5 9

2
CHAPTER
HACCP Plan
for
Canned Tuna
60

Good Manufacturing Practices (GMP) refers to all the measures implemented to ensure product
quality, safety and fitness for human consumption; from raw material quality, fish plant
construction, personnel hygiene and hygienic operating practices. All processors need to process
under GMP's using a system o f Quality Control. Hazard Analysis Critical Control Point
(HACCP) is a technique for reviewing and analysing a specific manufacturing operation's
compliance with the GMP, with the objectives o f identifying control procedures and
implementing preventive measures required to ensure consumer safety and to prevent economic
fraud. It is a system of self-regulatory quality control which, if properly implemented, can be
used by both manufacturers and regulatory agencies to provide assurance about the safety o f the
product.

A number o f quality control points exist in the processing o f the product. However, critical
control points (CCP) are those points in a food production process where failure to carry out
control measures will introduce unacceptable risks to the consumers. These CCP's need to be
identified, and a system o f monitoring and recording data at these points set up.

HACCP represents a major change in how seafood safety is guaranteed. In essence, Hazards are
Analysed in the processing o f canned tuna, and a system o f monitoring Critical Control Points
is set up to assure the processing is done in a correct manner so that problems can be prevented
before they occur. It is necessary to have monitoring records so that the process may be audited
for product safety assurance. This is what the regulator is concerned with, not product quality
as there are different markets for different quality products.

A HACCP Plan for the product has to be developed and this section provides information for the
development o f such a plan. Every manufacturer must develop its own plan (or plans). The
HACCP concept is based on developing a plan tailored to particular production lines, thus there
may be differences in the plans developed by different companies producing the same product;
however, the information presented here is generic to the process o f canning tuna.

While it is a system of self-inspection rather than government inspection, the government

inspection services will periodically conduct audits o f manufactures programmes, to assure that
the system is working to prevent hazards to food safety. Importers in countries may have to
verify that the programme has been followed; this may include on-site inspection, review o f
records and the quality program.

Regulatory authorities are concerned with safety; however, many authorities are also concerned
with aspects o f quality and the prevention o f economic fraud. While there are different markets
for different qualities of product, the differing limits o f acceptability for the markets should not
be exceeded. Therefore, the HACCP plan may need concern itself not only with safety, but also
with quality and marketing requirements.

To ensure that the quality of the product is maintained, consider merging the HACCP plan
developed with the overall quality control programme, but maintaining the HACCP documents
separately for HACCP program audit purposes.

Two aspects o f a good HACCP plan are not covered in this manual, economic fraud and recall.
 61

T h e firs t h a s to d o w ith la b e llin g . P ro c e d u r e s h a v e to b e in p la c e to e n s u r e th a t th e p r o d u c t is n o t

m is la b e lle d to c o n te n t s u c h a s s p e c ie s s u b s titu tio n , o r w e ig h t a n d th a t la b e llin g is d o n e in m a n n e r

re q u ire d b y th e in te n d e d m a rk e t. T h e s e c o n d a s p e c t d e la y w ith s a le s a n d s h ip p in g re c o rd s ,

c o d in g o f th e p ro d u c t a n d re c a ll p ro c e d u re s e s ta b lis h e d ; to e n s u re a n a b ility to tra c e th e p ro d u c ts

to th e c u s to m e r s to w h o m th e y w e r e s o ld .

T h is in f o r m a tio n is b a s e d o n th e e x p e r ie n c e o f th e T h a ila n d D e p a r tm e n t o f F is h e r ie s in th e

c o n d u c t o f th e ir a c tiv itie s . It is g iv e n a s g u id a n c e f o r th e m a n u f a c tu r e r s to d e v e lo p th e ir o w n

H A C C P p la n s . T h e in f o r m a tio n is g e n e r ic a n d m u s t b e m o d if ie d to s u it e a c h m a n u f a c tu r e r s

c o n d itio n s . F u rth e r, a s n o te d a b o v e , it is n o t c o m p le te . A H A C C P p la n n e e d s to m e e t th e

r e q u ir e m e n ts o f th e c o m p e te n t a u th o r ity h a v in g ju r is d ic tio n .

L o t a c c e p ta n c e s h o u ld be based on a s a m p lin g p la n a n d a n e x a m p le is a tta c h e d a s ta b le 3.

S a m p le s o f fo rm s w h ic h c a n b e u s e d to r e c o rd k e e p in g p u rp o s e a re g iv e n a s ta b le 4 .

T h e R e c o m m e n d In te rn a tio n a l C o d e o f H y g ie n ic P ra c tic e fo r lo w -a c id a n d a c id ifie d lo w -a c id

c a n n e d fo o d s is a tta c h e d a s A p p e n d ix .
62 Generic HACCP Plan for Canned Tuna

Processing GMP Hazad Hazard CCP Preventive Measures M onitoring

Step No Type

Receiving 1.1 Quality - Decomposed Receiving - Control supply source - Measure temperature
Safety fish area - Have supplier provide a upon receipt
- Damaged fish product temperature - Visual inspection
history - Sample for histamine
testing

Butchering 1.2 Quality - Decomposed Butchering - Control temperature of - Measure backbone

1.3 Safety fish tables fish temperature
- Histamine - Control lag time from end - Sensory inspection
o f thaw to end o f - Take sample for
butchering histamine analysis

Loin 6.4 Quality - Decomposed Loin - Control lag time from end - Measure temperature
Cleaning fish cleaning o f cooking to end o f and time o f cooling
- Green meat, tables cooling - Visual inspection
orange meat - Control time o f loin - Sanitation inspection
or honeycomb cleaning and hygienic
practices
- Train workers to detect
loin

Packing 7.2 Safety - Defect empty Empty can - Select can suppliers - Visual and seam tear
7.3.2 can storage - Set up empty can down inspection upon
area sampling plan and arrival
specification required - Visual inspection prior
- Train workers on to feeding to line
container integrity

7.3.2 Safety - Over fill W eighing - Adjust packing machine - On-line weigh check
table - Calibrate balance and - Calibration o f balance
weigh used

Seaming 7.4.3 Safety - Defect double Seamer - Adjustment o f seamer - Visual seam inspection
seam - Test run before use - Seam tear down
- Train Q.C./seam mechanic

Retorting 8 Safety - Improper Retort area - Train retort operators - All thermal processes
processing - Establish schedule process operations
resulting in - Retort equipment checked
outgrowth of and calibrated
microbes and - Close surveillance o f
toxins operations (by Q.C./Q.A.)

Post 9.2 Safety - Post process Cooling - Restricted area traffic - Check admittance to
Process contamination zone control area (visual inspection)
Handling - Sanitation - Daily sanitation check
 63

Critical Limits Corrective Actions Verification Records

Frozen fish < -18°C - Inform/change supplier - Annually, conduct survey o f - Supplier temperature record
Fresh fish ~0°C - If histamine >50ppm, increase supplier handling system - Raw materials receiving
Histamine < 50ppm surveillance at butchering - Conduct histamine/ record
temperature relationships - Supplier sources and
history

Histamine <50ppm - If > 10% grade 3 fish, lot should - Occasional increased - Raw fish grading form
Fish temperature 0 - be individually culled samplings for sensory and - Chemical analysis form
5°C - If >10% grade 4 (rejected) fish histamine analysis - Lot processing record
Lag time 2 hours found, lot should be rejected - Check graders’ competence - Training record
• If histamine >50ppm, increase with histamine and sensory
surveillance, more culling for determination
sensory test
- Inform supplier
- Reduce volume on line

- Lag time not >6 - If lag time exceed limits, adjust - Run pre-cooking test - Cooling time and
hours production volume, fish should - Conduct histamine/ temperature record
- Loin cleaning time be put in chilled room for any temperature relationship - Loin cleaning and quality
<1 hour delay anticipated - Check samples on workers record
- No defect or - Increase surveillance at at and graders - Training record
decomposed loin butchering table • Plant sanitation inspection
- Sanitation: - Improve cleaning and sanitation daily
visually
accepted

[Based on sampling - Segregate defect cans - Inspection o f can - Record o f can

plan and can - If more than acceptance no. manufacturers manufacturers audit
specifications] reject lot - Obtain Q.C. program o f can - Empty can inspection
manufacturers record
- Can storage, depalletization
and feeding log
- Can specifications
- Training record

[Based on value - Segregate defect can - Inspection o f performance and - Record o f empty can
specified in process - If more than acceptance no. practice manufacturers audit
establishment] adjust packing machine - Record check - Empty can inspection
record
- Can storage, depalletization
and feeding log
- Can specification
- Training record

[As determinated in - Closing machine maintenance - Inspection o f performance and Seamer inspection report
initial verification and adjustment practice - Visual inspection report
according to size of - Hold products for further - Record check - Seam tear down report
can] investigation - Investigation report

[As determined in - Hold lot/reprocess lot - Periodic checks on heat - Retort operation record
initial verification - distribution in retort and - Temperature recording
calculated for each temperature recording charts
retort, can size and equipment. Have process - Investigation report
product type] verified by competent
authorities. Check
competence o f operation.
- Record review daily

Entrance to - Stop unauthorized entrees - Review of traffic control Product control report
authorized personnel program by inspection Investigation report
only - On site verification
64

Table 3
Sampling plan and rejection numbers for the inspection of fish

The sample size, (the number of fish to be inspected) is determined by randomly sampling at least 10 fish from
the lot to determine the average weight of each fish. Divide the average weight into the estimated or actual
weight of the lot to be examined to determine the total number of fish in the lot. Based on the total number of
fish the following sampling schedule shall be applied:
No. of Fish in the lot Sample Size Rejection Number *

2 - 15 2 1

16-25 3 1

26-90 5 1

91 - 150 8 2

151 - 500 13 2

501 - 1200 20 3

1201 - 10000 32 4

10001- 35000 50 6

35001 - 500000 80 8

500000+ 125 11
*the minimum number of defective units needed to reject the lot. Once the rejection number has been
exceeded, the inspection may be stopped. Please note: this plan does not apply to lots of fish that were hand
culled or graded individually.

Example of Incoming Shipment Inspection Form

Date

Item

Supplier

Code Marks

Quantity

No. Units

Sample Size

Rejection Level

No. Rejected

Accept/Reject

Condition.

Consigned to:

Internal Code No.

Initial

Corrective Action/ Notes

 65

Table 4

P. of

Raw Tuna Temperature Inspection

Date_______________ Trailer_________________ Temperature Reading___________________

Time Unloading Started_______________ Time Finished________________

Total Number Species Weight Temperature Comments

(Developed by DFO Canada)

66
P . ____ o f _____

Raw Fish Grading Form

Plant_________________ Location__________________
Date__________________ Lot Number_________________
Species_______________

SAMPLE

TOTE

GRADE

EYES

GILLS

TEXTURE

PHYSICAL
DAMAGE
Edible portion of
fish

BELLY CAVITY
Internal organs and
belly wall

ODOUR
Belly cavity and
cut through nape

GRADE
ASSIGNED

Comments

Signature of Grader :

Signature of Grader :

Signature of Grader :

(Developed by DFO. Canada)

 CANNED TUNA GMP CHECK LIST THAWING TO STAGING
Plant: ________________ Date : _________________
Shift : _____________ Inspector : ______________

Tank Tote Species Fish Water Temperature Thaw Time Fish Temperature Comments Staging Rack Staging Staging Butcher Ambient
No. No. Wt. End of Thaw Start No. End Duration Duration Temp.
(Kg) Time/Temperature Start End Steam On (Staging)
1 2 3 4

(Developed by DFO Canada)

67
68

RECORD OF VISUAL EXTERNAL SEAM EXAM INATION

D ATE _L IN E NO. _ CAN SIZE _CAN CODE:_

Time No. cans Decision on Seams Remarks

Accept Reject
 DOUBLE SEAM INSPECTION REPORT - 3 PIECE CANS ONLY

DATE PLANT INSPECTOR

Line Can Code Time Head Vac Thickness Width Countersink End Hook Body Hook Actual Tightness Pressure Juncture Sealing
Size No. (in) Overlap Rating Ridge Rating Compound

69
 70
DAILY STERILIZATION PROCESS INSPECTION
DATE

SCHEDULED VENT TIME TEMP. UP ESTIMATED TIME ACTUAL ACTUAL PROCESS TEMP. CHECK AMB­ RETORT COOLING UNLO­ RESIDUAL CHLORINE

RT CODE NO.OF I.T. PROCESS STEAM OFF PROCESS TIME (: C ) IENT STEAM TEMP. ADING LEVEL CHECK, ppm

NO BSK (:C ) TEMP. PRESSURE TIME

TEMP. MIN. TEMP TIME RECO­ ACTUAL RECO­ ACTUAL RECO­ ACTUAL MERCURY RECORDER ( :C) ( lb / sq. in.) RT CAN TIME I N/ EX RETORT

(:C) (:C) RDER RDER RDER

SUPERVISOR : ....................................................... INSPECTOR : ..........................................

RT NO. = RETORT NO.

 71

EXAMPLE NUOCA

No:

Company Name

Notice o f Unusual Occurrence

(NUOCA)

L ine:_____________________ Time:___________________ D a te:__________

Control Point: _________________________________________________________________

Cited f o r : _______________________________________________________________________

Signature (Foreman):_____________________________________________________________
Signature (QA/QC): _____________________________________________________ _______

(Developed by National Marine Fisheries Service)