HACCP PLAN IN RED MEAT
INDUSTRY
Presented by,
GOWRI BALAH.G
PRESENTED BY,
ISWARYA.V
GOWRI BALAH G
ISWARYA V
RED MEAT
Red meat is a meat which is red when raw and dark
in colour when cooked because it has more
myoglobin than white meat
E.g.: beef, pork
MEAT PRODUCTION IN INDIA
India stands 5th in meat production with the annual
production of 6.3 million tonnes and the share of
RED MEAT is 77%.All the EOU are registered with
the APEDA after inspection
COMPONENTS OF MEAT INDUSTRY
Trading live animals-buffaloes,sheep,pig
Slaughtering the animals for retail domestic market
Slaughtering in municipal abattoirs for both
domestic and export markets
Slaughtering in integrated mechanized abattoirs for
export
Transportation services for fresh frozen meat
Production of pet foods
Marketing of bones for further processing of
gelatin,ossein and blood for pharmaceutical
production.
PROCESSING
The animal is brought from a disease free zone which is
monitored by state Govt veterinary dept to the EOU
Animal is brought to the slaughter house with identification
tag
Veterinary doctor issues the animal health certificate during
the transit of the animal through trucks
The trucks with animals are passed through foot path with
1% formaldehyde
The veterinary doctor is assigned to conduct 96 ante
mortem examinations per day in a shift of 8 hours per day
The animals are washed in the lairage
Its then held in the knocking box and stunned
All animals are slaughtered by halal method and allowed
to bleed completely,whereafter the legs are cut, dehiding is
done and carcass is split into two halves
Veterinarian conducts the postmortem examination
Washed, stamped and transferred to chiller of 2-4 ̊C
Deboning temp- 7 ̊C and pH is below 6.Prime cuts are
made at the deboning hall and packed as per requirement
Cartons are frozen at -40 ̊C for 10- 12 hours and then
brought to cold storage after microbial analysis.
FLOW CHART OF SAFE AND HYGIENIC MEAT PRODUCED IN MEAT PLANTS
• Receiving and holding • Evisceration
• Post-mortem
• Ante mortem
CCP-1 CCP-2 examination
• Lairage • Washing
• Animal washing CCP-3
• Chilling
• Halal • Deboning
• Skinning & hide removal • Processing
• QC Inspection
• Packaging,cartoning
CCP-4
• Metal detector
• Weighing of cartons
CCP-5
• Freezing
CCP-6
• Cold storage
EQUIPMENTS USED IN MEAT PROCESSING
MEAT GRINDER
Used to force meat trimmings by means of a feeding worm
under pressure through a horizontally mounted cylinder
BOWL CUTTER
Commonly used meat chopping equipment designed to
produce small or very lean meat and fat particles
Contains revolving bowl and a set of curved knives rotating
vertically on a horizontal axle
FILLING MACHINE (SAUSAGE STUFFER)
Used for filling all types of batter in containers
A piston is moved inside a cylinder forcing the meat material
through the filling nozzle into the containers
CLIPPING MACHINE
Clipping machines place small aluminium sealing clips on
the sausage ends and replace the manual tying of sausages
Can be connected to filling machines
SMOKE HOUSES
Used for smoking. In traditional operations the most
common methods of smoke generation include burning damp
hardwood sawdust
BRINE INJECTOR
Used for the injection of brine into meat
Before the injector is used again all hoses and needles should
be rinsed with warm water as micro organisms would be
injected deep into the meat pieces
MIXER/BLENDER
Used to blend meat and spices or coarse and finely chopped meat.
The machine generally consists of a rectangular or round bottom
vessel through which two parallel shafts operate
SSOP
• Slaughter house
• processing room
• smoke house
• coolers
SLAUGHTER ROOM/OFFAL ROOM/HOLDING PENS
PRE-OPERATIONAL SANITATION
•Visual inspection of walls , floors and equipments
•Boot dip mats filled with hot water and bleach are placed in
front of doors.
OPERATIONAL SANITATION
•Carcass dressing will be performed under sanitary conditions in
order to prevent contamination of the carcass.
• Employee hygiene during slaughter and carcass dressing.
• Cleaning of equipments during slaughter and carcass dressing to
prevent contamination of the carcass.
• The splitting saws will be sanitized between carcasses using hot
water.
• Eviscerating employees will maintain clean hands, arms,
clothes, aprons, boots and knives during the evisceration
process.
• If contamination occurs, the employee is required to step away
from the carcass to clean and sanitize the contaminated items.
PROCESSING ROOM
PREOPERATIONAL SANITATION
•Visual inspection
•If needed, the general cleaning and sanitizing procedures are
implemented.
• Condensation is wiped from rails and oil is applied.
OPERATIONAL SANITATION
• All fabricating and processing will be performed under
sanitary conditions and in a manner to prevent
contamination of any product.
• All equipments will be cleaned and sanitized with hot water
(140°F for cleaning and 180°F for sanitizing) as often as
necessary during fabrication and processing to prevent
contamination of any product. This must be done between
fabricating beef and pork.
POST OPERATIONAL SANITATION
• After fabricating and processing, all floors, walls, and
equipment (including tables) will be properly cleaned and
sanitized according to specific procedures.
Stuffer :
• Disconnect from power source
• Disassemble all parts including horns, linking attachment,
scraper, feed worms, gaskets, etc...
• Rinse stuffer and all disassembled parts with warm water and
scrub to remove any meat and fat debris
• Apply chlorine bleach according to instructions
• Rinse and sanitize with hot water (180°F)
• Inspect all parts and repeat cleaning and sanitizing if necessary
• Dry parts (oil with mineral oil if necessary) and store in
designated area in small dry storage room
Skinner:
• Disconnect from power source
• Rinse entire skinner with warm water and scrub to remove any
skin and fat debris (follow good safety habits when scrubbing
the blades)
• Apply chlorine bleach according to instructions
• Rinse and sanitize with hot water
• Inspect and repeat cleaning and sanitizing if necessary
• Allow to dry and apply mineral oil to outside surface
Grinder :
• Areas commonly overlooked are inside
and around the neck, meat guard, inside
the grinder where the paddles rub the side,
inside the grinder where the feeding worm
attaches and around the control buttons.
• Apply chlorine bleach according to instructions
• Rinse and sanitize with hot water
• Inspect and repeat cleaning and sanitizing if necessary
• Allow to dry (wipe excess water from inside of neck) and
lubricate inside of neck, feeding worm and grinder plates and
knife
• Hang grinder plates and knife on pegboard in small dry storage
room
Smoke Room.
• Employees will wash hands and arms with soap and hot water
as they enter the smoke room and as often as necessary during
smoking to prevent product contamination.
• All equipment (including smokehouse, kettle, and sink, etc...)
and equipment parts will be cleaned and sanitized with hot
water as often as necessary during processing to prevent
contamination of any product.
Coolers
Check Weekly and Perform as Needed:
• Check cleanliness and orderliness of all coolers (including
cooler shelving).
• Dispose of materials no longer needed.
• If needed, clean floors, walls and shelving.
• remove products from cooler or protect from splash
• rinse floors and walls with warm/hot water
• apply soap and scrub any areas with strongly attached soil --
rinse away soap
• clean shelving which contacts products according to basic
cleaning procedures
• squeegee water from floor into drains
• inspect effectiveness of cleaning
CORRECTIVE ACTION
VERIFICATION
RECORD KEEPING
REFERENCE
http://traceability.apeda.gov.in/Meatnet/UserLogin/Login.asp
x?RequestID=27420698
http://www.fao.org/docrep/010/ai407e/ai407e25.htm
http://apeda.gov.in/apedawebsite/Announcements/procedure_
for_meat_plant.pdf
QUESTIONS???
MILLIONS SAW THE APPLE FALL, NEWTON WAS
THE ONLY ONE WHO ASKED WHY?
