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A.INTRODUCTION
HACCP (Hazard Analysis Critical Control Point) is the systematic preventative
approach to food safety.It addresses physical, chemical, and biological hazards as a
means of prevention rather than finished product inspection.This approach has
significant benefits to organisations operating within the food supply chain as it
enables them to determine key controls over processes and concentrate resources on
activities that are critical to ensuring safe food.
The information, tables, and other materials in this generic HACCP plan for Hot
Smoked Fish represent only one possible way to write a HACCP plan. It should be used
only for illustrative purposes. Each processor is obligated by law to write a flow diagram
specific to their own facility and conduct a hazard analysis for their own processes andproducts. The primary purpose of this generic plan is to illustrate how a firm might
simplify record keeping by writing a single plan, which could include several similar
smoked fish products having different brining and smoking procedures.
According to law, certain HACCP functions must be performed by someone who has
completed training equivalent to the HACCP Training Curriculum developed by The
National Seafood HACCP Alliance for Training and Education. These functions include
developing the plan, changing the plan, and conducting record review. This training may
be obtained through classroom instruction or by equivalent on-the-job training. This
generic HACCP plan for hot smoked fish is based on the principles detailed in that
manual and in guidance contained in the FDA's Fish & Fisheries Products Hazards &
Controls Guide, First Edition, September 1996.
Seafood processors also should be aware that FDA's HACCP regulation
(Procedures for the Safe and Sanitary Processing and Importing of Fish and Fishery
Products; Final Rule, December 18, 1995) requires that they monitor and keep records on
their sanitation procedures. This is best done by writing and implementing an SSOP
(Sanitation Standard Operating Procedure).
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B.PREREQUISITE PROGRAMS
1. PRELIMINARY STUDIES
1.1Sanitation IssuesAs with any food product, proper worker hygiene, raw ingredient handling and
storage procedures, and the final product handling and storage procedures are essential to
control product contamination by organisms that are harmful to humans.
Raw ingredients are typically inspected prior to entering the hot smoking fish
production facility/area. However, the manufacturer should not assume that these
ingredients are free of pathogenic organisms. The manufacturer must ensure that raw
ingredients are properly stored in refrigerated areas to minimize the opportunities for
growth of pathogens. Workers handling these raw materials must not also handle
completed hot smoking fish products, since cross contamination can occur. Equipment
and facilities should be designed to prevent cross contamination between raw and cooked
products. And, of course, hot smoking fish production workers should follow the standard
hygienic procedures that are required for all food production workers.
Hot smoking fish production equipments must be maintained in a clean and
sanitary condition, under conditions that minimize the potential for growth of pathogens.
And finally, the final products must be handled and stored according to acceptable
standards to minimize the opportunities for cross contamination and spoilage. The same
key sanitation principles outlined in the Seafood HACCP requirement can be utilized for
retail hot smoking fish production:
1.2.Safety of water
Water must be potable. Private wells or sources must be certified.
1.3.Condition and cleanliness of food contact surfaces
The portions of this area that should be monitored daily are cleaning and sanitizing of
equipment, utensils, gloves, and outer garments that come in contact with food, and the
condition of gloves and outer garments.
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1.4.Prevention of cross-contamination
The issues in the area of cross-contamination that should be monitored are employee
practices and physical separation of raw and cooked products.
1.5.Maintenance of hand-washing, hand-sanitizing, and toilet facilities
The issues that should be monitored are the concentration of hand-sanitizing solutions
and that the toilet facilities are in good repair.
1.6.Protection from adulterants and toxic compounds
Food must be protected from contaminants such as condensation, floor splash, glass,
and toxic chemicals.
1.7.Employee health conditions
Employee health conditions must be monitored daily.
1.8.Pest control
Pests must be excluded from food handling areas.
1.9.Proper Labelling,Use,and Storage of Potentially Hazardous Chemicals
Potentially hazardous chemicals used in factory include pesticides, cleaners, sanitizers,
disinfectants, fuels, coolants, paints, and solvents. All chemicals must be labeled, used
according to the manufacturers instructions, and stored in a safe manner so that chemical
contamination of hot smoking fish is prevented. All relevant government regulations relating
to the application, use, or holding of these products should be carefully followed.
1.10.Tracebility and Recall ProcessingIf a food borne disease outbreak occurs, traceability procedures are useful for determining
the source and distribution of suspected products. A trace-back and recall program can,
therefore, protect individual growers and the seafood industry by limiting an investigation to
a specific region, packing facility.
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2.PRODUCT CHRACTERISTICS
Table 1. Product Description and intended useProduct Specifications Product Label Sample
Name of product Hot smoking fish
Description
Refrigerated, vacuum-
packaged, cooked ready-to-eatsmoked fish (no mercury-containing species used )
Customer Specifications
Smoked fish are bright andglossy. There is no dried blood
or mold on the product.
Conditions of storageStored and transported under
refrigeration
Shelf life
Packaged smoked fish storage
for years without refrigerationand when package is opened it
is stored in fridge
Intended useReady to eat by general public
without further cooking
Packaging
Vacuum packaging,
MAP packaging and skinpackaging
Target consumer Public, food industry
Water activity 0.89-0.99
pH 4.1-8.4
Label information
Lot number, weight, name of
receiver, name of seller, date
number
AdditivesSalt (0.1-6.8g salt/100gproduct)
3.HACCP TEAM AND RESPONSIBILITIES
Table 2. HACCP Team
Team Member Department Responsibilities
. Hazard Analysis &
CCP AnalysisHazard analyses of processing and determinethe critical control points.
. Hygiene & SanitationControl hygiene and sanitation of plant andpersonnel.
. Monitoring
Controlling the process and corrective results.
Verification&
Documentation
Preparing all the documents according to the
monito
ed results.
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4. PROCESSING
5
RECEIVING
FROZEN FISH
STORAGE
THAWING
THAWED
FISH STORAGE
BUTCHERING
RINSING( BRINE
MAKEUP)
BRINING
RINSING
SMOKING/DRYING/
COOKING/COOLING
(INTEGRATED
COOLING (FINAL)
PACKAGING/LABELING
STORAGE
SHIPPING
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Receiving
(non-scombroid fish)
Fish headed, gutted, frozen and glazed in 50 lb. Boxes.Salt on wood pallets into dry
storage.
Frozen fish storage
On pallets in -10F cold store until needed.
Thawing
Partially thawed in mobile tubs with fresh flowing water at less than 70F the day
proceeding smoking operations.
Thawed fish storage
In raw product cold room at 40F or less in mobile tubs. Fish must be still partially frozenat time of butchering.
Butchering
Remove sides manually leaving skin on. Cut into pieces for brining. Processing takes
place in an air-conditioned area.
Rinsing (brine makeup)
Fish rinsed in fresh water at less than 70F to remove debris.Brine makeup in cold water
and stored in raw product cold room (less than 40F) until needed.
Brining
In a specified strength of salt brine for a specified time. These are relatively strong brines
and short times. This hazard analysis assumes short brining times in strong salt solutions.
If long brining times in weak solutions are used, the hazard analysis should consider the
possibility of a biological hazard (pathogen growth and/or histamine formation), resulting
in a critical control point at this brining step.
Rinsing
In fresh water at less than 70F to remove surface brine.
Smoking/Drying/Cooking/Cooling (integrated steps)
To surface dry, apply smoke, dehydrate, cook, and cool enough to remove excess heat
prior to final cooling. Product goes into cooler immediately upon removing from cooker.
Cooling (final)
In a special unpackaged final product cooler at 38F or less which is isolated from other
raw or processed products.
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Packaging/labeling
In vacuum packages then into 20 lb. master cartons
Storage
In cartons on pallets in finished product cooler at 38F or less.
Shipping
In refrigerated vans at 38F or less (commercial carrier).
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5.PLANT LAYOUT
8
Natural gas
station
Electri-city
supplierInfirmary
SecurityMain entrance
Ot
op
ar
k
Shipping
Mainta
nance
holl
Administer
Fitting room
WC
R
A
W
M
A
TE
R
I
AL
S
TO
R
A
GE
PR
O
DU
C
T
S
TORA
GE
Quality
Lab.
Packaging
Thawed fishstorageThawing
Rinsing
Brining
Rinsing
Smoking
Cooling
Butchering
Frozen
FishStorage
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C.HACCP STUDY
Table 3. Hazard analysis for hot smoking fish production
Process
name/step
Process
descriptions
Potential
Hazards
Cause analysis* Hazard Analysis (Y/N)***
Causes
(Sources
and
reasons)
Prerequisite
programs**Q1 Q2 Q3 Q4 Q5
Significant
Hazard
Fish (non-scombro-
toxin)
Receiving non-scombrotoxin
forming fish
Pathogen
inclusion,mercury,
parasites, metal
R,E P;6,7 Y - - Y Y N
Salt Receiving salt None R P;6 Y - - Y Y N
StorageFrozen fish
storage
Pathogengrowth and
adulteration
E P;7,8 - Y Y Y Y N
ThawingPartly thawed in
cool waterPathogengrowth
E,M,R P;5,6 - Y N - - N
Thawed
fish storage
Thawed fish is
storage
Pathogen
growthR P;5,6,7,8 - Y Y Y Y N
Butchering
Removal of fish
bone
Pathogen
growthP,M P;10 - Y N - - N
Rinsing Washed with
waterNone M P;5,6 Y - - Y Y N
BriningPrepared salt
concentration
pathogen
growth during
smoking and infinal product
R,M P;5,6 Y - - Y N Y
RinsingWashed with
waterNone M P;5,6 Y - - Y Y N
Smoking
/initial
Smoking is
applied
pathogen
growth onsurface during
smoking/drying/cooking
M P;5,6,7 - Y N - - N
Smoking/
drying
Smoking and
drying
operations are
done
pathogen
growth in final
product
M P;5,7 - Y Y Y N Y
Smoking/cooking
Smoking and
cookingoperations are
done
pathogengrowth in final
product
M P;5,6 - Y Y Y N Y
CoolingCooling
treatment is
applied
pathogen
growth duringcooling, cross
contamination
M P;5,7,8 - Y Y Y N Y
Packaging/labeling
Packaging ofhot smoking
fish
pathogen
growth intemperature
abused product
M,P,E P;5,7,8 - Y Y Y N Y
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StorageHot smoked
fish are stored
pathogen
growthR,E P;7,8 - Y Y Y N Y
ShippingFinal products
are shipped
pathogen
growthE P;5,7 - Y N - - N
* Cause and effect analyses (Figure 1.) ** Prerequisite programs (Table 1.) *** Hazard analysis (Figure 2.)
Table 4. Risk assesment and CCPs in the processing of hot smoking fish
Process
name/step
Significant
Hazard
Risk analysis*Preventive
actions/control measures
CCP analysis
(Y/N)**
Severity ProbabilityRisk
class
Q
1.
Q
2.
Q
3.
Q
4.
CCP
no:
Brining
Pathogen growth
during smoking and
in final product
C 3 3minimum brine strength and times
as per process scheduleY Y - - 1
Smoking/
drying
Pathogen growth in
final productD 2 3
minimum smoke-house cycle time
as per process scheduleY Y - - 2
Smoking/
cooking
Pathogen growth in
final productE 2 4
minimum final cook time/center
temp as per process scheduleY Y - - 3
CoolingPathogen growth
during coolingB 3 3 maximum cooler temperature Y N Y N 4
Packacaging/la
beling
pathogen growth intemperature abusedproduct
B 1 2all products labeled "keep at 38F
or less"Y N Y N 5
Storage of
finished
productPathogen growth B 1 2 38F or less Y N Y N 6
* Risk analysis (Table 9) ** CCP analysis (Figure 3.)
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Table 5. HACCP plan for the processing of hot smoking fish
CC
P
No:
Process
name/step
Significant
hazard
Critical
limits
Monitoring
Corrective
actionMethod Frequency Responsible
Record
1 Brining
Pathogengrowth during
smoking andin final
product
0 EnumerationEach brining
batch (lot)
Safety control
manager
productionlog
Rebrine orhold for
evaluation
2Smoking/dr
ying
Pathogengrowth in
final product
0 Enumeration Each batchSafety control
manager
productionlog and
recordercharts
Reprocess orhold for
evaluation
3Smoking/co
oking
Pathogen
growth infinal product
0 Enumeration Each batchSafety control
manager
productionlog and
recorder
charts
Reprocess or
hold forevaluation
4 CoolingPathogengrowth duringcooling
0 Enumeration ContinuousSafety controlmanager
production
log and temprecordercharts
Hold for
evaluation/adjust coolertemp
5Packaging/labeling
Pathogen
growth intemperature
abusedproduct
0 Enumeration Each lotSafety controlmanager
production
log
Relabel
6Storage offinished
product
Pathogen
growth
0 Enumeration ContinuousSafety control
manager
productionlogs/ recordercharts
Hold forevaluation/adjust cold
room temp
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D.DISCUSSION
The overall purpose of this report is to evaluate the published and unpublished data
concerning likely hazards of public health concern derived from the consumption of hot-
smoked fish. The application of the Hazard Analysis and Critical Control Point (HACCP)
principles to the processing of domestically produced and imported fishery products.
Although HACCP, with its focus on science, holds great promise for minimizing the risk of
foodborne disease, the application of HACCP principles to foods and food processes such as
hot-smoked fish is challenging.
Specifically, to provide an in-depth review of pathogens that might be found in hot-smoked
fish products, to identify processing parameters that may contribute to pathogen growth, and
to review options available to eliminate or inhibit foodborne pathogens in smoked fishproducts. A review of the safety of current fish harvesting and handling practices as well as
an evaluation of packaging options and their influence on survival or growth of the organisms
of concern.To address these issues, the report begins by describing the situation with regard to
the safety of consuming cold-smoked fish. Focusing attention on cold-smoked finfish, the
panel reviewed the most significant and likely to occur hazards in cold-smoked product
Listeria monocytogenes, Clostridium botulinum, human parasites, and biogenic amines. For
each hazard, the report evaluates the effectiveness of methods for eliminating or preventing
contamination in the processing environment, identifies possible control points for each step
in the process, and, where there is scientific evidence, offers processing parameters that would
control the hazard. Based on these findings, the panel offers information for reducing the risk
of hazard in hot-smoked fish products. The report also identifies research needs for further
investigating control methods for the hazards reviewed in this report.
The microbiological hazards exist at various points, but measures can be taken to control
these hazards. The anticipation of hazards and the identification of control points are therefore
key elements in HACCP. The system offers a rational and logical approach to control
(microbiological) food hazards and avoid the many weaknesses inherent in the inspectional
approach. Once established, the main effort of the quality assurance will be directed towards
the Critical Control Points (CCPs) and away from endless final product testing. This will
assure a much higher degree of safety at less cost.
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REFERENCES
en.wikipedia.org/wiki/Smoked_fish
www.fao.org/wairdocs/tan/.../x5953e01.ht
http://www.mexican-barbecue-recipes.com/smoked-fish.html
http://www.fishingmag.co.nz/smoker.htm
http://bbq.about.com/cs/fish/a/aa030400a.htm
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http://www.fao.org/wairdocs/tan/.../x5953e01.hthttp://www.mexican-barbecue-recipes.com/smoked-fish.htmlhttp://www.fishingmag.co.nz/smoker.htmhttp://bbq.about.com/cs/fish/a/aa030400a.htmhttp://www.fao.org/wairdocs/tan/.../x5953e01.hthttp://www.mexican-barbecue-recipes.com/smoked-fish.htmlhttp://www.fishingmag.co.nz/smoker.htmhttp://bbq.about.com/cs/fish/a/aa030400a.htm7/30/2019 Hot Smoking Fish HACCP Report
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APPENDICES
Tabel 7. Prerequisite programs
Prerequisite programmes1-construction and lay-out of buildings and associated utilities
2-lay-out of premises, including workspace and employee facilities
3-supplies of air, water, energy and other utilities
4-supporting services, including waste and sewage disposal
5-the suitability of equipment and its accessibility for cleaning, maintenance
and preventative maintenance
6-management of purchased materials (e.g. raw materials, ingredients,
chemicals and packaging), and supplies
7-measures for the prevention of cross contamination
8-cleaning and sanitizing
9-pest control
10-personnel hygiene
Table 8. Five-class hazard scoring matrix
Risk Classes
Sever
ity
Catastro
phicDeath or lasting damage E 3 4 4 4 4
CriticalMany concerned people and lasting or
continuous damagesD 3 3 4 4 4
Serious Many concerned people, no lasting damages C 2 3 3 4 4
LowSingle case, no lasting damages or minimal
concentrationB 2 2 3 3 4
IgnorableHazard to be discovered prior to consumption
or minimal indispositionA 1 2 2 3 3
Control measures I II III IV V
Riskc
lasses
1. No measure necessary.
Un
like
ly
(