Ham HACCP Plan. Deseret Meat & Livestock Co North 200 East Spanish Fork, UT Phone: (801)

Transcription

1 Deseret Meat & Livestock Co North 200 East Spanish Fork, UT Phone: (801) Ham HACCP Plan Cameron Bardsley, Tiffany Chu, Rick Dreiling, Emily Frame, Caitlin Stryker 1

2 Table of Contents HACCP Team..3 Product Description..4 Flow Diagram....5 Process Description..6 HACCP Summary Table...8 HACCP Plan Summary Table. 11 2

3 Ernie Hawkins: Plant Manager HACCP Team - Ensures that QA team is performing proper procedures to produce Key Daley: QA Manager - Verifies daily that quality procedures are being followed. - Monitors QA and CCP checks - Received HACCP training Courtney Honka: QA Specialist - Identifies possible hazards in the facility. - Received HACCP training. James Purkey: Production Manager - Oversees the process related with the CCP s Mike Harris: Microbiology Specialist - Verify that product is within biological specifications Steven Groneman: Assistant Microbiology Specialist - Verify that product is within biological specifications 3

4 Product Description Description of Food: - This ham is a ready- to- eat product that is brined and then smoked for several hours and is fully cooked. It is intended to be eaten directly out of the packaging without needing any additional cooking, but can be used as an ingredient in other foods. Description of Distribution: - This product is produced by Deseret Meats and Livestock Co for LDS Welfare Services, which is a non- profit organization. LDS Trucking distributes this product across the nation to Bishop s Storehouses and is then distributed to the consumer at these locations. Surplus product is sent overseas to areas in need of humanitarian aid. Description of Intended Use/Consumer: - This product is not for sale and is intended to be given to those in need, whether in the United States or abroad. Most of the time in the US, the recipient of this product is a member of the LDS church. However if this product is distributed as a component of humanitarian aid, the intended consumer may belong to any demographic or nation. Ingredient Declaration/ List of Raw Materials - Fully Cooked Cured Ham Water Added - Cured with: Water, Salt, Sodium Tripolyphosphate, Sugar, Seasoning (Sugar, Dextrose, Spice Extractives of Allspice, Cloves, Capsicum, and Cassia) Sodium Erythorbate, Sodium Nitrite 4

5 Flow Diagram 5

6 Description of Process RECEIVING: A trained employee visually inspects raw product before being accepted from the supplier. This employee will take the temperature of the product to ensure that the product is at or below 45 degrees Fahrenheit to safe handling and will look for visible signs of damage such as: rodent droppings, insect damage, damage to the box, signs of leakage or spillage, discoloration, or signs of rotting. The product is also required to have a Certificate of Analysis declaring the results from various Salmonella assays. STORAGE: Product is stored in a refrigerator that is continuously monitored and has an emergency alert system if the cooling operations fail to alert a mechanic of an issue. The product is stored at or below 45 degrees Fahrenheit in these coolers until use. BRINING: Brine is made fresh every day and is continuously recycled until the end of the day when the remaining brine is thrown out. Pieces of pork are loaded by hand on to a conveyor, which feeds them into an injector system. The injector presses a block with metal needles into the pieces of pork to inject the brine into the tissue. The brined pork continues on the conveyor until it lands in a holding bin. Twenty pounds of pork are weighed, then brined, rested, then weighed again to calculate the amount of brine being injected. If the level of brine is too low, the pork is simply re- brined. RESTING: The brined pork is allowed to rest for half an hour so the salt in the brine solution can begin the oxidation process, turning the flesh from pink to brown. TUMBLING: The oxidized brined pork is then loaded into a tumbler by hand. The tumbler has three large paddles, which turn the hams in the chamber for fifteen minutes at around 35 degrees Fahrenheit. This tumbling action works to extract the myosin from the hams and gives the pork the appearance of being covered with a thin white frosting. This helps the pork pieces combine easier during the casing process. CASING: The tumbler is unloaded into another holding bin that feeds into an auger. This auger packs the hams under a vacuum into the correct shape to be cased. It eliminates gaps and allows the ham to be almost extruded into the casings. If a casing breaks, the ham is added to the next batch to be sent through the auger. Clips and casings are counted to ensure safety and the newly packed cases are referred to as logs. A cart full of logs is called a tree. 6

7 Description of Process (cont.) SMOKING: This facility has two smokers, which can hold three trees each. The ham is flavored with liquid smoke and cooked for about eight to ten hours in the smokers that employ continuous monitoring systems. Probes are strategically placed in the cold spots to ensure the necessary temperature of at least 150 degrees is reached in even the weakest spots. A trained employee will take the temperature of logs closest to these cold spots after every cook with a calibrated probe, usually aiming for a stable temperature of 150 degrees Fahrenheit for at least two minutes. If the temperature of these logs is too low, other logs are randomly selected for temperature testing. Unacceptable temperature readings, while rare, result in wasted product as these logs are thrown away. CHILLING: After smoking, trees are cooled from 130 degrees Fahrenheit down to 80 degrees Fahrenheit within five hours. Then they are cooled from 80 degrees Fahrenheit down to 45 degrees Fahrenheit within ten hours. Again continuous monitoring systems are used to alert technicians of issues before they become irreversible. Such problems are usually corrected within half an hour SLICING: Hams are kept at 40 degrees Fahrenheit before slicing. They then have the casing removed and are fed into an automatic slicer, which produces about two lb hams from the three- foot logs. PACKAGING: The sliced hams are placed by hand into packaging wells. The conveyor moves the filled wells into a vacuum sealer, which adds the top layer with the product label, USDA approval badge, and the nutritional information. The now sealed hams have the Julian date laser printed on them for tracking purposes. Forty- six packaged hams fit into a single cardboard box. X- RAY / METAL DETECTOR: Boxes are then fed through either an X- ray machine or a metal detector to determine if extraneous material is present. If a problem is detected, the problem package is removed from the box and the technician operating the machine, indicating it is ready to be shipped, signs the cleared box. 7