Cooked Sausage HACCP Plan Example

Cooked Sausage

Cooked Sausage Flow Chart (Word)

Cooked Sausage

HACCP Form A
 

Process

Step

Potential Hazards

Reasonably likely to occur?

Justification for decision made in previous column

Preventive Measures

CCP?

Receive meat

B1-pathogen contamination


P1- needles, shot

C-none identified

Yes



No

Pathogens are likely to be present on incoming meat.


Not likely to occur, based upon company history, supplier's letter of guarantee, and no reported incidence of these hazards has occurred between January 1, 1996 to July 27, 2004

Cooking to minimum of 158ºF.

 

Refer to CCP-1 below

Store fresh meat

B2- pathogen growth

 

C-none identified

P-none identified

No

Cooler temperature records show hazard not likely to occur. (See Minimum, optimal and maximum growth reference information in ARS Pathogen Modeling Program).

   

Store frozen meat

B-none identified

P-none identified

C-none identified

       

Thaw frozen meat

B3- pathogen growth

 

C-none identified

P-none identified

Yes

Product temperature increase into danger zone is likely to occur during thawing process.

Maximum water temperature of 70ºF while thawing and cooking to minimum of 158ºF.

Refer to CCP-1 below

Formulate

& weigh meat

B4-pathogen growth


B5-pathogen contamination

C1-nitrite level

P-none identified
Yes



No


No
Product temperature increase is likely to occur during weighing.

Not likely to occur, based upon SSOP records

Premixed nitrite not a hazard based upon AMI paper (Borchert & Cassens, 1998)

Maintain raw meat temperature at 45ºF or below during weighing, plus cooking to minimum of 158ºF.

Refer to CCP-1 below

Grind meat

B6-pathogen growth


B7-pathogen contamination

P2-metal shavings




P3-bone chips



C2-cleaners & sanitizers
Yes



No


No




No



No
Grinding is likely to cause temperature rise in product.

Not likely to occur, based upon SSOP records.

Not likely to occur, based upon plant history, maintenance and re-inspection records.

Not likely to occur, based upon plant history and re-inspection records

Not likely to occur, based upon SSOP records

Maintain raw meat temperature at 45ºF or below during grinding, plus cooking to minimum of 158ºF.

 

 

Refer to CCP-1 below

Rework raw product

 

 

 

 

B8-pathogen growth


B9-pathogen contamination

C-none identified

P-none identified
Yes



No
Additional handling may cause temperature rise in product

Not likely to occur, based upon plant history

Maintain reworked meat temperature at 45ºF, plus cooking to minimum of 158ºF.

 

Refer to CCP-1 below

Rework cooked product

 

 

 

 

B10-pathogen growth


B11-pathogen contamination

C-none identified

P-none identified
Yes



No
Additional handling may cause temperature rise in product

Not likely to occur, based upon plant history

Maintain reworked meat temperature at 45ºF, plus cooking to minimum of 158ºF.

 

Refer to CCP-1 below

Mix product

B12-pathogen growth



B13-pathogen contamination

C3-cleaners & sanitizers

P-none identified
Yes




No


No
Temperature rise during grinding may cause temperature rise in product

Not likely to occur, based upon SSOP records

Not likely to occur, based upon SSOP records

Maintain raw meat temperature at 45ºF or below during mixing, plus cooking to minimum of 158ºF.

Refer to CCP-1 below

Final grind sausage

B14-pathogen growth



B15-pathogen contamination

P4-metal shavings




P5-bone chips

C-none identified
Yes




No


No




No
Temperature rise during grinding may cause temperature rise in product

Not likely to occur, based upon SSOP records

Not likely to occur, based upon plant history, maintenance and re-inspection history

Not likely to occur, based upon plant history and re-inspection records

Maintain raw meat temperature at 45ºF or below during final grinding, plus cooking to minimum of 158ºF.

Refer to CCP-1 below

Receive casings

P6-foreign materials

C-none identified

B-none identified

No

Not likely to occur, based upon plant history, letters of guarantee

   

Store casings

P7-foreign materials

B16-pathogen contamination

C-none identified
No


No
Not likely to occur, based upon SSOP records

Not likely to occur, based upon SSOP records
   

Stuff product

B17 -pathogen growth



B18-pathogen contamination

P8-foreign materials

C4-cleaners & sanitizers
Yes




No


No


No
Temperature rise during stuffing may cause temperature rise in product

Not likely to occur, based upon SSOP records

Not likely to occur, based upon plant history

Not likely to occur, based upon SSOP records

Maintain raw meat temperature at 45ºF or below during final stuffing, plus cooking to minimum of 158ºF.

Refer to CCP-1 below

Cook & smoke product

B19-pathogen survival

C-none identified

P-none identified

Yes

Pathogen survival could occur.

Cooking to internal temperature of 158ºF.

CCP-1

Chill product

B20-pathogen growth

C-none identified

P-none identified

Yes

C.perfringens could grow, after cooking if not chilled properly between 130ºF and 80ºF. C.perfringens not likely to grow between internal product temperatures of 80ºF and 40ºF.

Chill from 130ºF to 80ºF in 1.5 hrs.

 

CCP-2

 

Receive packaging materials

P9-foreign materials

C-none identified

B-none identified

No

Not likely to occur, based upon plant history, and letters of guarantee

   

Store packaging materials

P10-foreign materials

B21-pathogen contamination

C-none identified
No


No

 

Not likely to occur, based upon SSOP records

Not likely to occur, based upon SSOP records 


 

 

   

Package product

B22-pathogen contamination

C-none identified

P-none identified

Yes

Pathogen contamination could occur,following the cooking step, but prior to packaging.

Proper handling of fully cooked, RTE products, proper personal hygiene, and sanitation of product contact surfaces.

CCP-3

Store pkg'd product

B23-pathogen growth

C-none identified

P-none identified

No

Not likely to occur, based upon cooler temperature records

   

Literature Cited:

Borchert, L.L. and R.G. Cassens, 1998. Chemical hazard analysis for sodium nitrite in meat curing. American Meat Institute Foundation Paper. Available here.

ARS Pathogen Modeling Program (PMP)7.0 is accessible at http://www.arserrc.gov/mfs/PATHOGEN.HTM

Minimum, optimum and maximum growth temperatures of selected pathogens from ARS PMP 7.0 can be access at: www.ag.ohio-state.edu/~meatsci/ARSTemperatureGuide03.doc

Cooked Sausage Example

HACCP Form B

Process Step/CCP

 

Critical Limits

Monitoring Procedures

 

Corrective Action

What

How

Frequency

Who

CCP-1 Cooking

Final internal temperature to not be less than 158ºF

Product internal temperature

Smokehouse chart recorder

End of each cycle

Smoke-house operator, plant manager or trained designee

Action will be taken to ensure:

1. The cause of the deviation is identified and eliminated;.

2. The CCP will be under control after the corrective action is taken;

3. Measures to prevent recurrence are established, and

4. No product that is injurious to health or otherwise adulterated as a result of the deviation enters commerce.

CCP-2 Chilling cooked product

Meet rapid chill guidelines of AppendixB: 130ºF to 80ºF in 1.5 hrs, 80ºF to 40ºF in 5 hrs.

Cooked product time and temperature

Record time to reach internal temperatures of 80ºF and 40ºF

Each batch or lot

Smoke-house operator, plant manager or trained designee

Action will be taken to ensure:

1. The cause of the deviation is identified and eliminated;.

2. The CCP will be under control after the corrective action is taken;

3. Measures to prevent recurrence are established, and

4. No product that is injurious to health or otherwise adulterated as a result of the deviation enters commerce.

CCP-3

Packaging cooked product

No positive Listeria spp.

Environmental contamination by Listeria spp.

Swab table tops, packaging surfaces, workers gloves, aprons, etc., that make contact with exposed cooked product.

Two tests, per line per month

Smoke-house operator, plant manager or trained designee

Action will be taken to ensure:

1. The cause of the deviation is identified and eliminated;.

2. The CCP will be under control after the corrective action is taken;

3. Measures to prevent recurrence are established, and

4. No product that is injurious to health or otherwise adulterated as a result of the deviation enters commerce.

Cooked Sausage

HACCP Form C

Process Step/CCP

Verification Activities

Recordkeeping Activities

CCP-1

Cooking

Calibrate thermometers and house chart recorder - weekly by trained designee

Daily verification of monitoring & corrective action records by manager, supervisor, or trained designee.

Check the checker weekly manager, supervisor, or trained designee.

Reassess plan - annually by HACCP team.

Pre-shipment review - each batch.

Monitoring & Verification (meat temperatures) records - Form 101

Corrective action records - Form 101

Calibration records - Form 103

Pre-shipment review records - Form 102

CCP-2

Chilling

Daily verification of monitoring & corrective action records.

Check the checker - each batch by manager, supervisor, or trained designee.

Reassess plan - annually by HACCP team.

 

Pre-shipment review - each batch

Monitoring & Verification (meat temperatures) records - Form 201

Corrective action records - Form 201

Calibration records - Form 203

Pre-shipment review records - Form 202

CCP-3

Packaging

Daily verification of monitoring & corrective action records.

Check the checker - each batch by manager, supervisor, or trained designee.

Reassess plan - annually by HACCP team.

 

Pre-shipment review - each batch

Monitoring & Verification records - Form 201

Corrective action records - Form 201

Calibration records - Form 203

Pre-shipment review records - Form 202