haccp - canned tuna

HACCP TASK – CANNED TUNA

Micheal Amoafo MensahBobby Antan CaiquoSophia D. Amenyah

FOOD SAFETY

Introduction

Main Hazards

• Quality of raw material – tuna (chemicals, microbes• Survival of pathogens (C. botulinum spores) during the

retorting process• Presence of heat stable toxins/allergens/biogenic

amines e.g. Histamine• Contamination with physical material• Recontamination of product after heat processing –

defective containers, poor sealing, contaminated cooling water, poor handling of cans

Sources of Contamination

Inappropriate work

methodology

Equipment Personnel

Processing Environment

• Clostridium botulinum A,B,E,F• Salmonella spp• Shigella spp• Staphylococcus aureus• Escherichia coli O157:H7

Associated Microorganism

s

Process Flow Chart

Concerning Potential hazard Type Preventive measure PxE = R CCP CP PRP

Reception of Tuna and Salt

1.Insufficient microbiological qualitya. delivery of insufficiently fresh fishb. delivery at too high temperaturec. delivery of bruised or physically injured fishd. poor hygienic conditions of fishing vessel, equipment and storage facilities 2. High levels of biogenic amines (histamine)

3. Presence of chemicals and or their residues in fish

4. Presence of foreign materials in: a.Tuna b.Salt

M

A

C

P

1. Clear supply specification: fish must be fresh, delivered at the right temperature and with no physical injury.Fishing vessel must be in a good hygienic condition

2. Clear Supplier Specification: rapid chilling of fish immediately after capture. Generally, fish should be packed in ice or chilled sea water in less than 12 h after catch or – in case of large fish such as tuna – chilled to an internal temperature of 10°C or less within 6 h after capture.

3. Check for limits of mercury

4. Visual inspection to detect presence of foreign materials in tuna and salt

1 x 3 = 3

3 x 3 = 4

3 x 3 = 3 1 x 1 = 1

-

CCP 1a

CCP 1b

-

CP 1

- -

-

9

-

9/ 12

Concerning Potential hazard Type Preventive measure P x E = R CCP CP PRP

Intermediate Storage of Fish

1. Growth of microbes due to interruption of the cold storage temperature.

M Fish after quality checks must be stored immediately at -18oC. Temperature must be controlled and monitored.

1 x 3 = 3 - - 4/ 9


Receipt and storage of cans and lids

1. Delivery of low quality or damaged cans and lids

2. Damaged cans and lids due to improper handling and storage

3. Contamination of cans due to poor storage conditions.

P

P

M

1. Purchase policy / Purchase specifications Visual inspection of all lots of empty cans and lids 2. Cans must not be stacked too high (2m limit) and carefully handled. 3a. Humidity of storage room must be kept low to prevent growth of microorganisms.b. Good air quality.

1 x 3 = 3

1 x 3 = 3

2 x 3 = 4

CCP 1c -

-

-

- -

-

9

3/ 9

Concerning Potential hazard Type Preventive measure P x E = R CCP CP PRP Preparation of Brine

1.Insufficient microbiological qualitya. use of non-potable waterb. poor hygienic conditions of mixing equipment and personnelc. poor hygienic conditions of pump d. Insufficient heating of brine 2. Presence of foreign materials in brine

M

P

1a. Use and analysis of potable waterb. Proper cleaning of equipment and adherence to strict personal hygiene by personnelc. Pump must be cleaned regularly d . Control and registration of temperature of brine

2. Monitoring and changing filter regularly

2 x 3 = 4

2 x 2 = 3

-

-

-

-

3

5/66

4 7/ 12

Concerning Potential hazard Type Preventive measure P x E = R CCP CP PRP Thawing Microbial growth due to time

and temperature abuse resulting in under or over thawingPoor quality of thawing water

M Monitoring and control of backbone temperature of tunaUse of potable water to reduce bacterial growth

3 x 3 = 4 - - 4 3

Concerning Potential hazard Type Preventive measure P x E = R CCP CP PRP Pre-cooking

Growth of microbes, development of resistance and survival of spores

M Adequate cooking time and temperature control to prevent microbial growth

2 x 3 = 4 - CP 2

4

Concerning Potential hazard Type Preventive measure P x E = R CCP CP PRP Cooling Microbial growth and

germination of sporesM Fast cooling of precooked tuna

Use of potable water2 x 3 = 4 - - 4

3

Concerning Potential hazard Type Preventive measure P x E = R CCP CP PRP Heading/gutting/filleting

1. Additional microbiological contamination through knives and gutting equipment 2. Additional microbiological contamination through personnel 3. Contamination with broken parts of knives and other gutting equipment

M

M

P

1. Clear work instructions; only clean knives must be used and also be changed regularly 2. Personal hygiene and strict hygienic practices by personnel

3. Visual check of cutting tools, replacement and regular maintenance.

2 x 3 = 4

2 x 2 = 3

-

- -

- - -

5

6

6/7

Concerning Potential hazard Type Preventive measure P x E = R CCP CP PRP Cutting 1. Additional microbiological

contamination through cutting equipment

M Cutting equipment must be clean.Visual checks and maintenance must be carried out regularly.

2 x 3 = 4 - - 6/7/14


Metal Detection

1. Presence of metal pieces in tuna

P Use of an effective metal detector 4 x 3 = 6 CCP 2

- -


Unpalleting of cans

1. Introduction of foreign objects through the environment.2. Damaged cans due to improper handling during unpalleting

P/M

C

General guidelines for hygiene and guidelines for order and cleanliness

Proper handling of cans during unpalleting to maintain their quality

2 x 3 = 4 1 x 3 = 3

- -

- -

6/12 12/14


Washing and turning of cans

Microbial contamination through washing water

M Use of potable water 2 x 3 = 4 - - 3


Filling 1.Cross contamination from previous fish stuck/left in the filler

2.Improper heat penetration due toi. Over filling ii. under filling of cans

P 1. Proper cleaning of filler before filling begins

2. Regular visual check (every half hour) by floor supervisor

2 x 2 = 3 - - 1/14

14

Concerning Potential hazard Type Preventive measure P x E =R CCP CP PRP

Sealing and Coding

1. Additional microbial contamination from- microbes on the lids- the sealer2. Additional cross contamination with dust, small pieces of metal or plastic from the can lids/coverings

3. Faulty sealing of cans due to- faulty sealing machines- poor quality cans

4. Lack of traceability

M

P

M/P

M/P/C/A

1&2. Proper cleaning and disinfection of cans and lids/coverings before they are used

3a. Visual inspection to check if cans are hermetically sealed.3b.Can closures must be checked at regular intervals visually and always when setting up a new machine or adjusting an old one. 3c. Tear down measurements must be done at the beginning of the shift and every 30min thereafter by Q.C.

4. Proper coding of the cans must be ensured.

2 x 3 = 4

2*2 = 3

2*3 = 4

2*3 = 4

-

-

-

-

-

-

CP 3 -

1/14

1/14

7/14

10

Concerning Potential hazard Type Preventive measure P x E = R

CCP

CP PRP

Heat Processing

1. Survival of pathogens, spoilage microbes and spores due to improper time temperature combination during retorting2. Contamination via retorting water3. Damage of cans due to pressure and agitation during retorting

M MP

1. Monitoring of heat processing machine panels to make sure the right heating temperature and time is in use.2. Use of potable water3. Proper caging of cans before retorting

4 x 4 = 7 CCP 3

- -


CCP

CP PRP

Caging Damage to cans during caging P Proper handling of cans 1*2 = 2 - - 14


CCP

CP PRP

Washing after sealing

1. Microbial contamination of products due to poor quality of washing water.2. Chemical contamination

M C

Use of potable water Washing water must not exceed the critical limit for certain chemicals

2*3 = 4 2*3 = 4

- -

- -

3 3/14


CCP

CP PRP

Transport/Dispatch/Retail

Damage of cans during transporta. Dented cansb. Rusted cans

PC

Proper handling and stacking of packaged cans on pallets.

2 x 2 = 3 - - 12/ 14


CCP CP PRP

Storage/Release

1. Poor storage conditions

M Clear work instructions; good hygienic and storage conditions

2 x 2 = 3 - - 1/ 9/14


CCP CP PRP

Uncaging Damage to cans during

uncagingP Proper handling of cans 2 x 3 = 4 - - 12/

14


CCP CP PRP

Cooling/Drying

1. Additional microbial post-contamination via cooling water

M Use of potable water 4 x 3 = 6 CCP 4 - -

CCP Critical Limits &Tolerances

Monitoring Corrective Actions Action by

1.Reception

2. Metal Detection 3. Heat Processing

4.Cooling/Drying

Frozen fish < -18oC- Fresh fish 0˚C- Histamine < 50ppm- Mercury < 0.8ppm- Cans must meet container specification for safety.

- Absence of metal pieces

- Critical limit is the botulinum cook or 12-D process

- There must be measurable residual chlorine in the water (critical limit- 0.5mg/l)

- Measure temperature upon receipt and request temperature history of tuna- Visual inspection- Sample for histamine and mercury- Letter of guarantee from supplier. Visual examination of all lots of empty cans

- Regular checks and cleaning of metal detector

- Periodic checks on heat distribution in retort and temperature recording equipment - Records on all actions and measurements must be kept and reviewed daily

- Cooling water should be tested (microbial quality and chlorine residue) at least two times per day by a designated person

- Inform/change supplier- If histamine < 50ppm, increase surveillance at gutting and filleting- Reject defective cans, contact supplier

- Stop production, fix and recalibrate the detector before continuing production - If time/temperature requirements are violated, products must be put on hold for reprocessing and the cause must be identified. - Review of all operations and monitoring procedures and calibration of thermometers and automatic recorders - Production must be stopped if water is contaminated or critical limit exceeded, water treatment must be adjusted and the source of contamination investigated

QC manager and QC analyst ControlProduction workerCorrectionProduction manager ControlProduction worker CorrectionProduction manager QC analyst and manager

HACCP-HANDBOOK Page : 23

NAME Company CCP MONITORING TABLE Date : PRODUCT: CANNED TUNA Flow chart :

CP Description CP Monitoring Corrective action Documents Action By

1 2

3

Raw Tuna – Number of microbes and spores Pre-Cooked Tuna – Number of microbes and spores

Canned Tuna – Faulty Sealing

- Measure temperature upon receipt- Conduct microbial analysis for each batch received - Monitor cooking time and temperature- Measure, record and review all actions

- Check can closures at regular intervals- Visual inspection of seam- Seam tear down

Do not use batch until the certificate of analysis is delivered If time/temperature requirements are violated, products must be put on hold for adjusted time and temperature retorting and the cause must be identified.- Recalibration of thermometers and automatic recorders - Shut down processing line and inform production manager- All products produced since last check should be put on hold.- Cause of problem must be investigated- Record all actions

- Purchase specifications- Certificate of analysis- Work instructions for incoming raw material - Temperature recording charts- Investigation report

- Seamer inspection report - Visual inspection report - Seam tear down report - Investigation report

QC AnalystReceipt Responsible Production Manager

Production Manager

HACCP-HANDBOOK Page : 24

NAME Company CP MONITORING TABLE Date : CANNED TUNA

haccp - canned tuna

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