| Processing Step |
GMP No |
Hazard Type |
Hazard |
CCP |
Preventive Measures |
Monitoring |
|
Receiving
|
1.1
|
Quality Safety
|
- Decomposed fish
- Damaged fish |
Receiving area |
- Control supply source
- Have supplier provide a product
temperature history |
- Measure temperature upon receipt
- Visual inspection
-Sample for histamine testing |
|
Butchering
|
1.2
1.3
|
Quality Safety
|
- Decomposed fish
- Histamine |
Butchering tables
|
- Control temperature of fish
- Control lag time from end of thaw to end of butchering
|
- Measure backbone temperature
- Sensory inspection
- Take sample for histamine analysis
|
|
Loin Cleaning
|
6.4
|
Quality
|
- Decomposed fish
- Green meat, orange meat or honeycomb
|
Loin cleaning tables
|
- Control lag time from end of cooking
to end of cooling
- Control time of loin cleaning and
hygienic practices
- Train workers to detect loin
|
- Measure temperature and time of
cooling
- Visual inspection
- Sanitation inspection |
|
Packing
|
7.2
7.3.2
|
Safety
|
- Defect empty can
|
Empty can storage area
|
- Select can suppliers
- Set up empty can sampling plan and
specification required
- Train workers on container integrity |
- Visual and seam tear down inspection
upon arrival
- Visual inspection prior to feeding to
line |
|
7.3.2
|
Safety
|
- Over fill |
Weighing table |
- Adjust packing machine
- Calibrate balance and weigh used
|
- On-line weigh check
- Calibration of balance
|
|
Seaming
|
7.4.3
|
Safety
|
- Defect double seam
|
Seamer |
- Adjustment of seamer
- Test run before use
- Train QC/seam mechanic
|
- Visual seam inspection
- Seam tear down |
|
Retorting
|
8
|
Safety
|
- Improper processing resulting in
outgrowth of microbes and toxins |
Retort area |
- Train retort operators
- Establish schedule process
- Retort equipment checked and calibrated
- Close surveillance of operations (by
QC/QA) |
- All thermal processes
- Operations |
|
Post Process Handling
|
9.2
|
Safety
|
- Post Process contamination |
Cooling zone |
- Restrict area
- Traffic control
- Sanitation |
- Check admittance to area (visual
inspection)
- daily sanitation check |
| Processing Step |
Critical Limits |
Corrective Actions |
Verification |
Records |
|
Receiving
|
Frozen fish < -18°C
Fresh fish ~0°C
Histamine < 50ppm |
- Inform/change supplier
- If histamine >50ppm, increase
surveillance at butchering |
- Annually, conduct survey of supplier
handling system
- Conduct histamine/
temperature relationships
|
- Supplier temperature record
- Raw materials receiving record
- Supplier sources and history
|
|
Butchering
|
Histamine <50ppm
Fish temperature 0 - 5°C
Lag time 2 hours |
- If >10% grade 3 fish, lot should be
individually culled
- If >10% grade 4 (rejected) fish found,
lot should be rejected
- If histamine >50ppm, increase
surveillance, more culling for sensory test
- Inform supplier
- Reduce volume on line
|
- Occasional increased samples for
sensory and histamine analysis
- Check graders' competence with histamine
determination |
- Raw fish grading form
- Chemical analysis form
- Lot processing record
- Training record |
|
Loin Cleaning
|
- Lag time not >6 hours
- Loin cleaning time <1 hour
- No defect or decomposed loin
- Sanitation: visually accepted |
- If lag time exceed limits, adjust
production volume, fish should be put in chilled room for any delay anticipated
- Increase surveillance at butchering table
- Improve cleaning and sanitation
|
- Run pre-cooking test
- Conduct histamine/
temperature relationship
- Check samples on workers and graders
- Plant sanitation inspection daily |
- Cooling time and temperature record
- Loin cleaning and quality record
- Training record |
|
Packing
|
[Based on sampling plan and can
specifications] |
- Segregate defect cans
- If more than acceptance no. reject
lot |
- Inspection of can manufacturers
- Obtain QC programme of can
manufacturers
|
- Record of can manufacturers audit
- Empty can inspection record
- Can storage, depalletization and feeding
log
- Can specifications
- Training record |
Packing
|
[Based on value specified in process
establishment] |
- Segregate defect can
- If more than acceptance no. adjust
packing machine |
- Inspection of performance and
practices
- Record check |
- Record of empty can manufacturers
audit
- Empty can inspection record
- Can storage, depalletization and feeding
log
- Can specification
- Training record |
| Seaming |
[As determined in initial verification according to size
of can] |
- Closing machine maintenance and adjustment - Hold
products for further investigation |
- Inspection of performance and practice - Record
check |
- Seamer inspection report - Visual inspection report
- Seam tear down report - Investigation report |
| Retorting |
[As determined in initial verification - calculated for
each retort, can size and product type] |
- Hold lot/reprocess lot |
- Periodic checks on heat distribution in retort and
temperature recording equipment. Have process verified by competent authorities.
Check competence of operation. - Record review daily |
- Retort operation record - Temperature recording
charts - Investigation report |
| Post-Process Handling |
Entrance to authorized personnel only |
- Stop unauthorized entrees |
- Review of traffic control programme by inspection -
On-site verification |
- Product control report - Investigation report |