1. Tuna HACCP Handbook Example 1. CANNED TUNA from Frozen Round Tuna
Chapter HACCP Plan Examples
Example 1. CANNED TUNA from Frozen Round Tuna

2. Tuna Council's Handbook
Example 1. CANNED TUNA 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
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3. Tuna Council's Handbook
Part 1. Product & Process Description
Tuna Council's Handbook

4. Tuna Council's Handbook
Part 1. Product Description
Canned Tuna Species included: Albacore (Thunnus alalunga) Bigeye tuna (Thunnus obesus) Skipjack tuna (Katsuwonus pelamis) Yellowfin (Thunnus albacares)
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5. Tuna Council's Handbook
Flow Diagram
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6. Tuna Council's Handbook
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
Receiving
Part 1. Process Description
Example Procedures
and
Variations & Considerations
Sorting
Frozen Storage
Thawing
Butchering
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8. Part 1. Process Description
Ingredient Prep. & Storage
Ingredient Recv. & Storage
Injection
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9. Tuna Council's Handbook
Part 1. Process Description
Pre-Cooking
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10. Tuna Council's Handbook
Part 1. Process Description
Cooling
Conditioning
Cleaning
Can Filling
Can Seaming
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11. Part 1. Process Description
Ingredient Recv. & Storage
Part 1. Process Description
Ingredient Prep. & Storage
Injection
Tuna Council's Handbook

12. Tuna Council's Handbook
Part 1. Process Description
Thermal Process
(retorting)
Metal Detector
Label, Pack & Storage
LACF
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13. Part 2. Hazard Analysis
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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
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15. Part 2. Hazard Analysis ‘Inclusive Approach’ for each processing step
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16. Receiving
Sign Justify Control CCP?
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17. Sorting
Sign Justify Control CCP?
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18. Frozen Storage
Sign Justify Control CCP?
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19. Thawing Sign. Justify Control CCP?
* Cumulative time for raw tuna exposure from start of thawing to pre-cooking to prevent elevated histamine levels.
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20. Butchering Sign. Justify Control CCP?
* Cumulative time for raw tuna exposure from start of thawing to pre-cooking to prevent elevated histamine levels.
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21. Ingredients Recv. & Storage
Sign Justify Control CCP?
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22. Ingredients Prep. & Storage
Sign Justify Control CCP?
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23. Injection Sign. Justify Control CCP?
* Cumulative time for raw tuna exposure from start of thawing to pre-cooking to prevent elevated histamine levels.
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24. Pre-Cooking
Sign Justify Control CCP?
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25. Cooling Sign. Justify Control CCP?
** Cumulative time for exposure of pre-cooked tuna from start of cooling until retorting cans to prevent elevated histamine levels.
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26. Conditioning Sign. Justify Control CCP?
** Cumulative time for exposure of pre-cooked tuna from start of cooling until retorting cans to prevent elevated histamine levels.
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27. Cleaning Sign. Justify Control CCP?
*** Cumulative time for exposure of pre-cooked tuna from start of cleaning until retorting cans that prevents potential growth of S. aureus and other bacteria.
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28. Can Filling Sign. Justify Control CCP?
** Cumulative time ….and …. *** Cumulative time
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29. Ingredients Recv. & Storage
Same as prior step
Ingredients Recv. & Storage
Sign Justify Control CCP?
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30. Ingredient Prep. & Holding
Sign Justify Control CCP?
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31. Ingredient Addition Sign. Justify Control CCP?
** Cumulative time ….and …. *** Cumulative time
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32. Can Seaming Sign. Justify Control CCP?
** Cumulative time ….and …. *** Cumulative time
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33. Thermal Processing (retorting)
Sign Justify Control CCP?
LACF Controls
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34. Metal Detector
Sign Justify Control CCP?
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35. Label, Pack & Storage Sign. Justify Control CCP?
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36. Tuna Council's Handbook
The Hazard Analysis identified 7 Critical Control Points:
Receiving to control incoming Scombrotoxins (elevated histamine levels)
Cumulative time* from start of Thaw through start of Pre-Cooking to control potential elevated histamine levels
Pre-Cooking to prevent subsequent histamine production
Cumulative time** from end of Pre-Cooking through start of Thermal Processing (can retorting) to prevent subsequent histamine production
Cumulative time*** from start of Cleaning through start of Thermal Processing (can retorting) to control potential S. aureus growth and potential production of enterotoxin
Metal Detection to eliminate metal fragments or inclusions
Labeling to declare potential food allergens
Tuna Council's Handbook

37. Part 3. HACCP Plan REMEMBER !
HACCP Plans must be reviewed and signed at least annually Or
whenever changes have occurred in the Hazard Analysis or HACCP Plan
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38. Tuna Council's Handbook
Part 3. HACCP Plan
Tuna Council's Handbook

39. Tuna Council's Handbook
Part 3. HACCP Plan
CCP 1. Receiving to control incoming Scombrotoxins (elevated histamine levels)
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40. Tuna Council's Handbook
Part 3. HACCP Plan
CCP 2. Cumulative time* from start of Thawing through start of Pre-Cooking to control potential elevated histamine levels
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41. Tuna Council's Handbook
Part 3. HACCP Plan
CCP 3. Pre-Cooking to prevent subsequent histamine production
Tuna Council's Handbook

42. Tuna Council's Handbook
Part 3. HACCP Plan
CCP 4. Cumulative time** from end of Pre-Cooking through start of Thermal Processing (can retorting) to prevent subsequent histamine production
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43. Tuna Council's Handbook
Part 3. HACCP Plan
CCP 5. Cumulative time*** from start of Cleaning through start of Thermal Processing (can retorting) to control potential S. aureus growth and potential production of enterotoxin
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44. Tuna Council's Handbook
Part 3. HACCP Plan
CCP 6. Metal Detection to eliminate metal fragments or inclusions
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45. Tuna Council's Handbook
Part 3. HACCP Plan
CCP 7. Labeling to declare potential food allergens
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46. Tuna Council's Handbook
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Tuna Council's Handbook