DEVELOPMENT OF A HAZARD ANALYSIS CRITICAL CONTROL POINT (HACCP) MANUAL FOR CHICKEN SAUSAGES, CHICKEN MEATBALLS, CHICKEN HAM, COOKED HAM, STREAKY AND BACK BACON

Abstract

The Cargills Quality Foods (Pvt.) Ltd, being a confineable food company* where safe products are provided, among consumers, the HACCP system should be applied by the company. After application of this approach and by eliminating hazards such as biological,chemical and physical, consumers would receive a free safe food product. Hazard Analysis Critical Control Point (HACCP) is a systematic approach to the identification and assessment of the hazards and risks associated with a food operation in defining the means to their control. HACCP manual was developed to establish such an effective system through dentifying critical control points, deals with the manufacturing processes of meat based products. This approach is enriched by seven principles as analysis of potential hazards, determination of critical control points, establishment of monitoring procedures, verification procedures and establishment of record keeping and documentation. After identification of all potential hazards from each and every raw material, ingredient and process step from receiving upto product distribution, the following critical control points were discovered. They are weighing of restricted ingredient (Nitrite: E 250), cooking in chamber, vacuum packaging and storage processes. Out of those steps, raw materials were covered under Supplier Quality Assurance (SQA). After chamber operation there was no any stage of addition of raw materials to processed products. That was the main element of controlling potential hazards associated with raw materials. Process steps were covered under Good Manufacturing Practices (GMPs). Critical Limits of chicken sausages and chicken meatballs manufacturing processes were nitrite as 125mg per Kg of meat (maximum limit), cooking in chamber at 68°C for 23 second,vacuum packaging where there must not be any leaked product to leave and storage in blast freezer at - 1 8°C for 3hrs. Critical limits of chicken ham and cooked ham manufacturing were nitrite as 125mg per Kg of meat (maximum limit), cooking in chamber at 64°C for 115 second. In vacuum packaging there must not be any leaked product to leave and storage in chiller at 10°C or below. Critical limits of streaky and back bacon manufacturing were nitrite as 125mg per Kg of meat (maximum limit), drying in chamber at 50°C for 30min and storage in blast freezer at - 1 8°C for 3hrs.