Tuna HACCP Guide Example 3. CANNED TUNA from Frozen Pre-Cooked Loins Chapter 6 HACCP Plan Examples Example 3. CANNED TUNA from Frozen Pre-Cooked Loins

Tuna Council's Handbook Example 3. CANNED TUNA from Frozen Pre-Cooked Loins 3 Parts in each Example Product and Process Descriptions (including Flow Diagrams) Hazard Analysis to determine the Critical Controls Points (CCPs) for all identified hazards through all processing steps (Inclusive Approach) HACCP Plans to determine the controls for each CCP Tuna Council's Handbook

Tuna Council's Handbook Example 3. CANNED TUNA from Frozen Pre-Cooked Loins Part 1. Product & Process Description Tuna Council's Handbook

Tuna Council's Handbook Example 3. CANNED TUNA from Frozen Pre-Cooked Loins Part 1. Product Description Canned Tuna Species included: Albacore (Thunnus alalunga) Bigeye tuna (Thunnus obesus) Skipjack tuna (Katsuwonus pelamis) Yellowfin (Thunnus albacares) Tuna Council's Handbook

Tuna Council's Handbook Example 3. CANNED TUNA from Frozen Pre-Cooked Loins Flow Diagram Tuna Council's Handbook

Tuna Council's Handbook Example 3. CANNED TUNA from Frozen Pre-Cooked Loins SPECIAL NOTES Ability to identify and track product ‘lots and batches’ from harvest through all steps of processing until final production Growing emphasis on product traceability Tuna Council's Handbook

Tuna Council's Handbook Example 3. CANNED TUNA from Frozen Pre-Cooked Loins TUNA Loins Frozen Part 1. Process Description Example Procedures and Variations & Considerations Receiving Frozen Storage Thawing Can Filling Tuna Council's Handbook

Part 1. Process Description Example 3. CANNED TUNA from Frozen Pre-Cooked Loins Part 1. Process Description Ingredient Prep. & Storage Ingredient Recv. & Storage Injection Tuna Council's Handbook

Part 1. Process Description Example 3. CANNED TUNA from Frozen Pre-Cooked Loins Can Seaming Part 1. Process Description Thermal Process (retorting) Metal Detector Label, Pack & Storage Tuna Council's Handbook

Part 2. Hazard Analysis Tuna Council's Handbook

Tuna Council's Handbook Part 2. Hazard Analysis Four potential hazards have been considered “reasonably likely to occur” Pathogenic Bacteria Growth Staphylococcus aureus (S. aureus) growth and enterotoxin production Clostridium botulinum (C. botulinum) growth and toxin production in reduced oxygen packaging (ROP); cans Scombrotoxin (elevated histamine levels) Allergens and Food Additives Metal Inclusions Tuna Council's Handbook

Part 2. Hazard Analysis ‘Inclusive Approach’ for each processing step Example 3. CANNED TUNA from Frozen Pre-Cooked Loins Part 2. Hazard Analysis ‘Inclusive Approach’ for each processing step Tuna Council's Handbook

Hazard Analysis Worksheet CANNED TUNA from Frozen Pre-Cooked Loins Receiving Sign. Justify Control CCP? Tuna Council's Handbook

Hazard Analysis Worksheet CANNED TUNA from Frozen Pre-Cooked Loins Frozen Storage Sign. Justify Control CCP? Tuna Council's Handbook

Hazard Analysis Worksheet CANNED TUNA from Frozen Pre-Cooked Loins Thawing Sign. Justify Control CCP? *Cumulative time for exposure of frozen, pre-cooked loins from start of thawing until start of retorting to prevent elevated histamine levels. Tuna Council's Handbook

Thawing PENDING STATUS: Thawing Ingredient Additions Can Seaming Hazard Analysis Worksheet CANNED TUNA from Frozen Pre-Cooked Loins Thawing Sign. Justify Control CCP? PENDING STATUS: Thawing Ingredient Additions Can Seaming *Cumulative time for exposure of frozen, pre-cooked loins from start of thawing until start of retorting to prevent elevated histamine levels. Tuna Council's Handbook

Hazard Analysis Worksheet CANNED TUNA from Frozen Pre-Cooked Loins Can Filling Sign. Justify Control CCP? *Cumulative time for exposure of frozen, pre-cooked loins from start of thawing until start of retorting to prevent elevated histamine levels. Tuna Council's Handbook

Ingredients Recv. & Storage Hazard Analysis Worksheet CANNED TUNA from Frozen Pre-Cooked Loins Ingredients Recv. & Storage Sign. Justify Control CCP? Tuna Council's Handbook

Ingredient Prep. & Holding Hazard Analysis Worksheet CANNED TUNA from Frozen Pre-Cooked Loins Ingredient Prep. & Holding Sign. Justify Control CCP? Tuna Council's Handbook

Hazard Analysis Worksheet CANNED TUNA from Frozen Pre-Cooked Loins Ingredient Addition Sign. Justify Control CCP? *Cumulative time for exposure of frozen, pre-cooked loins from start of thawing until start of retorting to prevent elevated histamine levels. Tuna Council's Handbook

Hazard Analysis Worksheet CANNED TUNA from Frozen Pre-Cooked Loins Can Seaming Sign. Justify Control CCP? *Cumulative time for exposure of frozen, pre-cooked loins from start of thawing until start of retorting to prevent elevated histamine levels. Tuna Council's Handbook

Thermal Processing (retorting) Hazard Analysis Worksheet CANNED TUNA from Frozen Pre-Cooked Loins Thermal Processing (retorting) Sign. Justify Control CCP? LACF Controls Tuna Council's Handbook

Hazard Analysis Worksheet CANNED TUNA from Frozen Pre-Cooked Loins Metal Detector Sign. Justify Control CCP? Tuna Council's Handbook

Hazard Analysis Worksheet CANNED TUNA from Frozen Pre-Cooked Loins Label, Pack & Storage Sign. Justify Control CCP? Tuna Council's Handbook

Tuna Council's Handbook The Hazard Analysis identified 4 Critical Control Points: 1. Cumulative time* from start of Thawing through start of Thermal Processing (can retorting) to prevent subsequent histamine production 2. Cumulative time** from start of Thaw through start of Thermal Processing (can retorting) to control potential S. aureus growth and potential production of heat-stable enterotoxin 3. Metal Detection to eliminate metal fragments or inclusions 4. Labeling to declare potential food allergens Tuna Council's Handbook

Tuna Council's Handbook Example 3. CANNED TUNA from Frozen Pre-Cooked Loins Part 3. HACCP Plan Tuna Council's Handbook

Tuna Council's Handbook Example 3. CANNED TUNA from Frozen Pre-Cooked Loins Part 3. HACCP Plan CCP 1. Cumulative time* from start of Thawing through start of Thermal Processing (can retorting) to prevent potential subsequent histamine production Tuna Council's Handbook

Tuna Council's Handbook Example 3. CANNED TUNA from Frozen Pre-Cooked Loins Part 3. HACCP Plan CCP 2. Cumulative time* from start of Thawing through start of Thermal Processing (can retorting) to control potential S. aureus growth and potential production of heat- stable enterotoxin Tuna Council's Handbook

Tuna Council's Handbook Example 3. CANNED TUNA from Frozen Pre-Cooked Loins Part 3. HACCP Plan CCP 3. Metal Detection to eliminate metal fragments or inclusions Tuna Council's Handbook

Tuna Council's Handbook Example 3. CANNED TUNA from Frozen Pre-Cooked Loins Part 3. HACCP Plan CCP 4. Labeling to declare potential food allergens Tuna Council's Handbook

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