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HACCP Generic Model: Acidified Low Acid Foods

Introduction

This model is to be applied to fermented pickled products that are acidified through natural fermentation. It is recognized that formulations and processes may vary with product and plant. The intent of the model is to assist in the identification of potential hazards and to provide guidance for their control. Pickles are fermentation products from fresh cucumbers and natural mixed starter lactic acid flora of cucumbers. Natural fermentation may take from six to nine weeks to fully achieve a finished product. However, fermentation of lactic acid required to reduce the pH to acidify the cucumbers to 4.0 or below must be achieved rapidly within 48 hours. The acidified low acid condition of fermented pickles will prevent growth of spores of Clostridium botulinum, which grows anaerobically at pH above 4.6. The model does not claim to address every plant situation and it is expected that the management team evaluate its product(s) accordingly.

A few clarifications regarding dud detection, glass breakage and prerequisite programs in this generic model are in order. Dud detection may be implemented to remove cocked caps. This defect is self-limiting from a health and safety point of view, since unsealed products will spill, spoil and damage surrounding product. Glass breakage of jars with possible glass inclusion in product may occur at any point along the processing line, from receiving to capping. A glass breakage procedure is part of the sanitation program to remove glass fragments, to prevent possible contamination and to remove open product that may have become contaminated with glass fragments. Certain parameters must be controlled to ensure that visual inspection is effective. These parameters include: training of inspectors, rotation time and number of inspectors, line speed, depth of product and lighting level.

This model, like all other FSEP models, assumes that personnel are properly trained to perform duties required to adequately implement prerequisite programs. Prerequisite programs require points of control to address identified hazard concerns. Points of control include the following: specifications, standard operating procedures, a person responsible for monitoring the specification and correcting deviations, as well as a person responsible to verify that the program is operating adequately. The intensity of control over a prerequisite program and its records is determined by the firm.

Prerequisite programs within this model have been assumed to fully address the reviewed hazards. Each individual plant developing a HACCP plan must review in-plant prerequisite programs for completeness and modify their prerequisite programs or HACCP plans accordingly.