HACCP - Canned Tuna

HACCP TASK – CANNED TUNA
Micheal Amoafo Mensah
Bobby Antan Caiquo
Sophia D. Amenyah
FOOD SAFETY

Introduction
Main
Hazards
• Quality of raw material – tuna (chemicals, microbes
• Survival of pathogens (C. botulinum spores) during the
retorting process
• Presence of heat stable toxins/allergens/biogenic
amines e.g. Histamine
• Contamination with physical material
• Recontamination of product after heat processing –
defective containers, poor sealing, contaminated
cooling water, poor handling of cans

Sources of
Contamination
Inappropriate
work
methodology
Equipment Personnel
Processing
Environment
• Clostridium botulinum A,B,E,F
• Salmonella spp
• Shigella spp
• Staphylococcus aureus
• Escherichia coli O157:H7
Associated
Microorganisms

Concerning Potential hazard Type Preventive measure PxE = R CCP CP PRP
Reception
of Tuna and
Salt
1.Insufficient microbiological
quality
a. delivery of insufficiently
fresh fish
b. delivery at too high
temperature
c. delivery of bruised or
physically injured fish
d. poor hygienic conditions of
fishing vessel, equipment and
storage facilities
2. High levels of biogenic
amines (histamine)
3. Presence of chemicals and or
their residues in fish
4. Presence of foreign materials
in: a.Tuna b.Salt
M
A
C
P
1. Clear supply specification: fish must
be fresh, delivered at the right
temperature and with no physical
injury.
Fishing vessel must be in a good
hygienic condition
2. Clear Supplier Specification: rapid
chilling of fish immediately after
capture. Generally, fish should be
packed in ice or chilled sea water in
less than 12 h after catch or – in case of
large fish such as tuna – chilled to an
internal temperature of 10°C or less
within 6 h after capture.
3. Check for limits of mercury
4. Visual inspection to detect presence
of foreign materials in tuna and salt
1 x 3 =
3
3 x 3 =
4
3 x 3 =
3
1 x 1 =
1
-
CCP
1a
CCP
1b
-
CP
1
-
-
-
9
-
9/
12

Concerning Potential hazard Type Preventive measure P x E = R CCP CP PRP
Intermediate
Storage of
Fish
1. Growth of microbes due
to interruption of the cold
storage temperature.
M Fish after quality checks must be
stored immediately at -18oC.
Temperature must be controlled and
monitored.
1 x 3 = 3 - - 4/ 9
Receipt
and storage
of cans and
lids
1. Delivery of low quality or
damaged cans and lids
2. Damaged cans and lids due
to improper handling and
storage
3. Contamination of cans due
to poor storage conditions.
P
P
M
1. Purchase policy / Purchase
specifications
Visual inspection of all lots of empty
cans and lids
2. Cans must not be stacked too
high (2m limit) and carefully
handled.
3a. Humidity of storage room must
be kept low to prevent growth of
microorganisms.
b. Good air quality.
1 x 3 = 3
1 x 3 = 3
2 x 3 = 4
CCP
1c
-
-
-
-
-
-
9
3/ 9

Preparation
of Brine
1.Insufficient microbiological
quality
a. use of non-potable water
b. poor hygienic conditions of
mixing equipment and
personnel
c. poor hygienic conditions of
pump
d. Insufficient heating of brine
2. Presence of foreign
materials in brine
M
P
1a. Use and analysis of potable water
b. Proper cleaning of equipment and
adherence to strict personal hygiene
by personnel
c. Pump must be cleaned regularly
d . Control and registration of
temperature of brine
2. Monitoring and changing filter
regularly
2 x 3 = 4
2 x 2 = 3
-
-
-
-
3
5/6
6
4
7/
12
Thawing Microbial growth due to time
and temperature abuse resulting
in under or over thawing
Poor quality of thawing water
M Monitoring and control of
backbone temperature of tuna
Use of potable water to reduce
bacterial growth
3 x 3 = 4 - - 4
3

Pre-
cooking
Growth of microbes,
development of resistance and
survival of spores
M Adequate cooking time and
temperature control to prevent
microbial growth
2 x 3 = 4 - CP
2
4
Cooling Microbial growth and
germination of spores
M Fast cooling of precooked tuna
Use of potable water
2 x 3 = 4 - - 4
3
Heading/g
utting/filleti
ng
1. Additional microbiological
contamination through knives
and gutting equipment
2. Additional microbiological
contamination through
personnel
3. Contamination with broken
parts of knives and other
gutting equipment
M
M
P
1. Clear work instructions; only
clean knives must be used and also
be changed regularly
2. Personal hygiene and strict
hygienic practices by personnel
3. Visual check of cutting tools,
replacement and regular
maintenance.
2 x 3 = 4
2 x 2 = 3
-
-
-
-
-
-
5
6
6/7

Cutting 1. Additional microbiological
contamination through cutting
equipment
M Cutting equipment must be clean.
Visual checks and maintenance
must be carried out regularly.
2 x 3 = 4 - - 6/7/
14
Metal
Detection
1. Presence of metal pieces
in tuna
P Use of an effective metal detector 4 x 3 = 6 CCP
2
- -
Unpalleting
of cans
1. Introduction of foreign
objects through the
environment.
2. Damaged cans due to
improper handling during
unpalleting
P/M
C
General guidelines for hygiene and
guidelines for order and cleanliness
Proper handling of cans during
unpalleting to maintain their quality
2 x 3 = 4
1 x 3 = 3
-
-
-
-
6/12
12/1
4

Washing and
turning of cans
Microbial contamination
through washing water
M Use of potable water 2 x 3 = 4 - - 3
Filling 1.Cross contamination from
previous fish stuck/left in the
filler
2.Improper heat penetration
due to
i. Over filling
ii. under filling of cans
P 1. Proper cleaning of filler before
filling begins
2. Regular visual check (every half
hour) by floor supervisor
2 x 2 = 3 - - 1/14
14

Concerning Potential hazard Type Preventive measure P x E =R CCP CP PRP
Sealing and
Coding
1. Additional microbial
contamination from
- microbes on the lids
- the sealer
2. Additional cross
contamination with dust, small
pieces of metal or plastic from
the can lids/coverings
3. Faulty sealing of cans due
to
- faulty sealing machines
- poor quality cans
4. Lack of traceability
M
P
M/P
M/P/
C/A
1&2. Proper cleaning and disinfection
of cans and lids/coverings before they
are used
3a. Visual inspection to check if cans
are hermetically sealed.
3b.Can closures must be checked at
regular intervals visually and always
when setting up a new machine or
adjusting an old one.
3c. Tear down measurements must be
done at the beginning of the shift and
every 30min thereafter by Q.C.
4. Proper coding of the cans must be
ensured.
2 x 3 = 4
2*2 = 3
2*3 = 4
2*3 = 4
-
-
-
-
-
-
CP
3
-
1/14
1/14
7/14
10

Concerning Potential hazard Type Preventive measure P x E =
R
CC
P
CP PRP
Heat
Processing
1. Survival of pathogens,
spoilage microbes and spores
due to improper time
temperature combination
during retorting
2. Contamination via retorting
water
3. Damage of cans due to
pressure and agitation during
retorting
M
M
P
1. Monitoring of heat processing
machine panels to make sure the right
heating temperature and time is in use.
2. Use of potable water
3. Proper caging of cans before
retorting
4 x 4 = 7 CC
P 3
- -
R
CC
P
CP PR
P
Caging Damage to cans during caging P Proper handling of cans 1*2 = 2 - - 14
R
CC
P
CP PR
P
Washing
after
sealing
1. Microbial contamination of
products due to poor quality of
washing water.
2. Chemical contamination
M
C
Use of potable water
Washing water must not exceed the
critical limit for certain chemicals
2*3 = 4
2*3 = 4
-
-
-
-
3
3/1
4

R
CC
P
CP PRP
Transport/
Dispatch/R
etail
Damage of cans during
transport
a. Dented cans
b. Rusted cans
P
C
Proper handling and stacking of
packaged cans on pallets.
2 x 2 = 3 - - 12/
14
R
CCP CP PRP
Storage/
Release
1. Poor storage conditions M Clear work instructions; good
hygienic and storage conditions
2 x 2 = 3 - - 1/
9/14
R
CCP CP PRP
Uncaging Damage to cans during
uncaging
P Proper handling of cans 2 x 3 = 4 - - 12/
14
R
CCP CP PRP
Cooling/
Drying
1. Additional microbial post-
contamination via cooling water
M Use of potable water 4 x 3 = 6 CCP 4 - -

CCP Critical Limits
&Tolerances
Monitoring Corrective Actions Action by
1.Reception
2. Metal
Detection
3. Heat
Processing
4.Cooling/Dryi
ng
Frozen fish < -18oC
- Fresh fish 0˚C
- Histamine < 50ppm
- Mercury < 0.8ppm
- Cans must meet container
specification for safety.
- Absence of metal pieces
- Critical limit is the
botulinum cook or 12-D
process
- There must be measurable
residual chlorine in the water
(critical limit- 0.5mg/l)
- Measure temperature upon
receipt and request temperature
history of tuna
- Visual inspection
- Sample for histamine and
mercury
- Letter of guarantee from
supplier. Visual examination of
all lots of empty cans
- Regular checks and cleaning
of metal detector
- Periodic checks on heat
distribution in retort and
temperature recording
equipment
- Records on all actions and
measurements must be kept and
reviewed daily
- Cooling water should be
tested (microbial quality and
chlorine residue) at least two
times per day by a designated
person
- Inform/change supplier
- If histamine < 50ppm, increase
surveillance at gutting and filleting
- Reject defective cans, contact
supplier
- Stop production, fix and recalibrate
the detector before continuing
production
- If time/temperature requirements
are violated, products must be put on
hold for reprocessing and the cause
must be identified.
- Review of all operations and
monitoring procedures and
calibration of thermometers and
automatic recorders
- Production must be stopped if water
is contaminated or critical limit
exceeded, water treatment must be
adjusted and the source of
contamination investigated
QC manager and
QC analyst
Control
Production worker
Correction
Production
manager
Control
Production worker
Correction
Production
manager
QC analyst and
manager
HACCP-HANDBOOK Page : 23
NAME Company CCP MONITORING TABLE Date :
PRODUCT: CANNED TUNA Flow chart :

CP Description CP Monitoring Corrective action Documents Action By
1
2
3
Raw Tuna – Number of
microbes and spores
Pre-Cooked Tuna –
Number of microbes and
spores
Canned Tuna – Faulty
Sealing
- Measure temperature upon
receipt
- Conduct microbial analysis
for each batch received
- Monitor cooking time and
temperature
- Measure, record and review
all actions
- Check can closures at regular
intervals
- Visual inspection of seam
- Seam tear down
Do not use batch until the
certificate of analysis is
delivered
If time/temperature
requirements are violated,
products must be put on
hold for adjusted time and
temperature retorting and
the cause must be
identified.
- Recalibration of
thermometers and
automatic recorders
- Shut down processing
line and inform
production manager
- All products produced
since last check should be
put on hold.
- Cause of problem must
be investigated
- Record all actions
- Purchase specifications
- Certificate of analysis
- Work instructions for
incoming raw material
- Temperature recording
charts
- Investigation report
- Seamer inspection report
- Visual inspection report
- Seam tear down report
- Investigation report
QC Analyst
Receipt
Responsible
Production
Manager
Production
Manager
HACCP-HANDBOOK Page : 24
NAME Company CP MONITORING TABLE Date :
CANNED TUNA

HACCP - Canned Tuna

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