HACCP FOR IRISH BEEF, PORK

AND LAMB SLAUGHTER

Authors:
Declan J. Bolton B.Sc. Ph.D. Grad. Dip. (Business).
James J. Sheridan M.A. M.Sc. Ph.D.
Food Safety Department,
The National Food Centre, Dunsinea,
Castleknock, Dublin 15.
Teagasc acknowledges the assistance of The US/Ireland
Co-operation Programme in Agricultural Science and
Technology and the Non-Commissioned Food Research
Programme which is supported by the Department of
Agriculture, Food and Rural Development through EU
and national funds.
ISBN 1 84170 275 7
February 2002
Teagasc 19 Sandymount Avenue Ballsbridge Dublin 4
AGRICULTURE AND FOOD DEVELOPMENT AUTHORITY
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R5374 50 HACCP 8/3/02 2:44 PM Page ii
CONTENTS
Summary 1
Introduction 2
Control of beef, pork and lamb slaughter 3
Conclusions 5
Recommendations to industry 6
References 12
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iv
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SUMMARY
It is generally accepted that HACCP principles should be incorporated into
the food safety control systems in meat processing plants to better assure food
safety. The objective of this project was to publish detailed HACCP slaughter
documents for the Irish beef, pork and lamb processing industries. These
would provide the necessary information and detail to facilitate the
implementation of HACCP on the slaughter floor (from lairage to chilling) in
Irish meat plants. To this end HACCP for Irish Beef Slaughter was published
in October 2000, HACCP for Irish Pork Slaughter in December 2001 and
HACCP for Irish Lamb Slaughter will be available early in 2002. These are
non-generic, detailed documents which provide the scientific basis for
establishing critical control points (CCP), critical limits, monitoring and
corrective action procedures.
In each of these publications, the prerequisite components of the HACCP
plan; Good Manufacturing Practices (GMPs), Standard Operating Procedures
(SOPs) and supplier control (for chemical residues) are discussed. Following
a hazard analysis and risk assessment, potential critical control points are
identified and their operation described. Verification and record keeping
complete the HACCP system.
The HACCP documents are based on the best scientific knowledge currently
available. More research will inevitably lead to improvements in meat
slaughter hygiene and carcass decontamination technologies; these will be
incorporated into regular updated issues of these documents.
1
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INTRODUCTION
Concerns regarding meat safety are well founded. Meat is an important agent
of food-borne infection (Sockett, 1996). Studies in one Irish beef abattoir
found that 3.2% of carcasses were contaminated with Escherichia coli O157
while the corresponding figures for Salmonella and Listeria were 2% and 16%
respectively (McEvoy et al., 1999). Irish pork is also an important source of
food borne pathogens. The incidence of Salmonella on Irish pigs in an Irish pig
plant was up to 60% (Bolton et al., 2001). In a small survey of Dublin butcher
shops, the incidences of Salmonella, Yersinia and Listeria on retail pork
products was found to be 9.9%, (Cloak, 1999), 100% (Logue et al., 1996) and
45% (Sheridan et al., 1994) respectively. The latter pathogen is also prevalent
on retail lamb products with a reported incidence of up to 60% (Sheridan et
al., 1994).
It is generally accepted that HACCP is the most effective means of ensuring
the safety of food, thereby protecting consumer health. Concerns about food
safety led to the EC Decision of the 8
th
June, 2001 (2001/471/EEC), which
legally mandates HACCP in all meat and poultry facilities within the
European Union (Anon, 2001). Plants have 12 months to achieve
compliance. Beef, pork and lamb are annually worth approximately 1.5bn,
280m and 235m respectively to the Irish economy. In the wake of BSE,
Escherichia coli O157 and more recently, foot and mouth disease, HACCP
implementation is also the best means of avoiding further adverse publicity
and restoring consumer confidence, both at home and in international
markets.
2
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CONTROL OF BEEF, PORK AND LAMB SLAUGHTER
The key to food safety management is CONTROL of the plant, personnel,
process and product.
Plant: Control of the plant is achieved through the cleaning and
maintenance which come under the good manufacturing
practices (GMP) programme which includes:
- cleaning and maintenance of plant and equipment
Personnel: Control of personnel is achieved through training and
supervision, also part of the GMP programme, which includes:
- personnel training including personal hygiene and task
descriptions
Process: The process is controlled by:
- product handling, storage and distribution
- waste management
- product traceability
- product recall
- calibration of equipment (very important when critical limits
are temperatures)
- zoning (physical separation of activities to prevent cross-
contamination)
all of which are described in the GMP manual or as general
standard operating procedures (SOPs). GMP and SOP must be
documented and are the responsibility of plant management.
Product: Control of the product is achieved through the application of both
GMP and HACCP (Figure 1). In meat slaughter, as in any food production
process, there are factors which will adversely affect the quality of the final
product. These may be subdivided into food safety hazards such as
Salmonella, chemical residues or metal, which, if consumed, would inevitably
result in illness or injury, and food quality factors such as spoilage bacteria,
meat colour or drip. Food safety hazards may be subdivided into significant
3
R5374 50 HACCP 8/3/02 2:44 PM Page 3
and other hazards based on a risk assessment, which examines likelihood of
occurrence and severity of resultant illness.
Significant food safety hazards are controlled by the application of HACCP.
Food quality factors and food safety hazards deemed not to be significant by
risk assessment may be controlled as part of the GMP programme.
Chemical hazards: The control of chemical residues in meat may be
incorporated into the GMP programme or the HACCP plan. However, this
function is probably better accommodated as a separate sub-programme of
the overall food safety management programme. This control should include
sourcing of animals from farms that are registered with a recognised quality
assurance scheme and a requirement that a letter of guarantee of compliance
with correct veterinary procedures accompany each batch of animals. The
program should adopt basic HACCP principles and include test monitoring of
liver, kidney, urine and / or muscle for residues as appropriate. It should also
include an incremental corrective action regime, which will ensure future
compliance by an errant supplier.
4
Figure 1: Differentiating good manufacturing practice (GMP) and hazard analysis
and critical control point (HACCP) based on the hazards they control.
Food issues
Other food safety
hazards
(GMP)
Significant food
safety hazards
(HACCP)
Food safety hazards
RISK ASSESSMENT
Quality issues
(GMP)
R5374 50 HACCP 8/3/02 2:44 PM Page 4
Physical hazards: Foreign objects including metal, glass, plastics and knife
blades are called physical hazards. The risks associated with physical hazards
are considered to be low and more suitably controlled under the GMP
programme, implementation of which should prevent physical hazards
contaminating the meat during slaughter and dressing. Metal contaminants
may also be detected using a metal detector.
Biological hazards: Biological hazards, including pathogenic bacteria, are most
efficiently prevented, reduced or eliminated using HACCP. The National
Food Centre beef slaughter HACCP plan has 6 potential critical control
points (dehiding, evisceration, spinal cord removal, hot water washing, steam
pasteurisation and chilling). The pork HACCP plan has 5 CCPs (singeing,
evisceration, hot water washing, steam pasteurisation and chilling) while the
lamb equivalent has 6 CCPs (ante-mortem inspection, fleece removal,
evisceration, hot water washing, steam pasteurisation and chilling) (Table 1).
All of these are designed to prevent, reduce or eliminate biological hazards.
Details about critical limits, monitoring, corrective actions, validation and
record keeping are summarised in Table 1. More detailed information is in the
respective publications (HACCP for Irish Beef Slaughter, HACCP for Irish
Pork Slaughter and HACCP for Irish Lamb Slaughter), which are available
free of charge from the authors.
CONCLUSIONS
G The EC Decision of the 8
th
of June 2001 (2001/471/EEC) gives meat
and poultry plants 12 months to develop and implement effective
HACCP systems.
G The information required to comply with this regulation is available to
the Irish meat industry in detailed HACCP slaughter documents for beef,
pork and lamb slaughter.
G The physical hazards in meat slaughter are most effectively controlled as
part of the GMP programme.
5
R5374 50 HACCP 8/3/02 2:44 PM Page 5
G While chemical hazards may be controlled as part of the GMP or
HACCP programmes, this function is probably more effective if treated
as a separate sub-programme of the overall food safety management
programme.
G The biological hazards in beef slaughter are microbial pathogens and
prions. The potential critical control points are dehiding, evisceration,
spinal cord removal, hot water washing, steam pasteurisation and chilling.
G The biological hazards in pork slaughter are pathogenic bacteria, most
notably Salmonella, and these may be controlled at singeing, evisceration,
hot water washing, steam pasteurisation and chilling.
G The biological hazards in lamb slaughter are also microbial pathogens.
These may be prevented, reduced or eliminated at ante-mortem
inspection, pelt removal, evisceration, hot water washing, steam
pasteurisation and chilling.
RECOMMENDATIONS TO INDUSTRY
The EC Decision of the 8
th
June 2001 (2001/471/EEC) legally mandates
HACCP in all meat and poultry plants throughout the European Union and
sets out performance standards which, if not achieved, will result in corrective
actions. These will range from minor actions, such as training for operatives,
to plant closure.
Microbial and epidemiological data obtained to date suggests that several
different microbial pathogens may be associated with beef, pork and lamb
products. Baseline studies have shown that pathogenic bacteria are readily
transferred from contaminated hides/fleece and from the gastrointestinal tract
to the carcasses during slaughter. Cross contamination may also occur through
contact with contaminated equipment and the environment. Carcass
contamination may be prevented, reduced or eliminated through the
application of control procedures as part of the GMP and HACCP programmes.
The critical control points used as part of the HACCP programme may be
specifically designed food safety interventions such as hot water washing or
6
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steam pasteurisation. However, pathogens may also be prevented, reduced or
eliminated through the application of non-intervention technologies such as
chilling or through the application of control procedures for high risk
operations such as dehiding/pelt removal and evisceration.
It is recommended to the Irish meat industry to adopt a logical step-wise
approach to HACCP development. The hazards associated with slaughter
should first be identified. Control of these should be assigned to the GMP
and/or HACCP programmes based on the severity of the risk. The GMP
programme should then be developed before the HACCP system is put in
place. The former includes appropriate staff development and training. When
GMP is implemented, the plant is ready for HACCP. HACCP should be
developed in accordance with the Codex principles (Anon, 1997), taking cost
and related issues into account. The Food Safety and Food Training and
Technical Services departments at The National Food Centre have
considerable experience and expertise in HACCP development and
implementation and are available for consultation. In addition, The National
Food Centre publications; HACCP for Irish Beef Slaughter, HACCP for
Irish Pork Slaughter and HACCP for Irish Lamb Slaughter will prove
invaluable in the hazard identification & HACCP development and should be
studied at the outset of the process.
11
R5374 50 HACCP 8/3/02 2:44 PM Page 11
REFERENCES
Anon. 1997. Recommended International Code of Practice. General Principles
of Food Hygiene. Codex Alimentarius Commission, 1-1969, Rev. 3.
Anon. 2001. Commission Decision of the 8
th
of June. Official Journal of The
European Communities, 165, 48-63.
Bolton, D. J., Pearce, R. and Sheridan, J. J. 2001. Risk-based determination of
critical control points for pork slaughter. The National Food Centre Research
Report (in press).
Cloak, O. M. 1999. The development of rapid methods for the detection of
pathogens in meat and poultry. D. Phil. Thesis, University of Ulster.
Logue, C. M., Sheridan, J. J., Waulters, G., McDowell, D. A. and Blair, I. S.
1996. Yersinia spp. and numbers, with particular reference to Y. enterocolitica
bio/serotypes, occurring on Irish meat and meat products, and the influence
of alkali treatment on their isolation. International Journal of Food
Microbiology, 33, 257-274.
McEvoy, J.M., Doherty, A.M. & Sheridan, J.J. 1999. The incidence of
Escherichia coli O157:H7 and Salmonella in faeces, rumen contents and on
carcasses in a commercial Irish beef abattoir. Abstract: Handbook of the
Society for Applied Microbiology Summer Conference, University of York,
13-16
th
July.
Sheridan, J. J., Duffy, G., McDowell, D. A. and Blair, I. S. 1994. The
occurrence and initial numbers of Listeria in Irish meat and fish products and
the recovery of injured cells from frozen products. International Journal of
Food Microbiology, 22, 105 115.
Sockett, P.N. 1996. The epidemiology and costs of diseases of public health
significance, in relation to meat and meat products. In: HACCP: An integrated
approach to assuring the microbiological safety of meat and poultry, 171-192.
Eds: Sheridan, J.J., Buchanan, R.L. & Montville, T.J. Food & Nutrition Press,
Inc., USA.
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