Food Safety Enhancement Program Manual

Chapter 2 - Developing a HACCP System

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Section 3 - Generic Models

To help establishments develop their specific HACCP plans, the Canadian Food Inspection Agency and industry representatives have developed generic models. These models were designed by product or process. Individual establishments will customize the pertinent models for their own operations. Generic models are available as follows:

A - Meat and Poultry Products

1.	Beef Slaughter
2.	Boneless Beef
3.	Cooked Sausage
4.	Meat Spread (Cretons)
5.	Fermented Smoked Sausage
6.	Assembled Meat Product (Pizza)
7.	Dried Meat (Beef Jerky)
8.	Cooked/Sliced Ham
9.	Ready-to-Eat Poultry Products (Fully Cooked Chicken Wings)
10.	Ready-to-Cook Poultry Products (Chicken Breast Fillets)
11.	Chinese Style Dried Sausage
12.	Mechanically Separated Meat (Chicken)
13.	Poultry Slaughter (Chilled Ready-to-Cook Whole Chicken)
14.	Hog Slaughter
15.	Ready-to-Cook Poultry Products (Seasoned Formed, Breaded Chicken Burger)
16.	Prosciutto (Salted Ham)
17.	Fresh/Frozen Stored Products (Meat, Non-meat, Food, Non-food).

B - Egg and Processed Egg

Generic models for Egg and Processed Egg are not available at this time.

C - Processed Products (fruits, vegetables, honey, maple)

18.	Low Acid Canned Food
19.	Acidified Low Acid (Pickles)
20.	Frozen Vegetables
21.	Aseptic Fruit Juice
22.	Pasteurized Honey
23.	Maple Syrup (Packer).

D - Dairy Products

24.	Unsalted Butter
25.	Ice Cream
26.	Soft-serve Ice Cream
27.	UHT Milk.

E - Hatcheries

Generic models for Hatcheries are not available at this time.

3.1 - How to select a generic model

The generic models can be found on the CFIA Web site.

Your HACCP coordinator or team may select, from the list above, a model that best represents the process under review. You may need to add components from more than one model to accurately reflect your operation. (For example, your operation may include aspects similar to those in the generic models for both boneless beef and mechanically separated meat.)

3.2 - Limitations of generic models

Generic models serve as guidelines for various types of processes and products. You may find one or more of them useful as a starting point or template, but your establishment must adapt them to reflect specific plant conditions. By no means do the generic models list all hazards and/or control measures associated with each type of process and/or products.

The HACCP team at each establishment is responsible for identifying and controlling all hazards specific to the establishment's food processing operation. As a result of customizing HACCP generic models, HACCP teams may need to identify additional hazards that pertain to their establishments.

Similar considerations apply to sample flow diagrams that accompany the generic models. Your team must develop specific process flow diagrams and flow schematics to reflect the particular processes and layout of your establishment.

3.3 - Products or processes not covered

Although the generic models do not cover all products and processes, the models may contain processing steps that you would find useful for the development of a HACCP plan for similar products or processes.

For products or processes that differ significantly from any available generic model, the HACCP team must ensure that they continue to follow the seven principles of HACCP.

Section 4 - Developing HACCP plan(s)

Each establishment must conduct a complete hazard analysis for all of its processes and products in order to identify and control all hazards effectively. In performing the step-by-step analysis below, you may determine that several of your products share similar hazards, processing steps or equipment. In that case, the HACCP team may group these products or processes into one HACCP plan.

If your establishment chooses to group dissimilar processes or products into one HACCP plan, you will be required to demonstrate to the CFIA recognition team (see Chapter 3) that the HACCP plan identifies and controls all potential hazards.

There are 12 steps to developing each of your HACCP plans; these steps incorporate the 7 principles of HACCP. These steps are as follows:

1. Assemble your HACCP team.
2. Describe your product and identify its intended use.
3. List product ingredients and incoming material.
4. Construct a process flow diagram and a plant schematic.
5. Verify, on site, your process flow diagram and plant schematic.
6. List the hazards associated with each step and incoming material in your plant's process (Principle 1).
7. Apply the HACCP decision tree to determine CCPs (Principle 2).
8. Establish critical limits (Principle 3).
9. Establish monitoring procedures (Principle 4).
10. Establish deviation procedures (Principle 5).
11. Establish verification procedures (Principle 6).
12. Establish record keeping and documentation procedures for Principles 1 through 6 (Principle 7).

FSEP has taken these 12 steps and created 10 specific forms (found at the end of this chapter) that can be used for development of your HACCP plan.

Your company must perform a self-evaluation (internal audit) of its HACCP plan(s). You may use the FSEP/HACCP Plan Review and HACCP System Reassessment Checklist ( Appendix IV). During the self-evaluation, written and on-site, note any deficiencies you observe.  If a deficiency becomes known during the company's self-evaluation, either it must be corrected immediately or the company must develop a written action plan with specified time frames in which to address the deficiency.

4.1 - Assemble your HACCP team

Prior to selecting the members of your HACCP team, you will need to obtain, from all levels of management, full support for the HACCP initiative. Management will demonstrate such commitment by allocating resources to develop and implement HACCP. For example, resources will be needed for training employees who are responsible for HACCP and for maintaining the HACCP system on an ongoing basis.

Assemble a team of people with the expertise necessary to develop a HACCP plan. The team should be multidisciplinary and may include representatives from production, sanitation, quality assurance, food microbiology, maintenance and engineering.

The HACCP team should include personnel who are directly involved in the daily processing activities, since they will be familiar with the variability and limitations of the operations. By including these employees in the plan's development, you will foster a sense of ownership within your establishment. Your team may also solicit assistance from independent consultants for the development of its HACCP plans. However, a plan developed totally by outside sources may lack the support required from plant personnel.

When selecting the team, choose individuals who can help to identify hazards, determineCCPs, and monitor and verify CCPs.

HACCP team members should understand:

• the technology or equipment used on processing lines;
• the practical aspects of food operations;
• the flow and technology of processes;
• the applied aspects of food microbiology; and
• HACCP principles and techniques.

The remainder of this chapter describes how to complete the 10 forms that you may use for the development of your HACCP plan(s). If an establishment uses forms other than those found in this chapter, the content must be equivalent and provide sufficient detail as outlined on the FSEP forms.

4.2 - Description of product and identify of intended use (Form 1)

Provide a complete description of each food product. This will help the team identify hazards inherent in either the ingredients or the packaging materials.

To adequately identify and address hazards (including those affecting sensitive segments of the population), the HACCP team must be familiar with the product's properties, destination and use.

On Form 1, describe each product listed in the HACCP plan. Provide the following information:

4.2.1 - Process/product type name

Indicate the generic or common name of the product family or process covered by this HACCP plan. For example, in a dairy processing establishment, the HACCP plan for "Ice Cream" may apply to a process line for several varieties and flavours of products (ice cream, ice milk, frozen yogurt).

4.2.2 - Product name(s)

List, by brand name and/or common name, the individual products covered by this HACCP plan. Attach an additional page to Form 1 if you require more space.

In the dairy example mentioned above:

• the process/product type name is "Ice Cream;"
• the product names are "Cowland's Heavenly Hash Ice Cream," "No Name Chocolate Ice Milk" and "Cowland's Premium Vanilla Frozen Yogurt."

4.2.3 - Important product characteristics

Indicate those properties or characteristics of the product group that affect food safety.

Formulation or process schedules for specific characteristics are referenced.  In this case, any reference documents shall be made available at the time of review or subsequent audits.

4.2.4 - How the product will be used

Describe the uses of your product (e.g. ready-to-eat food product, ready-to-cook food product, or ingredient for a product destined for further processing).

4.2.5 - Packaging

List all types of packaging for this product (e.g. drums, pails, cryovac bags) and their applicable sizes. Include consumer-size packaging as well as bulk packs destined for further processing.

4.2.6 - Shelf life

List the anticipated shelf life of the product under normal marketing conditions at a given storage temperature and humidity. The generic model may indicate an industry-accepted shelf life. Confirm its applicability to your own food products. If your product's shelf life differs from that of the generic model, conduct validation studies to confirm the shelf life your team has specified.

4.2.7 - Where the product will be sold

List the points of sale or target groups for your product (e.g. retail - general population, retail - infant food, hospital).

4.2.8 - Labelling instructions

On the form, record any safe handling and usage information concerning the product. If applicable, include cooking and storage instructions and a "best before" date.

4.2.9 - Special distribution control

Describe special controls required during shipping and storage (e.g. temperature, humidity).

Form 1 Product Description Process/product type name: Pork Stew
1. Product name(s)	Pork Stew
2. Important product characteristics (aw, pH, preservatives, etc.)	N/A
3. How the product will be used	For further processing. Will be used in a prepared meal.
4. Packaging	Bulk product packaged in plastic pails with plastic liner and sealed with tamper-evident tape.
5. Shelf life	Frozen product: 12 months if kept at -18°C or colder Refrigerated product: "X" days at 4°C or less
6. Where it will be sold	Food processing establishment
7. Labelling instructions	(Frozen product) Keep frozen Production code (Refrigerated product) Keep refrigerated "Best before" date "Ready to eat" identified on label
8. Special distribution control	(Frozen product) Refrigerated truck -18°C or colder (Refrigerated product) Refrigerated truck +4°C or less

4.3 - List of product ingredients and incoming material (Form 2)

List all ingredients, incoming materials and processing aids that come in contact with the product or are used in preparing the product.

The HACCP team needs to ensure that all incoming materials and ingredients have been approved by the applicable regulatory agencies. Take particular care to check approvals for additives, processing aids and ingredients (including second generation ingredients), which are often approved for specific products only.

Form 2 List of Product Ingredients and Incoming Material Product name: Pork Stew
Meat	Non-meat ingredients	Packaging materials
Pork meat Product rework	Frozen vegetables Dried oregano Salt Pepper Dried gravy preparation (dehydrated vegetables (onions, garlic), salt, wheat flour, potato starch, corn syrup solids, MSG, sugar, natural flavour, canola oil, colour, spice, modified milk ingredient, sulphites) Water	Plastic liner Plastic pails

4.4 - Process flow diagram and plant schematic

4.4.1 - Process flow diagram (Form 3)

Construct the process flow diagram on Form 3 using information your team has gathered through interviews, observations of operations, and other sources (e.g. blueprints). In your process flow diagram, identify each step in the process, from receiving to final shipping. Include details useful in identifying hazards. The diagram should be simple; avoid cluttering it with unnecessary details.

4.4.2 - Plant schematic diagram (Form 4)

Construct the plant schematic diagram on Form 4. Indicate the flows of finished and raw products as well as employee traffic. Include the flows of all ingredients and packaging materials from the moment they are received through storage, preparation, processing, packaging, finished product holding and shipping. Indicate employee movement throughout the establishment, including change rooms, washrooms and lunchrooms. This diagram should be your primary tool for identifying potential areas of cross-contamination ( e.g. locations where allergen ingredients, food additives or raw ingredients could come into unplanned contact).

4.5 - On-site verification of process flow diagram and plant schematic

Once the process flow diagram and plant schematic have been drafted, conduct an on-site verification of their accuracy and completeness. Ensure that all the major process steps have been identified. Validate product and employee flows throughout the facility.

Form 3 Process Flow Diagram Product name(s) : Pork Stew

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Form 4 Plan Schematic Product name(s) : Pork Stew

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