Appendix 3 An Illustrated Example of A HACCP Plan - Processing Cooked Shrimp (See Chapter 3)
Appendix 3 An Illustrated Example of A HACCP Plan - Processing Cooked Shrimp (See Chapter 3)
Appendix 3 An Illustrated Example of A HACCP Plan - Processing Cooked Shrimp (See Chapter 3)
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Food Safety in Shrimp Processing
Laxman Kanduri, Ronald A. Eckhardt
Copyright © 2002 by Fishing News Books, a division of Blackwell Publishing
Appendix 3
An Illustrated Example of a HACCP
Plan – Processing Cooked Shrimp*
(See Chapter 3)
This is only a guideline. Depending on the size of the company, one person may actually be handling
more than one function.
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APPENDIX 3 131
Salt
Polyethylene bags
Potassium metabisulfite
Labels
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132 APPENDICES
CCP 1 8. Cooking
10. Cleaning
CCP 2
13. Glazing
14. Weighing/grading
15. Packaging
Master
Compressor– packaging
high pressure room
Packaging Shrimp processing Cook room
cleaning
room and 14. Sizing/ 11. 9.
weighing 12.
cleaning 15. Packaging 13. Brining 10. Cooling 8.
Freezing
agents (masters) Glazing and Cleaning and Cooking
(IQF) 6. Storage of unfrozen
storage draining peeling
shrimp
15. Packaging
(inners)
Storage
Vest
APPENDIX 3
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HAZARD ANALYSIS WORKSHEET (FORM #7)
134
1. Receipt of input Biological: Potential for incoming No Not reasonably likely to occur;
materials materials to be contaminated during controlled by SOP – receipt and
– packaging materials manufacture or transportation storage of packaging materials
– salt and ingredients
Chemical: Potential for incoming No Not reasonably likely to occur;
materials to be contaminated during controlled by SOP – receipt and
manufacture or transportation storage of packaging materials
and ingredients
Physical: Potential for incoming No Not reasonably likely to occur;
materials to be contaminated during controlled by SOP – receipt and
manufacture or transportation storage of packaging materials
and ingredients
2. Storage of input Biological: Potential for materials to No Not reasonably likely to occur;
APPENDICES
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3. Preparation of Biological: Water may be No Not reasonably likely to occur.
brine contaminated with pathogens Controlled through prerequisite
program
Chemical: Industrial chemicals No Not reasonably likely to occur.
Controlled by prerequisite
program through SOP for receipt
and storage of packaging material
and ingredients
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HAZARD ANALYSIS WORKSHEET (FORM #7) continued
136
5. De-icing and washing Biological: Contaminated wash water No Controlled by prerequisite programs
Chemical: Industrial chemicals No Controlled by prerequisite program
Physical: None identified n/a
6. Storage of unfrozen Biological: Contaminated ice No Controlled by prerequisite program
shrimp on ice (up to and water
2 days) Chemical: Industrial chemicals No Controlled by prerequisite program
Physical: Foreign material No Controlled by prerequisite program
7. Preparation of Biological: Contaminated wash water No Controlled by prerequisite program
shrimp for further Chemical: Industrial chemicals No Controlled by prerequisite program
processing (de-icing n/a
and washing) Physical: None identified
8. Cooking (steam) Biological: Pathogen survival Yes Pathogens that survive the cook will 1. Cooking
APPENDICES
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10. Cleaning Biological: Cross-contamination No Strict sanitation/hygiene controls
and recontamination with for the sanitary zone in prerequisite
pathogens programs will minimize contamination
Pathogen growth and toxin Yes The growth of Staphylococcus must Control process
formation (Staphylococcus) be controlled to prevent the speed to ensure a
formation of the Staphylococcus toxin rapid process (from
cooking to freezing)
Chemical: Industrial chemicals No Controlled by prerequisite program
Physical: Shell n/a Trained personnel in place to
remove undesirable pieces
11. Brining and Biological: Cross-contamination and No Minimized by prerequisite program
draining recontamination with pathogens and SOP for preparation of brine
Pathogen growth (Staphylococcus) Yes Prerequisite program minimizes Control process
contamination with this pathogen speed and ensure
but it will not prevent it entirely. no processing
The growth of Staphylococcus must delays
be controlled to prevent the
formation of the Staphylococcus toxin
APPENDIX 3
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138
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CCP DETERMINATION (FORM #8)
Q. #1
Do control
preventive
measures exist? Q. #2 Q. #3 Q. #4
No – not a CCP – Is the step specifically Could contamination Will a subsequent
However, designed to eliminate with identified hazards step eliminate
if control preventive or reduce the likely occur in excess of identified hazards or
measures are required occurrence of the acceptable levels or reduce the likely
to ensure safety then hazard to an could these increase occurrence to
modify step, product acceptable level? to unacceptable levels? an acceptable level?
or process. No – to Q. #3 No – not a CCP No – CCP CCP
Process step Hazard Yes – to Q. #2 Yes – CCP Yes – to Q. #4 Yes – not a CCP Yes or No
survival
(Listeria)
10. Cleaning Pathogen Yes No Yes No Yes
growth and
toxin formation
(Staphylococcus)
11. Brining Pathogen Yes No Yes No Yes
and growth and
draining toxin formation
(Staphylococcus)
139
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140 APPENDICES
CCP 1
8. Cooking Survival of Listeria Heat 2 min at Conveyor Conveyor
process 5D 100°C will belt speed speed with
Listeria provide stopwatch
reduction internal
product
temp. Temperature Recorder
of 80°C of cooker thermometer
for 1 s
Recorder Visual check
chart
CCP 2
10. Cleaning Growth of Rapid 3 h maximum Product Visual
Staphylococcus processing time exposure to observation
11. Brining time between elevated of index tag
and cooking and temperature
draining freezing between
cooking
and freezing
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APPENDIX 3 141
Corrective
action and
Frequency Who? Records records Verification