular can
Visual examination for double
seam and other container
defects at least every 30
minutes of continuous
operation
Stop production
FSO validation
Validation record
Check on vacuum
headspace after
cooling
Daily monitoring record
Double seam teardown
examination at intervals of
sufficient frequency to ensure
proper closure. Interval not to
exceed 4 operating hours (e.g.
every 2 hours)
Adjust seamer
Isolate defective stock
and detain
Additional visual and teardown
examinations to be made at the
start of production,
immediately after a seamer
jam, machine adjustment or a
prolonged shutdown
Isolate defective stock
and detain
9. Washing
cans
10. Stacking
Select, mark and set
aside coldest can for each
retort load
Calibration of vacuum
gauge every 12
months
Calibration and
maintenance records
Internal audit
Corrective action report
Extrinsic audit
Internal audit report
HACCP review
Extrinsic audit report
HACCP review record
Regular supervisor checks of
operator performance
R1
Visual examination and
teardown records
Talk to operator
Advise retort operator
to take appropriate
action associated with
deviation from process
schedule
#
#
#
MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group
A Guide to HACCP Systems in the Meat Industry
Appendix X.3: Canning
Amendment 3: August 1998
Page: X.3.20
Process
Step
Hazard ID
CCP no:
Critical limits
Monitoring procedures/tools
(consider who, what, when,
how)
Corrective action
procedures1
Verification
procedures2
HACCP records3
11. Heat
processing
and cooling
Enteric
pathogens
and
thermophiles
All cans heat processed
using a validated
process schedule that
will achieve a 12D
reduction in Clostridium
botulinum spores.
Monitor and record critical
parameters as per
requirements given in the
process schedule
Refer to IS 6 Section
8.6.9.5
FSO validation
Validation record
Internal audit
Retort log
Extrinsic audit
Corrective action report
HACCP review
Calibration and
maintenance records
Thermal process
parameters (e.g. product
initial temperature,
process time
/temperature) and other
critical factors that may
affect the attainment of
commercial sterility to
be established for each
process schedule.
Refer to IS 6 Section
8.6.3
12. Drying
13. Labelling
Sterility tests
Internal audit report
Incubation results
Extrinsic audit report
Calibration of
time/temp devices
every 6 months
HACCP review record
Product evaluation
records
#
#
#
MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group
A Guide to HACCP Systems in the Meat Industry
Appendix X.3: Canning
Process
Step
Hazard ID
CCP no:
Critical limits
Amendment 3: August 1998
Page: X.3.21
Monitoring procedures/tools
(consider who, what, when,
how)
Corrective action
procedures1
Verification
procedures2
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.
HACCP records3
#
#
#
MAF Regulatory Authority (Meat & Seafood) HACCP Steering Group
A Guide to HACCP Systems in the Meat Industry
Appendix X.3: Canning
Amendment 3: August 1998
Page: X.3.22
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.
