Kenneth S. Hilderbrand Jr.
OSU Sea Grant Extension Program
Revised 12/30/97
1. Introduction | 5. Process Schedule |
2. Flow Diagram | 6. Production Log |
3. Hazard Analysis Worksheet | 7. Temperature Recorder Verification Log |
4. HACCP Plan | 8. Drying Verification Log |
1. Introduction: The information, tables, and other materials in this generic HACCP plan for Hot Smoked Fish represent only one possible way to write a HACCP plan. It should be used only for illustrative purposes. Each processor is obligated by law to write a flow diagram specific to their own facility and conduct a hazard analysis for their own processes and products. The primary purpose of this generic plan is to illustrate how a firm might simplify record keeping by writing a single plan, which could include several similar smoked fish products having different brining and smoking procedures.
According to law, certain HACCP functions must be performed by someone who has completed training equivalent to the HACCP Training Curriculum (publication UNC-SG-96-02) developed by The National Seafood HACCP Alliance for Training and Education. These functions include developing the plan, changing the plan, and conducting record review. This training may be obtained through classroom instruction or by equivalent on-the-job training. For details, see Sec. 123.10 of the regulations. This generic HACCP plan for hot smoked fish is based on the principles detailed in that manual and in guidance contained in the FDA's Fish & Fisheries Products Hazards & Controls Guide, First Edition, September 1996.
Seafood processors also should be aware that FDA's HACCP regulation (Procedures for the Safe and Sanitary Processing and Importing of Fish and Fishery Products; Final Rule, December 18, 1995) requires that they monitor and keep records on their sanitation procedures. This is best done by writing and implementing an SSOP (Sanitation Standard Operating Procedure). An example of this can be found on University of California's Web site <seafood.ucdavis.edu>.
For information on purchasing the Training Curriculum ($20), write or call: North Carolina Sea Grant, Box 8605, N.C. State University, Raleigh NC 27695-8605. Tel. 919 -515-2454. Advance payment is required.
For information on obtaining a free copy of FDA's Hazard & Controls Guide, contact: U.S. Food and Drug Administration, Office of Seafood, 200 C St. S.W., Washington, D.C. 20204. Tel. 202- 418-3133; fax 202-418-3196.2.
Hot Smoked Fish Company, Inc.
Process Flow Diagram
RECEIVING non-scombroid fish | | |
RECEIVING scombroid fish | | |
RECEIVING salt | | |
Fish headed, gutted, frozen and glazed in 50 lb. boxes
---------- Salt on wood pallets into dry storage |
FROZEN FISH STORAGE | |
| | | |
On pallets in -10°F cold store until needed | |
| THAWING | |
| | | |
Partially thawed in mobile tubs with fresh flowing water at less than 70°F the day proceeding smoking operations | |
| THAWED FISH STORAGE | |
| | | |
In raw product cold room at 40°F or less in mobile tubs. Fish must be still partially frozen at time of butchering. | |
| BUTCHERING | |
| | | |
Remove sides manually leaving skin on. Cut into pieces for brining. Processing takes place in an air-conditioned area. | |
| | RINSING | | |
| BRINE MAKEUP | | |
Fish rinsed in fresh water at less than 70°F to remove debris ---------- Brine makeup in cold water and stored in raw product cold room (less than 40°F) until needed |
|
| BRINING | |
| <� |
In a specified strength of salt brine for a specified time. These are relatively strong brines and short times. (See note #1) | |
| RINSING | |
In fresh water at less than 70°F to remove surface brine | ||
| SMOKING/DRYING/COOKING/COOLING (INTEGRATED STEPS) | |
To surface dry, apply smoke, dehydrate, cook, and cool enough to remove excess heat prior to final cooling. Product goes into cooler immediately upon removing from cooker. | ||
| COOLING (FINAL) | |
In a special unpackaged final product cooler at 38°F or less which is isolated from other raw or processed products. | ||
| PACKAGING/LABELING | |
In vacuum packages then into 20 lb. master cartons | ||
| STORAGE | |
In cartons on pallets in finished product cooler at 38°F or less. | ||
| SHIPPING |
In refrigerated vans at 38°F or less (commercial carrier) |
Hot Smoked Fish Company Hazard-Analysis Worksheet
Firm Name: Hot Smoked Fish Company, Inc. | Product Description: Refrigerated, vacuum-packaged, cooked ready-to-eat smoked fish (no mercury-containing species used -- see note #2) | ||||
Firm Address: 123 Somewhere St., Anytown USA 97365 | Method of Storage and Distribution: Stored and transported under refrigeration | ||||
Intended Use and Consumer: ready to eat by general public without further cooking | |||||
(1) Ingredient/processing step |
(2) Identify potential hazards, controlled or enhanced at the step (1) |
(3) Are any potential food safety hazards significant? (Y/N) |
(4) Justify your decisions for column 3. |
(5) What preventive measures can be applied to prevent the significant hazards? |
(6) Is this step a critical control point? (Y/N) |
Receiving non-scombrotoxin forming fish | BIOLOGICAL pathogen inclusion |
no |
smoking/cooking step |
|
NO |
BIOLOGICAL parasites |
no |
using frozen fish only |
|
||
CHEMICAL mercury |
no |
species |
|
||
PHYSICAL metal |
no |
using H&G fish only |
|
||
Receiving scombrotoxin forming fish | BIOLOGICAL pathogen inclusion |
no |
smoking/cooking step |
|
NO |
BIOLOGICAL parasites |
no |
using frozen fish only |
|
||
BIOLOGICAL histamine |
no |
secondary processor of frozen fish only |
|
||
CHEMICAL mercury |
no |
species |
|
||
PHYSICAL metal |
no |
using H&G fish only |
|
||
Receiving salt | BIOLOGICAL none |
|
using only canners grade salt |
|
NO |
CHEMICAL none |
|
|
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||
PHYSICAL none |
|
|
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||
Frozen fish storage | BIOLOGICAL pathogen growth |
no |
SOP uses security alarms and continuous surveillance |
|
NO |
CHEMICAL none |
|
|
|
||
PHYSICAL adulteration |
no |
packaged fish only |
|
||
Thawing | BIOLOGICAL pathogen growth |
no |
partly thawed in cool water |
|
NO |
CHEMICAL none |
|
|
|
||
PHYSICAL none |
|
|
|
||
Thawed fish storage | BIOLOGICAL pathogen growth |
no |
cold temperatures and insufficient time with only partially thawed fish |
|
NO |
CHEMICAL none |
|
|
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||
PHYSICAL none |
|
|
|
||
Butchering | BIOLOGICAL pathogen growth |
no |
cool temperatures and insufficient time |
|
NO |
CHEMICAL none |
|
|
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||
PHYSICAL none |
|
|
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||
Rinsing | BIOLOGICAL none |
|
|
|
NO |
CHEMICAL none |
|
|
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||
PHYSICAL none |
|
|
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||
Brining (see Note #1) | BIOLOGICAL pathogen growth during smoking and in final product |
yes |
human error in brine makeup and brining times are possible |
sufficient brining |
YES |
CHEMICAL none |
|
|
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||
PHYSICAL none |
|
|
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||
Rinsing | BIOLOGICAL none |
|
|
|
NO |
CHEMICAL none |
|
|
|
||
PHYSICAL none |
|
|
|
||
Smoking/initial | BIOLOGICAL pathogen growth on surface during smoking/drying/cooking |
no |
SOP for natural wood-smoke flavor and color is sufficient to inhibit growth of surface pathogens |
|
NO |
CHEMICAL none |
|
|
|
||
PHYSICAL none |
|
|
|
||
Smoking/drying | BIOLOGICAL pathogen growth in final product |
yes |
dehydration of brined fish must be sufficient to raise water phase salt in finished product to control C. botulinum if product is temperature abused |
sufficient drying |
YES |
CHEMICAL none |
|
|
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||
PHYSICAL none |
|
|
|
||
Smoking/cooking | BIOLOGICAL pathogen growth in final product |
yes |
cook time and temperature must be sufficient at to destroy pathogens preventing their growth in finished product if product is temperature abused |
sufficient cooking |
YES |
CHEMICAL none |
|
|
|
||
PHYSICAL none |
|
|
|
||
Cooling | BIOLOGICAL pathogen growth during cooling |
yes |
pathogens can grow if cooling period is too long |
sufficient cooling |
YES |
BIOLOGICAL cross contamination |
no |
controlled by SSOP |
|
||
CHEMICAL none |
|
|
|
||
PHYSICAL none |
|
|
|
||
Packaging/labeling | BIOLOGICAL pathogen growth in temperature abused product |
yes |
temperature abuse by shippers, distributors, or consumers is possible and can cause pathogen growth if water phase salt is too low |
proper labeling |
YES |
CHEMICAL none |
|
|
|
||
PHYSICAL none |
|
|
|
||
Storage | BIOLOGICAL pathogen growth |
yes |
pathogens can grow in warm temperatures if water phase salt is too low |
proper storage temperatures |
YES |
CHEMICAL none |
|
|
|
||
PHYSICAL none |
|
|
|
||
Shipping | BIOLOGICAL pathogen growth |
yes |
pathogens can grow in warm temperatures if water phase salt is too low |
adequate warning labels on packages will control this hazard in previous step |
NO |
CHEMICAL none |
|
|
|
||
PHYSICAL none |
|
|
|
HOT SMOKED FISH COMPANY HACCP PLAN
Firm Name: Hot Smoked Fish Company, Inc. | Product Description: Refrigerated, vacuum-packaged, cooked, ready-to-eat, smoked fish (no mercury-containing species used - see Note #1) | ||||||||
Firm Address: 123 Somewhere St., Anytown USA 97365 | Method of Storage and Distribution: Stored and transported under refrigeration | ||||||||
Intended Use and Consumer: ready to eat by general public without further cooking | |||||||||
(1) Critical Control Point (CCP) |
(2) Significant Hazards(s) |
(3) Critical Limits for each Preventive Measure |
Monitoring | (8) Corrective Actions |
(9) Records |
(10) Verification |
|||
(4) What |
(5) How |
(6) Frequency |
(7) Who |
||||||
Brining (see note #1) | pathogen growth during smoking and in final product | minimum brine strength and times as per process schedule | brine strength and time | salometer and in/out time | each brining batch (lot) | operator | rebrine or hold for evaluation | production log | daily record review |
Smoking/ drying (see note #3) | pathogen growth in final product | minimum smoke-house cycle time as per process schedule | in/out process times | chart recorder | each batch | smoke-house operator | reprocess or hold for evaluation | production log and recorder charts | daily record review monthly wt. loss checks annual wps/a w checks |
Smoking/ cooking (see note #3) | pathogen growth in final product | minimum final cook time/center temp as per process schedule | cook temperature and center temperature | chart recorder | each batch | smoke-house operator | reprocess or hold for evaluation | production log and recorder charts | daily record review, weekly recorder check |
Cooling | pathogen growth during cooling | maximum cooler temperature | cooling room temp | chart recorder | continuous | operator | hold for evaluation/ adjust cooler temp | production log and temp recorder charts | daily record review, weekly recorder check |
Packaging/ labeling | pathogen growth in temperature abused product | all products labeled "keep at 38°F or less" | packaging material | visual | each lot | operator | relabel | production logs | daily record reviews |
Storage of finished product | pathogen growth | 38°F or less | cold storage | chart recorder | continuous | operator | hold for evaluation/ adjust cold room temp | production logs/ recorder charts | weekly recorder check |
Signature of Company Official: | Date of Revision: |
Note #1: This hazard analysis assumes short brining times in strong salt solutions. If long brining times in weak solutions are used, the hazard analysis should consider the possibility of a biological hazard (pathogen growth and/or histamine formation), resulting in a critical control point at this brining step.
If raw brined scombrotoxin fish are stored overnight in the raw fish cooler prior to smoking, then that storage step should be added to the flow sheet and Hazard Analysis Worksheet. The Hazard Analysis should list histamine formation as a significant biological hazard which can be controlled by refrigeration with a CCP at the raw brined fish storage step. The temperature recorder verification log should be changed to include the raw fish storage temperature recorder.
Note #2: Species known to have mercury are not included in this generic plan because the FDA's Hazard and Controls Guide does not cover this hazard (First Edition, September 1996, page 101). This should be resolved prior to Dec. 17, 1997.
Note #3: Brining, smoking, drying, cooking details for each species, size, and style of smoked fish are contained in the company process schedule.
HOT SMOKED FISH CO. PROCESS SCHEDULE
(FOR ILLUSTRATIVE PURPOSES ONLY)
OPERATING LIMITS (see note #4)
SPECIES | SIZE (maximum) |
BRINING (minimum) |
SMOKING (minimum) |
COOKING (minimum) |
DRYING (minimum) |
||||
thick (in) |
len (in) |
width (in) |
stren. deg (sal) |
time (hrs) |
total process time (hrs) |
time (min) |
temp (F) |
weight loss (%) |
|
Chinook (lg) Chinook (sm) |
2 1 |
9 6 |
4 4 |
62 62 |
2:35 1:00 |
8 6 |
35 35 |
148 148 |
20 25 |
Chum Salmon | 1 | 6 | 4 | 62 | :50 | 6 | 35 | 148 | 30 |
Blackcod | 1 1/2 | 5 | 4 | 62 | 1:30 | 6 | 35 | 148 | 15 |
Albacore | 2 | 4 | 3 | 62 | :45 | 6 | 35 | 148 | 15 |
Snapper | 1 | 4 | 2 | 62 | :20 | 5 | 35 | 148 | 20 |
CRITICAL LIMITS (see note #5)
SPECIES | BRINING (minimum) |
SMOKING (minimum) |
COOKING (note #6) (minimum) |
||
strength (sal) |
time (hrs) |
total process time (hrs) |
time (min) |
temperature (F) | |
Chinook (lg) Chinook (sm) |
60 60 |
2:20 :50 |
7:45 5:45 |
30 30 |
145 145 |
Chum Salmon | 60 | :45 | 5:45 | 30 | 145 |
Blackcod | 60 | 1:20 | 5:45 | 30 | 145 |
Albacore | 60 | :40 | 5:45 | 30 | 145 |
Snapper | 60 | :15 | 4:45 | 30 | 145 |
signed: | revision date: |
Note #4: THIS PROCESS SCHEDULE IS FOR ILLUSTRATIVE PURPOSES ONLY. THE VALUES CONTAINED HERE ARE NOT SUBSTANTIATED BY RESEARCH OR FIELD EXPERIENCE. EACH PROCESSING FIRM MUST ESTABLISH AND VERIFY THEIR OWN PROCESSES. Operating limits are values intended to exceed CRITICAL LIMITS so that deviations from CRITICAL LIMITS will not occur. They are margins of safety.
Note #5: THE CRITICAL LIMITS SUGGESTED HERE ARE FOR ILLUSTRATIVE PURPOSES ONLY. AS WITH OPERATING LIMITS, EACH PROCESSOR MUST ESTABLISH AND VERIFY THEIR OWN CRITICAL LIMITS BY TESTING PROCEDURES AND CONDUCTING PRODUCT ANALYSIS. Information on smoked fish HACCP plans can be obtained from FDA's Fish and Fishery Products Hazards and Controls Guide, First Edition, September 1996, Chapter 13 (Clostridium botulinum Toxin Formation) and Chapter 14 (Pathogen Growth and Toxin Formation as a Result of Inadequate Drying).
Note #6: Addition information on smoked fish critical limits can be found on the menus of University of California's Web SeafoodNIC site or specifically at :
HOT SMOKED FISH COMPANY PRODUCTION LOG
BRINING | ||||||||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|
Brine Strength (Sal) (minimum) |
Brining Time (hours) (minimum) |
|||||||||||
lot # | date 1997 |
species | size | operating limit | critical limit | actual SAL value | operating limit | critical limit | time in (clock) | time out (clock) | actual brining time | meets critical limit y/n |
032797-1 | 3/27 | Chinook | lg | 62 | 60 | 63 | 2:35 | 2:20 | 10:23 | 12:57 | 2:34 | y |
032797-2 | 3/27 | chum | 62 | 60 | 63 | :50 | :45 | 11:00 | 11:49 | :49 | y | |
Deviations: none | Corrective Actions: none | Operator initials: Date: |
CONTINUED FROM BRINING LOG ABOVE | SMOKING/DRYING | ||||||||
---|---|---|---|---|---|---|---|---|---|
total processing times | |||||||||
lot # | date 1997 |
species | size | operating limit (hr.) (minimum) |
critical limit (hr.) (minimum) |
time in (clock or recorder) |
time out (clock or recorder) |
actual process time (hr.) |
meets critical limit? (y/n) |
032797-1 | 3/28 | Chinook | lg | 8:00 | 7:45 | 7:30 | 15:29 | 7:59 | y |
032797-2 | 3/28 | chum | 6:00 | 5:45 | 8:00 | 14:01 | 6:01 | y | |
Deviations: none | Corrective Actions: none | Operator initials: Date: |
CONTINUED FROM SMOKING/DRYING ABOVE | COOKING TIME/TEMPERATURE (fish center temp) | |||||||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|
control limit minimum |
critical limits (CL) minimum |
actual time/temp from recorder chart File charts by date! |
meets critical limit? (Y/N) |
out of cooker at (note #7) | into cooler at: (clock) |
|||||||
lot # | date 1997 |
species | size | temp (°F) |
time (min) |
temp (°F) |
time (min) |
temp (°F) |
time above CL |
|||
032797-1 | 3/28 | Chinook | lg | 148 | 35 | 145 | 30 | 148 | 34 | y | 15:45 | 16:00 |
032797-2 | 3/28 | chum | 148 | 35 | 145 | 30 | 147 | 33 | y | 14:30 | 14:45 | |
Deviations: none | Corrective Actions: none | Operator initials: Date: |
||||||||||
Reviewed by (signature): | Date: |
HOT SMOKED FISH COMPANY TEMPERATURE VERIFICATION LOG
WEEKLY RECORDER CALIBRATION | ||||||
---|---|---|---|---|---|---|
Date 1997 |
Time | Recorder | Recorder Temp (°F) | Actual temp (°F) | Deviation from Actual | Corrective Action ? |
3/27 | 12:00 | Smokehouse #1 | 125 | 127 | -2 | none |
3/27 | 12:15 | Smokehouse #2 | 140 | 138 | +2 | adjust down 2 degrees |
3/27 | 2:30 | Smoked Fish Cooler | 35 | 35 | 0 | none |
3/27 | 2:40 | Finished Product Cooler | 38 | 37 | +1 | none |
Operator Signature: | Date: | |||||
Reviewer Signature: | Date: |
TRANSFER FROM PRODUCTION LOG | WEIGHT LOSS FROM DRYING (see note #1) |
ANNUAL WPS and/or aw checks when taken (see Note #2) | |||||||||
---|---|---|---|---|---|---|---|---|---|---|---|
date of testing | lot # | species | size | net wt in | net wt out | actual % loss | operating limit (%) |
corrective action | FDA guideline |
actual value |
corrective action |
3/31/97 | 030397-3 | Chinook | lg | wps=3.5% | 3.6% | none | |||||
3/31/97 | 032797-2 | chum | 275 | 195 | 29 | 30 | add 5 min to process schedule | ||||
Signature of Operator: | Date: | ||||||||||
Signature of Reviewer: | Date: |
Note #7: Tests done in plant show that unpackaged smoked fish taken from the smokehouse at 145°F or less and placed in cooler at 38°F or less will cool to 50°F in less than 3 hours and to 38°F in less than 12 hours.
Note #8: Weight loss checks can be made for representative samples placed in the smoker rather than on the weight of the entire load.
Note #9: FDA guidelines allow either or both Water Phase Salt (WPS) and Water Activity (Aw) to be used to judge the adequacy of protection from growth of Clostridium botulinum in the finished product (smoked fish).
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Publication No. ORESU-I-97-001
copyright Oregon Sea Grant
This publication is funded by Oregon Sea Grant through NOAA, Office of Sea Grant and Extramural programs, U.S. Department of Commerce under grant no. NA36RG0451, project no. A\SGE-3. Oregon Sea Grant is based at, and receives additional support from, Oregon State University, a Land Grant, Sea Grant, and Space Grant institution funded in part by the Oregon Legislature.
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