HACCP Generic Model: Chicken (Poultry) Slaughter - Forms

Table of Contents

Introduction

Product Description (Form 1)

List of Product Ingredients and Incoming Materials (Form 2)

Process Flow Diagram (Form 3)

Plant Schematic (Form 4)

Biological Hazards Identification (Form 5)

Chemical Hazards Identification (Form 6)

Physical Hazards Identification (Form 7)

Critical Control Points (CCP) Determination (Form 8)

Hazards not controlled by the Operator (Form 9)

HACCP Plan (Form 10)

Other Incoming Materials and Processing Steps

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Introduction

This generic model has been developed based on incoming materials and a sequence of processing steps that are common to a chicken slaughter establishment operating on a HACCP based inspection system including on-line reprocessing and reconditioning with downstream cavity defect detection). Considering the many variations in the set up of chicken slaughter establishments and numerous types of products produced, it would be difficult to include all possible scenarios. Operators, therefore, need to adapt this generic model to their plant specific environment when developing their HACCP plans.

Although this generic model has been developed for chicken slaughter, the model can also be used for the slaughter of other poultry species since similar process steps are also utilized. Some additional incoming materials and processing steps that are not common to chicken slaughter establishments have been provided at the end of this Generic HACCP plan. Operators need to include these in their HACCP plans if they are relevant to their operations and conduct a hazard analysis.

Additional hazards may also have to be considered when this model is used for either other poultry species or other classes of poultry: for instance, in the cases of mature poultry such as spent laying hens or spent breeder hens (any species of poultry), contamination and cross-contamination by eggs or egg proteins during the evisceration and chilling process must be considered as a significant chemical hazard that should be controlled and/or mitigated otherwise it could reach unacceptable levels. The ultimate control available for that allergen is the avoidance through the labelling of all products and by-products made of mature poultry to inform further users and/or consumers in order to prevent allergic reactions.

Hazards identified during the hazard analysis may be controlled through the use of Prerequisite Programs, Critical Control Points (CCPs) and/or Process Controls (PCs).

A Process Control (PC) is a control used at a point or step that will contribute to the effectiveness of the related CCP(s) or post mortem inspection activities. Poultry related PCs must be utilized by poultry slaughter establishments as described by the Canadian Food Inspection Agency in the Manual of Procedures (MOP) - Chapter 19. Any deviation at a CCP will require an evaluation of the supporting PC(s) as part of the deviation procedures associated with that CCP. The following is a list of CCPs and their supporting PCs in the Poultry Generic Model:

• CCP-1B Step 24 - Viscera Defect Detection:
  • PC 1 (Evisceration Standards)
  • PC 2 (Presentation Standards)
• CCP-2B Step 30 - Giblet and Neck Harvesting:
  • PC 1 (Evisceration Standards)
• CCP-3B Step 32 - Final Examination:
  • PC 1 (Evisceration Standards)
  • PC 2 (Presentation Standards)
  • PC 3 (Defect Detection Standards, carcass group)
  • PC 4 (Carcass Dressing Standards)
• CCP-4B Step 34 - Salvaging:
  • PC 1 (Evisceration Standards)
  • PC 3 (Defect Detection Standards, carcass group)
  • PC 4 (Carcass Dressing Standards)

Operators require a written program for each PC. The written program for PCs must meet the requirements found in the Manual of Procedures - Chapter 19 and must also contain establishment specific information such as:

1. Who will perform the specified activities
2. The exact locations where the required tests will be performed
3. Deviation procedures including preventative measures
4. Verification procedures

Hazards Associated With the Equipment Sanitation Program

The generic model addresses Chemical hazards associated with pooling of sanitary fluids and Biological hazards associated with inadequate sanitation of equipment by identifying and analyzing them on Forms 5, 6, and 8 only.

Each establishment is required to determine which equipment is associated with the potential pooling of sanitary fluids (e.g. sizing bins or reusable combos and containers) and ensure that the sanitation program addresses the drainage concern for them.

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Form 1: Product Description Process for Poultry Slaughter

1. Product name

Ready to cook chicken:

• raw whole chicken
• raw chicken portions (bone-in and deboned)
• giblets (heart, liver, gizzard)
• paws

2. Important product characteristics (A_w, pH, preservatives, etc.)

Carcasses, portions, giblets and paws:

• fresh - kept at ≤ 4°C
• frozen - kept at - ≤ -18°C.

3. How it is to be used

Carcasses, portions, giblets and paws:

• cooking;
• further processing.

4. Packaging

• styrofoam tray
• absorbent pads
• plastic liners / bags / film wrap
• waxed cardboard boxes
• combos (metal cages / plastic / cardboard)
• plastic containers
• plastic/metal clips
• straps
• pallets
• stainless steel vats
• plastic/metal breast tags
• Modified Atmosphere Packaging (MAP)

5. Shelf life

Carcasses & Portions - "Y" days at ≤ 4°C
Giblets - "Y" days at ≤ 4°C
Paws - "Y" days at ≤ 4°C

6. Where it will be sold

Further processing
Retail
Hotel, Restaurant, Institution

7. Labelling instructions

Keep refrigerated
Keep frozen
Safe handling instructions (recommended)

8. Special distribution control

Fresh product - maintain at ≤ 4°C
Frozen product - maintain in a frozen state

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Form 2: List of Product Ingredients and Incoming Material

Legend: Explanation of Codes

(B) = Biological
(C) = Chemical
(P) = Physical

Live Animals

• chickens (BC)

Non Meat Products

• water (BC)
• CO₂ (Modified Atmosphere Packaging - MAP) (C)
• salt (CP)
• air (compressed) (BC)

Packaging Materials

• absorbent pads (BCP)
• combos (metal cages / plastic / cardboard) (BCP)
• pallets (BCP)
• plastic containers (BCP)
• plastic liners / bags / film wrap (BCP)
• plastic / metal clips (BCP)
• plastic / metal breast tags (BCP)
• stainless steel vats (BCP)
• straps (BCP)
• styrofoam tray (BCP)
• waxed cardboard boxes (BCP)

Antimicrobial Agents

• Chlorine (Cl₂)(C)
• Acidified Sodium Chlorite (C)
• Trisodium Phosphate (TSP) (C)
• Lactic Acid (C)
• Chlorine dioxide (C)

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Form 3: Process Flow Diagram

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Form 3: Process Flow Diagram

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Form 4: Plant Schematic

Note: This form is to be specific for each establishment. The HACCP team must construct the plant schematic diagram on Form 4. The flows of products as well as employee traffic is clearly identified. The flows of all ingredients and packaging materials is also indicated from the moment they are received through storage, preparation, processing, packaging, finished product holding and shipping. And finally the employee movement throughout the establishment, including change rooms, washrooms and lunchrooms is also indicated. The product and employee flows throughout the facility must be validated following an on-site verification of their accuracy and completeness. This diagram is the primary tool to identify potential areas of cross-contamination (e.g. locations where allergen ingredients, food additives or raw ingredients could come into unplanned contact).

Next page: Form 5