Element 2: Background Product and Process Information

MINIMUM REQUIREMENTS

Processors are required to identify product and process information in the form of a product description for each type of product, a process flow diagram, and where necessary, a plant floor plan.

The product description must identify those product attributes and characteristics that are important in ensuring a safe and acceptable fish product.

The process flow diagram must outline all of the production steps and assists in identifying those steps that are important in processing a safe fish product meeting all regulatory requirements.

The plant floor plan is obligatory for plants with sanitary zones and restricted-access zones.

PRODUCT DESCRIPTION

A QMP Plan must include the necessary controls specific to the operations in place and the products produced. Therefore, before a QMP Plan can be written, information must be gathered about the attributes and characteristics of the products and processes that influence product safety and quality.

Step 1

Prepare a list of all products processed by the facility.

Step 2

For each product, record all relevant characteristics such as:

• product name;
• source of raw material;
• important characteristics of the final product;
• all ingredients;
• product packaging;
• end product use;
• product shelf life;
• market destination;
• labelling instructions for safe product storage (where applicable);
• special distribution controls or instructions (where applicable).

Figure 2 shows an example of a product description form that can be used to organize this information.

Step 3

Group the products according to their attributes and the controls they need.

Figure 2: Product Description Form

Note: A blank version of this form can be found in Appendix B

1. PRODUCT NAME(S)	Identify the species and method of processing; e.g. "Frozen sole fillets."
2. SOURCE OF RAW MATERIAL	State where it came from; e.g., "Locally caught" or "Imported from China."
3. IMPORTANT FINAL PRODUCT CHARACTERISTICS	List characteristics that affect product safety, especially those that influence pathogens, such as pH level or salt concentration.
4. INGREDIENTS	List every substance added during processing; e.g., water, salt. Also list all ingredients of sauces and batter or crumb coatings.
5. PACKAGING	List all packaging materials; e.g., waxed cardboard, polyethylene wrapping. Only approved materials may be used.
6. HOW THE END PRODUCT IS BEING USED	State how the final product is to be prepared for serving, especially whether it is ready to eat.
7. SHELF LIFE (IF APPLICABLE)	State the date when the product can be expected to begin to deteriorate if stored according to instructions; e.g., "Use within 21 days of shipping."
8. WHERE THE PRODUCT WILL BE SOLD	If the product is for export only - that is, it contains an ingredient or labelling not permitted in Canada - include this information so that the product goes only to a market where all its ingredients are permitted and the labelling is acceptable.
9. SPECIAL LABELLING INSTRUCTIONS	List all instructions for safe storage and preparation; e.g., "Keep refrigerated."
10. SPECIAL DISTRIBUTION CONTROL	List all instructions for safe product distribution; e.g., "Keep refrigerated."

PROCESS FLOW DIAGRAM

The purpose of the process flow diagram is to clarify and document the process and, eventually, to help the processor pick out the process steps where control measures and monitoring procedures would be most effective. Therefore, the process flow diagram should include all process steps and highlight the specific steps that are significant to product safety.

Step 1

Develop a process flow diagram for each of the products or groups of products that are produced at the facility. A plain block schematic, like the sample in Figure 3 for a fresh and frozen groundfish plant, is adequate.

Step 2

When the process flow diagram is finished, walk through the plant with it and verify that it is complete and accurate.

Step 3

When the QMP Plan is complete, indicate the RAPs and CCPs on the process flow diagram.

Click for larger image

Figure 3: Sample Process Flow Diagram - Fresh and Frozen Groundfish Plant [D]

PLANT FLOOR DIAGRAM

If, during the development of a HACCP Plan, hazards are identified that can be controlled by using sanitary zones or restricted areas (for example, in cooked or canned fish products), the QMP Plan must show where these areas will be. This can be achieved with a schematic indicating the flow of materials, traffic and product that outlines the sanitary zones and restricted access areas. An example of a floor plan for a hot-pack cooked lobster operation is shown in Figure 4.

Step 1

If the application of sanitary zones or restricted access areas have been identified as a control measure in the development of the HACCP Plan, develop a plant floor diagram outlining these areas.

Step 2

When the plant floor diagram is finished, walk through the plant with the diagram and check that it is complete and accurate.

Click for larger image

Figure 4: Sample Plant Floor Diagram - Hot Pack Lobster Operation [D]

 

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