Heat Treated, Shelf-Stable:Jerky Product HACCP Plan

Rosenthal Meat Science and Technology CenterDepartment of Animal Science

Texas A&M UniversityCollege Station, Texas

January 6, 2000

Signature Page

Heat Treated, Shelf-Stable:Jerky Product

Signature:_______________________________________________ _______________

Jeff W. Savell, HACCP Coordinator DateDepartment of Animal ScienceTexas A&M UniversityCollege Station, Texas 77843-2471Telephone: 409-845-3935E-mail: j-savell@tamu.eduWeb Site: http://meat.tamu.edu/

Member Telephone Number

Dr. Gary Acuff, Professor 409-845-4425

Ivan Brigman, Graduate Student 409-845-3957

Darrell Demel, Meat Lab Foreman 409-845-5651

Mike De La Zerda, Graduate Student 409-845-3957

Dr. Davey Griffin, Associate Professor 409-845-0435

Dr. Dan Hale, Professor 409-845-0435

Dr. Kerri B. Harris 409-862-3643

Dr. Jimmy Keeton, Professor 409-845-3936

Lisa Lucia, Research Assistant 409-845-4449

Rob Maddock, Graduate Student 409-845-3957

Misty Pfeiffer, Communication Specialist 409-862-2036

Ray Riley, RMSTC Manager 409-845-5651

Dr. Jeff Savell, Professor 409-845-3935

Heat Treated, Shelf Stable: Jerky Product

January 6, 2000 Version

HACCP Plan SummaryHeat Treated, Shelf-Stable: Jerky Product

Monitoring

CCP Hazard Critical Limits What How Frequency Who Corrective Actions1 Verification2 Records

CCP 1BColdStorage

Pathogens ≤45° F Producttemperature

RoomTemperature

TemperatureMonitoringDevice

Daily Cooleroperator

1. Identify and eliminatecause of deviation.

2. Bring the CCP undercontrol aftercorrective action istaken.

3. Measures to preventrecurrence areestablished.

4. No product that isinjurious to health oradulterated enterscommerce.

Weekly internalproduct temperaturein cooler.

Plant manager ordesignee will reviewcooler charts.

Weekly calibrationand/or verification oftemperaturemonitoring device byplant manager ordesignee.

ProductTemperatureVerification Log

Cooler Chart

Deviation/Corrective ActionLog

TemperatureMonitoringDeviceCalibration and/orVerification Log

CCP 2BHeatTreatment

Pathogens SmokehouseTemperature/Time,FSIS Directive 7110.3142° F 8 min.141° F 10 min.140° F 12 min.139° F 15 min.138° F 19 min.137° F 24 min.136° F 32 min.135° F 37 min.134° F 47 min.133° F 62 min.132° F 77 min.131° F 97 min.130° F 121 min.

Temperatureof theSmokehouse

Time atspecifiedtemperature

TemperatureMonitoringDevice

TemperatureMonitoringDevice

Continuous

Continuous

Smoke-houseoperator

Smoke-houseoperator

1. Identify and eliminatecause of deviation.

2. Bring the CCP undercontrol aftercorrective action istaken.

3. Measures to preventrecurrence areestablished.

4. No product that isinjurious to health oradulterated enterscommerce.

Visual observation ofmonitoring activity byplant manager ordesignee.

Weekly calibrationand/or verification oftemperaturemonitoring device byplant manager ordesignee.

On days of jerkymanufacturing, plantmanager or designeewill review records.

Temperature/TimeLog

Heating Chart

Deviation/Corrective ActionLog

TemperatureMonitoringDeviceCalibration and/orVerification Log

1 Plant manager or designee is responsible for performing corrective actions to ensure appropriate corrective actions are taken.2 Direct observation of corrective action by plant manager or designee will be conducted when a deviation is found during the pre-shipment record review.

January 6, 2000 Version

PRODUCT DESCRIPTION

COMPANY NAME: Rosenthal Meat Science and Technology Center

PRODUCT NAME:

PRODUCT DESCRIPTION:Cured, peppered, smoked and dried beef product

INTENDED USE OF PRODUCT?Retail sales for general public consumption

TYPE OF PACKAGE?Poly-lined boxes for bulk storageLaminated plastic bag, sealed without vacuuming, for retail

WHERE WILL IT BE SOLD?Retail sales area.

LABELING INSTRUCTIONS:Not applicable

DISTRIBUTION METHOD?Not applicable

January 6, 2000 Version

PRODUCTS/INGREDIENTS USED TO PRODUCE PRODUCT:

MEAT/POULTRY ANDBYPRODUCTS

NONMEAT FOODINGREDIENTS

BINDERS/EXTENDERS

Beef rounds

SPICES/FLAVORINGS RESTRICTEDINGREDIENTS

PRESERVATIVES/ACIDIFIERS

PepperSaltHydrolyzed Vegetable ProteinHickory Smoked Flavor

Prague Powder (6.25%Sodium Nitrite)

OTHER

Potable waterPackaging materials

Loading Truck

Heat Treatment

Cutting/Sizing

Rosenthal Meat Science and Technology CenterHeat Treated, Shelf-Stable: Jerky Flow Chart

Packaging

Storage

Distribution

Peppering, ifapplicable

Receiving• Packaging• Labels• Boxing

Storage

ReceivingNon-meatIngredients

Storage

Curing

ReceivingMeat

Brine Mixing

Slicing

(CCP 2B)

January 6, 2000 Version

Cold Storage (CCP 1B)

Heat Treated, Shelf Stable: Jerky Product

January 6, 2000 Version

Heat Treated, Shelf Stable: Jerky Product Hazard Analysis

Ingredient/ProcessStep

Potential hazardintroduced, controlled,enhanced or reduced at thisstep

Is the potentialfood safetyhazardsignificant?(Risk:Severity)

Justification for decision What controlmeasures can beapplied to preventthe significanthazard(s)?

Is this stepa criticalcontrolpoint(CCP)?

ReceivingMeat

Physical:BuckshotPlastic

Chemical:Antibiotic residuesPesticidesGrowth promotants

Biological:Enteric pathogens (i.e.Salmonella, Campylobacter,and verotoxigenic E. coli)and Listeria monocytogenes

No

No

Yes

Unlikely to occur. No reported incidences ofthese hazards have been made at this facility fromJan. 1, 1998 to Jan. 6, 2000.

Unlikely to occur. USDA Residue MonitoringProgram indicates that the great majority oflivestock are free of violative residues whenslaughtered in inspected facilities. Any animalused for research involving chemical exposure willfollow protocol for proper use.

Raw meat is a potential source of entericpathogens.

Eliminated bythermal destructionlater in the process.

No

ColdStorage ofMeat

Physical:None identified at this time.

Chemical:None identified at this time.

Biological:Potential pathogen growth.

No

Yes

Unlikely to occur. No reported incidences ofthese hazards have been made at this facility fromJan. 1, 1998 to Jan. 6, 2000.

Improper storage temperatures could result inpathogen growth

Cold storage Yes

Heat Treated, Shelf Stable: Jerky Product

January 6, 2000 Version

Ingredient/ProcessStep

Potential hazardintroduced, controlled,enhanced or reduced at thisstep

Is the potentialfood safetyhazardsignificant?(Risk:Severity)

Justification for decision What controlmeasures can beapplied to preventthe significanthazard(s)?

Is this stepa criticalcontrolpoint(CCP)?

Slicing

Physical:Metal fragments, knife bladetips, saw blades and plastic

Chemical:Sanitizers and lubricants.

Biological:None identified at this time.

No

No

Unlikely to occur. No reported incidences ofthese hazards have been made at this facility fromJan. 1, 1998 to Jan. 6, 2000.

Unlikely to occur. SSOPs address the proper useof sanitizers and lubricants are food-grade.

Curing

Physical:None identified at this time.

Chemical:None identified at this time.

Biological:None identified at this time.

Peppering

Physical:None identified at this time.

Chemical:None identified at this time.

Biological:None identified at this time.

Heat Treated, Shelf Stable: Jerky Product

January 6, 2000 Version

Ingredient/ProcessStep

Potential hazardintroduced, controlled,enhanced or reduced at thisstep

Is the potentialfood safetyhazardsignificant?(Risk:Severity)

Justification for decision What controlmeasures can beapplied to preventthe significanthazard(s)?

Is this stepa criticalcontrolpoint(CCP)?

LoadingTruck

Physical:None identified at this time.

Chemical:None identified at this time.

Biological:None identified at this time.

HeatTreatment

Physical:None identified at this time.

Chemical:None identified at this time.

Biological:Pathogens

Yes Thermal destruction of vegetative pathogens atspecified temperature and time.

Heat treatment. Yes

Cutting /Sizing

Physical:Saw bladesPlastic

Chemical:None identified at this time.

Biological:Staphylococcus aureus,Listeria monocytogenes

No

No

Unlikely to occur. No reported incidences ofthese hazards have been made at this facility fromJan. 1, 1998 to Jan. 6, 2000.

Low water activity of product will control growthof pathogens to prevent increase to toxic levels.

Heat Treated, Shelf Stable: Jerky Product

January 6, 2000 Version

Ingredient/ProcessStep

Potential hazardintroduced, controlled,enhanced or reduced at thisstep

Is the potentialfood safetyhazardsignificant?(Risk:Severity)

Justification for decision What controlmeasures can beapplied to preventthe significanthazard(s)?

Is this stepa criticalcontrolpoint(CCP)?

Packaging

Physical:None identified at this time.

Chemical:None identified at this time.

Biological:None identified at this time.

Storage

Physical:None identified at this time.

Chemical:None identified at this time.

Biological:None identified at this time.

Distribution

Physical:None identified at this time.

Chemical:None identified at this time.

Biological:None identified at this time.

Heat Treated, Shelf Stable: Jerky Product

January 6, 2000 Version

Ingredient/ProcessStep

Potential hazardintroduced, controlled,enhanced or reduced at thisstep

Is the potentialfood safetyhazardsignificant?(Risk:Severity)

Justification for decision What controlmeasures can beapplied to preventthe significanthazard(s)?

Is this stepa criticalcontrolpoint(CCP)?

ReceivingNon-meatIngredients

Physical:Metal fragments, woodsplinters, and plastic

Chemical:Chemical contaminants inseasoning

Biological:Pathogens

No

No

No

Unlikely to occur. No reported incidences ofthese hazards have been made at this facility fromJan. 1, 1998 to Jan. 6, 2000.

Letters of guarantee from seasoningmanufacturers on file.

Letter of guarantee for irradiation or fumigationof seasonings.

Storage ofSeasonings

Physical:None identified at this time.

Chemical:Pesticides

Biological:None identified at this time.

No Only food-grade approved pesticides are used inthe facility.

BrineMixing

Physical:None identified at this time.

Chemical:Sodium Nitrite

Biological:None identified at this time.

No Brine mixing SOP in place to assure propersodium nitrite use.

Heat Treated, Shelf Stable: Jerky Product

January 6, 2000 Version

Ingredient/ProcessStep

Potential hazardintroduced, controlled,enhanced or reduced at thisstep

Is the potentialfood safetyhazardsignificant?(Risk:Severity)

Justification for decision What controlmeasures can beapplied to preventthe significanthazard(s)?

Is this stepa criticalcontrolpoint(CCP)?

ReceivingPackaging,Labels andBoxingMaterials

Physical:None identified at this time.

Chemical:Deleterious chemicalcontaminants

Biological:None identified at this time.

No Only food-grade packaging materials are used.Letters of guarantee from packaging company onfile.

Storage ofPackaging,Materials

Physical:None identified at this time.

Chemical:Pesticides

Biological:None identified at this time.

No Only approved pesticides are used in the facility.

Heat Treated, Shelf-Stable: Jerky Product

January 6, 2000 Version

CCP Description, Critical Limits, Monitoring Procedures, Corrective ActionsPRODUCT: Heat Treated, Shelf-Stable: Jerky Product

Process Step CCP Number CCP Description Critical Limits Establishment MonitoringProcedures:(What/How/Frequency/Responsible Person)

Corrective Actions1

Cold Storage CCP 1B Producttemperature

≤45° F producttemperature

What: Room temperatureHow: Temperature Monitoring DeviceFrequency: DailyResponsible Person: Cooler Operator

1. Identify and eliminate cause ofdeviation.

2. Bring the CCP under control aftercorrective action is taken.

3. Measures to prevent recurrence areestablished.

4. No product that is injurious tohealth or adulterated enterscommerce.

HeatTreatment

CCP 2B Heat Treatment Temperature/Time142° F 8 minutes141° F 10 minutes140° F 12 minutes139° F 15 minutes138° F 19 minutes137° F 24 minutes136° F 32 minutes135° F 37 minutes134° F 47 minutes133° F 62 minutes132° F 77 minutes131° F 97 minutes130° F 121 minutes

What: Temperature of smokehouseHow: Temperature Monitoring DeviceFrequency: ContinuousResponsible Person: Smokehouse Operator

What: Time at specified temperatureHow: Temperature Monitoring DeviceFrequency: ContinuousResponsible Person: Smokehouse operator

1. Identify and eliminate cause ofdeviation.

2. Bring the CCP under control aftercorrective action is taken.

3. Measures to prevent recurrence areestablished.

4. No product that is injurious tohealth or adulterated enterscommerce.

Unforeseen HazardsThere are chances that unforeseen hazards may occur at the Rosenthal Meat Science and Technology Center. Therefore, if an unforeseen hazard occurs, this establishment will:1. Segregate and hold the affected product, at least until the requirements of (2) and (3) are met;2. Perform a review to determine the acceptability of the affected product for distribution;3. Take action, when necessary, with respect to the affected product to ensure that no product that is injurious to health or otherwise adulterated, as a result of the deviation,

enters commerce;4. Perform or obtain reassessment by an individual trained in accordance with section 417.7 of the USDA/FSIS Pathogen Reduction; Hazard Analysis and Critical Control Point

(HACCP) Systems; Final Rule, to determine whether the newly identified deviation or other unforeseen hazard should be incorporated into the HACCP plan. 1 Plant manager or designee is responsible for performing corrective actions to ensure appropriate corrective actions are taken.

Heat Treated, Shelf Stable: Jerky Product

January 6, 2000 Version

Heat Treated, Shelf Stable: Jerky ProductVerification and Recordkeeping

PROCESS STEP/CCP VERIFICATION1 RECORDS

CCP 1BCold Storage

Weekly internal product temperature one timeper week when product is available.

Weekly calibration and/or verification oftemperature monitoring device by plantmanager or designee.

Plant manager or designee will review coolercharts.

• Product Temperature Verification Log• Cooler Chart• Deviation/Corrective Action Log• Temperature Monitoring Device Calibration

and/or Verification Log

CCP 2BHeat Treatment

Visual observation of monitoring activity byplant manager or designee.

On days of jerky manufacturing, plant manageror designee will review records.

Weekly calibration and/or verification oftemperature monitoring device.

• Time/Temperature Log• Heating Chart• Deviation/Corrective Action Log• Temperature Monitoring Device Calibration

and/or Verification Log

1 Direct observation of corrective action by plant manager or designee will be conducted when a deviation is found during the pre-shipment record review.

Rosenthal Meat Science and Technology CenterTexas A&M University

Temperature Monitoring Device Calibration and/or Verification Log

Date Time TemperatureMonitoring Device

Identification

TemperatureReading at:

32°F 212°F

Action Taken Performed by

Date Time Location TemperatureMonitoring

Device Reading °F

CalibratedThermometer

MonitoringDevice Reading °F

Action Taken Performed by

Holding Cooler

Aging Cooler

Cooked Meat Cooler

Cured Meat Cooler

Freezer

Smokehouse Probe 1

Smokehouse Probe 2

Chill-Down Probe 1

Chill-Down Probe 2

Reviewed by:_____________________________________ Date:_____________________________

Date:_________________________

Rosenthal Meat Science and Technology CenterTexas A&M University

Product Temperature Verification Log

Location InternalTemperature of

Product (°F)

Time

Holding Cooler

Aging Cooler

Cooked Meat Cooler

Cured Meat Cooler

Freezer

Performed by:

Rosenthal Meat Science and Technology CenterTexas A&M UniversityPre-Shipment Review Log

Cold Storage

Date CookedCooler

CuredCooler

HoldingCooler

AgingCooler

Freezer Time Comments Review Signature

Temperature/Time LogHeat Treated, Shelf-Stable: Jerky Product CCP Record

CCP 1B Cold Storage

Date:

Cooler Chart Freezer Chart

Pre-shipmentReview Signature:_________________________________________ Date:___________________________

Temperature/Time LogHeat Treated, Shelf-Stable: Jerky Product CCP Record

CCP 2B Heat Treatment

Date:

CCP 2: Temperature/TimeSmokehouseTemperature/Time142° F 8 min.141° F 10 min.140° F 12 min.139° F 15 min.138° F 19 min.137° F 24 min.136° F 32 min.135° F 37 min.134° F 47 min.133° F 62 min.132° F 77 min.131° F 97 min.130° F 121 min.

Pre-shipmentReview Signature:_________________________________________ Date:___________________________

Deviation/Corrective Action Record

1. Identify and eliminate cause of deviation2. Bring CCP under control after corrective action is taken3. Measures to prevent recurrence are established4. No product that is injurious to health or adulterated enters commerce.

CCP No. ProductI.D.

Deviation CorrectiveActionNo. 1

CorrectiveActionNo. 2

CorrectiveActionNo. 3

CorrectiveActionNo. 4

PerformedBy

Time

Pre-shipment Review Signature:________________________________________ Approved Date:____________________ Time:_________________