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

2. 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

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

4. 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

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

6. 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

7. 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

8. 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

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

10. 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

11. 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

12. 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

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

14. 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

15. 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

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

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

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

19. 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

20. 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

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

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

23. 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

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

25. 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

26. 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

27. 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

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

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

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

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

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

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

34. 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

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

36. 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

37. 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

38. 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

39. 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

40. 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

41. 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

42. 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

43. Tuna Council's Handbook
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Tuna Council's Handbook