HACCP IMPLEMENTATION IN MEAT INDUSTRY

Nandhu Lal A.M.KrishnaprabhaKCAET, Tavanur

Kerala Agricultral University

HACCP HACCP is a management

system in which food safety is addressed through the analysis and control of biological, chemical, physical hazards from raw materials production and handling to manufacture, distribution and consumption of the finished products.

7 HACCP PRINCIPLES1) Identify the potential hazards2) Identify the critical control points(CCP)3) Establish critical limits 4) Establish and implement effective

monitoring procedures at CCPs5) Establish corrective actions6) Establish procedures to verify that the

measures outlined above are working effectively

7)Establish documents and records

Basic elements of HACCP in Meat Processing Plants

Every single meat product with product specific technology requires a specifically designed individual HACCP scheme.

As a precondition for implementing HACCP concepts, hazard analysis and risk assessment referring to meat plant specific processing methods or products, have to be carried out.

Critical control points (CCPs) have to be identified, critical limits be established and monitoring systems properly implemented.

HAMHam is pork leg that has been

preserved through salting, smoking and wet curing.

Processing steps for Cured Cooked Ham

RECEPTION OF RAW MATERIALS

LEG & SHOULDER

INJECTION/TENDERIZATION

STORAGE

LEG/SHOULDER PREPARATION

BRINE PREPARATION

WEIGHINGWEIGHING

POTABLE WATER

STORAGE

CONDIMENTS/ADDITIVES

TUMBLING

FILLING OR VACCUM PACKAGING

MOLDING

COOKING

COOLING

UNMOLDING

PACKAGING

STORAGE

DISTRIBUTION

STEPS BIOLOGICAL CHEMICAL PHYSICAL

ReceptionGrowth of pathogens on fresh meat due to time/temp abuse

Non food grades packaging material/ improper printed labels

Storage

Growth of pathogens on meat due to time/temp abuse

Pork leg/ shoulder deboning

& preparatio

n

Contamination & Growth of pathogens on meat due to time/temp abuse

Bone& metal particles falling into meat during cutting

Weighing ingredient

s &

additives

Excess of nitrites , phosphates or other additives due to weighing errors

POTENTIAL HAZARDS

Brine preparation

Contamination & Growth of pathogens on meat due to time/temp abuse

Foreign material falling into the pickle solution

Injection/Tenderization

Contamination & Growth of pathogens on meat due to time/temp abuse

Excess of nitrites or other additives Detergent, disinfectant , lubricant residue

Bone and metal particles, broken needlesMetal fragments from damaged inadequately mounted equipment

Tumbling

Contamination & Growth of pathogens on meat due to time/temp abuse

Metal fragments from damaged inadequately mounted equipment

Filling

Contamination & Growth of pathogens on meat due to time/temp abuse,Contamination with pathogensby poor hygiene practices

Detergent, disinfectant , lubricant residue

Packaging bursts, bone particles, metal clips falling into meat during filling.Metal fragments from damaged inadequately mounted equipment

Molding

Contamination with pathogen by rupture of vacuum bag and poor hygiene practices

Cooking + Cooling

Contamination with pathogens by time/temp and use of contaminated water

Unmolding

Contamination by improper sealing and vacuum packaging ,poor hygiene practices

Packaging Leakage of labeling colorsand packaging materials

Storage

Growth of pathogens on meat due to time/temp abuse

HACCP PLANProduct: Cured Cooked Ham (cooked in vacuum bag and cooking mould)

Processsteps Hazar

dCritical

limit

Monitoring

ProcedureCorrective actions Records

Reception ofraw meatmaterials(pork hindlegs without feet)

CheBio

Red meat color, pHnot above 6.2,no visual defects ofmeat/fat/skinsurfaces, coretemperature ≤4°c

Check purchasespecification.Inspection by randomsampling ofappearance, odour ,temperature and pH

Trim surface if only fewMinor visiblecontaminations or remaining hairs.Reject delivery, if other target levels not met

Physicalcharacteristics of meat received,certificate ofsanitary statusand origin ofmeat.Meat temperaturerecordings.

Storage inreceptionchiller

BioChiller temperature≤4°c

Periodic temperaturecontrol

Minor temp deviation:Adjust temperatureMajor temperaturedeviation: Reject meat

Temperature/time recordings

Cutting,deboning,Trimming

Bio

Room temperature+10°c, meattemperature ≤+7°c.Absence of alterationsin meat such asabscesses, blood infiltrations

Meat temperaturecontrol.Check for meatalterations andabnormal tissues

Further cooling if meattemperature too high.Reject / discard entiremeat parts withalterations such asabscesses, bloodinfiltrations

Record meattemperature.Record accidentalfindings

Evaluationand weighingof non-meatIngredients

Che

Nitrite content incuring salt ≤0.6% (ifcuring salt mix doneby operator).Curing salt free ofimpurities. Noimpurities in other non-meat ingredients

Check storageconditions of nitritesalt, exact weighing ofnitrite portion (if mixdone by operator),Curing salt quality check. Check othernon-meat ingredientsfor impurities

Adjust weight of nitriteportion correctly or use freshly mixed curing salt.Replace other non-meatingredients

Records of statusand expirationdates of non-meatingredients.Results ofweighing nitriteportions

Preparationand injectionof curingBrine C C P

PhyCheBio

Brine temperature atinjection ≤+4°c

Check brineTemperature , use metal detectors

No utilization of curing brines failing temperatureand purity requirements

Record conditionsencountered

Tumbling Bio

Room temperature≤+4°c, time ≤ 8 hours

Check temperature/ time

Adjust room temperature if too high

Temperature/ timerecording

Packaging,Molding

Bio

Cleanliness ofsynthetic materials,tightness of enclosureby clip or seal

Check quality ofmaterials and clipping/sealing

Reject unsuitable syntheticbags, correct clipping/sealing failures

Record onpackagingmaterial,equipment

Cooking

C C PBio

Internal cookingtemperature (coretemperature) ≥+70°c.Temperature ofcooking media +79°C

Check coretemperature by electronic temperaturemeasurement

Increase cookingtemperature or prolongcooking time until requiredcore temperature is reached

Recordtemperature ofproduction batch.Record anydeviation intemperature

Cooling (in

water)Bio

Cooling to +15°C coretemperature in icewater

Check coretemperature / time.Check cooling watertemperature

Add ice if cooling watertemperature too high

Time/ temperature record of coolingperiod

Packaging Che

Clean packaging materials

Check packaging failure

Use appropriate packaging materials

Results of packaging

Storing(chiller) Bio

Temperature ofcooling room ≤+4°c

Check temperaturedaily

Adjust temperature as thecase may be

Record of coldchain temperature

CCP during Processing

CCP1Preparation and

injectionof curing Brine

CCP2 Cooking

Recommended microbiological criteria for fresh meatGood

microbiological

standard

Criticalmicrobiologic

alcondition

Notacceptable

Total plate count per square cm

Less than10,000

Between10,000 and 1,00,000

More than1,00,000

Enterobacteriacae

per square cm

<100 >100 - <1000 >1000

THANK YOU…