Tuna HACCP Handbook Example 1. CANNED TUNA from Frozen Round Tuna Chapter 6 HACCP Plan Examples Example 1. CANNED TUNA from Frozen Round Tuna

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 Tuna Council's Handbook

Tuna Council's Handbook Part 1. Product & Process Description Tuna Council's Handbook

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) Tuna Council's Handbook

Tuna Council's Handbook Flow Diagram Tuna Council's Handbook

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

Tuna Council's Handbook ROUND TUNA Frozen Receiving Part 1. Process Description Example Procedures and Variations & Considerations Sorting Frozen Storage Thawing Butchering Tuna Council's Handbook

Part 1. Process Description Ingredient Prep. & Storage Ingredient Recv. & Storage Injection Tuna Council's Handbook

Tuna Council's Handbook Part 1. Process Description Pre-Cooking Tuna Council's Handbook

Tuna Council's Handbook Part 1. Process Description Cooling Conditioning Cleaning Can Filling Can Seaming Tuna Council's Handbook

Part 1. Process Description Ingredient Recv. & Storage Part 1. Process Description Ingredient Prep. & Storage Injection Tuna Council's Handbook

Tuna Council's Handbook Part 1. Process Description Thermal Process (retorting) Metal Detector Label, Pack & Storage LACF Tuna Council's Handbook

Part 2. Hazard Analysis Tuna Council's Handbook

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

Part 2. Hazard Analysis ‘Inclusive Approach’ for each processing step Tuna Council's Handbook

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

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

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

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

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

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

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

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

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

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. Tuna Council's Handbook

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. Tuna Council's Handbook

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. Tuna Council's Handbook

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

Ingredients Recv. & Storage Same as prior step Ingredients Recv. & Storage Sign. Justify Control CCP? Tuna Council's Handbook

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

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

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

Thermal Processing (retorting) Sign. Justify Control CCP? LACF Controls Tuna Council's Handbook

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

Label, Pack & Storage Sign. Justify Control CCP? Tuna Council's Handbook

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

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 Tuna Council's Handbook

Tuna Council's Handbook Part 3. HACCP Plan Tuna Council's Handbook

Tuna Council's Handbook Part 3. HACCP Plan CCP 1. Receiving to control incoming Scombrotoxins (elevated histamine levels) Tuna Council's Handbook

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 Tuna Council's Handbook

Tuna Council's Handbook Part 3. HACCP Plan CCP 3. Pre-Cooking to prevent subsequent histamine production Tuna Council's Handbook

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 Tuna Council's Handbook

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 Tuna Council's Handbook

Tuna Council's Handbook Part 3. HACCP Plan CCP 6. Metal Detection to eliminate metal fragments or inclusions Tuna Council's Handbook

Tuna Council's Handbook Part 3. HACCP Plan CCP 7. Labeling to declare potential food allergens Tuna Council's Handbook

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