Haccp v2 Appx-6

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MAF Food Assurance Authority (Animal products Group)

A Guide to HACCP Systems in the Meat Industry
Appendix X.6: Manufacture of Beef Jerky
Amendment 6 : June 1999

Page: X.6.1
Appendix X.6: Generic HACCP Plan for Manufacture of Beef Jerky

1.
Prerequisite Requirements
The following are documented prerequisite programmes/sanitation standard operating procedures

(SSOPs):
sanitary design;
potable water quality;
sanitation and cleanup procedures for edible areas and food contact surfaces
(preoperational and operational);
personal hygiene (protective clothing requirements, personal equipment and use of

amenities);
training;
hygienic processing (processing techniques and procedures including separation of raw

and cooked product, damaged carton procedures, dropped meat);
rework procedures;
recall procedures;
food contact materials (specifications, handling and storage);
supplier quality assurance (ingredient specifications, supplier audits, certifications, product

testing);
handling and storage of incoming raw materials and finished product (food additives/
ingredients, refrigeration management);
product testing procedures;
calibration, installation and maintenance of heat processing equipment and instruments;
repairs and maintenance of equipment;
control of chemicals;
vermin control;
waste disposal;
handling and disposition of detained and nonconforming products.
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2.

Page: X.6.2
Scope of HACCP Plan
HACCP application:
Food safety
Species:
Bovine
Product:
Beef jerky
Process:
Processing of beef jerky from receipt of raw materials (meat and

non-meat) to loadout of packed product.
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3.

Page: X.6.3
Product Description and Intended Use
Form 1: Product description and intended use

1.
Product name(s)
Beef jerky
2.
Important product characteristics
Shelf stable, packaged, flavoured beef jerky produced from

intact muscle cuts.
Product meeting company and regulatory specifications for
water activity, sensory and microbiological quality, foreign
objects and packaging.
3.
How is it to be used:
a. By a further processor or retailer
b. By the consumer
a. Not applicable
b. Ready to eat
4.
Intended consumer
General public (high-risk groups not specified for this plan)
5.
Packaging
Company/regulatory specification
6.
Shelf life and storage requirements
7.
Where it will be sold:

a. Export market
b. Local market
List countries, if applicable
8.
Labelling instructions
9.
Special distribution controls required
Handle packages with care
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4.

Page: X.6.4
Initial Food Safety Objectives
(To be confirmed after hazard analysis and CCP determination. See Section 8 for confirmed
objectives.)
To minimise microbiological hazards in the product to levels not exceeding specified targets.
To ensure that chemical hazards in the product do not exceed specified targets.
To ensure that the product does not contain any food additives at a level that may represent a
hazard to human health.
To prevent the occurrence of foreign objects in the product to levels not exceeding specific
targets.
5.
Process Flow Diagram
Form 2: Raw materials/other inputs

Product name:
Beef jerky
Raw materials / other inputs
Description / specification
Frozen boneless beef cuts
Complies with company, industry and regulatory

requirements
Salt/sugar/spices/flavourings (e.g. soy sauce)/additives (e.g.

1
sodium nitrite)
As per written company specifications and the New Zealand

Food Regulations 1984
Food contact packaging materials

(e.g. plastic bags, oxygen scavengers, etc.)
Suitable for use as food contact materials
1.
These inputs and possible hazards must be addressed by a prerequisite programme/SSOP, a separate
HACCP plan, or be specifically considered during hazard identification within this HACCP plan.
2.
Specifications and hygienic handling of these materials are covered by premises prerequisite programme
for food contact materials.
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Page: X.6.5
Form 3: Process flow diagram

Processes that allow reuse or recycling of marinade must clearly reflect this practice in the
process flow. The impact of recycling at the relevant steps must be considered during hazard
analysis and CCP determination. Strict compliance to documented recycling or rework
procedures must be observed.
Process: Manufacture of beef jerky
Inputs
Process steps
Frozen beef and non-meat

!
ingredients
1.
1a. Receipt of non-meat

ingredients
Receipt of meat
"
"
2.
"
Frozen storage
2a. Storage
"
3.
"
"
"
Tempering
"
4.
Weighing
3a. Weighing
"
5.
Decartoning
"
6.
Slicing
"
7.
Marinating
and tumbling
Edible outputs
"
"
"
"
"
"
8.
Drying
"
9.
Cooling
"
Packaging materials
10. Packing
"
11. Storage
"
12. Dispatch
Packaged jerky
1. Various processes may differ as to when the meat is reduced in size, marinated/tumbled, or whether there is an
initial drying or cooking step. Thus, individual premises must customise this generic plan to suit their own product
and process.
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6.

Page: X.6.6
Job Descriptions
Form 4 should be completed and confirmed for each step in the particular process.
Form 4: Template for job description
Job Description
Process step no:
Summary list of food safety responsibilities of operator: (confirm after HACCP plan completed)
Reference:
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Page: X.6.7
7.
Hazard Analysis and CCP Determination
7.1
Raw material hazard identification
Form 5a: Hazard identification for meat and non-meat ingredients1

Raw material
Biological hazard
Chemical hazard
Physical hazard
B1 Enteric pathogens
associated with
contamination from faeces,
ingesta, hide, e.g.
Salmonella spp.,
E. coli O157:H7,
Campylobacter jejuni,
Clostridium spp.
C1 Chemical hazards
associated with unidentified
chemical residues, e.g.
anthelmintics, antibiotics,
environmental contaminants
None
Food grade salt
None
None
None
Sugar
None
None
None
Soy sauce
None
None
None
B2 Spore forming
organisms e.g. Bacillus
cereus, Clostridium spp.
C2 Chemical residues,
e.g. herbicides, pesticides,
fumigants
None
None
C2 Nitrite
None
Meat ingredients
Frozen boneless beef
Non-meat ingredients
Spices (decontaminated)
Sodium nitrite
1.
The following codes are used in this generic plan:

B Biological B1 Microbiological hazards associated with meat ingredients
B2 Microbiological hazards associated with non-meat ingredients
B3 Microbiological hazards associated with other inputs
B4 Microbiological hazards associated with contamination due to a process step
requirement not being met (sporadic occurrence)
C Chemical
C1 Chemical hazards associated with meat ingredients

C2 Chemical hazards associated with non-meat ingredients
C3 Chemical hazards associated with other inputs
C4 Chemical hazards associated with contamination due to a process step requirement
not being met (sporadic occurrence)
P Physical
P1
P2
P3
P4
Physical hazards associated with meat ingredients

Physical hazards associated with non-meat ingredients
Physical hazards associated with other inputs
Physical hazards associated with contamination due to a process step requirement
not being met (sporadic occurrence)
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Page: X.6.8
2.
Hazards listed for meat are those that have been identified in the Generic HACCP Plan for Cooling and
Boning of Beef as food safety hazards that may be reasonably associated with beef cuts and trimmings. Note
that new codes have been used in this generic plan. Biological hazards associated with beef are discussed
in Sections 1 and 2 of the Annex to Appendix IX.2: Background Information to the Generic HACCP Plan
for Slaughter and Dressing of Cattle.
3.
If a supplier can give an assurance that there are adequate controls for chemical hazards in their HACCP
plan (e.g. by providing producer or manufacturers guarantees whereby compliance can be verified under
the supplier quality assurance (SQA) programme), then these hazards need not appear in this raw material
hazard identification.
4.
Powdered spices used in commercial processing of beef jerky are generally decontaminated to reduce
microbiological contaminants. Included in their specifications is that they are free from foreign objects.
Compliance to these specifications should be verified under the SQA programme.
5.
This hazard can occur at unacceptable levels when sodium nitrite is used to excess, i.e. the incorrect amount
is weighed out and added to a particular batch of jerky.
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MAF Food Assurance Authority (Animal Products)

7.2
Amendment 6: August 1999

Page: X.6.9
Hazard analysis and CCP determination (raw material, other inputs and process steps)
Hazard analysis may result in changes to the initial food safety objectives set in Section 4. See Section 8 for confirmed objectives.
Form 5b: Hazard analysis and CCP determination (raw material, other inputs and process steps)
Process Step
Inputs
Raw Material
Component
Hazards
(i) Process
step hazards1
Other Inputs
Component
Hazards
(ii) Potential
impact of
process step
on existing
hazards1
Q1. Could the hazard be

present in or on the product2
at unacceptable3 levels at this
step?
If yes, answer Q2 and Q3
Yes/No
Q2. Is there a
control measure at
this step that
would prevent
unacceptable
levels of the
hazard?
Justification
If yes, this step is a
CCP
If no, not a CCP
Receipt and preparation of non-meat ingredients

1a. Receipt of
non-meat
ingredients
2a. Storage of
non-meat
ingredients
Salt
None
Sugar
None
Soy sauce
None
Spices
B2. Spore
forming org.
No
C2. Chemical
residues
No
Sodium
nitrite
C2. Nitrite
No
Salt
None
Sugar
None
Soy sauce
None
Q3. Is there a
control measure
available at a
previous step?
If yes,
retrospectively
assign the previous
step as a CCP
CCP
No.
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Process Step

Page: X.6.10
(i) Process
step hazards1
Inputs
Raw Material
Component
Hazards
Other Inputs
Component
Hazards
(ii) Potential
impact of
process step
on existing
hazards1

step?
Yes/No
Q2. Is there a
control measure at
this step that
would prevent
unacceptable
levels of the
hazard?
Justification
CCP
Q3. Is there a
control measure
available at a
previous step?
CCP
No.
If yes,
retrospectively
assign the previous
step as a CCP
If no, not a CCP

Spices
B2. Spore
forming org.
No
C2. Chemical
residues
No
Sodium
nitrite
C2. Nitrite
No
3a. Weighing of
non-meat
ingredients
Salt
None
Sugar
None
(To step 7)
Soy sauce
None
Spices
B2. Spore
forming org.
No
C2. Chemical
residues
No
C2. Nitrite
Yes
Sodium
nitrite
Incorrect amount
may cause nitrite
poisoning
Refer to Annex,
Section 3.3.
Yes weighing of
correct amount of
nitrite per batch
No
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Process Step

Page: X.6.11
(i) Process
step hazards1
Inputs
Raw Material
Component
Hazards
Other Inputs
Component
Hazards
(ii) Potential
impact of
process step
on existing
hazards1

step?
Yes/No
Q2. Is there a
control measure at
this step that
would prevent
unacceptable
levels of the
hazard?
Justification
CCP
Q3. Is there a
control measure
available at a
previous step?
If yes,
retrospectively
assign the previous
step as a CCP
If no, not a CCP

Main process
1. Receipt of
meat
2. Frozen
storage of meat
3. Tempering of
meat
Beef cuts
Beef cuts
Beef cuts
B1. Enteric
pathogens
Yes
C1. Chemical
residues
No
B1. Enteric
pathogens
Yes
C1. Chemical
residues
No
B1. Enteric
pathogens
Yes
Unacceptable levels
of microorganisms
in relation to FSO 1
are likely to be
present.
Refer to Annex,
Sections 2 & 6.1.
No
No
Unacceptable levels
of microorganisms
are likely to be
present.
Refer to Annex,
Section 2.
No
No
Unacceptable levels
of microorganisms
are likely to be
present.
Refer to Annex,
Sections 2 & 6.2.
No
No
CCP
No.
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Process Step

Page: X.6.12
(i) Process
step hazards1
Inputs
Raw Material
Component
Hazards
Other Inputs
Component
Hazards
(ii) Potential
impact of
process step
on existing
hazards1

step?
Yes/No
Q2. Is there a
control measure at
this step that
would prevent
unacceptable
levels of the
hazard?
Justification
CCP
Q3. Is there a
control measure
available at a
previous step?
If yes,
retrospectively
assign the previous
step as a CCP
If no, not a CCP
4. Weighing of
meat
5. Decartoning
Beef cuts
Beef cuts
C1. Chemical
residues
No
B1. Enteric
pathogens
Yes
C1. Chemical
residues
No
B1. Enteric
pathogens
Yes
C1. Chemical
residues
No
Unacceptable levels
of microorganisms
are likely to be
present.
Refer to Annex,
Section 2.
No
No
Unacceptable levels
of microorganisms
are likely to be
present.
Refer to Annex,
Section 2.
No
No
CCP
No.
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Process Step

Page: X.6.13
(i) Process step

hazards1
Inputs
Raw Material
Component
Hazards
Other Inputs
Component
Hazards
(ii) Potential
impact of
process step
on existing
hazards1

step?
Yes/No
Q2. Is there a
control measure at
this step that
would prevent
unacceptable
levels of the
hazard?
Justification
CCP
Q3. Is there a
control measure
available at a
previous step?
If yes,
retrospectively
assign the previous
step as a CCP
If no, not a CCP

6. Slicing of
meat
Beef cuts
B1. Enteric
pathogens
Yes
(ii) Cross
contamination
7. Marinating &
tumbling
Sliced beef &

marinade
No
No
Unacceptable levels
of microorganisms
are likely to be
present.
Refer to Annex,
Sections 2 & 6.4.
No
No
No
C1. Chemical
residues
No
B1. Enteric
pathogens
Yes
(ii) Cross
contamination;
growth of
vegetative
microorganisms4
Unacceptable levels
of microorganisms
are likely to be
present.
Refer to Annex,
Sections 2 & 6.3.
No
CCP
No.
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Process Step

Page: X.6.14
(i) Process
step hazards1
Inputs
Raw Material
Component
Hazards
Other Inputs
Component
Hazards
(ii) Potential
impact of
process step
on existing
hazards1

step?
Yes/No
Q2. Is there a
control measure at
this step that
would prevent
unacceptable
levels of the
hazard?
Justification
CCP
Q3. Is there a
control measure
available at a
previous step?
CCP
No.
If yes,
retrospectively
assign the previous
step as a CCP
If no, not a CCP

B2. Spore
forming org.
8. Drying
9. Cooling
Sliced,
marinated
beef
Beef jerky
(ii) Cross
contamination
No
C1/C2.
Chemical
residues5
No
C2. Nitrite
No
B1. Enteric
pathogens
(ii) Destruction
of some
vegetative
pathogens
Yes
B2. Spore
forming org.
(ii) Growth of
some
pathogens
No
C1/C2.
Chemical
residues
No
C2. Nitrite
No
B1. Enteric
pathogens
No
Unacceptable levels
of microorganisms
are likely to be
present.
Refer to Annex,
Sections 2 & 6.5.
Yes - correct drying

schedule
No
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Process Step

Page: X.6.15
(i) Process
step hazards1
Inputs
Raw Material
Component
Hazards
Other Inputs
Component
Hazards
(ii) Potential
impact of
process step
on existing
hazards1

step?
Yes/No
Q2. Is there a
control measure at
this step that
would prevent
unacceptable
levels of the
hazard?
Justification
CCP
If no, not a CCP
10. Packing
Beef jerky
B2. Spore
forming org.
No
C1/C2.
Chemical
residues
No
C2. Nitrite
No
B1. Enteric
pathogens
No
B2. Spore
forming org.
No
C1/C2.
Chemical
residues
No
C2. Nitrite
No
Packaging
materials
11. Storage
Packed beef
jerky
None
B1. Enteric
pathogens
No
B2. Spore
forming org.
No
Q3. Is there a
control measure
available at a
previous step?
If yes,
retrospectively
assign the previous
step as a CCP
CCP
No.
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Process Step

Page: X.6.16
(i) Process
step hazards1
Inputs
Raw Material
Component
Hazards
Other Inputs
Component
Hazards
(ii) Potential
impact of
process step
on existing
hazards1

step?
Yes/No
Q2. Is there a
control measure at
this step that
would prevent
unacceptable
levels of the
hazard?
Justification
CCP
Q3. Is there a
control measure
available at a
previous step?
CCP
No.
If yes,
retrospectively
assign the previous
step as a CCP
If no, not a CCP
12. Dispatch
Packed beef
jerky
C1/C2.
Chemical
residues
No
C2. Nitrite
No
B1. Enteric
pathogens
No
B2. Spore
forming org.
No
C1/C2.
Chemical
residues
No
C2. Nitrite
No
1.
Once these hazards have been identified, they may become part of the product hazards at subsequent steps if immediate and complete control of the hazard is not possible.
2.
Product is defined as the edible component of final product.
3.
Unacceptable as demonstrated by data (scientific literature, applied research or on-site experience) associated with achieving the FSOs established for the process. In
the determination of unacceptability, hazards should be considered in terms of:
level;
frequency;
transfer and redistribution;
severity of effect on consumer.
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4.
Consideration should be given to the growth of environmental hazards on product at this step, and whether the levels are unacceptable.
5.
The C1 and C2 hazards are combined at this step because it is not possible to distinguish whether residues are from the meat or the spices.

Page: X.6.17
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MAF Food Assurance Authority (Animal Products Group)

8.

Page: X.6.18
Confirmed Food Safety Objectives (FSOs)
FSO1: To minimise microbiological hazards in the product to levels not exceeding specified
targets.
FSO2: To ensure that chemical hazards in the product do not exceed specified targets.
FSO3: To ensure that the product does not contain sodium nitrite at levels exceeding specified
targets.
9.
Completion of the HACCP Plan
Full documentation is required for the remaining elements of the HACCP plan:
critical limit setting;

monitoring procedures;
corrective action procedures;
verification procedures including validation;
documentation and record keeping procedures.
Refer to Sections 9-13 of the Template for Establishing a HACCP Plan for Further Processing
of Meat and Meat Products for detailed requirements.
Form 6 provides a summary of the plan. References to documented procedures located elsewhere
should be shown in this form.
10.
Verification of the HACCP Plan
10.1
Validation of the HACCP plan
Validation of the HACCP plan involves the initial confirmation that the HACCP plan is complete
and will achieve each of the identified food safety objectives (FSOs). Critical control points
(CCPs) should be evaluated to ensure that the control measure applied at that particular process
step will achieve or contribute to the achievement of the relevant FSO. Some FSOs may be
partially or wholly dependent on prerequisite programmes rather than the HACCP plan itself.
An example of how this generic HACCP plan may be validated is given below:
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Page: X.6.19
FSO1: To minimise microbiological hazards in the product to levels not exceeding specified
targets.
FSO1 is primarily achieved by adequate control measures at CCP2 (drying). Effective
prerequisite programmes (e.g. sanitation and cleanup procedures, personal hygiene, hygienic
processing) will contribute to the achievement of this FSO. The microbial quality of the raw meat
and other ingredients can have a significant impact on the final microbial level of the product,
therefore an effective supplier quality assurance programme will also contribute to the
achievement of this FSO.
Supplier compliance to agreed specifications (e.g. microbiological, chemical, etc) may be verified
by testing meat and non-meat ingredients, reviewing suppliers processing data and inspection of
ingredients at receiving. Reviews of incoming material records and suppliers HACCP plans or
food safety programme audits could be used to validate that meat and other ingredients are
sourced from suppliers that have an effective HACCP plan (or an equivalent programme).
The use of microbiological observations is appropriate for evaluating the adequacy of the CCP
to achieve the FSO. This information may be obtained from relevant published scientific
literature, in-house historical data, and/or by gathering new data.
However, measuring water activity could be a more practical and cost-effective means of
routinely verifying the process than microbiological testing if a premises has a water activity
meter available.
Scientific evidence from published literature may be used to justify the effectiveness of a control
measure applied at a specific step or steps. The use of this type of scientific information will be
a sufficient basis for validation only if it can clearly be shown that the conditions or variables
considered in the scientific study are applicable to those existing in the process being validated.
Considering the variability of commercial drying processes and parameters (e.g. time,
temperature, air velocity, relative humidity, loading, product size and composition, etc.), it is
unlikely that information solely from published literature will be sufficient to fully validate the
process.
The relationship between water activity and the growth and survival of microorganisms is well
established (refer to Annex, Section 6.5). It is therefore acceptable to use water activity
measurements in addition to initial microbiological testing for evaluating the adequacy of the
process to achieve the FSO. The water activity target should be set at a level that is appropriate
for the type of microorganism that is intended to be controlled. The effectiveness of the drying
process can be validated by measuring the water activity of jerky samples using standardised
testing methods. Water activity measurements can also be used for ongoing verification of the
process.
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Page: X.6.20
Premises that have previously collected microbiological data may use this historical information
for evaluating CCP2 in relation to the achievement of the FSO. Historical data may be used
provided there has been no significant change in the product and process from the time the data
were collected, sampling and the analytical tests are based on standardised methods and the
amount of data available is adequate for validation.
When published scientific information or historical data is not available or is inadequate,
microbiological validation will involve the collection of new data from the time that the HACCP
plan is implemented.
Prerequisite programmes
Prerequisite programmes should be validated in accordance with the requirements in IS 8.
FSO2: To ensure that chemical hazards in the product do not exceed specified targets.
FSO2 is expected to be achieved by an effective supplier quality assurance programme that
specifies chemical residue levels for both meat and non-meat ingredients.
Compliance with agreed specifications may be verified by testing ingredients, and reviewing
suppliers processing data. Reviews of incoming material records and suppliers HACCP plans
or food safety programme audits could be used to validate that meat and other ingredients are
sourced from suppliers that have a HACCP plan (or an equivalent programme) that effectively
controls chemical residues.
FSO3: To ensure that the product does not contain sodium nitrite at levels exceeding
specified targets.
FSO3 is expected to be achieved by CCP1 at step 3a (weighing of non-meat ingredients). The
control measure reflects a regulatory requirement in the New Zealand Food Regulations 1984.
It is therefore expected that the premises will already have historical data to show that procedures
in place are adequate to achieve the regulatory standard and therefore the FSO. Product test
results for nitrite content should also be available to validate this FSO.
Importing country regulations may have maximum permissible levels for sodium nitrite that differ
from the New Zealand requirement. This should also be taken into account when setting the
critical limits for CCP1 and validating the FSO.
10.2
Ongoing verification
Ongoing verification activities confirm whether the HACCP plan is operating effectively and
according to documented procedures. Examples of these activities are internal and extrinsic
audits, HACCP review, calibration and product testing programmes.
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10.3

Page: X.6.21
Revalidation
A revalidation of the HACCP plan is required whenever changes are made (e.g. changes to
premises, product, process, intended use of the product) that could have a significant impact on
hazards and their controls, or when process failure that may compromise product safety occurs.
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Page: X.6.22
Form 6: HACCP plan summary spreadsheet for the manufacture of beef jerky
1
Process step
Hazard ID
CCP no.
Critical limits
Monitoring procedures/
tools
(consider who, what,
when and how)
Corrective actions
Verification procedures
HACCP records
3a. Weighing of
non-meat
ingredients
C2. Nitrite
Predetermined amount
per batch size that will
result in 125 ppm of
nitrite in final product.
Visual check of weighing

operation at a
predetermined frequency
Detain product and test for

nitrite
FSO validation
Validation record
Finished product testing

for nitrite content
Nitrite monitoring record
Correctly identified batch

lots
Visual check for correct

identification of batch lots
at a predetermined
frequency
Dispose of non-conforming
product
Corrective action report

Internal audit
Correct procedures and/or

train operator to prevent
reoccurrence
Extrinsic audit
Product evaluation
records
HACCP review
Internal audit report

Extrinsic audit report
HACCP review record
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Process step
Hazard ID
CCP no.
8. Drying
B1. Enteric
pathogens

Page: X.6.23
Critical limits
Monitoring procedures/
tools
(consider who, what,
when and how)
Corrective actions
Verification procedures
HACCP records
Drying parameters that

will achieve a specified
water activity
Operator to monitor
relevant drying
parameters (e.g. time,
temperature, humidity, air
velocity, dryer loading,
etc.) for each batch at
predetermined frequency
Correct drying parameter
FSO validation
Validation record
Extend drying process until

required water activity
reached
Product testing (e.g.

microbiological, water
activity)
Daily monitoring record
Dispose of non-conforming
product
Calibration of time/temp/
water activity devices
Corrective action report
and/or:
A specified water activity
and/or:
Product testing record
Calibration record
Internal audit
Operator to measure
water activity for each
batch at predetermined
frequency
Internal audit report

Extrinsic audit (e.g.
regulator, client)
Extrinsic audit report
HACCP review
HACCP review record
Refer to IS 6, Sections 8
&9
1.
Corrective actions should reflect an escalating response when ongoing non-compliance occurs.
2.
Verification procedures apply to all aspects of the HACCP plan.
3.
HACCP records apply to all aspects of the HACCP plan. Refer to IS 8, Section 4 regarding requirements for documentation and record keeping.
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Ensure that detailed documentation (and evidence where relevant) exists for the following:
rationale for critical limits;

monitoring procedures, including whos responsible, what monitoring will take place, when or at what frequency it will take place, how it will
be done;
corrective action procedures, including whos responsible, how control will be restored, what happens to affected product, how prevention
of re-occurrence might be achieved;
verification procedures, including whos responsible, what verification consists of, how verification will be done, when and at what frequency
ongoing verification activities will occur, when revalidation is necessary;
documentation and record keeping.
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Annex to Appendix X.6: Background Information to the Generic HACCP Plan

for the Manufacture of Beef Jerky
The processes covered by the Generic HACCP Plan for the Manufacture of Beef Jerky continue
on from the cooling and boning of beef. The raw material hazard identification for this plan is
based on the assumption that the beef was processed under a HACCP plan which covers slaughter
and dressing, and cooling and boning. Hazards identified in the Generic HACCP Plan for
Cooling and Boning of Beef as those that may be reasonably associated with beef cuts, are carried
through to the manufacture of beef jerky.
Jerky is a dried product which is also known as biltong (South Africa), carne seca (Mexico),
charqui (South America), and rou gan (China). It may be produced in a number of forms. The
simplest and most basic is where primal cuts are cut into strips and dried. Variations include
salting the meat, producing a type of cured product, and marinating. The drying process may also
include smoking. Jerky is normally dried to a water activity (aw) of 0.75 to 0.8, or a final water
content of 15 to 20%. The USDA has established a moisture:protein ratio requirement of 0.75
for jerky (USDA, 1983). Some processes use comminuted meat, but this generic plan is limited
to the use of intact muscle cuts.
1.
Foodborne Illness Associated With Dried Meat Products
Dried meats such as jerky are microbiologically stable at ambient temperature because of their
low water activity. However, clostridia, bacilli, Staphylococcus aureus, Salmonella and other
pathogenic bacteria, originally present on the raw meat or as contaminants during preparation,
may survive the drying process (ICMSF, 1998a). Biltong (van der Riet, 1982) and commercially
prepared beef jerky have caused salmonellosis (CDC, 1967, 1985, 1995). Home-made venison
jerky has caused type F botulism (Midura et al., 1972). Home-prepared venison jerky has also
been implicated in an infection of Escherichia coli O157:H7 (Keene et al., 1997).
2.
Biological Hazards Associated with Raw Materials
2.1
Meat
Enteric pathogens, such as Salmonella spp., E. coli O157:H7, Campylobacter jejuni, and
Clostridium spp., are the biological hazards of major food safety concern that may be present on
beef cuts, the raw material commonly used in the manufacture of beef jerky.
Pathogens associated with meat that can grow at chiller temperatures, such as Listeria and
Yersinia, have also been identified in recent years. Although these cold-tolerant pathogens may
pose some health risk, this has not been quantified and is considered by Gill (1993) to be
insignificant.
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Biological hazards associated with raw beef are briefly discussed below. Refer to Annex to
Appendix IX.1: Background Information to the Generic HACCP Plan for Slaughter and Dressing
of Cattle for more details on these biological hazards.
Salmonella spp.
Salmonella spp. is the primary bacterial aetiological agent responsible for beef-related foodborne
outbreaks in the USA and Canada (Bryan, 1980; Todd, 1989; Bean and Griffin, 1990). Examples
of beef products that have been implicated in outbreaks are roast beef, jerky and ground beef.
There have been several outbreaks of salmonellosis in the USA associated with beef jerky or
similar products (CDC, 1967, 1985, 1995).
E. coli O157:H7
E. coli O157:H7 was first recognised as a foodborne pathogen after two outbreaks of
haemorrhagic colitis in the USA in 1982, attributed to the consumption of undercooked
hamburgers from a fast-food restaurant chain. Since then, several beef-related outbreaks caused
by E. coli O157:H7 have been reported in other countries, including the USA (Bean et al., 1990;
Tarr, 1994), Canada and the UK (Chapman et al., 1993). The principal vehicle implicated in
outbreaks has been ground beef and evidence suggests that in most instances the meat was
undercooked (Doyle, 1991; Doyle et al., 1997).
No published reports have implicated beef jerky as the source of an outbreak. However, an
outbreak of E. coli O157:H7 infections was traced to home-prepared venison jerky in the USA
(Keene et al., 1997).
E. coli O157:H7 infection was first identified in New Zealand in 1993. From 1993 to the end of
June 1998, there have been a total of 61 reported cases of infection by the pathogen (ESR, 1998).
A source of infection has not been reported for any of these cases.
Campylobacter
In New Zealand, the most significant factors associated with cases of campylobacteriosis are the
consumption of raw or undercooked foods (notably poultry, but also unpasteurised dairy products)
and the consumption of untreated drinking water (ESR, 1996). Campylobacter is far less
frequently associated with red meat. This appears to be due to the lower carriage rate of
mammals compared to birds and the fact that the bacteria appear to die off on the dry carcass
surface (Hasell, 1994). Freezing also significantly reduces the number of viable organisms
(Hasell, 1994).
There are no reports available that indicate Campylobacter has been associated with beef jerky,
and it is also unlikely to survive the drying process (ICMSF, 1996).
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Staphylococcus aureus
Staphylococcal food poisoning results from the ingestion of food containing the enterotoxin
produced by certain strains of Staphylococcus aureus. The organism competes poorly with other
bacteria and thus seldom causes food poisoning in raw meat products (ICMSF, 1996). Foodborne
illness due to S. aureus enterotoxin is primarily a result of contamination by food-handling
personnel and is generally associated with temperature abuse of cooked products (Bryan, 1980;
Bergdoll, 1989). Animal strains of S. aureus have rarely been associated with outbreaks of
staphylococcal food poisoning in man (Wilks and Humble, 1997).
2.2
Non-meat ingredients
Spices
Spices are not major contributors to foodborne disease; however, they occasionally contain
bacteria that can cause foodborne infections (ICMSF, 1998b).
Spore-forming organisms that are capable of causing gastroenteritis when ingested in large
populations are found in spices, but usually in small populations. Bacillus cereus was found in
53% of 110 various spices tested for prevalence and levels of the organism ( Powers et al., 1976).
A relatively high incidence of Clostridium perfringens has also been found in several spices
(Powers et al., 1975).
Spices have also been implicated in several outbreaks of salmonellosis (ICMSF, 1998b). The
New Zealand microbiological reference criteria for Salmonella in herbs and spices (Ministry of
Health, 1995) is zero in 25g. Commercial suppliers of treated spices in New Zealand normally
provide a guarantee that their products meet this criteria.
As bacterial spores may survive drying conditions and will grow in many foods at temperatures
between 3 C and 50 C, spices harbouring these spores must be considered as a potential health
hazard if the foods in which the spices are added are not properly prepared and handled (ICMSF,
1998b). Surviving pathogens will grow in rehydrated product if held at temperatures permitting
their development (ICMSF, 1998a).
If the introduction of pathogens from spices is of concern, then the use of spices that have been
treated to reduce microbiological levels may be advisable. The effectiveness of decontamination
methods such as fumigation or irradiation (currently being discussed for New Zealand) is
dependent on the initial microbial load of the spices and the treatment parameters. Alternatively,
the use of essential oils and oleoresin can avoid spices being a source of microbial contamination.
The above points stress the importance of sourcing spices from preferred suppliers, setting of
correct quality specifications and managing the procurement of spices under an effective supplier
quality assurance (SQA) programme.
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Page: X.6.28
Soy sauce
Soy sauce and other similar derivatives are commonly used as flavouring agents for beef jerky
in New Zealand. There have been no reports of illnesses due to enteropathogenic microorganisms
associated with soy sauces (ICMSF, 1998b). Under normal circumstances, pH, water activity
(salt content) and the presence of competing harmless and desirable microorganisms prevent
growth of undesirable microbes during and after the fermentation of soy sauces and thereby
ensure preservation during the primary storage in closed containers. The main control factor is
high salt content. Pasteurisation is becoming more widely accepted as a means of prolonging
microbiological stability (ICMSF, 1998b).
Sugar
The refining of sugar destroys pathogenic organisms, if they are present in the raw material
(ICMSF, 1998c).
3.
Chemical Hazards
3.1
Meat
Chemical hazards that could be present in beef and meat products include agricultural chemicals
(e.g. pesticides, herbicides, veterinary drugs) and environmental contaminants (e.g. heavy metals,
organochlorines). New Zealand MAF maintains a National Residue Testing programme that
monitors the residue status of animals slaughtered for human consumption.
Chemical hazards associated with identified chemical residues (e.g. suspect lines) are addressed
under the Generic HACCP Plan for Slaughter and Dressing for Cattle. Carcasses and products
from chemically suspect animals are sampled and detained according to MAF Food
specifications. Suspect products are stored separately until their disposition is determined by the
regulator.
Chemical hazards associated with unidentified chemical residues (e.g. antibiotics, environmental
contaminants) are addressed outside the HACCP plan, under the National Residue Testing
programme. Sporadic chemical residues at some level will always occur, but recent results from
the programme indicate that residue levels in meat are generally in compliance with national
requirements.
Chemical hazards associated with visible injection site lesions (ISLs) are usually addressed at post
mortem inspection and at cutting and boning. Deep-seated ISLs may remain undetected in some
cuts, but this is expected to be a rare occurrence.
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3.2

Page: X.6.29
Spices
Chemical residues of pesticides, herbicides and fumigants may be present in herbs and spices. Of
particular concern are residues of methyl bromide, a fumigant used to control insect infestation
in spices, and ethylene oxide, a chemical used for reducing microbial contamination. The SQA
programme should ensure that chemical residue levels in non-meat ingredients are below the
maximum permissible levels specified in New Zealand and importing country regulations.
3.3
Nitrite
The New Zealand Food Regulations 1984 require that meat products do not contain more than
125 ppm total nitrite and nitrate. Excessive levels of nitrites can cause difficulty in breathing, and
dizziness or headaches (Hanssen et al., 1994).
Other additives (e.g. sodium erythorbate, MSG) may also be used instead of or in addition to
sodium nitrite. It is important that the presence of hazards is also considered for these additives,
and that the levels in the final product are below the maximum permissible levels specified in
New Zealand and importing country regulations. Some countries also have other specific
requirements in relation to additives, e.g. labelling for MSG.
4.
Physical Hazards Foreign Objects
4.1
Meat
The presence of foreign objects, such as metal and bone pieces, is of major concern to meat
manufacturers (Archibald et al., 1993; 1995) because of their potential for causing injury such
as cuts, broken teeth, choking (Rhodehamel, 1992), and intestinal perforation (Gunn, 1966).
Intact muscle cuts tend to have a very low occurrence of bone chips, metal or other foreign
objects, and any such items can be removed from the meat surface when the meat is sliced. An
effective SQA programme should include specifications for metal and bone.
4.2
Salt, sugar and spices
The New Zealand Food Regulations 1984 require that salt, sugar and spices are free from foreign
matter. The SQA programme should ensure that non-meat ingredients are free from foreign
objects which may pose a food safety hazard.
5.
Supplier Quality Assurance Programme
In order to make safe products, it is important that the hazards associated with raw materials are
clearly understood and controlled to acceptable levels. Obviously, the microbiological quality
of dried foods depends on the microbiological quality of the raw materials and their handling
prior to drying (Farkas, 1997; van der Riet, 1982).
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Page: X.6.30
Some of the elements which form part of an effective SQA programme include having agreed
specifications, auditing suppliers and certificates of analysis (Mortimer and Wallace, 1994).
Manufacturing plants should also have procedures in place for the verification of compliance to
agreed specifications, such as physical inspection and microbiological testing of incoming
materials based on statistically valid sampling plans.
6.
Key Process Steps: Hazards and Potential Impact on Existing Hazards
6.1
Receipt of meat
Frozen beef muscle cuts used for jerky manufacture a usually obtained in New Zealand in 27 kg
cartons. Meat temperature is commonly measured as part of incoming material inspection. A
slight increase in temperature of frozen products during transport and handling prior to receipt,
although undesirable, is not expected to compromise product safety.
Aside from temperature measurements, most processors also inspect incoming raw materials for
compliance with other agreed specifications such as packaging integrity, age of product and the
presence of foreign objects. The microbial quality of the raw meat, and other ingredients, will
have a significant impact on the final microbial loading of the jerky (ICMSF, 1998a); thus it is
important to source from suppliers that have an effective HACCP plan (or an equivalent
programme).
6.2
Tempering
In New Zealand, frozen meat is generally tempered to a maximum of 2 oC so as to maintain a

firm texture for slicing. Microbial growth is unlikely at such low temperatures. The tempering
process should meet the requirements of IS 6 and be validated accordingly.
Some processes require that meat is thawed (e.g. when meat is injected or tumbled before slicing).
The potential for growth of microorganisms during the thawing process should be carefully
assessed, taking time and product temperature into consideration.
6.3
Slicing
The tempered meat is usually sliced into 1.5 to 5 mm thick slices. Normal time-temperature
conditions during slicing do not favour microbial growth, but there is potential for pathogen
growth if the meat temperature is not controlled after slicing. Batch size and the type of process
and product will have an impact on how long the slicing takes, and how long the meat can be kept
in a sliced form before continuing to the next process step. To prevent mesophilic pathogen
growth the temperature should be kept below 7 oC. There is also potential for cross
contamination between the meat and the slicer during this process, but it is expected to be
adequately addressed by GMP.
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6.4

Page: X.6.31
Marinating/Massaging/Injecting/Tumbling
There are many variations on how flavouring is applied to meat prior to drying, such as passive
marination, injection, marination and tumbling. Injecting and/or massaging is more commonly
used for intact muscle cuts that are sliced afterwards. On the other hand, marination and tumbling
tend to be more common for meat that is already sliced. Marination and tumbling times can vary
from 1 to 12 hours. During this time, the temperature of the meat can rise, and to prevent growth
of mesophilic pathogens, care should be taken to ensure that the meat temperature does not rise
above 7 oC.
High concentrations of salt or sugar products in the marinade may have an effect on the water
activity (aw) of the product, and consequently slow microbial growth at this stage of the process.
For example, traditional biltong is left to cure in salt overnight prior to drying (van der Riet,
1982). However, most New Zealand processes use marinades for flavour reasons, rather than for
any possible effect on water activity.
Some processors recycle or reuse their marinades. This may have a significant effect on the
microbiological loading of subsequent batches, and must be considered carefully when
conducting the hazard analysis. Any reuse or recycling of marinade must have documented
procedures, and these must be implemented correctly at all times. Factors that may impact on the
reuse of marinade include (but are not limited to): the formulation; the number of times a batch
(or part of a batch) of marinade may be reused; whether any processing affecting the marinade
occurs (e.g. pasteurisation or cooking); how long, and under what conditions the prepared
marinade may be stored before being reused; etc. Hazards associated with the production and use
of a marinade may be better controlled by a separate HACCP plan.
6.5
Drying
During drying, microorganisms on the raw materials are affected by both the drying temperature
and changes in water activity (aw ). Microbiological consequences of the drying technology are
influenced by a number of other factors (e.g. size and composition of food pieces, timetemperature combinations, relative humidity, air velocity, loading, etc.) (Farkas, 1997). The
formulation of the marinade may also have an effect on aw (e.g. use of humectants). In New
Zealand, jerky is generally dried in mechanical air dryers with control of temperature and relative
humidity.
During the warming-up period of drying, the temperature is still low and the relative humidity
high. The length of this phase depends mainly on the size of the food particles. If this phase is
long, microorganisms may even grow during the slow increase of temperature in the range 20 to
40 oC under the existing high aw (Farkas, 1997). Holley (1985) has shown that if Staphylococcus
aureus is present in large numbers, this organism can nearly double in number during the first 2
hours of the drying period. Traditional jerkies are sometimes dried over 2 to 3 days at close to
ambient temperature, which certainly has the potential to allow growth of microorganisms before
aw is suitably lowered. This traditional type of drying is not common in New Zealand. During the
later phases of heated-drying, the temperature may exceed 50 to 70 oC. At such temperatures
there is no opportunity for growth, but heat destruction is not significant either, because the higher
temperature develops parallel to decreased moisture content. Pathogens such as Salmonella and
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Page: X.6.32
Escherichia coli have been reported to survive drying conditions. If the drying lasts long enough
(at least 30 min) at these high temperatures (50 to 70 oC), time-temperature combinations that
irreversibly damage microbial cells occur. The major microbicidal effect is due to hightemperature-low humidity conditions that last for a long time. Loss of viability continues during
storage because irreversibly damaged cells, being unable to regenerate at low aw, gradually die
(Farkas, 1997).
Most commercially produced jerky in New Zealand has an aw of 0.75 to 0.80. This aw is lower
than the critical value for microbial growth. In general, foodborne pathogenic bacteria are
inhibited by a water activity of 0.92 or less. The exception to this is Staphylococcus aureus,
which has a minimum water activity for growth of 0.83-0.86, but has a higher minimum water
activity for enterotoxin production of 0.88. As the enterotoxins produced by S. aureus are key
to food intoxications caused by this organism, it is notable that 105 organisms/g are required
before enterotoxin production can be observed (Holley, 1985). Production of staphylococcal
enterotoxin in food slurries has not been observed below aw 0.93. Most spore-forming bacteria
do not grow below aw 0.93. Germination and outgrowth of spores from food poisoning strains
of Bacillus cereus are prevented at aw 0.97 to 0.93, depending on the nature of the bulk solute.
The minimum aw for the growth and spore germination of Clostridium perfringens is usually
between 0.97 and 0.95 (Farkas, 1997), but other research reports that C. perfringens may grow
at aw as low as 0.93 (McClane, 1997). Salmonella die slowly at water activity levels below those
allowing growth (Jay et al., 1997).
Holley (1985) recommends initial heated-drying of meat at or above 55 oC to establish a
significant margin of safety for the elimination of low numbers of naturally occurring pathogens.
The drying rate (and hence the reduction of aw, and any consequent microbial effect) will vary
depending on the temperature, the product size and composition, the loading of the dryer (total
amount of product and separation of slices), the air velocity (if forced air drying is used) and the
relative humidity, with all variables interacting in different ways during various stages of the
drying process. Temperature variations within the dryer (e.g. hot or cold spots) should be
considered, as well as the effect that dryer loading may have on these hot spots. If the drying
temperature is high enough to actually cook the product, then thermal death times of various
bacteria may need to be considered. Smoking of the product (in addition to drying) may introduce
some effect on the microbial population. If the product is of a reasonable size or thickness, then
case hardening may occur (Beever, 1999) whereby the surface of the product is dry, but the centre
is still moist, and hence capable of supporting microbial growth. This can occur if the drying
parameters fluctuate either due to some uncontrolled or improperly controlled external parameter,
e.g. humidity or temperature, or the slice thickness is incorrect for the given drying procedure.
Often it is best controlled by skilled operators paying attention to process detail (e.g. colour
variation through a cross section of slice). Additional drying of case-hardened product can be of
little value as the moisture is sealed into the product by the surface hardening.
These factors and their effect on each other will have to be considered when validating the
process, and in particular the drying CCP. If a number of different jerky products are produced,
then the drying conditions will have to be validated for each product type.
6.6
Cooling, packaging and storage
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Page: X.6.33
Although the product is dried to a point where microbial growth cannot occur, minimising postprocessing contamination is still important. In the main this is achieved by good cleaning and
sanitation programmes and good personal hygiene practices (including separation of raw and
cooked product). Dried products are stable microbiologically, provided the relative humidity of
the storage atmosphere is less than 70% (Farkas, 1997). Surviving pathogens (or spores), or
pathogens transferred by post-processing contamination, will grow in rehydrated product if held
at temperatures permitting their development. Poor storage conditions (allowing moisture
reabsorption from the atmosphere) may also allow pathogen growth.
Provided the product has been properly dried to the correct aw, cooling of the product should not
be a critical process step. However, good manufacturing practice indicates that cooling should
still occur as rapidly as possible. At this stage it may be possible to do some sorting of the jerky,
for possibly both quality and food safety reasons, e.g. variable product thickness may result in
some product being too dry and hard to suit customer requirements, while thicker sliced product
may result in jerky that is too soft, and may not be dried to the appropriate aw. Hard dried product
may also go through greater deformation during the drying process, making it difficult to pack,
and possibly prone to piercing the packaging.
It is important to maintain packaging integrity so that the product does not rehydrate, which may
allow the growth of surviving pathogens. The type of packaging used will be dependent on the
type of jerky produced. The type of packaging, the construction, the thickness and the oxygen
permeability of the packaging all need to be considered, particularly if the product is to be stored
or sold in humid conditions. Traditional strap jerky produced from intact muscle is a very hard
product, and therefore has a high potential for bag damage. Hence vacuum packaging may not
be appropriate for this type of product. Gas flushing or packing with oxygen absorbers is
recommended (Beever, 1999), and appears to be the common practice in New Zealand. There
are usually strict requirements associated with the use of gas flushing.
The microbial stability depends on the aw of the product. Moulds and yeast may grow during
storage, particularly when moisture is absorbed from the environment. This can be prevented by
drying to an aw < 0.80 and vacuum packing, or by drying and maintaining the aw at 0.70 or lower
(ICMSF, 1998). Holley (1985) found that during refrigerated storage of jerky, surviving
organisms were stabilised. When storage took place at 20 oC and high relative humidity, the
surviving pathogens were eliminated within 28 days. Thus, from a microbiological viewpoint,
it appears that refrigerator storage of beef jerky is less desirable than storage under cool ambient
conditions.
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Page: X.6.34
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MAF Food Assurance Authority (Animal products Group)

Amendment 6 : June 1999

Appendix X.6: Generic HACCP Plan for Manufacture of Beef Jerky

The following are documented prerequisite programmes/sanitation standard operating procedures

potable water quality;

personal hygiene (protective clothing requirements, personal equipment and use of

hygienic processing (processing techniques and procedures including separation of raw

food contact materials (specifications, handling and storage);

supplier quality assurance (ingredient specifications, supplier audits, certifications, product

product testing procedures;

calibration, installation and maintenance of heat processing equipment and instruments;

repairs and maintenance of equipment;

handling and disposition of detained and nonconforming products.

MAF Food Assurance Authority (Animal products Group)

Amendment 6 : June 1999

Scope of HACCP Plan

Processing of beef jerky from receipt of raw materials (meat and

MAF Food Assurance Authority (Animal products Group)

Amendment 6 : June 1999

Product Description and Intended Use

Form 1: Product description and intended use

Important product characteristics

Shelf stable, packaged, flavoured beef jerky produced from

General public (high-risk groups not specified for this plan)

Shelf life and storage requirements

Where it will be sold:

List countries, if applicable

Special distribution controls required

Handle packages with care

MAF Food Assurance Authority (Animal products Group)

Amendment 6 : June 1999

Initial Food Safety Objectives

Process Flow Diagram

Form 2: Raw materials/other inputs

Raw materials / other inputs

Frozen boneless beef cuts

Complies with company, industry and regulatory

Salt/sugar/spices/flavourings (e.g. soy sauce)/additives (e.g.

As per written company specifications and the New Zealand

Food contact packaging materials

Suitable for use as food contact materials

MAF Food Assurance Authority (Animal products Group)

Amendment 6 : June 1999

Form 3: Process flow diagram

Frozen beef and non-meat

1a. Receipt of non-meat

MAF Food Assurance Authority (Animal products Group)

Amendment 6 : June 1999

MAF Food Assurance Authority (Animal products Group)

Amendment 6 : June 1999

Hazard Analysis and CCP Determination

Raw material hazard identification

Form 5a: Hazard identification for meat and non-meat ingredients1

Food grade salt

Frozen boneless beef

The following codes are used in this generic plan:

C1 Chemical hazards associated with meat ingredients

Physical hazards associated with meat ingredients

MAF Food Assurance Authority (Animal products Group)

Amendment 6 : June 1999

MAF Food Assurance Authority (Animal Products)