1

Hazard Analysis Critical Control Point (HACCP) Model

for
Frankfurters

by
Dennis E. Burson
Erin Dormedy
University of Nebraska
Lincoln, NE 68583-0908

Introduction
Hazard Analysis Critical Control Point (HACCP) is a process control system. This
preventative system is designed for the safe production of food by applying controls at any point
in production where hazards occur or where previously introduced hazards can be controlled
before consumption. The application of HACCP is based on technical and scientific principles
that assure safe food. An ideal application of HACCP would include all processes in food
production from the farm to the table.

The food industry has embraced HACCP as the best system for preventing food safety
problems. HACCP has been used as early as the late 1950's when the Pillsbury Company used
HACCP to assist with the production of foods for the space program. Recently numerous meat
and poultry companies have utilized HACCP to address concerns with food safety. Additionally,
in 1996 the USDA Food Safety and Inspection Service (FSIS) published the final rule for
pathogen reduction and Hazard Analysis Critical Control Point (HACCP) Systems.
Implementation of HACCP will be required for larger federally inspected meat and poultry
operations by 1998 and very small establishments will need to comply by 2000.

The HACCP plan is specific for each production plant and the design and implementation
of a HACCP plan should be conducted by a team of individuals from the company and the
production facility. Many companies have the expertise available to develop and implement
HACCP; however, some companies, especially the smaller business meat companies, will
require assistance from extension, industry associations, consultants, and government for
development of a HACCP plan. One form of assistance is the use of generic or model HACCP
plans.

Model HACCP plans have been developed by the USDA, FSIS through a contract with
the International Meat and Poultry HACCP Alliance. Teams of scientists, consumers and
industry representatives developed ten model plans representing different product categories. The
ten product categories represent most of the meat products produced. The model plans have been
reviewed by a scientific and industry panel and are available from FSIS and are also at the
International Meat and Poultry HACCP Alliance web site. Generic or model HACCP plans can
serve as useful guidelines for a production facility; however, it is impossible for model plans


2
developed for a broad number of production systems to be readily applied to an individual meat
processing facility or product.

Several additional points should be considered when using a model plan.

1. Many HACCP model plans were developed for a product category by using specific
products for simplicity in developing the plan. A production facility developing a plan
for a different product in the same category will need to consider changes in the flow
charts, hazard analysis and critical control point analysis.

2. Model plans make the assumption that facilities have established sanitation Standard
Operating Procedures (SOPs) and follow Good Manufacturing Practices (GMPs).

3. Critical limits and critical control points in models were developed with the best
information available at that time. As knowledge of food safety hazards increases and
new technology to measure hazards develops, the critical control points used to control a
process may also change. Additionally, some plants may require more CCPs and some
plants may require less CCPs to maintain control.

4. The method of record keeping is highly dependent on the systems in the individual plant.
Some plants may be able to adjust current quality assurance records, while others will
have no record keeping system. Additionally, some plants may be able to utilize
computer record keeping.

5. Scientific and technical input into the HACCP plan will still be important. Production
facilities may still need to seek outside input into the development, implementation and
review of their HACCP plan.

6. The HACCP plan will change with time and adjustments to keep the process in control
will need to be made.

Processing plants will find model HACCP plans a useful starting point but should not
consider a model plan as the only answer for food safety hazards in their facility.

Frankfurter model HACCP plan
The frankfurter model HACCP plan is presented not only as a model for meat processors
for HACCP development, but is also designed for group evaluation. Therefore, this plan
includes details that may not be included with other model plans. The frankfurter model plan
includes product descriptions, product ingredients, the CCP decision tree used in the model, the
hazard analysis (Principle 1), the CCP determination (Principle 2), a table of critical limits,
monitoring and corrective actions (Principles 3, 4 and 5), a table of record keeping and
verification (Principles 6 and 7), and a HACCP plan. Sample record keeping forms and
references that are useful in developing the plan are also included. Finally, a HACCP plan


3
checklist is included specifically for use with the group exercise, but could also be used to
evaluate establishment HACCP plans.
Additionally the frankfurter model plan includes and excludes critical control points that
can be debated. The group will need to review the plan with this in mind. A description of the
CCPs identified follows.

Frankfurter model HACCP plan CCPs

CCP 1 addresses the risk of pathogen growth in the frankfurter and the potential
carcinogenic risk of the ingredient nitrite. Residual nitrite in frankfurters and other cured meat
products has antibacterial properties, especially for Clostridium botulinum and Listeria
monocytogenes. The risk of adding too much nitrite is that it is a carcinogen and very high levels
could be toxic. Nitrite is required in this product to meet the standards of identity by USDA
FSIS, and the legal limit for nitrite in the frankfurter formulation is 156 ppm. However, the level
needed for food safety protection may be debatable. Most of the nitrite added to the formulation
is converted to nitrous oxide during processing and only the residual nitrite will provide the
antibacterial activity. Including nitrite in the formulation at the proper levels should minimize the
risk of the carcinogen and maximize the antibacterial benefit.

CCP 2 addresses the risk of pathogen growth during the tempering of frozen meat. Since
most sources of meat contain some level of pathogen contamination, including controls for
thawing temperature and thawing time should assist with controlling the growth of pathogens
during this processing step.

CCP 3 also addresses the risk of growth of pathogen due to inappropriate storage
conditions of too high temperature and too long of time that could occur before the product
enters the establishment. The plant can use established good manufacturing practices (GMPs) to
control pathogen growth in their facility, but the control is placed on incoming product to
encourage the suppliers and transportation providers to also use GMPs.

CCP 4 is an important pasteurization step for the production of frankfurters. Thermally
processing to a proper end point temperature will result in a significant reduction in pathogens in
the product.

CCP 5 provides control over the hazard of metal fragments in the product. Metal
detection at other locations in the product flow would be important for quality assurance and for
reducing the expense of equipment breakdown, but does not need to be controlled as a hazard
until the finished product is produced.



4
ESTABLISHMENT NO.
PRODUCT/PROCESS
DATE
HACCP PLAN CHECKLIST


A. DESCRIBE THE PRODUCT
1. Does the HACCP plan include:
a. The producer/establishment and the product name?
b. The ingredients and raw materials used along with the product receipt or formulation?
c. The packaging used?
d. The temperature at which the product is intended to be held, distributed and sold?
e. The manner in which the product will be prepared for consumption?
2. Has a flow diagram for the product of the product been developed that is clear, simple and descriptive
of the steps in the process?
3. Has the flow diagram been verified for accuracy and completeness against the actual operating
process?
B. CONDUCT A HAZARD ANALYSIS
1. Have all steps in the process been identified and listed where hazards of potential significance occur?
2. Have all hazards associated with each identified step been listed?
3. Have safety concerns been differentiated from quality concerns?
4. Have preventive measures to control the identified hazard been identified, if they exist, and listed?
C. IDENTIFY CRITICAL CONTROL POINTS
1. Has the CCP Decision Tree been used to help determine if a particular step is a CCP for a previously
identified hazard?
2. Have the CCPs been entered on the forms?
3. Have all significant hazards identified during the hazard analysis been addressed?
D. ESTABLISH CRITICAL LIMITS
1. Have critical limits been established for each preventive measure at each CCP?
2. Has the validity of the critical limits to control the identified hazard been established?
3. Were critical limits obtained from the regulations, processing authority, etc?
4. Is documentation attesting to the adequacy of the critical limits maintained on file at the
establishment?
E. ESTABLISH MONITORING PROCEDURES
1. Have monitoring procedures been developed to assure that preventive measures necessary for control
at each CCP are maintained within the established critical limits?
2. Are the monitoring procedures continuous or, where continuous monitoring is not possible, is the
frequency of monitoring sufficiently reliable to indicate that the hazard is under control?
3. Have procedures been developed for systematically recording the monitoring data?
4. Have employees responsible for monitoring been identified and trained?
5. Have employees responsible for reviewing monitoring records been identified and trained?
6. Have signatures of responsible individuals been required on the monitoring records?
7. Have procedures been developed for using the results of monitoring to adjust the process and
maintain control?
F. ESTABLISH CORRECTIVE ACTIONS
1. Have specific corrective actions been developed for each CCP?
2. Do the corrective actions address:
a. Reestablishment of process control?
b. Disposition of affected product?
c. Procedures to correct the cause of non-compliance and to prevent the deviation from recurring?
3. Have procedures been established to record the corrective actions?
4. Have procedures been established for reviewing the corrective action records?
G. ESTABLISH RECORDKEEPING PROCEDURES
1. Have procedures been established to maintain the HACCP plan on file at the establishment?
2. Do the HACCP records include:
Description of the product and its intended use?
Flow diagram for the process, indicating CCPs?
Preventative measures?
Critical limits?
Monitoring system:
Corrective action plans for deviations from critical limits?
Recordkeeping procedures for monitoring?
Procedures for verification of the HACCP system?
H. ESTABLISH VERIFICATION PROCEDURES
1. Have procedures been included to verify that all significant hazards were identified in the HACCP
plan when it was developed?
2. Have procedures been included to verify that the critical limits are adequate to control the identified
hazards?

YES









YES




YES




YES




YES










YES







YES










YES

NO









NO




NO




NO




NO










NO







NO










NO


5
3. Are procedures in place to verify that the HACCP system is functioning properly?
4. Are procedures in place to reassess the HACCP plan and system on a regular basis or whenever
significant product, process or packaging changes occur?

Product Category Description

Product: Frankfurters

The following areas need to be defined when developing the product category description:

1. Common Name/Description:
A small diameter comminuted, semi-solid sausage prepared from meat or meat and
poultry, seasoned and cured. Defined in regulations under Sausage, Cooked 319.180
Definitions and Standards of Identity or Composition, Subpart G, Cooked Sausage.

2. How is it to be used?
As a sandwich item, a meat item by itself, or as an ingredient in other foods.


3. Type of Package?
Vacuum package for retail, bulk vacuum package for Foodservice, bulk packaged in lined
boxed for Foodservice.


4. Length of Shelf Life; at what temperature?
Varies with packaging of product and storage temperature. Usually stored at refrigeration
but may be frozen


5. Where will it be sold?
Retail
Foodservice

6. Labeling instructions:
Sell by date, Lot number, Julian code.
Keep refrigerated or Keep frozen depending upon the intended customer and use.

7. Is special distribution control needed?
Yes, refrigerated conditions are required.




6
Date:______________________ Approved by: ___________________________


7
Product and Ingredients

Product: Frankfurters

Meat Ingredients:
Raw meat
Raw poultry
Product rework

Non-Meat Ingredients:
Salt
Water/ice
Sugar
Dextrose
Corn syrup
Spices and flavorings
Liquid smoke
Nonfat dry milk

Restricted Ingredients:
Potassium or sodium nitrite
Ascorbate or erythorbate
Phosphate


Packaging Materials:
Roll stock oxygen barrier film for vacuum package
Box liner film and box for bulk package

Casing:
Cellulose casing
Collagen casing
Natural




8
Frankfurter Production Flow Chart


Recieving Fresh
Meat and Poultry


Receiving
Frozen Meat
and Poultry



Utilizing
Rework



Receiving Non-
Meat Ingredients


Receiving
Restricted Non-
Meat Ingredients

Storing

Storing

Storing

Storing

Storing


Tempering

Grinding





Grinding

Block
Chipping







Scaling

Scaling

Scaling Scaling Scaling
Mixing


Chopping


Emulsifing


Stuffing/Linking

Preparing
Casing
Storing Receiving
Casing

Acid spraying/
Cooking/Smoking


Brine Chilling


Peeling


Collating


Packaging

Storing Receiving
Packaging

Storing


Shipping and


9
distributing


10

CCP Decision Tree


Q1. Does this step involve a hazard of sufficient risk and severity to warrant its control?



Yes No Not a CCP



Q2. Does a preventive measure for the hazard exist at this step?



No Modify the step, process or product

Is control at this step necessary for Safety? Yes



Yes No Not a CCP


Q3. Is control at this step necessary to prevent eliminate or reduce the risk of the hazard to
consumers?



Yes CCP No Not a CCP



11

Hazard Analysis
Product: Frankfurters

Process Step

Potential hazard introduced,
controlled or enhanced at
this step
B= Biological
C= Chemical
P= Physical

Is the
potential
food safety
hazard
significant?

Justification for decision

What control measures can be
applied to prevent the significant
hazards?

Receiving
and storing
restricted
non-meat
ingredients

B - Not applicable
C - Nitrite/cure
P - Foreign material

C - No
P - No

C - Not likely to occur as plant
GMPs include letter of
guarantee
P - Not likely to occur



Scaling of
restricted
non-meat
ingredients

B - Pathogens
C - Nitrite
P - Foreign material

B - Yes
C - Yes
P - No

B - Residual nitrite provides
control for Colstridium
botulinum and Listeria
monocytogenes
C - Excessive levels of nitrite
may be carcinogenic

B,C = Proper weighing and
correct product formulation.

Receiving
and storing
non-meat
ingredient

B - Pathogen
C - Allergens
P - Foreign material

B-No
C- No
P-No

B - Not likely to occur and will
be controlled at later processing
steps.
C - Not likely to occur



Receiving
and storing
casings

B - Pathogen
C - Not applicable
P - Foreign material

B - No
C - No

N - Not likely to occur
P - Plant GMPs control




12

Hazard Analysis
Product: Frankfurters

Process Step

Potential hazard introduced,
controlled or enhanced at
this step
B= Biological
C= Chemical
P= Physical

Is the
potential
food safety
hazard
significant?

Justification for decision

What control measures can be
applied to prevent the significant
hazards?

Receiving
storing
packaging
material

B - Not applicable
C - Not applicable
P - Foreign material

P - No

P - Not likely to occur due to
plant GMPs



Utilizing
rework,
storage,
scaling and
grinding

B - Pathogen
C - Not applicable
P - Foreign material

B - No
P - No

B - Not likely to occur with
plant GMPs addressing storage
temperature and cross
contamination



Receiving
frozen meat
and poultry

B - Pathogen
C - Antibiotics
P - Foreign material

B - No
C - No
P - No

B - Raw meat is a known source
of pathogen
C - USDA and producer
program control
P - Low incidence



Tempering
of frozen
meat and
poultry

B - Pathogen
C - Not applicable
P - Not applicable

B - Yes

Pathogen growth if time and
temperature are not controlled

Temper meat at 40F and block
chip while still frozen

Block
chipping of

B - Pathogene
C - Sanitizer and cleaner

B - No
C - No

Plant sanitation SOPs and
GMPs control

B -


13

Hazard Analysis
Product: Frankfurters

Process Step

Potential hazard introduced,
controlled or enhanced at
this step
B= Biological
C= Chemical
P= Physical

Is the
potential
food safety
hazard
significant?

Justification for decision

What control measures can be
applied to prevent the significant
hazards?
tempered
meat and
poultry
F - Foreign material P - No

Receiving
fresh meat
and poultry

B - Pathogen
C - Antibiotics
P - Foreign material

B - Yes
C - No
P - No

B - Raw meat is a known
source of pathogen

B - Product age, receiving
temperature, and
organoleptic evaluation

Storing of
fresh meat
and poultry

B - Pathogen
C - Not applicable
P - Not applicable

B - Yes


B - Presence of pathogen

Appropriate time/temperature
monitoring and plant GMPs

Grinding
fresh meat
and poultry

B - Pathogen
C - Sanitizer and cleaner
P - Foreign material

B - No
C - No
P - No

Sanitation SOP for sanitation
and plant GMP for foreign
material control



Scaling of
fresh and
frozen meat
and poultry

B - Pathogen
C - Sanitizer and cleaners
P - Foreign material

B - No
C - No
P - No

Sanitation SOPs and plant
GMPs




14

Hazard Analysis
Product: Frankfurters

Process Step

Potential hazard introduced,
controlled or enhanced at
this step
B= Biological
C= Chemical
P= Physical

Is the
potential
food safety
hazard
significant?

Justification for decision

What control measures can be
applied to prevent the significant
hazards?

Mixing

B - Pathogen
C - Sanitizers and cleaners
P - Not applicable

B - Yes
C - No


Proper addition of Nitrite



Chopping
and Grinding

B - Pathogen
C - Sanitizer and cleaner
P - Foreign material

B - No
C - No
P - No

Sanitation SOPs and plant
GMPs



Emulsifying

B - Pathogen
C - Sanitizer and cleaner
P - Foreign material

B - No
C - No
P - No

Sanitation SOPs and plant
GMPs



Stuffing and
Linking

B - Pathogen
C - Not applicable
P - Not applicable

B - No

Sanitation SOPs and plant
GMPs




15

Hazard Analysis
Product: Frankfurters

Process Step

Potential hazard introduced,
controlled or enhanced at
this step
B= Biological
C= Chemical
P= Physical

Is the
potential
food safety
hazard
significant?

Justification for decision

What control measures can be
applied to prevent the significant
hazards?

Acid
spraying/
cooking/
smoking

B - Pathogen
C - Cleaners and Sanitizers
P - Not applicable

B - Yes
C - No

Improper cooking
Temperatures allow growth of
pathogen

Time and temperature to control
pathogens

Brine
chilling

B - Not applicable
C - Not applicable
P - Not applicable

B - No
C - No
P - No

Sanitation SOPs and plant
GMPs



Peeling

B - Pathogen
C - Not applicable
P - Foreign material

B - No
C - No
P - No

Sanitation SOPs and plant
GMPs



Collating

B - Pathogen
C - Sanitizers and cleaners
P - Foreign material

B - Yes
C - No
P - No

Cross contamination form
environment or personnel

Plant SOPs for sanitation


16

Hazard Analysis
Product: Frankfurters

Process Step

Potential hazard introduced,
controlled or enhanced at
this step
B= Biological
C= Chemical
P= Physical

Is the
potential
food safety
hazard
significant?

Justification for decision

What control measures can be
applied to prevent the significant
hazards?

Packing

B - Not applicable
C - Not applicable
P - Foreign material



P - Yes

Metal

Metal detection

Storing

B - Pathogen
C - Not applicable
P - Foreign material

B - No

P - No

Proper time and temperature
GMPs



Shipping

B - Pathogen
C - Not applicable
P - Not applicable

B - No



Proper time and temperature
GMPs



Distributing

B - Pathogen
C - Not applicable
P - Not applicable

B - No
C - No
P - No

Proper time and temperature
GMPs




17

Principle 2 - CCP Determination
Product: Frankfurters A critical control point is defined as a point, step or procedure at which control can be applied and a
food safety hazard can be prevented, eliminated or reduced to acceptable levels.

Process step

Hazard
Biological = B
Chemical = C
Physical = P

Q1. Does this step
involve a hazard
of sufficient risk
and severity to
warrant its
control?

Q2. Does a
preventive
measure for
the hazard
exist at this
step?

If Q2. is no:
Is control at
this step
necessary for
safety?

Q3. Is control at this
step necessary to
prevent, eliminate or
reduce the risk of the
hazard to
consumers?

#CCP

B - Not applicable











C - Nitrite

No









Receiving &
storing
restricted
non-meat
ingredient

P - Foreign material

No









B - Pathogens

Yes

Yes



Yes

CCP-1B

C - Nitrite

Yes

Yes



Yes

CCP-1C

Scaling of
restricted
non-meat
ingredients

P - Foreign material

No









B - Pathogen

No









C - Allergins

No









Receiving and
storing non-
meat
ingredient

P - Foreign material

No









B - Pathogen

No









C - Not applicable











Receiving and
storing
casings

P - Foreign material

No










18

Principle 2 - CCP Determination
Product: Frankfurters A critical control point is defined as a point, step or procedure at which control can be applied and a
food safety hazard can be prevented, eliminated or reduced to acceptable levels.

Process step

Hazard
Biological = B
Chemical = C
Physical = P

Q1. Does this step
involve a hazard
of sufficient risk
and severity to
warrant its
control?

Q2. Does a
preventive
measure for
the hazard
exist at this
step?

If Q2. is no:
Is control at
this step
necessary for
safety?

Q3. Is control at this
step necessary to
prevent, eliminate or
reduce the risk of the
hazard to
consumers?

#CCP

B - Not applicable











C - Not applicable











Receiving &
storing
packaging
material

P - Foreign material

No









B - Pathogen

No









C - Not applicable











Utilizing
rework
storaging and
grinding

P - Foreign material

No









B - Pathogen

Yes

Yes



Yes



C - Antibiotics

No









Receiving
frozen meat
and poultry

P - Foreign material

No









B - Pathogen

Yes

Yes



Yes

CCP-2B

C - Not applicable











Tempering of
frozen meat
and poultry

P - Not applicable











Block

B - Pathogen

No










19

Principle 2 - CCP Determination
Product: Frankfurters A critical control point is defined as a point, step or procedure at which control can be applied and a
food safety hazard can be prevented, eliminated or reduced to acceptable levels.

Process step

Hazard
Biological = B
Chemical = C
Physical = P

Q1. Does this step
involve a hazard
of sufficient risk
and severity to
warrant its
control?

Q2. Does a
preventive
measure for
the hazard
exist at this
step?

If Q2. is no:
Is control at
this step
necessary for
safety?

Q3. Is control at this
step necessary to
prevent, eliminate or
reduce the risk of the
hazard to
consumers?

#CCP

C - Sanitizers and Cleaner

No








chipping of
tempered
meat

F - Foreign Material

No









B - Pathogen

Yes

Yes



Yes

CCP-3B

C - Antibiotics

No









Receiving
fresh meat

P - Foreign material

No









B - Pathogens

No









C - Not applicable











Storing of
fresh meat

P - Not applicable











B - Pathogen

No









C - Sanitizer and cleaner

No









Grinding
fresh meat

P - Foreign Material

No









B - Pathogen

No







Scaling of
fresh and
frozen meat

C - Sanitizer and cleaners

No










20

Principle 2 - CCP Determination
Product: Frankfurters A critical control point is defined as a point, step or procedure at which control can be applied and a
food safety hazard can be prevented, eliminated or reduced to acceptable levels.

Process step

Hazard
Biological = B
Chemical = C
Physical = P

Q1. Does this step
involve a hazard
of sufficient risk
and severity to
warrant its
control?

Q2. Does a
preventive
measure for
the hazard
exist at this
step?

If Q2. is no:
Is control at
this step
necessary for
safety?

Q3. Is control at this
step necessary to
prevent, eliminate or
reduce the risk of the
hazard to
consumers?

#CCP
frozen meat

P - Foreign material

No









B - Pathogen

No









C - Sanitizers and cleaners

No









Mixing

P - Not applicable











B - Pathogen

No









C - Sanitizer and cleaner

No









Chopping and
Grinding

P - Foreign material

No









B - Pathogen

No









C - Sanitizer and cleaner

No









Emulsifying

P - Foreign material

No









B - Pathogen

No









C - Not applicable











Stuffing and
linking

P - Not applicable












21

Principle 2 - CCP Determination
Product: Frankfurters A critical control point is defined as a point, step or procedure at which control can be applied and a
food safety hazard can be prevented, eliminated or reduced to acceptable levels.

Process step

Hazard
Biological = B
Chemical = C
Physical = P

Q1. Does this step
involve a hazard
of sufficient risk
and severity to
warrant its
control?

Q2. Does a
preventive
measure for
the hazard
exist at this
step?

If Q2. is no:
Is control at
this step
necessary for
safety?

Q3. Is control at this
step necessary to
prevent, eliminate or
reduce the risk of the
hazard to
consumers?

#CCP

B - Pathogen

Yes

Yes



Yes

CCP-4B

C - Cleaners and sanitizers

No









Acid
spraying/
cooking/
smoking

P - Not applicable











B - Not applicable











C - Contaminants in brine

No









Brine chilling

P - Not applicable











B - Pathogen

No









C - Not applicable











Peeling





P - Foreign material

Yes

Yes



No



B - Pathogen

No









C - Sanitizers and cleaners

No









Collating

P - Foreign material

Yes

Yes



No




22

Principle 2 - CCP Determination
Product: Frankfurters A critical control point is defined as a point, step or procedure at which control can be applied and a
food safety hazard can be prevented, eliminated or reduced to acceptable levels.

Process step

Hazard
Biological = B
Chemical = C
Physical = P

Q1. Does this step
involve a hazard
of sufficient risk
and severity to
warrant its
control?

Q2. Does a
preventive
measure for
the hazard
exist at this
step?

If Q2. is no:
Is control at
this step
necessary for
safety?

Q3. Is control at this
step necessary to
prevent, eliminate or
reduce the risk of the
hazard to
consumers?

#CCP

B - Not applicable











C - Not applicable











Packing

P - Foreign material

Yes

Yes



Yes

CCP-5P

B - Pathogen

No









C - Not applicable











Storing

P - Not applicable











B - Pathogen

No









C - Not applicable











Shipping





P - Not applicable











B - Pathogen

No









C - Not applicable











Distributing

P - Not applicable












23

Principles 3, 4 and 5
Critical Limits, Monitoring and Corrective Actions

Product:

Process Step/
CCP

Critical Limits

Monitoring Procedures
(Who/What/When/How)

Corrective Actions

Scaling of restricted
non-meat
ingredients
CCP-1B

120 ppm or greater
nitrite added to the
product formulation.
The weight of cure
added will depend on
nitrite concentration in
cure.

Scale master for cure ingredients will
weigh out the correct weight for each
batch and check the weight against the
formulation sheet. Quality assurance
personnel will verify the weight
before addition to the batch.

Curing ingredients will be reweighed and the amount
corrected as needed.

Scaling of restricted
non-meat
ingredients
CCP-1C

156 ppm or less nitrite
added to the product
formulation. The
weight of cure added
will depend on nitrite
concentration in cure.

Scale master for cure ingredients will
weigh out the correct weight for each
batch and check the weight against the
formulation sheet. Quality assurance
personnel will verify the weight
before addition to the batch.

Curing ingredients will be reweighed and the amount
corrected as needed.














Tempering of frozen
meat.
CCP-2B

Less than 40F or
plant established time
and temperature
requirements to
preclude the growth of

A thermometer with a recorder will
monitor the tempering room on a
constant basis. Tempering room
manager will monitor the room
temperature twice per production shift

Refrigeration will be adjusted. Product will be
placed on hold for further evaluation of significance.
Established procedures will be used for product
disposition.


24

Principles 3, 4 and 5
Critical Limits, Monitoring and Corrective Actions

Product:

Process Step/
CCP

Critical Limits

Monitoring Procedures
(Who/What/When/How)

Corrective Actions
pathogens. and verify this reading with the
reading of the recording thermometer.


Receiving fresh
meat and poultry
CCP-3B

Internal temperature
of fresh meat should
be less than 40F and
less than three days
from fabrication or
plants specifications
for product age.

Temperature of each combo of fresh
meat will be checked by the receiving
clerk using a calibrated thermometer.
Product age and organoleptic
evaluation will be recorded.

Product will be placed on hold by the receiving clerk
and further evaluated by quality assurance. Quality
assurance personnel will either reject the product or
conduct further evaluations for disposition of the
product.

Acid Spraying/
Cooking/
Smoking
CCP-4B

Internal temperature
of the finished product
of 160F or greater.

At the end of the cooking cycle, the
internal frankfurter temperature will
be checked in three separate house
locations for each smokehouse batch.
Temperature will be monitored with a
calibrated thermometer by the
smokehouse operator.

Continue cooking until frankfurters reach 160F.

Packaging
CCP-5P

No foreign material.
Metal detection set for
the maximum
sensitivity of the metal
detector

Each package will be checked for
metal by an in-line metal detector that
will automatically reject packages.
Visual inspection for other foreign
material will be preformed by the

Packages identified to have foreign material will be
reverified and if possible the source of foreign
material identified. Product will be retained and
reworked or discarded.


25

Principles 3, 4 and 5
Critical Limits, Monitoring and Corrective Actions

Product:

Process Step/
CCP

Critical Limits

Monitoring Procedures
(Who/What/When/How)

Corrective Actions
packaging operator and periodically
by quality assurance personnel.


26

Principles 6 and 7
Record Keeping and Verification

Product:

Process Step/CCP

Records

Verification
Procedures

Scaling restricted non-meat ingredients
CCP-1B, C

Formulation sheets for each batch.
Scale weights for cure.
Incident report forms of deviations and corrective
actions.

Audit of the formulation and scale weight
log.
Review of incident report.
Daily calibration of scales by quality
assurance.
HACCP coordinator will observe on-site
implementation on a periodic basis.

Tempering of frozen meat.
CCP-2B

Daily strip chart log from tempering room
temperature monitor. Tempering room
temperature log by quality assurance. Incident
report of deviations and corrective actions taken.

The plant HACCP coordinator will audit
the daily temperature logs and will calibrate
the thermometers on a periodic basis.
HACCP coordinator will review the
deviations and corrective actions and will
periodically observe implementation of
monitoring and records.

Receiving fresh meat and poultry
CCP-3B

Receiving log that includes the date, product,
producer, date of production, temperature of meat
and the organoleptic observations.
Incident report of deviations and corrective
actions taken.

The plant HACCP coordinator will audit
the daily receiving log. Thermometers will
be calibrated daily.
Plant HACCP coordinator will review the
log of deviations and corrective actions.
HACCP coordinator will perform periodic
onsite observations of records and
implementation.



27

Principles 6 and 7
Record Keeping and Verification

Product:

Process Step/CCP

Records

Verification
Procedures

Acid spraying/
cooking/
smoking
CCP-4B

Smokehouse log of product internal temperature.
Incident report of deviations and corrective
actions taken

HACCP coordinator will audit the daily
smokehouse log. Thermometers will be
calibrated daily. Plant HACCP coordinator
will review the log of deviations and
corrective actions. HACCP coordinator
will perform periodic on-site observations
of records and implementation.

Packaging
CCP-5P

Foreign material log that includes a description of
the metal or other foreign material found.
Incident report of deviations and corrective
actions.

Metal detector will be calibrated every shift
by quality assurance. HACCP coordinator
will review the log of foreign material and
the incident report of deviations and
corrective actions. HACCP coordinator
will perform periodic on-site observations
of records and implementation.


28

UNL

Process Category: Summer Sausage

Process Step

Hazard Description

CCP Description

Critical Limit

Monitoring
Procedures

Corrective Action/
Person Responsible

HACCP
Records

HACCP
Verification
Procedures

Scaling of restricted
non-meat ingredients


CCP-1B


B - Residual nitrite
provides control for
Colstridium
botulinum and
Listeria
monocytogenes


120 ppm or greater
nitrite added to the
product formulation.
The weight of cure
added will depend on
nitrite concentration
in cure.

Scale master for cure
ingredients will
weigh out the correct
weight for each batch
and check the weight
against the
formulation sheet.
Quality assurance
personnel will verify
the weight before
addition to the batch.

Curing ingredients
will be re weighed
and the amount
corrected as needed.

Formulation sheets
for each batch.
Scale weights for
cure.
Incident report forms
of deviations and
corrective actions.

Audit of the
formulation and scale
weight log.
Review of incident
report
Daily calibration of
scales by quality
assurance.
HACCP coordinator
will observe on-site
implementation on a
periodic basis.



























Scaling of restricted
non-meat ingredients
CCP-1C

C - Nitrite


C - Excessive levels
of nitrite may be
carcinogenic

156 ppm or less
nitrite added to the
product formulation.
The weight of cure
added will depend on
nitrite concentration
in cure.

Scale master for cure
ingredients will
weigh out the correct
weight for each batch
and check the weight
against the
formulation sheet.
Quality assurance
personnel will verify
the weight before
addition to the batch.

Curing ingredients
will be reweighed
and the amount
corrected as needed.

Formulation sheets
for each batch.
Scale weights for
cure.
Incident report forms
of deviations and
corrective actions.

Audit of the
formulation and scale
weight log.
Review of incident
report
Daily calibration of
scales by quality
assurance.
HACCP coordinator
will observe on-site
implementation on a
periodic basis.

Tempering of frozen

B - Pathogen

Pathogen growth if
i d

Less than 40F or

A thermometer with
d ill

Refrigeration will be
dj d d

Daily strip chart log
f i
The plant HACCP
di ill di


29

UNL

Process Category: Summer Sausage

Process Step

Hazard Description

CCP Description

Critical Limit

Monitoring
Procedures

Corrective Action/
Person Responsible

HACCP
Records

HACCP
Verification
Procedures
meat.
CCP-2B
time and temperature
are not controlled
plant established time
and temperature
requirements to
preclude the growth
of pathogens.
a recorder will
monitor the
tempering room on a
constant basis.
Tempering room
manager will monitor
the room temperature
twice per production
shift and verify this
reading with the
reading of the
recording
thermometer.
adjusted. Product
will be placed on
hold for further
evaluation of
significance.
Established
procedures will be
used for product
disposition.
from tempering room
temperature monitor.
Tempering room
temperature log by
quality assurance.
Incident report of
deviations and
corrective actions
taken.
coordinator will audit
the daily temperature
logs and will
calibrate the
thermometers on a
periodic basis.
HACCP coordinator
will review the
deviations and
corrective actions and
will periodically
observe
implementation of
monitoring and
records.

Receiving fresh meat
and poultry
CCP-3B

B - Pathogen

B - Raw meat is a
known source of
pathogen

Internal temperature
of fresh meat should
be less than 40F and
less than three days
from fabrication or
plants specifications
for product age.

Temperature of each
combo of fresh meat
will be checked by
the receiving clerk
using a calibrated
thermometer.
Product age and
organoleptic
evaluation will be
recorded.

Product will be
placed on hold by the
receiving clerk and
further evaluated by
quality assurance.
Quality assurance
personnel will either
reject the product or
conduct further
evaluations for
disposition of the
product.

Receiving log that
includes the date,
product, producer,
date of production,
temperature of meat
and the organoleptic
observations.
Incident report of
deviations and
corrective actions
taken.

The plant HACCP
coordinator will audit
the daily receiving
log. Thermometers
will be calibrated
daily.
Plant HACCP
coordinator will
review the log of
deviations and
corrective actions.
HACCP coordinator
will perform periodic
on-site observations
of records and
implementation.


Acid Spraying/
Cooking/
Smoking
CCP-4B

B - Pathogen

Improper cooking
Temperatures allow
growth of pathogen

Internal temperature
of the finished
product of 160F or
greater.

At the end of the
cooking cycle the
internal frankfurter
temperature will be
checked in three
separate house

Continue cooking
until frankfurters
reach 160F.

Smokehouse log of
product internal
temperature.
Incident report of
deviations and
corrective actions
HACCP coordinator
will audit the daily
smokehouse log.
Thermometers will
be calibrated daily.
Plant HACCP


30

UNL

Process Category: Summer Sausage

Process Step

Hazard Description

CCP Description

Critical Limit

Monitoring
Procedures

Corrective Action/
Person Responsible

HACCP
Records

HACCP
Verification
Procedures
locations for each
smokehouse batch.
Temperature will be
monitored with a
calibrated
thermometer by the
smokehouse operator.
taken coordinator will
review the log of
deviations and
corrective actions.
HACCP coordinator
will perform periodic
on-site observations
of records and
implementation.

Packaging
CCP-5P

P - Foreign material

Metal

No foreign material.
Metal detection set
for the maximum
sensitivity of the
metal detector

Each package will be
checked for metal by
an in-line metal
detector that will
automatically reject
packages. Visual
inspection for other
foreign material will
be preformed the
packaging operator
and periodically by
quality assurance
personnel.

Packages identified
to have foreign
material will be
reverified and if
possible the source of
foreign material
identified. Product
will be retained and
reworked or
discarded.

Foreign material log
that includes a
description of the
metal or other foreign
material found.
Incident report of
deviations and
corrective actions.

Metal detector will be
calibrated every shift
by quality assurance.
HACCP coordinator
will review the log of
foreign material and
the incident report of
deviations and
corrective actions.
HACCP coordinator
will perform periodic
on-site observations
of records and
implementation.


31
References

American Meat Institute Foundation. 1994. HACCP: The Hazard Analysis and Critical Control
Point System in the Meat and Poultry Industry. American Meat Institute Foundation.
Washington, D. C.

Bean, N. H. and Griffin, P. M. 1990. Foodborne disease outbreaks in the United States, 1973-1987:
Pathogens, vehicles, and trends. J. Food Protect. 53:804-817.

Bean, N. H. and Griffin, P. M. 1990. Foodborne disease outbreaks, 5-year summary. 1983-1987. J.
Food Protect. 53:711.

Bowen, V. G., Cerveny, J. G., and Deibel, R. H. 1974. Effect of Sodium Ascorbate and Sodium
Nitrite on Toxin Formation of Clostridium Botulinum in Wieners. Appl. Microbiol. 27,
605.

Bowen, V. G. and Deibel, R. H. 1974. Effects of Nitrite and Ascorbate on Botulinal Toxin
Formation in Wieners and Bacon. Proc. Meat Ind. Res. Conf. American Meat Institute,
Washington, D. C.

Council for Agricultural Science and Technology. Risks Associated with Foodborne Pathogens.
February, 1993.

Department of Agriculture, Food Safety and Inspection Service. 1996. Pathogen Reduction; Hazard
Analysis and Critical Control Point (HACCP) Systems; Final Rule. Federal Register, July
25, 1996. Vol. 61, No. 144, 38805.

Glass, K. A. and Doyle, M. P. 1989. Fate of Listeria monocytogenes in processed meat products
during refrigerated storage. Appl. Environ. Microbiol. 55, 1565-1569.

Grau, F. H. and Vanderline, P. B. 1992. Occurrence, numbers and growth of Listeria
monocytogenes on some vacuum packaged processed meats. J. Food Protection 55(1). 4.

Hustad, G. O. et al. 1973. Effect of sodium nitrite and sodium nitrate on botulinal toxin production
and nitrosamine formation in wieners. Appl. Microbiol. 26, 22.

International Commission on Microbiological Specification for Foods. 1989. Microorganisms in
Foods 4. Application of hazard analysis and critical control point (HACCP) system to ensure
microbiological safety and quality. Blackwell Scientific Publications, Boston.

Mortimore, Sara and Wallace, Carol. 1994. HACCP: A practical approach. Chapman & Hall.


National Advisory Committee on Microbiological Criteria for Foods (NACMCF). June 1993--


32
Report on Generic HACCP for Raw Beef. Food Micr. 10:449-488.

National Advisory Committee on Microbiological Criteria for Foods (NACMCF). March 20, 1992--
Hazard Analysis and Critical Control Point System. Int. J. Food Micr. 16:1-23.

Oblinger, J. L., ed. 1988. Bacteria associated with foodborne illnesses, a scientific status summary
by the institute of food technologists expert panel on food safety and nutrition. Food
Technol. 42(4).

Pierson, M. D. and Corlett, D. A., Jr. ed. 1992. HACCP/Principles and Applications. Van Nostrand
Reinhold.

Stevenson, K. E. ed. 1993. "HACCP-Establishing Hazard Analysis Critical Control Point
Programs." A Workshop Manual. The Food Processors Institute. Washington, D. C.

Todd, E. 1990. Epidemiology of Foodborne Illness: North America. The Lancet 336:788.

Tompkin, R. B. 1990. The use of HACCP in the production of meat and poultry products. J. of
Food Protect. 53(9): 795-803.

Tompkin, R. B. 1995. The use of HACCP for producing and distributing processed meat and
poultry products. In Advances in Meat Research. Volume 10. Hazard Analysis Critical
Control Point (HACCP) in Meat, Poultry, and Seafoods. Chapman & Hall (In Press).

United States Department of Agriculture, Food Safety and Inspection. 1986. Meat and Poultry
Inspection Regulations. July 1986. Washington, D. C. 20250



33
Critical Control Point Record
CCP# 1B, 1C
Nitrite Weight Log
Critical Limit: Acceptable level to maintain product safety as established by USDA regulations.
Corrective Actions: 1) Adjust to correct weight before nitrite enters the product, 2) Place
unacceptable product on hold and follow protocol for product disposition, 3) Evaluate cause
of deviation and take action to prevent further occurrence.




Date



Lot ID


Product
Batch Size

Nitrite
Required for
Batch Size

Actual
Nitrite
Weight


Deviation,
Corrective Action


Verification
(Initials)

QA
Supervisor
(Initials)

















































































































































































































































Reviewed by:



Date:




34
Critical Control Point Record
CCP# 2B
Receiving Log for Fresh Meat
Critical Limit: Acceptable level to maintain product safety as established by GMPs.
Corrective Actions:


Temperature of
Meat in Combo



Date



Time


Combo
Number

T
1


T
2


T
3



Product
Date



Organoleptic
Observations



Corrective Action


Verificatio
n (Initials)

























































































































































































































































































































Reviewed by:



Date:





35
Critical Control Point Record
CCP# 3B
Check Temperature Log Chart in Tempering Room
Critical Limit: Acceptable temperature to maintain product safety as established by GMPs.
Corrective Actions: Adjust temperature to acceptable level as established by GMPs.



Date


Time

Temperature
Recorded on Log


Corrective Action

Verification
(Initials)





















































































































































































Reviewed by:



Date:




36
Critical Control Point Record
CCP# 4B
Cooking Temperature Log
Critical Limit: Acceptable internal temperature of product to maintain product safety as established
by GMPs.
Corrective Actions: Adjust cooking temperature to acceptable level as established by GMPs.



Date


Time

Cooking
Temperature


Corrective Action

Verification
(Initials)

































































































































































Reviewed by:



Date:




37
Critical Control Point Record
CCP# 5P-1
Metal Detection Log
Critical Limit:
Corrective Actions:



Date


Time

Name of
Rejected Product

Source of
Contamination


Corrective Action

Verificatio
n (Initials)

























































































































































































































Reviewed by:



Date:




38
Critical Control Point Record
CCP# 5P-2
Calibration Metal Detecter Log
Critical Limit:
Corrective Actions:




Date



Time



Calibration



Corrective Action


Verificatio
n (Initials)

QA
Supervisor
Initials













































































































































































































Reviewed by:



Date: