Processing Step | GMP No | Hazard Type | Hazard | CCP | Preventive Measures | Monitoring |
Receiving | 1.1 | Quality Safety | - Decomposed fish - Damaged fish
| Receiving area | - Control supply source - Have supplier provide a product temperature history
| - Measure temperature upon receipt - Visual inspection -Sample for histamine testing |
Butchering | 1.2 1.3
| Quality Safety | - Decomposed fish - Histamine | Butchering tables | - Control temperature of fish - Control lag time from end of thaw to end of butchering
| - Measure backbone temperature - Sensory inspection - Take sample for histamine analysis |
Loin Cleaning | 6.4 | Quality | - Decomposed fish - Green meat, orange meat or honeycomb
| Loin cleaning tables | - Control lag time from end of cooking to end of cooling - Control time of loin cleaning and hygienic practices - Train workers to detect loin
| - Measure temperature and time of cooling - Visual inspection - Sanitation inspection |
Packing | 7.2 7.3.2
| Safety | - Defect empty can | Empty can storage area | - Select can suppliers - Set up empty can sampling plan and specification required - Train workers on container integrity
| - Visual and seam tear down inspection upon arrival - Visual inspection prior to feeding to line |
7.3.2 | Safety | - Over fill | Weighing table | - Adjust packing machine - Calibrate balance and weigh used
| - On-line weigh check - Calibration of balance |
Seaming | 7.4.3 | Safety | - Defect double seam | Seamer | - Adjustment of seamer - Test run before use - Train QC/seam mechanic
| - Visual seam inspection - Seam tear down |
Retorting | 8 | Safety | - Improper processing resulting in outgrowth of microbes and toxins | Retort area | - Train retort operators - Establish schedule process - Retort equipment checked and calibrated - Close surveillance of operations (by QC/QA)
| - All thermal processes - Operations |
Post Process Handling | 9.2 | Safety | - Post Process contamination | Cooling zone | - Restrict area - Traffic control - Sanitation
| - Check admittance to area (visual inspection) - daily sanitation check |
Processing Step | Critical Limits | Corrective Actions | Verification | Records |
Receiving | Frozen fish < -18°C Fresh fish ~0°C Histamine < 50ppm
| - Inform/change supplier - If histamine >50ppm, increase surveillance at butchering
| - Annually, conduct survey of supplier handling system - Conduct histamine/ temperature relationships
| - Supplier temperature record - Raw materials receiving record - Supplier sources and history |
Butchering | Histamine <50ppm Fish temperature 0 - 5°C Lag time 2 hours
| - If >10% grade 3 fish, lot should be individually culled - If >10% grade 4 (rejected) fish found, lot should be rejected - If histamine >50ppm, increase surveillance, more culling for sensory test - Inform supplier - Reduce volume on line
| - Occasional increased samples for sensory and histamine analysis - Check graders' competence with histamine determination
| - Raw fish grading form - Chemical analysis form - Lot processing record - Training record |
Loin Cleaning | - Lag time not >6 hours - Loin cleaning time <1 hour - No defect or decomposed loin - Sanitation: visually accepted
| - If lag time exceed limits, adjust production volume, fish should be put in chilled room for any delay anticipated - Increase surveillance at butchering table - Improve cleaning and sanitation
| - Run pre-cooking test - Conduct histamine/ temperature relationship - Check samples on workers and graders - Plant sanitation inspection daily
| - Cooling time and temperature record - Loin cleaning and quality record - Training record |
Packing | [Based on sampling plan and can specifications] | - Segregate defect cans - If more than acceptance no. reject lot
| - Inspection of can manufacturers - Obtain QC programme of can manufacturers
| - Record of can manufacturers audit - Empty can inspection record - Can storage, depalletization and feeding log - Can specifications - Training record |
Packing | [Based on value specified in process establishment] | - Segregate defect can - If more than acceptance no. adjust packing machine
| - Inspection of performance and practices - Record check
| - Record of empty can manufacturers audit - Empty can inspection record - Can storage, depalletization and feeding log - Can specification - Training record |
Seaming | [As determined in initial verification according to size of can] | - Closing machine maintenance and adjustment - Hold products for further investigation
| - Inspection of performance and practice - Record check
| - Seamer inspection report - Visual inspection report - Seam tear down report - Investigation report |
Retorting | [As determined in initial verification - calculated for each retort, can size and product type] | - Hold lot/reprocess lot | - Periodic checks on heat distribution in retort and temperature recording equipment. Have process verified by competent authorities. Check competence of operation. - Record review daily
| - Retort operation record - Temperature recording charts - Investigation report |
Post-Process Handling | Entrance to authorized personnel only | - Stop unauthorized entrees | - Review of traffic control programme by inspection - On-site verification
| - Product control report - Investigation report |