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Advances in Meat Research - Volume 10 HACCP in Meat, Poultry and Fish Processing The Advances in Meat Research series reviews recent advances in meat science and technology. Each volume concentrates on one specific topic and discusses it in depth. The chapter authors are recognized as authorities in their fields and are drawn from around the world providing an international perspective. The following volumes are also available: Volume 6 Meat and Health Volume 7 Growth Regulations in Farm Animals Volume 8 Inedible Meat By-Products Volume 9 Quality Attributes and their Measurement in Meat, Poultry and Fish Products Advances in Meat Research - Volume 10 HACCP in Meat, Poultry and Fish Processing Edited by A.M. PEARSON Courtesy Professor Department of Animal Sciences Oregon State University and T.R. DUTSON Dean, College of Agricultural Sciences Director of Agricultural Experiment Station Oregon State University BLACKIE ACADEMIC & PROFESSIONAL An Imprint of Chapman & Hall London· Glasgow· Weinheim . New York· Tokyo· Melbourne· Madras Published by Blackie Academic & Professional, an imprint of Chapman & Hall, Wester Cleddens Road, Bishopbriggs, Glasgow G64 2NZ Chapman & Hall, 2--6 Boundary Row, London SE1 8HN, UK B1ackie Academic & Professional, Wester Cleddens Road, Bishopbriggs, Glasgow G64 2NZ, UK Chapman & Hall GmbH, Pappelallee 3, 69469 Weinheim, Germany Chapman & Hall USA, 115 Fifth Avenue, Fourth Floor, New York NY 10003, USA Chapman & Hall Japan, ITP-Japan, Kyowa Building, 3F, 2-2-1 Hirakawacho, Chiyoda-ku, Tokyo 102, Japan DA Book (Aust.) Pty Ltd, 648 Whitehorse Road, Mitcham 3132, Victoria, Australia Chapman & Hall India, R. Seshadri, 32 Second Main Road, CIT East, Madras 600 035, India First edition 1995 © 1995 Chapman & Hall Typeset in 10/12pt Times by Cambrian Typesetters, Frimley, Surrey ISBN 0 7514 0229 X Apart from any fair dealing for the purposes of research or private study, or criticism or review, as permitted under the UK Copyright Designs and Patents Act, 1988, this publication may not be reproduced, stored, or transmitted, in any form or by any means, without the prior permission in writing of the publishers, or in the case of reprographic reproduction only in accordance with the terms of the licences issued by the Copyright Licensing Agency in the UK, or in accordance with the terms of licences issued by the appropriate Reproduction Rights Organization outside the UK. Enquiries concerning reproduction outside the terms stated here should be sent to the publishers at the Glasgow address printed on this page. The publisher makes no representation, express or implied, with regard to the accuracy of the information contained in this book and cannot accept any legal responsibility or liability for any errors or omissions that may be made. A catalogue record for this book is available from the British Library Library of Congress Catalog Card Number: 95-76796 e Printed on permanent acid-free text paper, manufactured in accordance with ANSIINISO Z39.48-1992 (Permanence of Paper). Preface The RACCP (hazard analysis critical control point) concept for food products was an outgrowth of the US space program with the demand for a safe food supply for manned space flights by the National Aeronautics and Space Administration (NASA). The original work was carried out by the Pillsbury Company under the direction of Roward E. Bauman, who as the author of chapter 1 describes the evolution of the RACCP system and its adaptation to foods. The second chapter discusses the adoption of RACCP principles and explains how they fit into the USDA and FDA meat, poultry and seafood inspection systems. The next chapter discusses how RACCP principles can be extended to production of meat, poultry and seafoods, a most important area involved in producing a safe food supply. Chapter 4 deals with the use of RACCP in controlling hazards encountered in slaughtering and distribution of fresh meat and poultry, while chapter 5 discusses the problem - both spoilage and hazards - involved in processing and distribution of meat, poultry and seafood products. Chapter 6 covers the entire area of fish and seafoods, including both fresh and processed products from the standpoints of spoilage and hazards. Chapter 7 discusses the concept of statistical quality control and acceptable risk levels. The next chapter discusses the concept of total quality management and how it dovetails with and extends information obtained by RACCP. Chapter 9 reviews and suggests how RACCP can be utilized by delicatessens and meat, poultry and fish retailers. Chapter 10 discusses how RACCP can be adapted to improving the safety of meat, poultry and fish products by restaurants and food service establishments. Chapter 11 suggests how the RACCP program can be adopted by consumers to improve food safety in the home. Chapter 12 describes how RACCP should be organized and managed by the meat, poultry and fish industries. Chapter 13 discusses how predictive microbiology dovetails with the RACCP program. The final chapter covers national and international cooperation in governmental regulations and agreements for meat, poultry and fish inspection. This book should be useful to anyone involved in production, slaughter ing, processing and distribution of meat, poultry and fish products. The discussion herein should help in improving the safety and in preventing spoilage of these highly perishable products. Although almost all the authors are from the USA the principles of vi PREFACE HACCP are internationally recognized. Hence, the information in this book is applicable to the meat, poultry and fish industries throughout the world. The information provided and its adoption may be useful to these industries regardless of their location. A.M.P. T.R.D. Contributors G.R. Acuff International Meat and Poultry HACCP Alliance, Center for Food Safety, Texas A&M University, College Station, Texas 77843-2259, USA H.E. Bauman Consultant, 4580 Greenwood Drive, Hopkins, Minnesota 55343, USA formerly of The Pillsbury Company H.R. Cross International Meat and Poultry HACCP Alliance, Center for Food Safety, Texas A&M University, College Station, Texas 77843-2259, USA B.F. Dennis 24612 Lenah Road, Aldie, Virginia 22001, USA T.R. Dutson Agricultural Experiment Station, Oregon State University, Oregon 97331, USA E.S. Garrett Director, National Seafood Inspection Laboratory, National Marine Fisheries Service, 3209 Frederic Street, Pascagoula, Mississippi 39568, USA J. Gillespie Professor and Head, Veterinary Medicine Teaching Hospital, Department of Clinical Sciences, College of Veterinary Medicine, Kansas State University, Manhattan, Kansas 66506, USA S.J. Goodfellow Director of Technical Services, Deibel Laboratories, Inc., 10014 S.W. 56th Lane, Gainesville, Florida 32608, USA K.B. Harris International Meat and Poultry HACCP Alliance, Center for Food Safety, Texas A&M University, College Station, Texas 77843-2259, USA M. Hudak-Roos Vice President, Technical Food Information Spectrum, Atlanta, Georgia 30328, USA T .A. McMeekin University of Tasmania, PO Box 252-C, Hobart, Tasmania, Australia 7053 M.G. Manis USDA-FSIS; 341E Administration Building, Washington, DC 20250, USA viii CONTRIBUTORS J.L. Marsden Department of Animal Science and Industry, Kansas State University, Manhattan, Kansas 65506, USA B.1. Osburn Professor and Associate Dean for Research, School for Veterinary Medicine, University of California - Davis, Davis, California 95616, USA A.M. Pearson Department of Animal Sciences, Oregon State University, Corvallis, Oregon 97331, USA R.J. Price Sea Grant Extension Program, Department of Food Science and Technology, University of California, Davis, California 95616, USA M.R. Roberts State of Florida, Florida Department of Agriculture, The Capitol, Tallahassee, Florida 32399, USA T. Ross University of Tasmania, PO Box 252-C, Hobart, Tasmania, Australia 7053 O.P. Snyder, Jr Hospitality Institute of Technology and Management, 830 Transfer Road, Suite 35, St. Paul, Minnesota 55114, USA D.M. Theno Vice President of Quality Assurance and Product Safety, Foodmaker, Inc., 9330 Balboa Avenue, San Diego, California 92123, USA R.B. Tompkin Vice President Product Safety, Armour Swift-Eckrich, 3131 Woodcreek Drive, Downers Grove, Illinois 60515, USA H.F. Troutt Professor and Head, Department of Veterinary Clinical Medicine, College of Veterinary Medicine, University of Illinois, Urbana, Illinois 60801, USA D.R. Ward Professor and Associate Department Head, Depart ment of Food Sciences, North Carolina State University, Raleigh, North Carolina 27695, USA N.B. Webb Webb Technical Group, Inc., Raleigh, North Carolina 27612, USA Contents 1 The origin and concept of HACCP 1 H.E. BAUMAN 1.1 Introduction 1 1.2 Development of the HACCP concept 1 1.2.1 HACCP - A new approach 2 1.2.2 HACCP -A preventative system 3 1.3 Acceptance of HACCP by the food industry 4 1.3.1 Establishment of HACCP by other companies 4 1.3.2 Role of various agencies 5 1.4 Summary 5 References 7 2 The HACCP system and how it fits into FSIS programs 8 M.G. MANIS 2.1 Introduction 8 2.1.1 FSIS background 8 2.1.2 Industrial responsibility and HACCP 8 2.1.3 FSIS and HACCP 9 2.2 HACCP study 10 2.2.1 Background 10 2.2.2 Consultations and public hearings 10 2.2.3 Workshops 12 2.3 Critical control points for various models 14 2.3.1 Refrigerated foods (cooked and assembled) critical control points 14 2.3.2 Raw beef pattie critical control points 14 2.3.3 Whole young chickens critical control points 14 2.3.4 Cooked sausage critical control points 15 2.3.5 Pork slaughter market hogs critical control points 15 2.4 In-plant testing of HACCP models 15 2.4.1 Background 15 2.4.2 Plant specific plan 16 2.4.3 Inspection during phases II and III 17 2.4.4 Phase II: Implementation 18 2.4.5 Phase III: Operational 19 2.5 Evaluation 19 2.5.1 Background 19 2.5.2 Limitations 20 2.5.3 HACCP model checklist 20 2.5.4 National profiles 23 2.5.5 Quantitative plant data 23 2.5.6 Qualitative plant data 25 2.5.7 Inspector and plant personnel survey 26 2.5.8 Workshop evaluation 26 2.5.9 Training 27 2.5.10 In-plant changes 27