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 |
Yes |
Pathogens are likely to be present on incoming meat. |
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). |
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|
Store frozen meat |
B-none identified P-none identified C-none identified |
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|
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 |
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|
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 |
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|
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 |
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|
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
|
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|
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.www.ag.ohio-state.edu/meatsci/borca2.htm
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 |