Hot Smoking Fish HACCP Report

7/30/2019 Hot Smoking Fish HACCP Report

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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.htm


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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

(

Hot Smoking Fish HACCP Report

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