Tuna HACCP Handbook Chapter 6 HACCP Plan Examples Example 2. FROZEN PRE-COOKED LOINS from Frozen Round Tuna

Tuna Council's Handbook Example 2. FROZEN PRECOOKED LOINS from Frozen Round Tuna 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 2. FROZEN PRE-COOKED LOINS from Frozen Round Tuna Part 1. Product & Process Description Tuna Council's Handbook

Tuna Council's Handbook Example 2. FROZEN PRE-COOKED LOINS from Frozen Round Tuna 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 2. FROZEN PRE-COOKED LOINS from Frozen Round Tuna Flow Diagram Tuna Council's Handbook

Tuna Council's Handbook Example 2. FROZEN PRE-COOKED LOINS from Frozen Round Tuna 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 ROUND TUNA Frozen Example 2. FROZEN PRE-COOKED LOINS from Frozen Round Tuna Receiving Part 1. Process Description Example Procedures and Variations & Considerations Sorting Frozen Storage Thawing Butchering Tuna Council's Handbook

Part 1. Process Description Example 2. FROZEN PRE-COOKED LOINS from Frozen Round Tuna Part 1. Process Description Ingredient Prep. & Storage Ingredient Recv. & Storage Injection Tuna Council's Handbook

Tuna Council's Handbook Example 2. FROZEN PRE-COOKED LOINS from Frozen Round Tuna Part 1. Process Description Pre-Cooking Tuna Council's Handbook

Tuna Council's Handbook Example 2. FROZEN PRE-COOKED LOINS from Frozen Round Tuna Part 1. Process Description Cooling Conditioning Cleaning Bagging Bag Sealing Tuna Council's Handbook

Part 1. Process Description Example 2. FROZEN PRE-COOKED LOINS from Frozen Round Tuna Ingredient Recv. & Storage Part 1. Process Description Ingredient Prep. & Storage Injection Tuna Council's Handbook

Tuna Council's Handbook Example 2. FROZEN PRE-COOKED LOINS from Frozen Round Tuna Part 1. Process Description Metal Detector Freezing Palletize & Label) Frozen 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 2. FROZEN PRE-COOKED LOINS from Frozen Round Tuna Part 2. Hazard Analysis ‘Inclusive Approach’ for each processing step Tuna Council's Handbook

Receiving Sign. Justify Control CCP? Tuna Council's Handbook

Sorting Sign. Justify Control CCP? Tuna Council's Handbook

Frozen Storage Sign. Justify Control CCP? Tuna Council's Handbook

Thawing Sign. Justify Control CCP? * Cumulative time for raw tuna exposure from start of thawing to pre-cooking to prevent elevated histamine levels. Tuna Council's Handbook

Butchering Sign. Justify Control CCP? * Cumulative time for raw tuna exposure from start of thawing to pre-cooking to prevent elevated histamine levels. Tuna Council's Handbook

Ingredients Recv. & Storage Sign. Justify Control CCP? Tuna Council's Handbook

Ingredients Prep. & Holding Sign. Justify Control CCP? Tuna Council's Handbook

Injection Sign. Justify Control CCP? * Cumulative time for raw tuna exposure from start of thawing to pre-cooking to prevent elevated histamine levels. Tuna Council's Handbook

Pre-Cooking Sign. Justify Control CCP? Tuna Council's Handbook

Cooling Sign. Justify Control CCP? ** Cumulative time for exposure of pre-cooked tuna until freezing pre-cooked and bagged loins to prevent elevated histamine levels. Tuna Council's Handbook

Conditioning Sign. Justify Control CCP? ** Cumulative time for exposure of pre-cooked tuna until freezing pre-cooked and bagged loins to prevent elevated histamine levels. Tuna Council's Handbook

Cleaning Sign. Justify Control CCP? *** Cumulative time for exposure of pre-cooked from start of cleaning until freezing to prevent potential growth of S. aureus and other bacteria. Tuna Council's Handbook

Bagging Sign. Justify Control CCP? ** Cumulative time ….and …. *** Cumulative time Tuna Council's Handbook

Bag Sealing Sign. Justify Control CCP? ** Cumulative time ….and …. *** Cumulative time Tuna Council's Handbook

Metal Detection Sign. Justify Control CCP? Tuna Council's Handbook

Freezing Sign. Justify Control CCP? Tuna Council's Handbook

Palletize & Label Sign. Justify Control CCP? Tuna Council's Handbook

Frozen Storage Sign. Justify Control CCP? Tuna Council's Handbook

Tuna Council's Handbook The Hazard Analysis identified 7 Critical Control Points: 1. Receiving to control incoming Scombrotoxins (elevated histamine levels) 2. Cumulative time* from start of Thaw thru start of Pre-Cooking to control potential elevated histamine levels 3. Pre-Cooking to prevent subsequent histamine production 4. Cumulative time** from end of Pre-Cooking to start of freezing to prevent subsequent histamine production 5. Cumulative time*** from start of Cleaning to frozen storage to control potential S. aureus growth and potential production of enterotoxin 6. Metal Detection to eliminate metal fragments or inclusions 7. Labeling to declare potential food allergens Tuna Council's Handbook

Tuna Council's Handbook Example 2. FROZEN PRE-COOKED LOINS from Frozen Round Tuna Part 3. HACCP Plan Tuna Council's Handbook

Tuna Council's Handbook Example 2. FROZEN PRE-COOKED LOINS from Frozen Round Tuna Part 3. HACCP Plan CCP 1. Receiving to control incoming Scombrotoxins (elevated histamine levels) Tuna Council's Handbook

Tuna Council's Handbook Example 2. FROZEN PRE-COOKED LOINS from Frozen Round Tuna Part 3. HACCP Plan CCP 2. Cumulative time* from start of Thawing through start of Pre-Cooking to control potential elevated histamine levels Tuna Council's Handbook

Tuna Council's Handbook Example 2. FROZEN PRE-COOKED LOINS from Frozen Round Tuna Part 3. HACCP Plan CCP 3. Pre-Cooking to prevent subsequent histamine production Tuna Council's Handbook

Tuna Council's Handbook Example 2. FROZEN PRE-COOKED LOINS from Frozen Round Tuna Part 3. HACCP Plan CCP 4. Cumulative time** from end of Pre-Cooking to start of freezing to prevent subsequent histamine production Tuna Council's Handbook

Tuna Council's Handbook Example 2. FROZEN PRE-COOKED LOINS from Frozen Round Tuna Part 3. HACCP Plan CCP 5. Cumulative time*** from start of Cleaning to start of freezing to control potential S. aureus growth and potential production of enterotoxin Tuna Council's Handbook

Tuna Council's Handbook Example 2. FROZEN PRE-COOKED LOINS from Frozen Round Tuna Part 3. HACCP Plan CCP 6. Metal Detection to eliminate metal fragments or inclusions Tuna Council's Handbook

Tuna Council's Handbook Example 2. FROZEN PRE-COOKED LOINS from Frozen Round Tuna Part 3. HACCP Plan CCP 7. Labeling to declare potential food allergens Tuna Council's Handbook

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