Heat Treated, Shelf Stable

Directions for Using the HACCP Plan Form

1. Examine your Hazard Analysis form to determine which steps are CCP’s and what type
of hazard (Biological, Chemical, or Physical) each CCP controls.
2. Check to see whether each CCP is already listed on the HACCP Plan Form. If a CCP is
not already listed, enter the CCP number and step in the column labeled “CCP # and
Location”.
3. For CCP’s already listed on the model form, examine the Critical Limits listed. In the
HACCP Plan Form for some HACCP categories there will be several options for Critical
Limits. If this is the case, choose the Critical Limits that will work best in your plant and
cross out, white out, or delete the other Critical Limits and the Monitoring Procedures
that go with them. It may be helpful to check the “Monitoring Procedures and
Frequency” column during your decision-making. For CCP’s already on the model form,
supporting scientific documentation is already included in your manual.
4. If you are adding a new CCP, you will need to determine the scientifically valid Critical
Limits to be used with the CCP. You must also obtain scientific information supporting
your choice of Critical Limits. Consult your inspector or university extension specialists
for help.
5. Examine the “Monitoring Procedures and Frequency” column for each CCP. If you wish
to change the procedure and/or the frequency, check with your inspector or a university
extension specialist for help. If a change is OK, you will need to write down your
reasoning for making the change and include this reasoning in your HACCP manual.
6. Examine the “HACCP Records” column. If you are using different forms for record-
keeping in this HACCP Plan, please put the correct form title(s) in the “HACCP
Records” column.
7. The verification activities listed in the “Verification Procedures and Frequency” column
are required by the regulation. However, you may choose to do additional activities; for
example, for verification, beef jerky samples may be sent to the lab each quarter for water
activity testing. Moisture:Protein Ratio (MPR) testing would not be necessary to meet
HACCP requirements for jerky. However, MPR testing and/or water activity testing may
be needed to meet HACCP requirements for other shelf-stable products. If you do any
additional verification activities, enter them in the “Verification Procedures and
Frequency” column. If you choose to use a frequency for the required verification
activities that is different than the frequency shown, you must provide written
justification for the different frequency. Consult your inspector or university extension
specialists for help.
8. We suggest that you make no changes in the “Corrective Actions” column. Be sure to
have a form for documenting corrective actions that you take. A corrective action form is
included in this model.

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 Heat Treated, Shelf Stable

HACCP PLAN
PROCESS CATEGORY: Heat treated, shelf stable
Product example: Snack Sticks, Summer Sausage, Jerky
CCP# and Critical Limits Monitoring HACCP Records Verification Corrective
Location Procedures and Procedures and Actions
Frequency Frequency
1B pH ≤ 5.3 – achieved within one Fermentation Log Establishment owner or If a deviation
Fermenting of the following time limits designee will review the from a critical
(Snack (based on a constant chamber Corrective Action Fermentation Log, limit occurs, the
Sticks, temperature). Log Corrective Action Log, establishment
Summer Thermometer Calibration owner or designee
Sausage
Constant Thermometer Log, and pH Meter is responsible for
produced w/
Chamber Calibration Log Calibration Log once per corrective action
a
fermentation Temp (°F) Max Hrs week. protocol as stated
step) 75 80 pH Meter in
80 60 Calibration Log Establishment owner or 9 CFR, 417.3
85 48 designee will calibrate all 1. The cause of
90 33 thermometers to a known the deviation
95 28 standard monthly. will be
identified and
100 25 Thermometers will be
eliminated.
105 20 calibrated to ± 2° F or
2. The CCP will be
110 18 taken out of operation as under control
stated in the SOP. after the
In addition, pH and water Calibration actions are corrective
activity must be reduced to recorded in the action is taken.
one of the following Thermometer Calibration 3. Measures to
combinations: Log. prevent
Max. pH Max. water activity recurrence will
be established.
5.3 0.91 Establishment owner or
4. No product that

05/04/2012 version. Supersedes all previous versions.

 Heat Treated, Shelf Stable

HACCP PLAN
PROCESS CATEGORY: Heat treated, shelf stable
Product example: Snack Sticks, Summer Sausage, Jerky
CCP# and Critical Limits Monitoring HACCP Records Verification Corrective
Location Procedures and Procedures and Actions
Frequency Frequency
5.2 0.91 designee will check the pH is injurious to
5.1 0.92 meter used for monitoring, health or
5.0 0.93 to verify accuracy before otherwise
adulterated as a
4.9 0.96 each batch of product is
result of the
4.8 0.96 produced. The SOP for
deviation will be
4.7 0.96 calibration will be used and permitted to
calibration will be accurate enter
to ± 0.1. Calibration commerce.
activities will be recorded
in the pH Meter Calibration
Log.

Establishment owner or
designee will observe
monitoring of temperature
and pH at least once per
month.
2B Snack Sticks to be cooked to Smokehouse operator or Smokehouse/ Establishment owner or If a deviation
Heat an internal temperature of at designee will take the Product designee will review from a critical
Treatment least 150°F for at least 72 internal temperature at Temperature Log Smokehouse/Product limit occurs, the
(summer seconds, or another pre- appropriate times using a Temperature Log, establishment
sausage, determined Appendix A calibrated internal probe Thermometer Corrective Action Log, and owner or designee
snack sticks temperature/time combination. or thermometer and/or Calibration Log Thermometer Calibration is responsible for

05/04/2012 version. Supersedes all previous versions.

 Heat Treated, Shelf Stable

HACCP PLAN
PROCESS CATEGORY: Heat treated, shelf stable
Product example: Snack Sticks, Summer Sausage, Jerky
CCP# and Critical Limits Monitoring HACCP Records Verification Corrective
Location Procedures and Procedures and Actions
Frequency Frequency
with Summer sausages to be cooked review smokehouse chart Log once per week. corrective action
fermentn./ to a pre-determined Appendix for each lot at completion Corrective Action protocol as stated
acidificn. A temperature/time of cooking cycle and Log Once per week the in
step) combination. Note that less before removal of product establishment owner or 9 CFR, 417.3
severe temperature/time from smokehouse. The designee will observe the 1. The cause of the
combinations have been number of product pieces monitoring of process time deviation will be
validated for some products monitored for and temperature. identified and
eliminated.
with low pH: summer sausage temperature will be
2. The CCP will be
with pH 4.6 or lower can be determined based on lot Thermometer calibration
under control
heated to an internal size, product history, will be done in accordance after the
temperature of at least 130°F recent changes in with the SOP for corrective
instantaneous, summer sausage formulation, previously Calibration of action is taken.
with pH 5.0 or lower can be observed variation, etc. Thermometer. 3. Measures to
heated to an internal prevent
temperature of at least 130°F recurrence are
and held for at least 30 established.
minutes, pepperoni with pH 5.0 4. No product that
is injurious to
or lower can be heated to an
health or
instantaneous internal
otherwise
temperature of at least 145° adulterated as a
or can be heated to an internal result of the
temperature of least 128°F deviation will be
and held at least 60 minutes. permitted to

05/04/2012 version. Supersedes all previous versions.

 Heat Treated, Shelf Stable

HACCP PLAN
PROCESS CATEGORY: Heat treated, shelf stable
Product example: Snack Sticks, Summer Sausage, Jerky
CCP# and Critical Limits Monitoring HACCP Records Verification Corrective
Location Procedures and Procedures and Actions
Frequency Frequency
enter
commerce.

2 B Heat Application of one of the Oven temperature will be Smokehouse/ Smokehouse operator or If a deviation
Treatment processing schedules below: monitored using Product designee will verify that from a critical
(Jerky 1. Set oven dry-bulb calibrated smokehouse Temperature and the wet bulb wick is clean limit occurs, the
except temperature to reach 170°F dry-bulb and wet-bulb Yield Log and the wet-bulb water well establishment
Poultry) within 30 minutes, and then thermometers. contains the appropriate owner or designee
apply one of the following wet- Corrective Action amount of water prior to is responsible for
bulb temperature spikes. Log startup. corrective action
a. 125°F for 60 min. protocol as stated
b. 130°F for 60 min. Thermometer Once per week, the in
c. 135°F for 30 min. Calibration Log establishment owner or 9 CFR, 417.3
d. 140°F for 10 min. designee will review the 1. The cause of
Then dry to required dryness Smokehouse/Product the deviation
at a dry-bulb temperature of Temperature Log, will be
identified and
at least 170 °F. Corrective Action Log,
eliminated.
2. Increase dry-bulb Smokehouse/ Thermometer Calibration
2. The CCP will be
temperature to reach at least Product Log. under control
170°F within 15 minutes, and Temperature and after the
then dry to required dryness Yield Log Once per month the corrective
at a dry-bulb temperature of establishment owner or action is taken.

05/04/2012 version. Supersedes all previous versions.

 Heat Treated, Shelf Stable

HACCP PLAN
PROCESS CATEGORY: Heat treated, shelf stable
Product example: Snack Sticks, Summer Sausage, Jerky
CCP# and Critical Limits Monitoring HACCP Records Verification Corrective
Location Procedures and Procedures and Actions
Frequency Frequency
at least 170°F. Relative Corrective Action designee will observe the 3. Measures to
humidity at the start of the Log smokehouse operator or prevent
process must be at least 27% designee perform the recurrence are
established.
(wet-bulb temperature of at Thermometer monitoring activity.
4. No product that
least 105°F) and relative Calibration Log
is injurious to
humidity after 120 minutes of Smokehouse operator or
health or
processing must be at least designee will verify that otherwise
17% (wet-bulb temperature of the wet bulb wick is clean adulterated as a
at least 112°F). and the wet-bulb water well result of the
contains the appropriate deviation will be
amount of water prior to permitted to
startup. enter
3. Increase dry-bulb commerce.
temperature to reach at least
170°F within 90 minutes, and
then dry to required dryness
at a dry-bulb temperature of
at least 170°F. Relative
humidity at the start of the
process must be at least 41% Oven temperature will be Once per week, the If a deviation
(wet-bulb temperature of at monitored using establishment owner or from a critical
least 115°F) and relative calibrated smokehouse designee will review the limit occurs, the
humidity after 180 minutes of wet-bulb thermometers. Smokehouse/Product establishment

05/04/2012 version. Supersedes all previous versions.

 Heat Treated, Shelf Stable

HACCP PLAN
PROCESS CATEGORY: Heat treated, shelf stable
Product example: Snack Sticks, Summer Sausage, Jerky
CCP# and Critical Limits Monitoring HACCP Records Verification Corrective
Location Procedures and Procedures and Actions
Frequency Frequency
processing must be at least Temperature Log, owner or designee
21% (wet-bulb temperature of Corrective Action Log, is responsible for
at least 117°F). Thermometer Calibration corrective action
Log. protocol as stated
in
4. Increase dry-bulb Once per month the 9 CFR, 417.3
temperature in smokehouse in establishment owner or 1. The cause of the
1-hour intervals to 120°F, designee will observe the deviation will be
130°F, 140°F, and 170°F, then smokehouse operator or identified and
eliminated.
dry to required dryness at dry- designee perform the
2. The CCP will be
bulb temperature of at least monitoring activity.
under control after
170°F. Relative humidity at the the corrective
start of the process must be action is taken.
at least 43% (wet-bulb 3. Measures to
temperature of at least 98°F) prevent recurrence
and relative humidity after are established.
240 minutes of processing 4.No product that is
must be at least 15% (wet-bulb injurious to health
or otherwise
temperature of at least 109°F).
adulterated as a
result of the
deviation will be
permitted to enter
2B Heat 1) Dry-bulb temperature commerce.

05/04/2012 version. Supersedes all previous versions.

 Heat Treated, Shelf Stable

HACCP PLAN
PROCESS CATEGORY: Heat treated, shelf stable
Product example: Snack Sticks, Summer Sausage, Jerky
CCP# and Critical Limits Monitoring HACCP Records Verification Corrective
Location Procedures and Procedures and Actions
Frequency Frequency
Treatment in chamber must reach
(poultry at least 165°F and be
jerky) maintained for at least
210 minutes. Relative
humidity at the start
of the process must be
at least 49% (wet-bulb
temperature of at least
139°F) and relative
humidity after 210
minutes of processing
must be at least 30%
(wet-bulb temperature
of at least 124°F).
2) Dry-bulb temperature
in chamber must reach
at least 180°F and be
maintained for at least
150 minutes. Relative
humidity at the start
of the process must be
at least 49% (wet-bulb
temperature of at least

05/04/2012 version. Supersedes all previous versions.

 Heat Treated, Shelf Stable

HACCP PLAN
PROCESS CATEGORY: Heat treated, shelf stable
Product example: Snack Sticks, Summer Sausage, Jerky
CCP# and Critical Limits Monitoring HACCP Records Verification Corrective
Location Procedures and Procedures and Actions
Frequency Frequency
153°F) and relative
humidity after 150
minutes of processing
must be at least 24%
(wet-bulb temperature
of at least 134°F).

3B Drying Yield pre-determined to result Smokehouse operator or Smokehouse/ Once per week, the If a deviation
in either: jerky with MPR of designee will determine Product establishment owner or from a critical
0.75 or lower and water product yield (see SOP Temperature and designee will review the limit occurs, the
activity of not higher than for relating product yield Yield Log Smokehouse/Product establishment
0.85 (air storage) or 0.88 to water activity and Temperature and Yield Log, owner or designee
(oxygen-free packaging), OR Moisture:Protein Ratio) Corrective Action Corrective Action Log,. is responsible for
non-jerky product with pH and for every lot. Log corrective action
water activity must be reduced Once per month the protocol as stated
to one of the following Thermometer establishment owner or in
combinations: Calibration Log designee will observe the 9 CFR, 417.3
Max. pH Max. water activity smokehouse operator or 1. The cause of the
5.3 0.91 Results of yield designee perform the deviation will be
5.2 0.91 and/or water monitoring activity. identified and
eliminated.
5.1 0.92 activity testing.
2. The CCP will be
5.0 0.93 May be part of Twice per year (once during
under control after
4.9 0.96 Smokehouse/Product warm weather, once during the corrective

05/04/2012 version. Supersedes all previous versions.

 Heat Treated, Shelf Stable

HACCP PLAN
PROCESS CATEGORY: Heat treated, shelf stable
Product example: Snack Sticks, Summer Sausage, Jerky
CCP# and Critical Limits Monitoring HACCP Records Verification Corrective
Location Procedures and Procedures and Actions
Frequency Frequency
4.8 0.96 Temperature and cold weather), water action is taken.
4.7 0.96 Yield Log activity and MPR will be 3. Measures to
tested to ensure that prevent recurrence
are established.
product meets shelf-
4.No product that is
stability standards (see
injurious to health
SOP for Relating Product or otherwise
Yield to Water Activity and adulterated as a
Moisture:Protein Ratio)> result of the
deviation will be
permitted to enter
commerce.

Sign and date at initial acceptance, modification, or annual reassessment.

Signed __________________________________ Date ___________________________

Signed __________________________________ Date ___________________________

Signed __________________________________ Date ___________________________

05/04/2012 version. Supersedes all previous versions.

Heat Treated, Shelf Stable

Signed __________________________________ Date ___________________________

05/04/2012 version. Supersedes all previous versions.