HACCP PLAN

FOR
THE PRODUCTION OF
MINCED MEAT
 HACCP TEAM WORKSHEET
Product: Minced Meat Brand: Bar Code:
Production facilities: Date: Revision №: original
Veterinary Reg. No. Prepared By:

POSITION NAME AND FAMILY SPECIAL SKILLS SPECIAL EXPERIENCE

NAME KNOWLEDGE

HACCP
Team Coordinator

HACCP
Team Member

HACCP
Team Member

HACCP
Team Member

HACCP
Team Member

HACCP
Team Member

DATE: _________________ Approved by QC/Manufacturing unit: ___________________

 PRODUCT DESCRIPTION WORKSHEET
Product:Minced Meat Brand: Bar Code:
Production facilities: Date: Revision №: original
Veterinary Reg. No. Prepared By:

1. Product name:
minced meat

2. Important characteristics of the end product

Row product

3. How the product is to be used?

It is to be consumed after heat treatment - baking or frying

4. Packing type
In foiled plates

5. Storage conditions
Temperature – 1–2º C and moisture 75-80 %
Temperature –18º C and moisture 75-90 %

6. Shelf – life
Best before: 5 days from the date of production, preserved at 0–2º C
and 30 days, preserved at –18º C,

7. Where is the product to be sold?

On the market, public catering establishment

8. Labelling instructions
Company name, head office and address
Composition
Shelf-life
Storage
Net weight
Batch No. and date

9. Other distribution requirements

- 1–2º C for chilled minced meat and –minus 18º C for frozen minced meat

DATE: _________________ Approved by QC/Manufacturing unit: ___________________

 PRODUCT AND INGREDIENTS WORKSHEET
Product: Minced Meat Brand: Bar Code:
Production facilities: Date: Revision №: original
Veterinary Reg. No. Prepared By:

Meat and Meat Products Non-meat Products Binding Compounds / Fillings

Pork meat Lactose PRO 900 (Protein)

Veal meat Fibrex
Bacon

Spices / Flavours Limited (Restricted) Stabilizers / Acidifiers

-
Ascorbic Acid
Salt

Packing Materials Water Other

Flavoring
Plastic boxes Ice
Plates
Foil
Paper

DATE: _________________ Approved by QC/Manufacturing unit: ___________________

 PROCESS FLOW DIAGRAM
Product: Minced meat Brand: Bar Code:
Production facilities: Date: Revision №: original
Veterinary Reg. No. Prepared By:

Storage of
carcass meat
Receipt of not Receipt of pork,
restricted non-meat veal and beef
ingredients (carcass meat)

Deboning room
Premises for
mechanical
processing/
intermediate
products and mince: Technological chilling
• Measuring room
• Grinding
• Mixing
• Stuffing machine
Ice from the ice • Fine mixing Receipt of folio and
generator • Putting in plates packing

Packing line:
• Minced meat plates packing in folio
• Labeling
• Packing table
• Arranging plates in plastic boxes for
multiple use and paper is put between rows

Wholesale
premises
Finished product
chilling room
CCP Q-2
Loading on
trucks

DATE: _________________ Approved by QC/Manufacturing unit: ___________________

 HAZARDS / CONTROL MEASURES IDENTIFICATION WORKSHEET
Product: minced meat Brand: Bar Code:
Factory: Date: Version No. Original, page1
Veterinary Reg. No.: Prepared by:

TECHNOLOGICA Biological HAZARD(S) which is (are) highly Is the hazard If “No” If “Yes” --
L STAGE Chemical probable to occur at every substantial? Motives for determining What control measures can be applied to eliminate the hazard?
Physical technological stage by type (BCP) Yes / No hazard substantiality
(BCP)

Receiving Biological B – bacteria reproduction ( B- Yes, B- meat should leave the slaughterhouse with a
meat –B Salmonella, Clostridium, bacteria temperature of < 7о С and an оinspection of the
Listeria…) with may harm appropriate temperature ( < 7 ) is done when
temperature increase. humans receiving one carcass Bovine animals and three pork
carcasses.
.
Chemical – None
C
Physical - P

Receiving B None All packaging

packaging C None materials are
materials accompanied by
P None certificates
guaranteeing
safety

Receiving B None
non-meat P None
components
C C- limited components not .
used in minced meat

DATE: __________________ Approved by Factory Manager:

 HAZARDS / CONTROL MEASURES IDENTIFICATION WORKSHEET
Product: minced meat Brand: Bar Code:
Factory: Date: Version No. Original, page 2
Veterinary Reg. No.: Prepared by:

TECHNOLOGIC Biological HAZARD(S) which is (are) highly Is the hazard If “No” If “Yes” --
AL STAGE Chemical probable to occur at every substantial? Motives for determining hazard What control measures can be applied to eliminate the
Physical technological stage by type (BCP) Yes / No substantiality hazard?
(BCP)
Refrigerated B B – temperature may grow if B- No B – refrigerating premises have an
preservation of refrigerator functions improperly alarm signaling of temperature
carcass meat which may lead to the increase above 7оС.
development of bacteria

C None
P None
Transport B B – Bacteria may reproduce if B- No B – Good manufacturing practices
room temperature grows above (GMP) require that temperature be
12оС for more than two hours. maintained under 12о С. The
introduction of GHP supposes
No C good worker hygiene.

P – bone particles and metal

particles on the knives.

P – GHP for physical inspection

of the products before mincing
and periodic inspection of the
P- No equipment.
Technological B B, P, C None Room temperature does not
refrigerator exceed 2о С which prevents
C bacteria reproduction; availability
P of an alarm in the refrigerator.

DATE: __________________ Approved by Factory Manager:

 HAZARDS / CONTROL MEASURES IDENTIFICATION WORKSHEET
Product: minced meat Brand: Bar Code:
Factory: Date: Version No. Original, page 3
Veterinary Reg. No.: Prepared by:

TECHNOLOGIC Biological HAZARD(S) which is (are) highly Is the hazard If “No” If “Yes” --
AL STAGE Chemical probable to occur at every substantial? Motives for determining hazard What control measures can be applied to eliminate the
Physical technological stage by type (BCP) Yes / No substantiality hazard?
(BCP)
Machine room B B – If product temperature B- No B- GHP requirements are that
for semi- exceeds10о С for more than two room temperature should be <
finished hours biological growth of some 120C, and the product should not
products and bacteria may develop in remain for longer than two hours.
minced meat hazardous dimensions. E. coli O This time/temperature
157 are particularly dangerous requirement will prevent
pathogenic bacteria reproduction
in dangerous amounts.

C – there are GHP introduced for

C C – Limited components in C - No worker hygiene and recipe control.
minced meat are not used Visual inspections are also
performed for physical hazards
P- None (GHP)
P

Ice machine B B - Ice may be contaminated with B- No B – Ice is poured directly in clean
Listeria, which is pathogenic for tanks and from there it goes
humans which develops under directly into the grinder. Drinking
minus temperatures. water is used for which there is a
certificate. An analysis is done
C C – None twice a year.
P P - None
Packaging В B – workers have access to the B - No B – GHP for worker hygiene and
machine product and may contaminate it training; low temperature and the
with Staph aureus or other short processing time prevent
C bacteria. bacteria development.
P C и P - None P – GHP for visual monitoring
when packaging
Metal detector.
DATA: __________________ Approved by Factory Manager:
 HAZARDS / CONTROL MEASURES IDENTIFICATION WORKSHEET
Product: minced meat Brand: Bar Code:
Factory: Date: Version No. Original, page 4
Veterinary Reg. No.: Prepared by:

TECHNOLOGICA Biological HAZARD(S) which is (are) highly Is the hazard If “No” If “Yes” --
L STAGE Chemical probable to occur at every substantial? Motives for determining hazard What control measures can be applied to eliminate the
Physical technological stage by type (BCP) Yes / No substantiality hazard?
(BCP)
Semi-finished B B – Listeria or bacteria may B -Yes B – room temperature is controlled - <1о С which
products and develop if preservation time and prevents the development of bacteria; salt in the
minced meat temperature are exceeded. product prevents freezing. There is a GHP check of
labels– “first in, first out”. There is a GHP for
Refrigerator for P and C None arranging products in the refrigerator.
finished C
products
P

Wholesale B B – increased room temperature B – No B – There is a GHP for

room may lead to the development of maintaining constant temperature
bacteria, particularly of Listeria (5о С) and check of labels– “first
C and Staph aureus, if the product in, first out”.
remains too long
C - No

Transport B B – Temperature increase during B – No B –GHP introduced for

distribution transport may lead to the temperature maintenance during
means development of pathogenic transport – 20C.
C bacteria
C- Disinfection and cleaning C - No
substances may contaminate the C- When GHP and standard
finished product. sanitary practices are introduced
chemical agents contamination is
P P - None prevented.
DATE: ________________________ Approved by Quality Control/Production Department: _____________________
 CRITICAL CONTROL POINTS IDENTIFICATION WORKSHEET IN FOUR STAGES
Product: Minced meat Brand: Bar Code:
Factory: Date: Version No.: Original
Veterinary reg. No.: Prepared by:
TECHNOLOGICAL
STAGE HAZARD TYPE - Question 1. Are there control Question 2. Is the occurrence of Question 3. Is it possible that Question 4. Will the next stage CCP No
measures for the identified a hazard eliminated or possibly contamination may occur when eliminate the hazard identified
hazard? reduced to an acceptable level at exceeding acceptable levels of or will it reduce the probability
Biological- B this stage? identified hazard or will of its occurrence to acceptable
Chemical - C contamination increase to an levels?
• If “No” – Is the control unacceptable level?
Physical - P stage required for safety? • If “NO” - go to the next
If “Yes” – Modify the question. • If “Не” - CCP
and technological process or • If “Yes” - CCP • If “No” – Not a CCP • If “Yes” – Not a CCP
the product. • If “Yes” - go to the next
If “No” – Not a CCP. question.
Hazard description
• If “Yes” – go to the next
question.

Receiving meat B – Bacteria may Yes – control measures Yes – meat temperature is CCP
develop if meat exist checked on delivery; B-1
temperature grows;

Finished products B – If the product Yes – temperature is Yes – temperature is CCP

refrigerator remains in the controlled and GHP have maintained at
refrigerator for too been introduced for “first <5о С and labels are B -2
long or temperature in, first out” checked for production
grows bacteria may date.
develop and
particularly Listeria

DATE: ________________________ Approved by Quality Control/Production Department: _____________________

 MONITORING AND CRITICAL LIMITS WORKSHEET

Product: Minced meat Brand: Bar Code:

Factory: Date: Version No.: Original
Veterinary reg. No.: Prepared by:

TECHNOLOGI CRITICAL
CAL STAGE MONITORING
and LIMITS
CCP #
WHO WHAT HOW WHEN

Receiving Carcass meat Warehouse attendant or a Internal temperature is Calibrated hand-held Each truckload of meat is
meat temperature trained technologist checked initially on one thermometer is placed inspected on arrival and
B-1 < 7о С beef and one pork carcass inside the meat during unloading.
and then on two additional
pork ones (in the middle
and at the end of unloading)
Semi- Room Technologist or other Refrigerator temperature; Automatic (calibrated) Permanently; an alarm is
finished temperature trained staff. The process is visual inspection of labels room wall thermometer; activated. Daily inspection
products and is <1оС; automated and computer for production date. visual inspection of labels. of labels for complying
minced meat. production archived with the principle “first in,
Refrigerator dates on the first out”.
for finished label are
products inspected on
B -2 a daily basis
DATE: ________________________ Approved by Quality Control/Production Department: _____________________
CORRECTIVE MEASURES WORKSHEET
Product: Minced meat Brand: Bar Code:
Factory: Date: Version No.: Original
Veterinary reg. No.: Prepared by:
Formulation of
measures to
Technological stage Critical limits Who is responsible Formulation of Formulation of Formulation and
prevent the
/ CCP for applying measures for measures for establishment of
appearance on the
corrective identification and implementing measures for
market of products
measures? eliminating the repeated control on preventing
hazardous for the
reasons for the CCPs repetitions
health or
deviations
counterfeit
products

RECEIVING Carcass meat Technologist or Temperature check Ensuring the Worker training in Carcass meat is
MEET temperature <7о С other trained staff in lorries; required temperature proper placed for keeping in
thermometer when unloading; loading/unloading; the refrigerator
calibration; refrigerator equipment immediately; temp.
maintenance of inspection; fastest maintenance; <7 С; using carcass
contact with the possible placement equipment meat only for
slaughterhouse staff. of carcasses in the preventive thermal processing.
refrigerator; worker inspections schedule
control
Semi-finished Temp. <1-2о С; Technologist or Thermometer Verification of Equipment Moving the product
products and minced
meat. Refrigerator Daily inspection of other trained staff calibration and workers’ practices, repairs/replacement in another
for finished products labels for complying inspection; equipment and as required; frequent refrigerator (there
B -2 with the principle inspection of computer according preventive should be no raw
“first in, first out”. workers’ practice for to the GMP inspections; repeated materials in the
monitoring labels; staff training as vicinity); if the
closing doors; required. product is not kept
correct product for four hours under
placement; a temperature of
refrigerator <50 С it becomes
inspection; principle unfit.
“first in, first out”.
Date: ________________________ Approved by Quality Control/Production Department ___________________________________
 IDENTIFICATION VERIFICATION AND REGISTRATION PROCEDURES
Product: Minced meat Brand: Bar Code:
Factory: Date: Version No.: Original
Veterinary reg. No.: Prepared by:

TECHNOLOGIC CCP VERIFICATION PROCEDURES LOGBOOKS KEPT

AL STAGE AND AND
CCP No. PERSON(S), PERSON(S) RESPONSIBLE FOR THE LOGBOOKS
RESPONSIBLE FOR THE
VERIFICATION PROCEDURES
Receiving - thermometer calibration at the beginning Chief technologist or other The Chief technologist (HACCP coordinator) shall maintain:
meat of the shift trained staff
B-1 - Daily control on the CCP documentation
- worker inspection
- Thermometer calibration protocols
- daily control on the monitoring
documentation - Correction measures protocols
- contact maintenance with the - Product disposition when corrective measures
slaughterhouse manager . are required

-
Semi-finished - thermometer calibration at least once a Chief technologist or other The Chief technologist (HACCP coordinator) shall maintain:
products and week; temperature verification inside the trained staff
minced meat. product according to the GMP and - Daily control on the CCP documentation
Refrigerator maintainingо refrigerator temperature of at
for finished - Thermometer calibration protocols
products least. <1- 2 С.
- Correction measures protocols
B -2 - worker inspection
- Product disposition when corrective measures
- daily monitoring of documentation are required
- microbiological tests every quarter in
order to ensure product safety (minimum:
Salmonella E. coli, Listeria
monocytogenes)
Date: ________________________ Approved by Quality Control/Production Department: __________________________________
 Summary НАССР Plan
Product: Minced meat Brand: Bar Code:
Factory: Date: Version No.: Original
Veterinary reg. No.: Prepared by:
Monitoring procedures /
TECHNOLOGICA Биологични frequency / Corrective action / HAССР Logbooks Verification procedures /
L STAGE Химични CCP Critical Responsible persons responsible person Responsible person
Физични Limits

Описание на
опасността
Receiving meat Bacteria B-1 Carcass Inside temperature is checked Worker training in proper The Chief technologist The Chief technologist
B-1 (Salmonella, E. meat initially on one beef and one loading/unloading; equipment (HACCP coordinator) shall (HACCP coordinator) shall :
coli, Listeria temperature pork carcass and the on two maintenance; equipment maintain:
monocytogenes <7о С more pork ones (in the middle preventive inspections schedule - calibrate thermometer at
) may develop and the end of unloading). - Daily control on the CCP the beginning of every shift
if meat Carcass meat is placed for keeping documentation
Warehouse attendant or other in the refrigerator immediately; - inspect worker practices
temperature - Thermometer calibration
grows и; trained staff temp. <70 С; using carcass meat - monitor logbooks and
only for thermal processing. protocols
other documentation on a
Technologist or other trained staff - Correction measures daily basis
protocols
- maintain contact with the
- Product disposition slaughterhouse
when corrective measures
are required
Semi-finished The Chief technologist
B – If product B-2 Room temp. Refrigerator temperature; Thermometer verification and The Chief technologist
products and temperature <1о-2о С; visual verification of the calibration; inspection of workers’ (HACCP coordinator) shall (HACCP coordinator) shall be
minced meat. exceeds 10 C0
label production date on the labels practices on monitoring labels; maintain: responsible for:- thermometer
Refrigerator for for more than inspection correct product placement; calibration once a week;
finished products two hours some refrigerator inspection, “first in, - Daily control on the CCP refrigerator inspection;
B -2 bacteria’s first out”. documentation temperature inside the product;
biological ensuring the required
growth may Technologist or other trained staff - Thermometer calibration preservation temperature of <2о
develop to protocols С; worker practices inspection;
hazardous - Corrective measures daily control on the
proportions.. E. protocols documentation; microbiological
coli O 157 are tests every quarter in order to
particularly - Shall ensure the correct ensure product safety
dangerous product disposition should (minimum: Salmonella, E. coli,
corrective action be required. Listeria monocytogenes of the
logbooks;

DATE: ________________________ : Approved by Quality Control/Production Department ______________________________________