Food safety plan hot dogs

Venitia Sequeira, Varshaa Narayanan, Goutham Matta

Food Safety Plan for Hot dogs

A hot dog is a cooked sausage, traditionally grilled or steamed and served in a sliced bun as a sandwich

Hot dog variants include the corn dog and pigs in blankets

What is a hot dog?

Fun Facts:

Food on the moon! Hot dogs were of the first food eaten on the moon. Apollo 11 astronauts Neil Armstrong and “Buzz” Aldrin Jr. ate hot dogs on their 1969 journey

Product: Fully cooked chicken sausage Plant Name: The Hot Dog Company Issue Date 12/6/2016Address: Menomonie, WI 54751 Supersedes 12/6/2015

Background Information:Company Overview and Food Safety TeamThe Hot dog Food Company’s ~150 employees produce meat-based products, including sausages, brats, wieners. Product is made 5 days a week in one 8 hour production shift, followed by 4 hours for sanitation. Cleaning and sanitizing of all processing equipment is conducted per a master sanitation schedule, which also includes cleaning and sanitizing between different products if needed for allergen control. Municipal water, which is treated and tested per EPA requirements by the city, is used throughout the facility. The company practices hygienic zoning to prevent cooked product exposure to environmental pathogens and employees working in the high hygiene areas wear color coded smocks and dedicated footwear. These employees are instructed on proper hand washing procedures, glove use, and importance of zoning.

Key terms: B – Biological Hazard P – Physical Hazard C – Chemical Hazard SOP – Standard Operating Procedure SSOP – Sanitation Standard Operating Procedure GMPs – Good Manufacturing Practices USDA – U.S. Department of Agriculture FSIS – Food Safety and Inspection Service

Product Description, Distribution, Consumers and Intended Use

Product Name(s) Chicken Sausage (Fully cooked, not shelf stable) Product Description, including Important Food Safety Charac-teristics

Refrigerated, chicken sausage pH 5.0-5.3, water activity>0.99 , with preservatives

Ingredients Chicken, water, salt, modified food starch, potassium chloride, spices, sodium phos-phatesodium erythorbate, sodium nitrite, collagen casings

Packaging Used Vacuum-packaged in plastic film; bulk-packed in plastic bag in cardboard box.

Intended Use The product is considered ready-to-eat, but is typically heated to hot holding tempera-ture (135°F (57°C)) or above for palatability. Heating is typically conducted using microwaves or convection oven. End user may thaw at refrigeration temperatures overnight to reduce cooking time. Sold for foodservice applications. Potential abuse: Some establishments may hold thawed product for longer than the recom-mended 24 hrs

Intended Consumers Retail consumersShelf Life 40-60 days with proper refrigeration (< 40°F)Labeling Instructions Keep frozen and serve within 7 days after opening. Thaw under refrigeration

(<40°F (5°C)) for <24 hours before cookingStorage and Distribution Shipped in refrigerated trucks. Product should remain in refrigerated or frozen state

(< 40°F)

Receiving packaging (labelled carton plastic

film and plastic bag)

Receiving shelf stable ingredients (Salt, modified food starch, spices, collagen casings, sodium nitrite,

sodium phosphate, sodium erythorbate and potassium chloride)

Receiving frozen ingredients

(Raw Chicken)

Packaging storage (labeled carton, plastic

film, plastic bag)

Ambient ingredient storage

Frozen ingredient storage

(Raw chicken) Weighing shelf stable ingredients

Chopping and mixing

Stuffing

Cooking

Cooling

Packaging/Labelling

Metal detector

Finished product storage

Shipping and distribution

Weighing and pre-grinding raw

meat

Water

Hazard Analysis

(1)Ingredient/Processing

Step

(2)Identify potential

food safety hazardsintroduced,

controlled orenhanced at this step

(3)Do any

potential food

safety hazardsrequire a

preventivecontrol?

(4)Justify your decision for column (3)

(5)What preventive control

measure(s) can be applied to significantly minimize prevent the food safety hazard? Process including CCPs, Allergen, Sanita-tion, Supply‐chain, other

preventive control

(6)Is the

preventivecontrol

applied atthis step?

Yes

No

Yes

No

Receiving packaging (labelled carton plastic film and plastic bag)

B Contamination with biological materials

Yes

Packaging may be contaminated with biological contaminants

•Visual inspection for container integrity, contamination, at receiving

•Letters of guarantee are received from all suppliers enclosed during transportation of packaging materials

Yes

C Non-food grade materials like color additives, inks, indirect additives

Yes Packaging may be contaminated with non-food grade materials like color additives, inks, indirect additives

Yes

P Foreign materials Yes

Packaging may be contaminated with foreign materials

Yes

Click to add title(1)

Ingredient/Processing

Step




(3)Do any

potential food safety

hazardsrequire a

preventivecontrol?

(4)Justify your decision for

column (3)


measure(s) can be applied to significantly minimize orprevent the food safety hazard? Process including CCPs, Allergen, Sanita-tion, Supply‐chain, other

preventive control

(6)Is the

preventivecontrol


Yes

No

Yes

No

Receiving shelf stable ingredients (Salt, modified food starch, spices, collagen cas-ings, sodium ni-trite, sodium phosphate, sodium erythorbate and potassium chloride)

B None No SOP for Receiving and Storage makes hazards unlikely to occur

C Ingredients con-taining undesirable substances

No Letters of guarantee are received from each supplier of food additives, spices, cure mix, binders, etc.

P Contamination from extraneous material (wood, nails from pallets, plastic pieces)

Yes Contamination from extraneous material (wood, nails from pallets, plastic pieces)

Product must be received in sound containers. This may be included in the plant's GMPs

Yes



Step




(3)Do any


hazardsrequire a

preventivecontrol?


Column (3)


measure(s) can be applied to significantly minimize or

prevent the food safety hazard? Process including CCPs, Allergen, Sanitation,

Supply‐chain, otherpreventive control

(6)Is the

preventivecontrol


Yes

No

Yes

No

Receiving frozen ingredi-ent(Raw Chicken)

B Presence of pathogens:Salmonella, Listeria mono-cytogenes, Staphylococcus aureus, Clostridium per-fringens, Clostridium bo-tulinum, Campylobacter je-juni/coli

Yes • Raw meat is a known source of pathogens• Likely to be present in

incoming meat

Hazard will be controlled later-- by cooking to minimum 158ºF (destroys vegetative cells) and cooling/freezing (prevents germination and growth of clostridial spores)

No – controlled in cooking step

C Antibiotics, Growth hormones

Yes

Chickens are supplemented with growth hormones and antibiotics

Letters of guarantee are received from supplierPeriodic hormone level check

Yes

P Foreign particle contamination, e.g., metal fragments or bones

Yes Raw chicken may contain pieces of bones or metal fragments

•Metal Detector•Product must be received from an approved supplier who follows food safety plan•Visual examination of product for foreign materials

No – controlled in metal -detection

step



Step




(3)Do any


hazardsrequire a

preventivecontrol?



measure(s) can be applied to significantly minimize or prevent the food safety

hazard? Process in-cluding CCPs, Allergen, Sanitation, Sup-ply‐chain, other preven-

tive control

(6)Is the

preventivecontrol


Yes

No

Yes

No

PackagingStorage (labeled carton, plastic film, plastic bag)

B Contamination with meat, other biological materials

No Product must be received from an approved supplier who produces packaging under a food safety plan

C Non-food grade materials like Color additives, inks, indirect additives

No Letters of guarantee are received from supplier

P Foreign materials No •Visual examination of product for foreign materials• No materials that appear to be contaminated with foreign material will be used



Step




(3)Do any


hazardsrequire a

preventivecontrol?


Column (3)

(5)What preventive controlmeasure(s) can be applied to significantly minimize or prevent the food safety hazard?

Process including CCPs, Allergen, Sanita-

tion, Supply‐chain, other preventive con-

trol

(6)Is the

preventivecontrol


Yes

No

Yes

No

Ambient ingredient storage (Salt, modified food starch, spices, collagen casings, sodium nitrite, sodium phosphate, sodium erythorbate and potassium chloride)

B Growth of L. monocytogenes due to insufficient use of antimicrobial agent

No Proper formulation ensures effectiveness of antimicrobial additives in preventing out-growth of certain pathogens

C None No SOP for Receiving and Storage makes hazards unlikely to occur

P None No SOP for Receiving and Storage makes hazards unlikely to occur



Step

(2)Identify

potentialfood safety

hazardsintroduced,

controlled orenhanced at this

step

(3)Do any

potential food safety hazards require aPreventive control?


column (3)


measure(s) can be applied to significantly minimize or

prevent the food safety hazard? Process including CCPs, Allergen, Sanitation,

Supply‐chain, otherpreventive control

(6)Is the

preventivecontrol


Yes

No

Yes

No

Frozen ingredient storage (raw chicken)

B Presence or growth of pathogens

Yes (Presence)

No (Growth)

Raw meat/poultry is a known source of pathogens

Pathogens are unlikely to grow if raw poultry is stored according to the SOP for storage

Hazard will be controlled by later CCP’s of cooking (destroys vegetative cells) and cooling/freezing (prevents germination and growth of clostridial spores)

C None No SOP for receiving and storage makes hazards unlikely to occur

P None No SOP for Receiving and Storage makes hazards unlikely to occur



Step




(3)Do any


hazardsrequire a

preventivecontrol?


column (3)


measure(s) can be applied tosignificantly minimize or

prevent the food safety hazard?Process including CCPs, Allergen,

Sanitation, Supply‐chain, otherpreventive control

(6)Is the

preventivecontrol


Yes

No

Yes

No

Thaw frozen meat

B Cross-contamination and outgrowth of the Salmonella and Campylobacter je-juni/coli

Yes Product temperature increase into danger zone is likely to occur during thawing process

Thaw meat below 40°F.When thawing meat, surface temperature is a concern and should be monitored

Maximum water temperature of 70°F while thawing and cooking to minimum of 158°F

(Reference: USDA Food Safety Education)

No

C No common hazard No SOP for thawing makes hazards unlikely to occur

P No common hazard No SOP for thawing makes hazards unlikely to occur



Step




(3)Do any


hazardsrequire a

preventivecontrol?

(4)Justify your decision for Column (3)


measure(s) can be applied to significantly minimize or prevent the food safety hazard? Process in-

cluding CCPs, Allergen, Sanitation, Sup-ply‐chain, other preven-

tive control

(6)Is the

preventivecontrol


Yes

No

Yes

No

Weighing shelf stable ingredi-ents

B Outgrowth of L. monocytogenes in the final ready-to-eat (RTE) product due to insufficient use of Antimicrobial agent

No Proper formulation ensures effectiveness of antimicrobial additives in preventing outgrowth of certain pathogens in the final RTE product

C Weighing and addition of improper levels of ni-trite or nitrate or other GRAS ingredients.

No When using nitrate or nitrite, a check system should be in place to ensure the correct amounts are usedThe USDA limit for nitrite is 156 ppm in hot dogs

P No common hazard No SOP for Receiving and Storage makes hazards unlikely to occur



Step




(3)Do any

potential food safety hazards require a preventive

control?


Column (3)

(5)What preventive controlmeasure(s) can be applied to significantly minimize or prevent the food safety hazard? Process including CCPs, Allergen, Sanitation, Supply‐chain, other

preventive control

(6)Is the

preventivecontrol


Yes

No

Yes

No

Weighing and pre- grinding raw meat

B Presence or growth of pathogens (Salmonella, Listeria monocytogenes, Staphylococcus aureus, Clostridium perfringens, Clostridium botulinum Campylobacter jejuni/coli)Cross-contamination with pathogens via equipment or workers

Yes(Presence)

No(Contamination)

Raw meat is a known source of pathogens

Pre-operational and Operational SSOPs make hazard unlikely to occur

Hazard will be controlled by later steps of processing like cooking to 157oF (destroys vegetative cells) and cooling/freezing to below 40oF (prevents germination and growth of clostridial spores)

No – controlled in cooking

step

C Cleaning/sanitizing chemical residues

No Pre-op and SSOP makes presence of chemical residues unlikely to occur

P Bones No SSOP makes hazards unlikely to occur


Step




(3)Do any

Potential food safety

hazardsrequire a

preventivecontrol?


(5)What preventive

control measure(s) can be applied to significantly min-

imize or prevent the food safety hazard? Process in-cluding CCPs,

Allergen, Sanitation, Supply‐chain,

otherpreventive control

(6)Is the

preventivecontrol


Yes

No

Yes

No

Addition of Water

B None No Municipal water is received and utilizedLetters of guarantee received from municipality

C Chlorine, lead, mercury, arsenic

No Frequent lab testing for chlorine, lead, arsenic, mercury

P Suspended sediments or organic materials

No Water must be received from an approved source, which makes presence of residues unlikely to occur

Click to add titleIngredient/Processing

Step

Identify potentialfood safety hazards

introduced,controlled or

enhanced at this step

Do anypotential food safety hazards require a

preventive control?

Justify your decision for Column (3)

What preventive controlmeasure(s) can be applied to significantly minimize or prevent the food safety hazard? Process including CCPs, Allergen, Sanitation, Supply‐chain, other preventive control

Is thepreventive

controlapplied atthis step?

Yes

No

Yes

No

Chopping and Mixing

B Potential outgrowth or presence of pathogens (Salmonella, Listeria monocyto-genesStaphylococcus aureus, Clostridium botulinum Campy-lobacter jejuni/coli)

Cross-contamination from unclean equipment

Yes(Presence)

No(Contamination)

Raw meat is a known source of pathogens Pre-op and Operational SSOPs make hazard unlikely to occur

Hazard will be controlled by later steps of processing like cooking (destroys vegetative cells) and cooling/ freezing (prevents germination and growth of clostridial spores)

No – controlled in cooking

step


No Pre-op SSOP makes presence of chemical residues unlikely to occur

P Metal and other physical contamination from grinder, mixer, or chub clips

No Implementing metal detector for screening which makes hazard unlikely to occur. No history of problem (must provide evidence)

FSIS Directive 7310.5 states that a processor should use the most sensitive detection technique available

Click to add titleIngredient/Processing

Step

Identify potentialfood safety hazards

introduced,controlled or

enhanced at this step

Do anyPotential food safety hazards require

aPreventive control?

Justify your decision for Column (3)

What preventive controlmeasure(s) can be applied to significantly minimize or prevent the food safety hazard? Process including CCPs, Allergen, Sanitation, Supply‐ chain, other preventive control

Is thepreventive

controlapplied atthis step?

Yes

No

Yes

No

StuffingB Potential outgrowth or

presence of pathogens (Salmonella, Listeria monocytogenes, Staphylo-coccus aureus, Clostrid-ium perfringens, Clostridium bo-tulinum Campylobacter jejuni/coli)

Contamination from unclean equipment

Yes(Presence)

No(Contamination)


Maintain raw meat temperature at 40ºF or below during final stuffing, plus cooking to minimum of 158ºF

SSOPs makes contamination via equipment and workers un-likely to occur

No – con-

trolled in

cooking step


No Pre-op SSOP makes presence of chemical residues unlikely to occur

P Metal Yes Possibility of presence of metal fragments from equipment

Metal detection No



Step




(3)Do any potential food safety

hazards re-quire a preven-

tivecontrol?

(4)Justify your decision for Column (3)

(5)What preventive control measure(s) can be applied to significantly minimize or prevent the food safety hazard? Process including CCPs, Allergen, Sanitation, Supply‐chain, other preventive con-

trol

(6)Is the

preventivecontrol


Yes

No

Yes

No

Cooking B Survival or growth of pathogens (Salmonella, Listeria monocytogenes, Staphylo-coccus aureus, Clostridium perfringens, Clostridium botulinum Campylobacter jejuni/coli)

Yes(Presence)


The final internal temperature and holding time of the product are recommended to reach a temperature of 158ºF, such that Salmonella lethality level is reduced 7.0 log units Source: FSIS

Yes

C No common hazard No SSOP makes hazards unlikely to occur

P No common hazard No SSOP makes hazards unlikely to occur



Step




(3)Do any potential food safety

hazards re-quire a preven-

tivecontrol?


Column (3)

(5)What preventive control measure(s) can be applied to significantly minimize or prevent the food safety hazard? Process including CCPs, Allergen, Sanitation, Supply‐ chain, other preventive control

(6)Is the

preventivecontrol


Yes

No

Yes

No

Cooling B Growth of spores Clostridium perfringens or Clostridium botulinum

Contamination with Listeria monocyto-genes and potential subsequent growth

No

No

Product should be cooled within a temperature range of 80-130 ºF in 1.5 hrs to prevent growth of Clostridium perfringens (> 1 log) or Clostridium botulinum

Listeria control measures, including testing program, make hazard unlikely.Pre-op and Operational SSOPs make contamination unlikely

C No common hazard No SSOP makes hazards unlikely to occur

P No common hazard No SSOP makes hazards unlikely to occur



Step




(3)Do any potential food safety hazards require a

preventive control?


Column (3)

(5)What preventive control measure(s) can be ap-plied to significantly min-imize or prevent the food safety hazard? Process in-cluding CCPs, Allergen, Sanitation, Supply‐

chain, other preventive control

(6)Is the

preventivecontrol


Yes

No

Yes

No

Packaging & Labeling

B Growth of Clostridium per-fringens or Clostridium botulinum

Presence or growth of Listeria monocy-togenes or other pathogens (post-cook contaminants)

No(Clostridial growth)

No(Presence of Listeria monocytogenes or

other pathogens)

No(Growth of Listeria monocytogenes or

other pathogens)

• Product does not get warm enough for a long enough time during packaging to result in growth• Listeria control measures,

including testing program, make hazard unlikely. Pre-op and operational SSOPs make contamination unlikely• Product is kept refrigerated/

frozen (minimizes/prevents pathogen growth) at below 40 ºF

C Improperly labeled allergens

No Labeling SOP and SSOP make hazard unlikely to occur

P None No SSOP makes hazards unlikely to occur


Step




(3)Do any potential food safety hazards require a preventive

control?


Column (3)



(6)Is the

preventivecontrol


Yes

No

Yes

No

Metal detection

B None No C None No P Metal fragments

present in product Metal missed by detector

Yes

No

Metal fragments introduced in previous steps Equipment Maintenance program makes it unlikely to occur

• Product must be passed through metal detectors • If metal fragments are

detected in a prod-uct, they must be discarded

Yes


Step




(3)Do any potential food safety hazards require a preventive

control?


Column (3)



(6)Is the

preventivecontrol


Yes

No

Yes

No

Finished product stor-age

B Potential for growth and/or contamination with foodborne pathogens

No Proper storage temperature of 40oF or lesser as part of SOP to reduce risk of growth

C None No Packaged productP None No Low risk. Packaged product


Step




(3)Do any potential food

safety haz-ards require a preven-tive con-

trol?


Column (3)



(6)Is the

preventivecontrol


Yes

No

Yes

No

Shipping and distribution

B Potential for pathogen growth like Listeria monocyto-genes

No Products labeled “Keep Refrigerated” on package and shipping carton. Products shipped only in refrigerated trucks. Recommended distribution time/temperature monitoring

C Potential Contamination by chemicals, oils,cleaners

No All products must be shipped in a clean truck with T < 40 ºF

P Introduction of foreign objects (container damage)

No Low risk. Packaged product. All products must be shipped in a clean truck.

Process Preventive Control

Process Control

Hazards(s) Critical Limits

Monitoring Corrective Action

Verification Records

What How Frequency Who

Receiving packaging

Contamination with biological

materials

Non-food grade materials like

color addi-tives, inks, indi-rect additives

Foreign materials

Letters of guarantee are received from all suppliers of packaging

materials

Ingredient listing matches

product

Container integrity and contamination is monitored at

receiving

Visual inspection

Every batch that is receivedbefore released to

production

QC Technician or designee

Damaged or contaminated packaging

materials must be re-

turned to sup-plier or

discarded

Review of label verification,

Corrective Action and Verification records within 7 working days

Corrective Action

Records


Process Control





Cooking Survival or growth of

pathogens

(Salmonella, Listeria

monocyto-genes, Staphy-lococcus au-

reus, Clostrid-ium perfrin-

gens, Clostrid-ium botulinum Campylobac-ter jejuni/

coli)

The final internal temperature and holding time of the product are recommended to reach a temperature of

158OF.

Internal temperature is ≥158oF

(70OC)

Infrared surface thermometer

Each cook station, 4 times per shift, about every 2-3

hours

QC technician or designee

Hold product back to the last good check and evaluate – rework, discard, or

release.

Determine root cause -- retain or correct as appropriate

Review of cook log, corrective action and verification records within 7 working days

Daily accuracy check for thermome-

ter

Annual calibration of thermometer

Cook Log- cook temperature by QA

technician

Corrective action

records

Verification records, including validation

study

Process Control





Metal Detection

Metal inclusion

Metal detector present and

operating

No metal fragments that would cause injury or choking are in the

product passing through the metal

detector

All the product passes through an operating metal detector

Kick out product for the presence of metal

fragments

Visual examination that the detector is on and reject device is

working

Examine product rejected by electronic metal detector to determine cause of kick

out

Beginning, middle and end of shift

When product is rejected

Production employee

Production employee

If product is processed with-out metal detec-

tion, hold for metal detec-

tion

Ensure that the product is not processed without metal

detection

If metal is found in prod-

uct, segregate product, re-

work or discard product.

Identify source

and fix dam-aged equipment

if relevant

Pass X mm Ferrous and Y mm Non- Ferrous and stainless standard wands through detec-tor at start up, mid-dle and end of shift to

assure equipment is functioning

Review of metal detector log and corrective action and verification within 7 working days

Metal Detector

Log

Manufact-urer’s Validation Study that deter-mine de-tector

settings and sensitivity standards

References:FSPCA Preventive Controls for Human Food First Edition - 2016http://www.fsis.usda.gov/OPPDE/rdad/FSISDirectives/5100.2/Meat_and_Poultry_Hazards_Controls_Guide_10042005.pdfhttp://meatsci-dev.cfaes.ohio-state.edu/node/86http://haccpalliance.org/alliance/sausage.pdfhttp://meathaccp.wisc.edu/Model_Haccp_Plans/https://www.foodsafety.gov/poisoning/causes/bacteriaviruses/cperfringens/

http://www.fsis.usda.gov/OPPDE/rdad/FSISDirectives/5100.2/Meat_and_Poultry_Hazards_Controls_Guide_10042005.pdf

http://www.fsis.usda.gov/OPPDE/rdad/FSISDirectives/5100.2/Meat_and_Poultry_Hazards_Controls_Guide_10042005.pdf

http://meatsci-dev.cfaes.ohio-state.edu/node/86

http://haccpalliance.org/alliance/sausage.pdf

http://meathaccp.wisc.edu/Model_Haccp_Plans/

https://www.foodsafety.gov/poisoning/causes/bacteriaviruses/cperfringens/