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

2. 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

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

4. 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

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

6. 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

7. 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

8. 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

9. 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

10. Part 2. Hazard Analysis
Tuna Council's Handbook

11. 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

12. 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

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

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

15. 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

16. 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

17. 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

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

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

20. 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

21. 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

22. 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

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

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

25. 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

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

27. 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

28. 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

29. 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

30. 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

31. Tuna Council's Handbook
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Tuna Council's Handbook