Provide Haccp Plan for Approval Before Using Rop for Beef.
By Jason Bolton, Ph.D. Assistant Extension Professor and Nutrient Safety Specialist, University of Maine Cooperative Extension.
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Table of Contents
- Benefits associated with ROP products
- Terms related to ROP products
- Types of Reduced Oxygen Packaging
- Food condom concerns with vacuum packaging or ROP products
- Gamble Analysis Disquisitional Control Plan (HACCP)
- In Summary
- Additional Data
- Reviewers
Many food service and commercial food processors have begun using Reduced Oxygen Packaging (ROP) (e.k. vacuum packaging) to help extend the shelf life of food products. The use of these packaging technologies has several benefits but information technology is essential to know the serious food condom risks and Maine Nutrient Code requirements associated with this type of packaging.
Benefits associated with ROP products
The removal or reduction of oxygen prevents the growth of most spoilage organisms. These microorganisms are responsible for off-odors and texture changes that occur when food spoils. Reducing oxygen also reduces fat oxidation and rancidity. These are the characteristic changes that allow the consumer to determine if a nutrient is still edible. Therefore, ROP technologies can prolong quality and extend the shelf life of refrigerated and frozen foods. Notwithstanding, at that place are very serious food safe risks if ROP food products are not handled and stored correctly.
Terms related to ROP products
Aerobic Atmospheric condition — The environs contains oxygen.
Anaerobic Weather condition — The environment does not contain oxygen.
Vegetative cells — A country in which bacteria tin can reproduce/grow and, in particular, bacteria produce toxins.
Spore Forming Leaner — Bacteria that is capable of forming spores, thick walled formations that tin can protect the bacterial cell against unfavorable or hostile environmental conditions (e.k. loftier acid, high temperature, drying, freezing) thus assuasive survival. Once a spore, the cell cannot reproduce or grow until it enters a vegetative land.
Canning — Canning is a method of preserving food in which the food contents are heat processed and sealed in an closed container. Examples: Dilly Beans, Acidified Pickles, Hot Sauces, BBQ sauces.
Sanitation Standard Operating Procedure (SSOP) — Procedures that will be used to reach sanitary nutrient handling and full general hygiene practices. They also document how monitoring and corrective deportment will exist accomplished and who is responsible.
Potentially Hazardous Foods (PHF) / Temperature Controlled for Safety (TCS) — The Nutrient Code defines PHF/TCS as a natural or synthetic food that requires temperature command because information technology is capable of supporting:
- The rapid and progressive growth of infectious or toxigenic microorganisms, or
- The growth and toxin production of Clostridium botulinum, or
- In raw shell eggs, the growth of Salmonella enteritidis.
Curing — Meat or poultry to which some combination of salt, sugar, nitrite and/or nitrate is added for the purposes of preservation.
- If you are adding nitrate and/or nitrites, then yous are curing.
Types of Reduced Oxygen Packaging
Vacuum Packaging — The air is removed from a food package and hermetically sealed (closed and so no air/oxygen tin can enter) and the vacuum inside the package remains until the seal is cleaved.
Cook Arctic — Cooked food filled into numberless/packaging while still hot, causing the air to exist expelled from the numberless/packaging. They are sealed or crimped with a metal or plastic closure while the food is still hot. The bags are and then speedily chilled and stored under refrigeration or are frozen.
Sous Vide — Raw or partially cooked foods are placed in a pocketbook, vacuum packed, and hermetically sealed. In general they are then cooked in the pocketbook, speedily chilled, and held under refrigeration.
Modified Atmosphere Packaging (MAP) — The air/atmosphere inside the package is altered so that the new composition is unlike from normal aerobic conditions (21% oxygen concentration) — ordinarily adding nitrogen and/or carbon dioxide and lowering or removing the oxygen. The package atmosphere does not have to maintain these conditions and may change over time due to the respiration of the food or permeability of the packaging materials.
Controlled Atmosphere Packaging (CAP) — The air/atmosphere inside a sealed package is altered so that the new composition is unlike from normal aerobic conditions (21% oxygen concentration) and continuous control of that air/temper is maintained. This air/atmosphere can be controlled and maintained past use of non-respiring nutrient, impermeable packaging or apply of oxygen scavenging products.
Food safe concerns with vacuum packaging or ROP products
Clostridium botulinum is a very dangerous bacterium that can thrive in anaerobic conditions if certain precautions are not taken. The danger lies in its ability to form a spore to protect itself in adverse conditions. As a spore there is no danger, just if there is improper handling of a susceptible product, then conditions in the nutrient parcel tin can become favorable for spores to transform into vegetative cells where they can grow, reproduce, and form a deadly neurotoxin. This is a rut stable toxin and very small quantities — nanograms — of this heat stable neurotoxin tin cause paralysis and death. When in the spore course, this bacterium tin exist fallow for years and survive farthermost conditions including freezer and fridge temperatures, boiling water (212°F), drought, high moisture, and aerobic and anaerobic atmospheric condition. C. botulinum is present everywhere, and whatever food tin be contaminated with it and should be treated to prevent or command growth and toxin formation.
There are several strains of C. botulinum. C. Bot type E and non-proteolytic types B and F are associated with fish and fishery products and can grow and produce toxin in temperatures equally depression as 38°F (iii.3°C). Every bit vegetative cells, C. Botulinum type A and proteolytic types B and F can grow and produce toxin at temperatures as low equally 50°F (10°C) and are associated with many commodities, i.e., red meat, poultry, pork, vegetables, etc.
If present, and proper processing, treatment, and storing are non in place, C. botulinum could potentially grow, produce toxin, and return an ROP nutrient toxic. Under ROP weather, most competing spoilage microorganisms cannot grow, therefore assuasive C. botulinum to abound unimpeded. Foods that contain C. botulinum toxin generally look, smell, and gustation normal.
Normal cooking (east.k. pasteurization or sous vide) does not destroy C. botulinum spores. In order to destroy C. botulinum, foods must be heat-treated to commercial sterility — such equally with canned foods. If this is not possible, and then C. botulinum must be controlled with refrigeration (41°F or 4.4°C or below) with the exception of C. bot blazon Eastward present in about fish and fisheries products, which should be held at 38°F (3.3°C) or below. In addition to these low temperatures, C. botulinum volition not grow in nutrient with a low pH (4.vi or less), or low h2o activity (Aw 0.935 or less for type A and proteolytic Type B and F OR Aw of 0.97 or less for blazon E and non-proteolytic type B and F).
Because of the high mortality rates and lack of alert signs when contaminated with C. botulinum toxin, foods held in anaerobic weather are strictly regulated. Therefore, PHF or TCS foods packed in ROP packages are required to employ multiple barriers to prevent the growth of C. botulinum and must be manufactured and/or packed nether a HACCP plan.
Hazard Analysis Critical Control Programme (HACCP)
HACCP is a food condom management organization, which identifies and controls biological, chemical, and physical nutrient safety hazards from raw material production, procurement, and treatment, to manufacturing, distribution, and consumption of the finished product. There are seven principles that must be addressed in HACCP including:
Principle ane — Conduct a Hazard Analysis (HA)
Principle 2 — Place the Critical Control Points (CCPs)
Principle iii — Establish Critical Limits (CLs)
Principle four — Monitor CCP
Principle 5 — Establish Corrective Action (CA)
Principle vi — Verification
Principle seven — Recordkeeping
HACCP was developed in the 1960s to ensure the safe of food for the infinite program and since the mid 1990s HACCP has become the foundation of our nutrient safety arrangement for all commodities in the US and countries worldwide.
Regulations (2013 Maine Food Code)
2013 Maine Food Code lists 2 Sections:
- Department three-502.12 — Any PHF products that are allowed to be packed under ROP Without a Variance must meet the criteria in 3-502.12 (low h2o activity, low pH, USDA cured, raw meat, raw poultry, and/or raw vegetables). HACCP programme required.
- Section iii-502.11 — Any PHF products that do non meet the criteria listed in 3.502.12 volition require a Variance and a HACCP plan.
1) Section 3-502.12 — Whatever PHF products that are immune to be packed under ROP Without a Variance must encounter the criteria in 3-502.12 (depression water activity, low pH, USDA cured, raw meat, raw poultry, and/or raw vegetables). HACCP plan required.
Products that run into these criteria have a barrier to preclude C. Bot growth and toxin formation. Strict temperature control will provide the second barrier.
If packaged on site at the eating establishment, a HACCP plan and recordkeeping is required and a shelf life of xiv days is allowed.
Minimal HACCP plan and CCP requirements for these products:
- If held at refrigerated temperatures:
- Continuous temperature monitoring to ensure production is stored at 41°F or lower.
- Written processing procedures, SSOP, and ongoing records to show that product is not temperature driveling during processing and vacuum packing.
- Labeling "Important — Must be kept refrigerated at 41°F (5°C) or below" and date coding for a shelf life of 14 days.
- If frozen:
- Written processing procedures, SSOP, and ongoing records to prove that product is not temperature driveling during processing and vacuum packing.
- Labeling "Important — Must be kept frozen," or "Important, go on frozen until used, thaw under refrigeration immediately before utilize" or "Of import, go on frozen until used, interruption seal prior to thawing."
- One time removed from freezer to thaw, the product must have date coding for a 14-day shelf-life.
- Written process for thawing:
- Pause the seal prior to thawing — OR —
- Thaw ROP product nether continuous monitoring
- All-time Practices (not required)
- Continuous monitoring (preferred selection) — OR —
- Periodic Temperature records (instance: record temperature of cooler every four hours)
Fish and seafood products may not exist vacuum packaged at retail unless the fish is frozen before, during, and afterward packaging. This process still requires a HACCP programme.
Sections iii-502.12 and 8-201.14 of the 2013 Maine Food Lawmaking list boosted requirements for these plans. Department iii-502.12 too describes the HACCP plan and control requirements for ROP storage of Sous Vide, Melt-Chill, and Cheese Products.
2) Section three-502.11 — Whatsoever PHF products that practise not meet the criteria listed in iii.502.12 will require a Variance and a HACCP plan.
These products will require a variance and a HACCP plan. The contents of the plan will include the items listed above and may also include additional monitoring depending on what secondary barrier is used.
The adequacy of the secondary barrier volition need to be evaluated past a food processing authority.
Product examples include but are not express to:
- Unfrozen processed fish and smoked fish packed by ROP;
- Soft cheeses such equally ricotta, cottage cheese, cheese mixed with meats, vegetables or fish;
- Smoked meat or cured meat and poultry cured on site.
Guidance for HACCP Plans that require Variances
- Develop a HACCP Plan. More than information at the FDA website.
- The licensee will demand to write the HACCP plan or they can contact recognized HACCP consultant.
- The HACCP plans and so demand to be sent to Dr. Jason Bolton, at the University of Maine Cooperative Extension, who volition review the process and plan and conduct sample testing of the product. Dr. Jason Bolton's contact: 207.581.1366, jason.bolton@maine.edu.
- A variance will need to be approved by DHHS if selling retail out of their eating house: contact 287.5671. If the eating house is wholesaling, they will need to contact the Department of Agriculture, Forestry and Conservation at 207.287.3841.
iii-201.12 Food in a Hermetically Sealed Container "Canning." Code of Federal Regulations, Championship 21, Parts 114 — Acidified Foods.
This includes acid, formulated acid, and acidified foods. The terminal pH of the product is less than 4.6. Examples include pickles, dilly beans, jams and jellies, salsas that are hermetically sealed in glass jars or bottles. You are not allowed to tin low acid foods (pH 4.6 or greater), i.e., pressure canning or h2o bath canning of meat, poultry, seafood, vegetables, dairy, etc.
Minimal HACCP plan requirements for acidified canned products:
- Submit each product in last packaging for Product and Procedure Review Testing.
- Follow all recommendations for process fourth dimension, temperatures, disquisitional limits/factors, procedures, scale records, and batch pH records that are stated in Product and Process Review Testing Letter of blessing.
In Summary
Steps to produce safe ROP products that meet all requirements in a eatery/food service entity:
- If you produce a potentially hazardous ROP food that meets one or more of the following criteria: low water activity, low pH, USDA cured, raw meat, raw poultry, raw vegetables, then you must:
- Develop a HACCP Plan
- Submit a HACCP program to the DHHS, if required
Health Inspection Programme
Key Bank Plaza 3rd Floor
11 SHS
Augusta, Maine 04333-0011
207-287-5671
Fish and fisheries products may not be vacuum packaged at retail unless it is frozen before, during, and after packaging. This requires a HACCP program.
- If you lot produce a potentially hazardous ROP food that does not meet the above criteria then you must:
- Develop a HACCP Plan
- Submit a variance to process authority for evaluation
- Submit a HACCP plan and variance to DHHS for review
- If you produce acidified canned food yous must:
- Submit each product in concluding packaging for Production and Process Review Testing.
- Follow all recommendations as stated in Product and Process Review Testing Letter of approving.
- Submit a HACCP plan and variance request to DHHS for review.
Additional Information
Sanitation
- General manufacture-wide sanitation 101: contact Theresa Tilton at tilton@maine.edu or 207.942.7396
- Dairy Sanitation: contact Melissa Libby at libby1@maine.edu or 207.581.2788
Adventure Assay Critical Control Point Certification
- Meat and Poultry: contact Theresa Tilton at tilton@maine.edu or 207.942.7396
- Seafood: contact Melissa Libby at libby1@maine.edu or 207.581.2788
Amend Process Control School
Acidified and low-acid canned nutrient processors are required by the FDA and USDA to obtain Better Process Command School certification. Contact Melissa Libby at melissa.libby1@maine.edu or 207.581.2788.
Reviewers
- Lori Pivarnik, Ph.D., University of Rhode Island
- Alfred Bushway, Ph.D., University of Maine, Emeritus
- Lisa Roy, Maine Health Inspection Program
- Becky Walsh, Maine Health Inspection Programme
- Thomas Jenkins, Maine Health Inspection Program
- Thomas Williams, Portland Public Health
- Maurice Anderson, Maine Health Inspection Plan
Data in this publication is provided purely for educational purposes. No responsibility is causeless for any problems associated with the utilise of products or services mentioned. No endorsement of products or companies is intended, nor is criticism of unnamed products or companies implied.
© 2015
Phone call 800.287.0274 (in Maine), or 207.581.3188, for data on publications and program offerings from University of Maine Cooperative Extension, or visit extension.umaine.edu.
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Source: https://extension.umaine.edu/publications/3107e/
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