HACCP

Burjan Anca Diana – HACCP PLAN FOR OBTAINING THE SEMICURED MEAT PRODUCTS – ITALIAN SALAMI

CONTENT

1.CONSTITUTION AND ORGANIZATION OF THE HACCP TEAM..................................4

2. PRODUCT DESCRIPTION (product specifications)AND IDENTIFYING THE INTENDED USE........................................................................................................................5

2.1 ITALIAN SALAMI RECIPE:.........................................................................................5

2.2 ORGANOLEPTIC PARAMETERS STIPULATED BY STAS FOR SALAMI............8

2.3 PHISICAL AND CHEMICAL PARAMETERS STIPULATED BY STAS FOR SALAMI..................................................................................................................................9

2.4 MICROBIOLOGICAL PARAMETERS STIPULATED BY STAS FOR SALAMI......9

3. DEVELOPING OF THE FLOW CHART AND DESCRIBING THE PROCESS OF PRODUCT................................................................................................................................11

3.1 COOKING THE INTERMEDIATES AND PREPARATION OF COMPOSITION FOR ITALIAN SALAMI......................................................................................................12

3.2 FILLING THE CASINGS..............................................................................................12

3.3 FASTENING THE MEMBRANES................................................................................13

3.4. BARS MATURATION..................................................................................................13

3.5 ITALIAN SALAMI HEAT TREATMENT...................................................................13

3.6 STORAGE OF FINISHED PRODUCT.........................................................................13

4. HAZARD IDENTIFICATION.............................................................................................14

4.1 CIRCUMSCRIPTION OF RISK IN CLASSES.............................................................19

5. IDENTIFICATION OF CRITICAL CONTROL POINTS AND CRITICAL LIMITS.......22

5.1 Establishing the critical control points (CCP).................................................................25

6. MONITORING.....................................................................................................................26

7. ESTABLISHING CORRECTIVE ACTIONS.....................................................................29

7.1 CORRECTIVE ACTION PLAN....................................................................................29

7.2 CORRECTIVE ACTION - implementation and responsibilities...................................30

1


7.3 REGARDING THE PROCESSES, THEY MAY INCLUDE:.......................................32

8. CONCLUSIONS AND RECOMMENDATIONS...............................................................34

REFERENCES.........................................................................................................................36

A HACCP plan is not compiled to replace the current directives, or existing programs in

business. It should focus on preventing risks to public health protection, to minimize these

risks or, if possible, eliminate them.

2


A major problem that may occur in fod industry is when the compny seeks to include all the

standard working procedures in a HACCP plan.

A second major problem occurs when customers claim that all their requirements should be

included in the provider's HACCP plan.

In the EU companies and companies from other countries there are two key programs used in

the manufacture of meat products: codes of good working practices (GMP) and sanitation

programs. Both programs are part of any effective HACCP plan, but cannot substitute it.

Food safety policy (outlining the purpose)

Implementing a quality management system and implicitly a HACCP system requires, as a

first step, the policy of manufacturing quality formulation, defined as a guide indicating the

objectives to be achieved regarding the compliance of GMP, GHP and implementing a food

safety management system based on HACCP method.

The objectives of the quality policy must be realistic and measurable; among these, two are

fundamental:

- Changing the mentality (where applicable) of all members of that unit towards approaching

a quality management system, as the only way to survive in a market economy in transition,

with increasing competition;

- Continuous maintaining of attention on questions about quality, the only ones capable of

streamlininig the activity of the entire unit.

Through the policy a better involvement of people is attempted. Its role is that of restriction,

and also of indicating ways forward, to better understand quality issues.

The developed policy must be credible and made public once it has been established and

endorsed by the entire staff of the company, so that all customers and suppliers know: the

objectives to which it aims, the members of the company and the administration task

management.

1.CONSTITUTION AND ORGANIZATION OF THE HACCP TEAM

3


The HACCP team is the operational structure essential to implementation of the HACCP

system. It is necessary to create a multidisciplinary team composed of experienced specialists.

It brings together participants from a production unit who have acquired specific knowledge

and experience in quality control (General Manager, Quality Officer, Technical Experts,

craftsmen, laborers, etc.).

The team should consist of no more than 5-6 people, depending on your needs. The team

structure should be functional and absolutely non-hierarchical. The HACCP team will work

with field staff who will afterwards implement the HACCP system. The study’s value will

consist of full knowledge of the product, process and hazard under study.

The selected personnel must possess the basic knowledge of: tools (equipment used in the

production process), and practical aspects of the technological and maintenance operations,

the technological flow, the issues related to food microbiology, the HACCP principles and

techniques. Individuals from outside the company can be part of the HACCP team, if

necessary.

The team outline the purpose and the objectives of the HACCP study (analysis of a

production line and a product as well as considering a category of hazard), consider the

critical limits and specify this HACCP plan. The objectives should be clearly defined. It

should be set clear whether the HACCP plan is limited to customer safety (biological,

chemical or physical hazards) or includes other aspects of the finished product specification.

Necessary information (list of raw materials, flow chart, data on product / process) in this case

must be prepared before the study.

The technological process of semicured salami is similar to that of fresh salami except that

after boiling the product is cold smoked and only afterwards is stored. Different sorts of

salami products are distinguished by the proportion of different components and the way of

chopping.

2. PRODUCT DESCRIPTION (product specifications)AND IDENTIFYING THE INTENDED USE

4


2.1 ITALIAN SALAMI RECIPE:

ITALIAN SALAMI:

Raw materials:

- Second quality meat paste obtained by finely grinding fresh beef, used in the salami

preparation (bradt) (beef)

- Beef

- Pork

- Hard-bacon

Auxiliary materials:

- Pepper

- Allspice

- Garlic

- Muscarit

- Polyphosphate

- Sodium-ascorbate

- 60 mm-caliber artificial casing (cutisin)

-String or clips

In preparation of the meat paste obtained by finely grinding fresh beef, used in the salami

preparation (bradt), Polyphosphates and sodium ascorbate in the recipe can be replaced with

STARO P.

To get to the finished product, raw materials must pass through a series of technological

phases, which are presented below.

Reception and storage of meat and bacon

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Beef is received in forequarters and hindquarters. Depending on the temperature condition,

the beef used for the manufacturing of the Italian salami must be refrigerated. For meat

products manufacturing low-fat meat is recommended and for the manufacture of bradt the

use of young animals meat, especially steers is indicated.

The pork is received in half carcasses, without heads, fat, feet and organs. Half-carcases may

be received with or without bacon. The meat delivered by the slaughterhouse is dry and

refrigerated.

The bacon is received dry, chilled or salted and can be: soft, hard or semi-hard.

Cutting, boning and meat selection

Cutting is the process by which the quarter- and half-carcasses are divided into major

anatomical parts.

Deboning is the process in which the meat is taken off the bones. In Romanian this operation

is also called „ciontolire”.

The choice of meat is the process in which the meat is sorted by quality. By choosing the

meat, the hard connective tissue (tendons) is removed, as well as the aponeurosis, vascular

and nerve cords, cartilage, bone debris and parts of fat. During this operation the meat

portioning into smaller pieces (150-500g) and apportionment according to quality is done.

Cutting beef carcass is done in quarters: the anterior and posterior, which are divided into

anatomical sections.

Beef deboning should be done on each anatomical section. The meat is fully detached from

the bones.

Choosing the beef must correspond in the end to the category of meat without excessive fat.

In making the Italian salami second quality beef with 6-20% tissue content is used.

After cutting and deboning, the parts selected for the Italian salami come from the deboned

shoulder without bacon coverage, from the meatloaf and from trimming other anatomical

parts. The meat will be cut in pieces of around l00g without large connective tissue, without

blood clots, bones or rind. The fat content of pork should not exceed 35%.

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In making Italian salami hard bacon resulting from fat trimming of the different anatomical

regions is used.

Auxiliary materials:

- Pepper

- Allspice

- Garlic

- Muscarit

- Polyphosphate

- Sodium-ascorbate

- 60 mm-caliber artificial casing (cutisin)

-String or clips

Condiments are substances of plant origin used in weighted doses for enhancing preparations’

taste and smell. They come under different forms: fruit, flower buds, leaves, bulbs, bark,

roots, each with specific taste. Aromatic and taste properties are given by the essential oils

they contain. Because of their high content of bacteria, a careful microbiological examination

is necessary on their reception.

Water is used as auxiliary material for the manufacture of preparations and must meet the

sanitary conditions (colorless, odorless, tasteless).

Ice must be obtained from drinking water and must not contain impurities. It is prohibited to

use natural ice.

STAS parameters refer to the processed meat from the semicured-"Salami" group made of:

beef, pork, bacon, spices and additives in different proportions, according to the company

recipe, in compliance with sanitary and veterinary requirements in force.The products are

manufactured by hot smoking, boiling and cold smoking.

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2.2 ORGANOLEPTIC PARAMETERS STIPULATED BY STAS FOR SALAMI

Characteristics Admissibility Analysis method

Form Cylindrical bars of diameter

corresponding to the casing used.

STAS 11061/88.

Exterior appearance Clean, non-sticky surface, free from fatty

lumps on their heads and under the

casings. Continuous shell, undamaged and

adhesive to the composition, reddish

brown, specific to smoked products and to

their casings.

Appearance in the section Compact mosaic composition, without

foreign bodies or fatty lumps. Rare air

gaps of about 3 mm in diameter are

admited.

Taste and odor Specific to components and spices used,

without foreign taste and odor (sour,

rancid, of mold)

Consistency Elastic, specific to its range.

2.3 PHISICAL AND CHEMICAL PARAMETERS STIPULATED BY STAS FOR SALAMI

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2.4 MICROBIOLOGICAL PARAMETERS STIPULATED BY STAS FOR SALAMI


Coliform bacteria max/g 10 STAS 4831-92 sau

4832-92

Escherichia coli max/g 1 STAS 2356-82

Salmonella /25g absent STAS 2356-82

Coagulase-positive staphylococci

max/g

10 ISO 6882-92

Sulphite-reducing bacteria max/g 10 STAS 2356-82

Bacillus cereus max/g 10 STAS 2356-82

Physico-chemical and microbiological parameters described above are regulated by

Professional Standard 401-95.

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Water % max 60 STAS 9065/3-73

Fat % min-max 24-38 STAS 9065/2-73

Easily hydrolyzable nitrogen

(mgNH3/100g) max

45 STAS 9065/7-74

Sodium Chloride % max 3 STAS 9065/5-73

Total proteic substances % min 11 STAS 9065/4-81

Nitrite (NO2 mg/l00g) max 7 STAS 9065/9-74

Collagen % maximum of

protein total

20 STAS 9065/13-81


3. DEVELOPING OF THE FLOW CHART AND DESCRIBING THE

PROCESS OF PRODUCT TECHNOLOGICAL SCHEME TO SEMICURED

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3.1 COOKING THE INTERMEDIATES AND PREPARATION OF COMPOSITION FOR ITALIAN SALAMI

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Sausage meat

Preparation of meat paste

Storage for maturing

Composition preparation

Filling, tying

Warm smoking

Pasteurization

Cooling

Storing

Labeling

Delivering

Additives

Spices

Bacon

Preservation by salting

Storage for maturing

Chopping

Cold smoking

Drying

PCCC

CC

PCCC

CC

PCCC

CC

PCCC

CC

PCCC

CC

PCCC

CC

PCCC

CC

PCCC

CC

PCCC

CC

PCCC

CC

PCCC

CCPCCC

CCPCCC

CC


Preparation of the meat paste (bradt). The meat paste is a finely cutter minced paste, mixed

with water, and with a salting mixture (salt, nitrate and sodium nitrite) to form a thick paste of

meat-water, which is stored in the cold curing. Lately, the meat paste is made of cured grit.

Cured beef is chopped through a 3 mm sieve, then is cutter processed until a fine,

homogeneous paste is obtained. During cutter processing chilled water or ice is added in an

amount of 15 kg/100 kg of meat.

Grit preparation can be obtained through conservation, dry salting or preservation by wet

salting.

Through the preservation by dry salting, the grits are made from deboned and sorted meat cut

into pieces of 200-300g and mixed with curing mixture, including polyphosphates. After

mixing, groats are placed in trays or containers on wheels, which are maintained in the

refrigerator for 24-48 hours. To decrease the duration of maturation, that meat for the grout

should be chopped in Volf through vorschneider or, for the Italian salami, the beef (second

quality) through a 3 mm sieve and the pork and the bacon through 6 mm sieve.

Preparation of the composition:

Mixing of the components is made in the mixer, where the meat paste is added first, chilled

water to ensure the low temperature composition, then the pork and beef grout, the spices and,

eventually, the chopped bacon.

3.2 FILLING THE CASINGS

The casings are filled with a vacuum spritz that also seals the product with a clip. is for The

casings used for Italian salami have a diameter of 60 mm. When placed in the casings, the

composition should be well pressed to avoid air pockets.

3.3 FASTENING THE MEMBRANES

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After filling, the salami bars are fastened with string at their ends and air pockets are

removed.

3.4. BARS MATURATION

After the salami bars were fastened, they are clung to sticks and stored in refrigerators, for

curing, for about 24 h at a temperature of 2°-4° C.

3.5 ITALIAN SALAMI HEAT TREATMENT

- Consists of: hot smoking, boiling and cold smoking.

Hot smoking is made in cells and starts with a prior casing drying at 60-65° C for 25-30

minutes, then hot smoking is run at 75-95° C for 35-45 minutes until product surface becomes

of a brick red colour.

Boiling is done in smoking-boiling cells at a temperature of 72-75° C for 1-2 hours until the

geometric center of the bar reaches a temperature of 69-70° C.

Cold smoking is done in smoking cells with indirect fire or in smokehouses with a smoke

generator at temperatures between 30 and 40° C for about 20-120 minutes. For smoking, the

product is placed on sticks, leaving distance both between bars and between the sticks for the

smoke to penetrate the entire surface of the product. Then it is dried at 16-18° C, in cold dry

ventilated rooms to reduce the water content of the product.

3.6 STORAGE OF FINISHED PRODUCT

Italian salami bars are arranged on sticks and racks and stored in dry conditions with

temperatures of 10-12° C, relative humidity of 75-80%, good ventilation, little light. Their

shelf life is 15 days.

Upon completion of technologic process and during storage the product is labeled.

Delivery and transportation of the product is made according the standards.

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4. HAZARD IDENTIFICATION

Factors to be considered in hazard analysis are:

• intrinsic properties of the product during and after manufacture;

• technological processes;

• microbial content during and after manufacture;

• design and location of equipment;

• packaging procedures;

• cleaning and disinfection techniques;

• health, hygiene and training workers;

• delivery and storage of the product;

• the preparation and consumption;

• consumer practices.

For hazard analysis on meat products, information concerning returned products, and analysis

of epidemiological data are very useful.

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Natural hazards.

The main natural hazards are: glass, metal, bones, wood, plastic, rubber, stones, shot, syringe

needles and other foreign bodies that may harm consumers. These risks can be best prevented

by selecting suppliers on basis of existence of effective HACCP programs, by checking

incoming raw materials and by controlling manufacturing conditions.

Preventing contamination with glass begins by making use of protected windows and lighting

in the sections of manufacturing.

Bone fragments are an ongoing concern in meat products. For some products, their presence

can be minimized, but not prevented (chopped coarse products). An effective control program

must include tracking the trend of occurrence of defects of this nature and responsibility of

workers to decrease the percentage of defects.

The use of a facility that detects foreign particles that have a minimum size of 0.8 mm and

with which products can be tested for suspected physical hazards has recently been approved.

It is considered that particles with sizes below 0.8 mm do not present a danger to consumer

health.

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Chemical hazards.

A possible chemical risk is the excess of sodium nitrite, which comes from the misuse of

curing mixtures. This risk was recognized decades ago by the USDA, which established the

need of control to minimize it. Other potential risks are residues of pesticides, antibiotics,

sulfur drugs, washing and sanitizing agents, lubricants.

Mixing meat from different animal species may be a risk. One reason is that a small number

of consumers are allergic to meat from certain species of animals. Also, a beef product where

pork was in undue introduced, risks to not had been treated properly for the destruction of

parasites. Therefore, you should use effective methods to prevent errors in prescriptions and

manufacturing technologies or contamination with meat remaining in the facility on shift from

product to product manufacture.

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Biological hazards.

Biological risk classification was based on their severity. This classification forms the basis

for establishing sampling plans, whose severity increases with the severity of the risks

identified.

Bellow are listed risk categories for meat products:

• pathogenic bacteria in vegetative form, which may be present in raw materials and

ingredients which are destroyed during production. Since non-sporulated pathogenic bacteria

do not survive the technological process, it is not necessary to test raw materials and

ingredients in this respect;

• Bacteria spores that can survive processes that do not provide a sterilization step.

Refrigeration below 10˚ C prevents the development of these bacteria. We will always start

from the assumption that the product contains pathogenic bacteria, no matter how small the

probability of their existence and therefore refrigeration is essential for the safety of not

sterilized products;

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• pathogenic bacteria can recontaminate products after manufacture, before consumption.

These bacteria will be controlled by hygienic design of the company to minimize the risk of

cross contamination from raw materials to processed products, applying an effective

sanitation and adequate information or training of personnel involved in handling, storing and

distributing the product.

4.1 CIRCUMSCRIPTION OF RISK IN CLASSES

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Stage Danger(s) Preventive / control measures

Type CR (=class of risk)

1.

Reception

Biological

3

- selecting suppliers

- pathogenic microorganisms

- health certificate

- GMP, GHP

- Personnel trainingChemical

3


- mycotoxins - analysis bulletins

-antibiotics and hormones

- health certificate

- pesticide residues - Personnel training

Physical

2


- foreign bodies - Personnel training- hairs - GMP- insects

2. Storage Biological3

- GMP, GHP- pathogenic microorganisms

- monitoring environmental parameters

Chemical2

- equipment maintenance - cooling agent - Personnel training

3. Sorting (Cutting)

Biological

3



- Personnel training - sanitation testsChemical

2

- GHP- detergent residues - Personnel training - pH testsPhysical

2

- GMP- insects - pest control - personnel items - personnel training- wood chips

4. Chopping

Biological

3

- personnel training- pathogenic microorganisms

- GHP, GMP

- temperature monitoring - sanitation testsChemical 2 - GHP

19


- detergent residues - alkalinity tests - personnel trainingPhysical

1

- GMP- insects - personnel training- personnel items - visual control - packing fragments - pest control

5. Dozare aditivi

Biological3

- GHP- pathogenic microorganisms

- personnel training

Chemical

3

- GMP- excessive additives - personnel training - metrological verification

Physical

1

- GMP- packing fragments - personnel training- insects - GHP - visual control

6.Malaxare Biological

3

- GHP, GMP- pathogenic microorganisms


- process monitoring

Chemical

2

- GHP- detergent residues - alkalinity tests - personnel training

Physical

2

- GMP, GHP- rubber gaskets - visual control - foreign bodies - equipment maintenance

7. Maturare

Biological

3



- compliance with process parameters

Chemical2

- GHP- detergent residues - alkalinity tests - personnel trainingPhysical

2- GMP

- insects - personnel training- personnel items - pest control

8. Umplere Biological

3



- compliance with process parameters

Chemical 2 - GHP- detergent residues - alkalinity tests - personnel training

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Physical

2

- GMP- insects - personnel training- personnel items - pest control

9. Răcire Biological

3



- compliance with process parametersChemical

2- GMP

- cooling agent - equipment maintenance - personnel trainingPhysical

1- GHP, GMP

- insects - pest control - dust

10. Depozitare

Biological

3




Chemical

2

- GMP- cooling agent - equipment maintenance - personnel training

Physical

1

- GHP, GMP- insects - personnel training- dust - pest control

11. Livrare Biological

3


- means of de transport temperature

- means of de transport hygiene - visual control - personnel training

5. IDENTIFICATION OF CRITICAL CONTROL POINTS AND CRITICAL LIMITS

Reception and preparation of raw materials.

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The mix composition (CCP2)

The preparatory operations category includes: boning, weighing, chopping, mixing, curing,

mixtures preparation etc. Physical and chemical risks are of major concern during these

operations.

Potential chemical hazards are adding an excess of sodium nitrite and mixing meat from

different animal species (where this is not provided for in the recipe).

Physical risks that can occur are bone fragments, metal, glass and other foreign materials.

These natural hazards are best controlled by purchasing ingredients from suppliers who have

implemented an efficient HACCP system and by monitoring incoming ingredients. The

degree of monitoring should reflect the type of risk, the level of risk for each ingredient and

the confidence in the effectiveness of the providers’ HACCP system.

Industrial procedures of reception and storage of fresh meat should not allow losing control of

biological risks. In addition, common procedures used to defrost the meat do not raise the

level of biological risk to an unacceptable value. The mistakes occured during storage and

thawing raw meat will have a greater influence on technological quality and possibly on

alteration rather than on the safety of the product.

Other ingredients used in meat production are rarely a source of biological hazards for the

manufactured products. The exceptions are spices that are added after the heat treatment and

can be a source of contamination. This risk can be controlled by applying some treatments

(radiation) on spices.

The cleanliness of the facilities and the environment where the raw meat is stored and the

composition is prepared is important, but not a real threat to the safety of products, if cleaning

programs are seriously developed and appropriately applied.

Heat treatment (CCP1)

There are many variants of heat treatments used in the manufacture of meat products: heating

in water bath, boiling, frying in oil, pasteurization, sterilization, hot smoking. Products may

be subjected to heat treatment in plastic bags or bowls, boxes, casing, shapes and special

trays.

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The heat treatment method used influences the speed of penetration of heat and uniformity of

heating. Heat treatment process must be controlled to achieve two objectives:

1. Preventing the excessive multiplication of microorganisms during heating, prior to reaching

lethal temperatures. Pathogenic bacteria can multiply during very slow heating in the

temperature range between 10˚ C and 52˚ C. Theoretically, this could result in the production

and accumulation of thermostable toxin. When lethal temperature is reached, vegetative cells

are destroyed. The risk of occurence and accumulation of toxins is very low, but must be

taken into account. Another problem is dehydration during the initial phase of warming,

particularly on the surface of products not covered tightly. Reduction of water activity on the

surface of the product may increase heat resistance and prompt survival of pathogenic

bacteria.

2. Obtaining the minimum internal temperature throughout the product, which requires the

maintenance of the product to a minimum internal temperature for a given time. This is the

easiest way to achieve microbiological safety of products.

As ready for on establishing the heat treatment regime, data on Salmonella and Listeria

monocytogenes will be taken into account.

Cooling (CCP2)

Cooling is required as a further thermal treatment process. On the other hand, cooling is very

important to control the multiplication of microorganisms and the germination of spores that

survived the heat treatment. The cooling rate is very important: from 52˚ C to 20˚ C. Under

20˚ C, pathogenic sporulated mesophilic bacteria that might be present in meat products

multiply slowly, and below 10˚ C multiplication ceases.

Cooling can be done in several ways: with water, water bath or ice-water bath, cold air,

carbon dioxide or liquid nitrogen. The product can be placed on grills, on conveyor belts or

immersed in water. The vacuum packed products must be refrigerated before packing to

prevent peeling and wrinkling of the foil. During cooling operation, and possibly during

portioning and packaging, the product is exposed to potential contamination. A general

problem is condensation, which can be a source of microbial contamination of cooling

products.

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Contamination caused by cooling water quality is a problem, but not for the consumption

safety of products sold in refrigerated or frozen state because the contamination

microorganisms can not grow.

Packaging (CCP2)

The meat is placed in crates or boxes for storage and subsequent delivery. Risk of

contamination with pathogenic microorganisms is controlled by the application of

environmental sanitation programs, and by training the workers. Coding and labeling of these

products is a checkpoint, because it is essential both for monitoring, and for verification of

product recast.

Storage and delivery (CCP2)

Ready for consumption meat products, being perishable, will be stored and delivered to more

than 5˚ C. Microbiological changes occurring on these products during storage and delivery

are influenced by several factors: ingredients, heating, cooling, product composition,

packaging, contamination after heat treatment. Biological risks are caused by the combined

effects of these factors and by the storage and delivery conditions.

5.1 Establishing the critical control points (CCP).

Process

phase

Important danger Questions from the decisional tree CCP/

CP

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CR Q1 Q2 Q3 Q4

1. Reception B - pathogenic microorganisms 3 YES NO YES YES CP1

C – mycotoxins, antibiotics

and hormons

3 YES YES - - CCP1

2. Storage B - pathogenic microorganisms 3 YES YES - - CCP2

3. Sorting

(Cutting)

B - pathogenic microorganisms 3 YES NO YES YES CP3

4. Chopping B - pathogenic microorganisms 3 YES NO YES YES CP4

5. Additive

dosing

B - pathogenic microorganisms

(personnel)

3 YES NO YES YES CP5

C – excess additives 3 YES YES - - CCP3

6. Mixing B - pathogenic microorganisms 3 YES NO YES YES CP6

7. Curing B - pathogenic microorganisms 3 YES NO YES YES CP7

8. Filling B - pathogenic microorganisms 3 YES NO YES YES CP9

9. Cooling B - pathogenic microorganisms 3 YES YES - - CCP5

10. Storage B - pathogenic microorganisms 3 YES YES - - CCP6

11. Delivery B - pathogenic microorganisms 3 YES NO NO - CP10

6. MONITORING

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Monitoring should be based on quick measurements, in order to correct in due time errors

occurred without compromising consumption safety of finished products. Monitoring

methods used are:

• visual observation;

• temperature measurement;

• duration measurement;

• pH measurement;

• humidity measurement.

Continuous monitoring would be ideal, coupled with automatic correction of manufacturing

conditions. If a continuous monitoring is not possible, frequency of monitoring should be

determined on a statistical basis.

HACCP system efficiency depends on the tools’ precision and training of the workers

involved in monitoring. They must:

• understand the purpose of each stage in the process;

• understand the importance of monitoring this phase;

• to know their responsibility regarding the control of a certain stage;

• realize that the consumption safety of the products depends on their work.

The activity of the workers involved in monitoring is checked by the staff responsible with

HACCP system evaluation.

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Monitorizarea CCP-urilor plan flux de control HACCP

Stage Important danger (s)

Control measures CCP/CP (no.)

Critical limits Monitoring procedures Corrective actions

Documents/Records

Corrective actions official

Official Method Rate

Reception

- mycotoxins, antibiotics and hormones

- veterinary certificate

- analysis report

CCP1 - according to. OMS 975/1998 and specific legislation

- Front panel Head

- documents control

- every reception

- batch rejection;

- suppliers selection;

- Personnel training

reception records

- Production Director

- Supply Chief

Meat storage



CCP 2 - temp. X

- humidity Y

- period Z

- administrator

- computer records

- continuous - transfer to another location;

- maintenance;


storage document


- mechanic

- administrator

Additives dosation

- excessive additives

- correct weighing CCP 3 - according to recipe

- operator - quantitative (physical)

- on every charge

- batch rejection;

- Mixing with another batch;

-

Production report

- Department Head

- responsabil DMM-uri

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metrological verification;


Cooling - pathogenic microorganisms


CCP 5 - temp. X

- humidity Y

- period Z

- operator - computer records


- maintenance;


Cooling document

- operator

- mechanic


Storing final product



CCP 6 - temp. X

- humidity Y

- period Z

- administrator

- computer records


- maintenance;


- urgent delivery

storage document

- administrator

- mechanic


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7. ESTABLISHING CORRECTIVE ACTIONS

Assigning responsibility to a specific operator for each CCP, for monitoring CCP parameters

involves at the same time identifying the person who will implement corrective actions when

the tend to overcome the critical limits manifests or when they are exceeded. In addition, have

a corrective action plan should be prepared for each CCP, an activity which is the

responsibility of the HACCP team.

7.1 CORRECTIVE ACTION PLAN

A deviation in a CCP is defined as a failure of observing the established critical limits.

Corrective action plan is a series of predetermined and documented interventions that will be

adopted when there is an excess of these critical limits. Early defining of corrective actions,

ensures rational and weighted decisions, excluding improvisations generated by emergency

that could prove more damaging, even if they seem to offer immediate benefits.

The objectives underlying the determination of corrective actions are as follows:

identifying the destination of the products manufactured in the period the deviation appeared,

ie, when the CCP was out of control. This is in fact "correction";

identifying the causes of deviation and correcting them to restore control of the CCP, ie

"corrective action" itself;

obtaining and maintaining records of actions taken;

In general, the CCP monitoring parameters of a process can highlight two different situations:

the tendency of a given parameter characteristic of the CCP to exceed the specified critical

limits or even actually overcoming of these limits. Activities conducted in the two cases are

obviously different: the first is to adopt corrective "intervention" to take appropriate control of

the CCP, before the danger becomes real; in the second case, however, it is necessary to take

such corrective action so that the CCP be brought under control and to take measures for the

product obtained under conditions of lack of safety.

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Thus, the HACCP team has the task to distinguish and describe a series of corrective actions

for the development of an intervention plan, applicable in due time when deviations occur in

any of the CCP identified on the production flow.

It is necessary that this plan include:

- Designation of responsibility for corrective action;

- Description of the means to use and the instruction to follow for correcting the occured

deviation;

- Correction made for the products obtained when the CCP was out of control (the destination

of these products);

- Recording the correction and the corrective actions taken.

7.2 CORRECTIVE ACTION - implementation and responsibilities

The person responsible for implementing corrective action usually coincides with that which

is monitoring. This person establishes that the requirements the first person has to meet also

stand for the second person.

Thus, training must provide the abilities to act promptly to adopt, from the range of corrective

actions, the ones appropriate to the manifested deviation and to apply all the pre-established

procedures.

The HACCP team must have a procedure of recording all manifested deviations on the

production flow and corrective actions to fix it.

This documentation is part of the HACCP Plan and must be maintained in the unit at least as

long as the product shelf life.

7.1 Establishing verification procedures

The HACCP team, through the activities undertaken so far on the HACCP plan has identified

all hazards associated with the process / product under discussion, has led the CCP,

established critical limits for each parameter characteristic of the CCP, completed the system

of monitoring and the corrective action to restore control CCP. Moreover, the guarantee of

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correct operation of the HACCP system can be given by defining an appropriate verification

procedure that will include: validation and internal audit.

Verification is first conducted on HACCP system implemention, along with the HACCP plan

validation. Validation is also required after any revision.

Verification is represented by all methods, procedures and tests used in addition to monitoring

to assess compliance of HACCP System and HACCP Plan established by the team. More

specifically, the objectives pursued by the HACCP team in this process are mainly the

following:

- Evaluation of the critical limits established for each CCP, through processes and methods of

scientific and technical nature;

- Confirmation of corrective action set for any deviations that occurred in the CCP;

- Ensuring the effective functioning of the HACCP Plan developed for the process / product

being studied, which means ensuring that all operations to be performed for the proper

functioning of the Plan and related activities are and continue to be fulfilled in an appropriate

manner.

The most difficult task falls on HACCP team especially on the first two objectives: in most

cases the problem of verifying the validity of critical limits and corrective actions related to

each CCP, calls for studies and analysis conducted by specialists with experience in various

sectors. Moreover, this phase is of fundamental importance for ensuring that identified

hazards are effectively controlled.

HACCP team is responsible of specifying what methods and procedures will be followed to

achieve the objectives mentioned earlier, frequency and responsibilities agreed. The following

are among the applicable methods:

- Taking samples for analysis (during the production flow or even on final product)

- Comments and analysis related to those critical points that have a major impact on product

safety;

-Analysis of raw materials to verify compliance with the data in accompanying documents;

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- Verification of the storage conditions, distribution and sale of final product and of the actual

use by consumers etc.

7.3 REGARDING THE PROCESSES, THEY MAY INCLUDE:

- inspections concerning the modality of conducting the operations;

- Assessment of the monitoring system;

- Validation of critical limits;

- Assessment of deviations and interventions implemented where the tendancy of overcoming

the critical limits manifests;

- Verification of document records made in the CCP relating to previous inspections;

- Certifying compliance of the HACCP Plan checks;

- thorough examination of the conducted HACCP Plan, etc.

Establishing documentation and records

Application of HACCP System, calls, on the one hand, the availability of adequate and

accurate data, and, on the other hand, keeping such documents.

Documentation Management

The fundamental objectives underlying this stage are:

- Preparing and maintaining the HACCP plan, generally in the form of a written document;

- Keep all records and documents resulting from the application of HACCP system within the

company.

The existence of a records storage system leads to satisfying one of the most important

requirements of the system: "traceability." All the entries, which in fact demonstrate how the

system works, represent the posibility of reconstruction the path followed by a product at any

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stage of manufacture. Thus, on verifying the functionality, the records represent the basic

elements.

Covering the steps to implement the HACCP system from the Product Description to the

Corrective Actions, is in fact obtaining the HACCP Study. This study ends with the HACCP

Plan, the basic document of this system.

The structure of a HACCP Plan is usually the following:

Stage of the

production

flow

Major

Risk

Control

Measures

CCP/AP

No.

Critical

limits

Monitoring Corrective

Actions

Records Responsible

for

corrective

actions

Responsible. Method Rate

The HACCP plan must contain all data on the hazards identified for each process / product or

product category, all the information leading to the identification of a monitoring system,

corrective actions and documents related to registration.

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8. CONCLUSIONS AND RECOMMENDATIONS

CONCLUSIONS

After implementing the HACCP plan on the quality of casing meat preparations (Italian

salami) and for a more effective operation, the following conclusions can be drawn:

• raw and auxiliary materials used to obtain the casing meat preparations (Italian salami),

should correspond to organoleptic and physico-chemical aspect.

• Final products should meet the organoleptic standards, except a small number where some

defects on casing (wrinkled appearance) were found.

• raw and auxiliary materials used in the production flow should be of high-quality, which can

prevent the emergence of defects in freshness, the finished product falling, from the freshness

point of view, under the category of fresh products, and could be put into use in all situations;

Samples examined should be within the parameters stipulated by STAS.

RECOMMENDATIONS

In order to improve the quality of meat products in terms of integrity and hygiene quality it is

recommended:

• Introducing in technology only batches of meat and fat categorized as fresh meat and fat and

prohibition of using relative fresh meat and fat or with its shelf life exceeded;

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• Observance of recipes on the manufacturing technological flow, of technological processing

parameters, of storage and delivery conditions, so as to avoid the possibility of technological

and freshness defects to finished products;

• Regularly checking the water quality used in technology, facilities, equipment and workers

hygiene, and decontaminating efficiency of the washing and disinfection substances used in

cleaning the unit;

• Complying with the microclimate of the raw materials storage areas, depending on their

thermal state, in cutting rooms, maturation of the semi-products, manufacturing and storage

areas for finished products until their delivery;

• Always check the operating mode of the equipment, especially the chopping equipment and

the spritzes;

• Checking the quality of each meat poduct batch prepared by laboratory tests (organoleptic,

physico-chemical and microbiological) to determine compliance with the parameters

stipulated by STAS.

A final and very important recommendation:

Write what you do and do just what you wrote.

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REFERENCES

1. BANU, C., ş.a. – Manualul inginerului de industrie alimentară, Vol I, II, Editura

Tehnică Bucureşti, 2002

2. BANU, C., ş.a. – Calitatea şi controlul calităţii produselor alimentare, Editura Agir,

Bucureşti, 2002

3. BANU, C., Procesarea industrial a cărnii, Editura Tehnică, Bucureşti, 2003;

4. GEORGESCU, Gh.; coordonator Banu, C., Tratat de producerea, procesarea si

valorificarea carnii, Editura Ceres, Bucuresti, 2000;

5. IURCA, Ionel Mircea, Ghid practic de tehnologia carnii si produselor din carne, Editura

ICPIAF, Cluj-Napoca, 2001;

6. LASZLO, C. – Controlul calităţii cărnii şi a produselor din carne, Editura Icpiaf, Cluj

Napoca, 1997;

7.LASZLO, C. – Controlul calităţii şi igiena produselor alimentare de origine animală,

Editura Risoprint, Cluj-Napoca, 2008;

8. LASZLO, C., ş.a Examenul de laborator al produselor alimentare de origine animala,

Editura AcademicPres, Cluj-Napoca, 2008;

9. ROTH, I., Ghid practica de la A la Z pentru fabricarea preparatelor din carne, Editura

IofoMega, 2004;

10. SĂLĂGEAN, C., Producţia,prelucrarea şi conservarea cărnii de pasăre şi de alte animale,

Editura AcademicPres, Cluj-Napoca, 2003

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11. ŢIBULCĂ, D., ş.a. – Tehnologia cărnii şi a produselor din carne, Vol II, Editura

Risoprint, Cluj Napoca, 1997;

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