HAZRD CONTROL PLAN

FOR
PRIME MEAT PACKERS (U) LIMITED
BASED ON PROCESSING OF CATTLE AND GOATS MEATS FROM RECEIVING OF THE LIVE CATTLE
GOATS AND PACKAGING TO DISPATCHED OF THEIR PROCESSED MEATS.
PMPL/HCP/PLAN/01
PREPARED AND REVIEWED Quality Analyst (QA)
BY:

APPROVED BY: Managing Director (MD)

PREFACE
This Document is written as per the requirements of ISO 22000:2018 under clause 7.6 as based
on the HCP principles. It describes the potential hazards, their analysis and the control
measures as design to help control contamination.
It goes ahead to give the module of identification of critical control points and their limits.
The system promotes the adoption of risk-based thinking, through the food processing chain
with aim of creating cautiousness and increase watchfulness of the different process owners at
all levels of the food chain.
The HCP system described in this plan is aimed to help strengthen the process of hazard
identification and analysis of Prime Meats Packers (U) Limited. Its emphasis controlling of
critical Processes in order to arrive at safe food products as per planned arrangements.
Prime Meat Packers (U) Limited is committed to meeting customer satisfaction through the
effective application of the food safety management system, including processes for continual
improvement of the system and the assurance of conformity to customer and applicable
statutory and regulatory requirements
This HCP plan is the property of Prime Meat Packers (U) Limited and contains vital information
restricting its circulation. Controlled copies are circulated only on approval from the Managing
Director.

1. PROJECT DESCRIPTION
Prime Meat Packers (U) Limited is a registered private Limited Company incorporated in 2019.
The company provides for and promotes its perishable processed meat products from Goats
and Cattle.
Prime Meat Packers (U) Limited processes and packages Cattle and Goats Meats for both
Hospitality and Domestic Industry in Uganda.
Among the processed Meats processed include Goats Meat and Beef parts such as Rib, Thigh,
Lions to mention but a few.
Prime Meat Packers (U) Limited has a big and effective team with a vast knowledge which has
enabled them run the operations of the company as can be seen in the organo-gram under Ref:
JPL/HR/CHT/01
1.1. FOOD SAFETY AND HCP TEAM
Out of the existing staff and after a clear understanding of the HCP concept, management of
PMPL has appointed a food safety / HCP team. This team of members is made up of members
with of multi-disciplinary knowledge and experience in developing and implementing the food
safety management system. This includes members of top management, members from the
quality assurance team to the human resource manager. These members have been trained on
the different food safety requirements and records to prove this are maintained by the HR.
Table 1: HCP/FOOD SAFETY TEAM
SR. NO NAME POSITION DESIGNATION
1. Julius Muhimbo Team Leader Quality Analyst
 2. Adan Issack Member Managing Director
3. Adan Mohamad Secretary Head of Operations
4. Eunice Gardenia Member Marketing Officer
5. Eit John Member Production Officer

1.1.1. Responsibilities and authority for the HCP team

This highly competent team has a number of responsibilities have been laid down for them to
accomplish if the company is to have the implementation of HCP and produce highly.
TABLE 2: SHOWING THE RESPONSIBILITIES OF THE HCP TEAM
Personnel Responsibilities in the Description of responsibility and authority
HCP system
HCP team leader Overall Manager of the Is the overall coordinator of all HCP activities.
HCP system
Monitoring the implementation of the different
HCP controls and proper use of the PRPs.
Communicates and reports to the certifiers at
regular basis and organizes all external and internal
audits
Has the authority with communication to MD to
organize or call off any activity with the intentions
of maintaining product safety.
Organize and spear head FSMS and HCP internal
audit.
Lead the team in Hazard identification and analysis.
Ensure that all members involved in food safety
have received proper training.
Report on the overall effectiveness of the Food
Safety Management System.
Secretary Taking minutes of all meetings including
resolutions laid down on HCP
the HCP documenting officer who receives all
activity reports and complies them into major HCP
reports
Ensure proper filing of all records in relation to

Team member
Note: these responsibilities do not except the team from other responsibilities as laid down in
their job descriptions IDNO: PMPL/HR/WI/01
food safety and HCP
Implementation of all identified parameters
including proper implementation of the controls
and observing the critical limits
Identification and reporting of hazards when
sighted.
Involvement in hazard analysis and identification of
controls
Being part of internal audits.

2. PRODUCT CHARACTERISTICS.
2.1. Product Descriptions details
Prime Meat Packers (U) Limited processes and packages Cattle and Goats Meats for both
Hospitality and Domestic Industry in Uganda.
Our capabilities include a highly mechanized processing line, with separate zoned process
points with an interlinked rail where the animals are hooked and then taken for storage in the
state-of-the-Art cold room. PMPL evaluates and adjusts to external and internal impacts while
also working to satisfy all the requirements of interested parties.
a) Product Name Meat, Goat Meat

b) Raw materials Live Cattle and Live Goats

c) Preservation Method Chilling and Frozen Refrigeration

d) Packaging including Secondary Different Double Sized Transparent Well Branded

Polythene and Sacks.

e) Shelf life Best use within 6 months at -18°C and Maximum 3days at
between 0°C- 5°C.

f) Where it will be sold Hospitality Industry, Domestic Use and Competitors

g) Labelling instructions Brand name as per client specification

h) How it is to be used Unpacked, Heat Treatment (Cooking or Roasting or

Grilled), Chilling(0°C-5°C) or Freezing -18°C and below, Re-
Heating and Serving.

Re-Sale.

i) Intended use of the product Food for Human Consumption.

j) Storage conditions Store in a clean, away from direct sunlight and

temperatures Chiller (0°C-5°C) and Frozen -18°C.

k) Who will consume Man

Scope of Hazards Biological: E-coli, Salmonella, Coliforms, Listeria,

C.Perifrigens, Styphyloccus Auerus.

Chemical: Oil, Grease, Detergent.

Physical: Glass, Dust, Metals

Applicable Statutory regulation US 28 EAS 39; 2002, ISO 9001; 2015 and ISO 22000; 2018
 1.1. Characteristics of end products
1.Safe Vacuum Sealed Beef.
2. Safe Vacuum Sealed Goats Meat.
1.2. Flow diagrams, process steps and control measures
 Procurement of
Raw Materials

Packaging Live Cattle Live Goats

The flow diagram above shows the meats processing. This process flow chart is an important tool and helps HCP team to develop a
precise representation of the food handling line that may be understood by individuals not conversant with storage stages of a given
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products. The stages start from receipt to dispatch. Anti Mortem Inspection Rejected
Note: During hazard identification and analysis all the above-mentioned processes are considered including their support processes
2.1.1. On-site Verification of the flow Diagram Stunning,Sticking and Bleeding Horns, Head, Skin and
This process flow diagram has been verified and confirmed by the HCP and food scientist as hired by the company. This is foundHoves
accurate and practicable.
Wasted
Skinning
2.1.2. Description of process steps and control measures
PMPL implements the above of processes as described below which controls as seen in the table for hazard analysis have) Viscera

➢ RECEIPT OF RAW MATERIALS. Evisceration Wasted

Raw Materials (Live Cattle, Live Goats and Packaging) are received at the company premise by Prime Meat Packers (U)
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Limited Staff from its suppliers. At this point the Van that has been used to deliver the products is inspected for hygiene
Post Mortem Inspection Incineration
under which the products have been transported at. This does to avoid any liability on the company for any contamination
that would have occurred during transportation of the raw materials.
➢ ARRIVAL QUALITY CHECKS, Deboning, Sizing and
ATTACHMENT Packaging
OF TRACEABILITY MARK. Splitting, Washing & Dressing
Upon receipt of the raw materials, these are inspected to ascertain their weight and whether they are healthy by the
company receiving supervisor and Vetinary Officer, they are kept in the Lairage if they are found conforming in terms of
weight and rejected if found non-conforming and The Packaging are received inspected and kept in the dry store if found
Weighing and Refrigeration
conforming and then rejected on spot if found non-conforming.

➢ TRANSFER TO APPROPRIATE STORAGE AWAITING DISPATCH FOR

Dispatch SLAUGHTER
and AND PROCESSING AND ANTI MORTEM
Distribution
After inspection of the Goats and Cattle, they are then moved to the Lairage to await dispatch for production and processing.
 I.e., The Live Animals are taken to the Pens where they are held waiting for Anti Mortem before they are slaughtered, here
it’s important to note that once animals are received, they should be held to for at least 2-3 hours to let the animals that
have been in transit to rest and cool down, because normally during transit the Animals tend to fight and rough handled
which causes glycogen (Sugar) to be released into the bloodstream. After Slaughter this is broken down in the muscles
producing lactic acid. High levels of acidity cause a partial breakdown in the muscles structure causing the meat to be Pale,
Soft and Exudative (PSE) and the Packaging (Polythene Bags and Sacks) suppliers at receipt should avail Certificate of
Conformity to prove that the polythene are food grade and not recycled polythene bags then are stocked in racks or on
pallets as need arises and based on the available resources. These are kept under safe storage until the there’s an order for
production. During storage the company also maintains and cleanliness of the lairage area.
➢ PRODUCTION PLANNING PREPARATION
The required raw materials are arranged as from the planned order that’s to say if a clients order for 200kg of Cattle Meat
then the company will do an estimate of how much raw material is required then the what is required is arranged and
dispatched from the storage area to the processing line. At this Point the Process Line is subjected to thorough cleaning and
Sanitization to reduce on the cross contamination during slaughter and processing of the meats.
➢ STUNNING, STICKING AND BLEEDING.
Once animals brought in from the pens, they are stationed in the stunning box were using the direct blow method to skull
using poleaxe. The blow is dealt with precision and force, so that the skull is immediately smashed, causing instantaneous
unconsciousness. In cattle the aiming point is in the middle of the forehead in line with the ears, where the skull is thinnest.
In sheep and goats, the brain is more easily reached from the back of the neck, The animals are immediately hoisted after
stunning and immediately sticked to sever the major arteries of the neck, the sticking knife is carefully inserted just above the
breastbone at 45° pointed toward the head. Ensure that the carotid arteries and jugular veins are severed in one movement.
The animal is then left to bleed because the main objectives of bleeding are to kill the animal with minimal damage to the
carcass and to remove quickly as much blood as possible as blood is an ideal medium for the growth of bacteria, Bleeding
must continue until the blood flow is negligible when carcass dressing should begin without further delay
➢ SKINNING
Skin
When removing the skins from the animals it’s important to note that the outer side of the hide must never touch the
skinned surface of the carcass. Operators must not touch the skinned surface with the hand that was in contact with the skin.
 Head
After bleeding, while the animal is still hanging from the shackling chain, the horns are removed and the head is skinned. The
head is detached by cutting through the neck muscles and the occipital joint. Hang the head on a hook. Lower the carcass on
its back into the dressing cradle.
Legs
Skin and remove the legs at the carpal (foreleg) and tarsal (hind leg) joints. The forelegs are not be skinned or removed
before the carcass is lowered on to the dressing cradle or the cut surfaces will get contaminated. The hooves may be left
attached to the hide.

➢ EVISCERATION AND POST MORTEM INSPECTION

With all animals care is taken in all operations not to puncture the viscera. All viscera are identified with the carcass until the
veterinary inspection has been passed and if not passed the animal is immediately taken to the condemn room where its
analyzed and then a final decision is taken to either dispose through incineration. After inspection the viscera is taken to
viscera processing room for better air circulation. The brisket is sawn down the middle. Vertical system is used where the
animal is resting on the cradle. The carcass is then raised to the half-hoist position and when hide removal is complete the
abdominal cavity is cut carefully along the middle line. The carcass is then fully hoisted to hang clear of the floor so that the
viscera fallout under their own weight. They are separated into thoracic viscera, paunch and intestines for inspection and
cleaning, if any of the stomachs or intestines are to be saved for human consumption, ties are made at the oesophagus
/stomach, stomach/duodenum boundaries, the oesophagus and rectum having been tied off during hide removal. This
prevents cross-contamination between the paunch and the intestines. The abdominal and thoracic viscera intact are then
removed. When that is done our staff tend to avoid contact with the floor or standing platform. The kidneys are removed
after the carcass has been split down the backbone.
➢ SPLITTING, WASHING AND DRESSING OF CARCASSES.
Splitting
Working facing the back of the carcass. Split the carcass down the backbone (chine) with a saw or cleaver from the pelvis to
the neck. Sawing normally gives a better result but bone dust must be removed. If a cleaver is used, it may be necessary to
saw through the rump and loin in older animals. The saw and cleaver are then be sterilized in hot (82°C) Water or sanitized
 solution between carcasses.
Carcass washing
The primary object of carcass washing is to remove visible soiling and blood stains and to improve appearance after chilling.
Washing is no substitute for good hygienic practices during slaughter and dressing since it is likely to spread bacteria rather
than reduce total numbers. Stains of gut contents must be cut off. Wiping cloths are prohibited at this point.
Carcass spraying is done to remove visible dirt and blood stains. Water must be clean. Soiled carcasses should be sprayed
immediately after dressing before the soiling material dries, thus minimizing the time for bacterial growth. Under factory
conditions bacteria will double in number every 20 or 30 minutes.
In addition to removing stains from the skinned surface, particular attention is paid to the internal surface, the sticking
wound and the pelvic region. A wet surface favors bacterial growth so only the minimum amount of water is used and chilling
is start immediately. If the cooler is well designed and operating efficiently the carcass surface will quickly dry out, inhibiting
bacterial growth.

Carcass dressing
The object of carcass dressing is to remove all damaged or contaminated parts and to standardize the presentation of
carcasses prior to weighing. Specifications will differ in detail for different authorities. Veterinary inspection of carcasses and
offal are carried out by the Company Vetinary Officer,
Where signs of disease or damage are found the entire carcass and offal may be condemned and must not enter the food
chain, but more often the veterinarian will require that certain parts, for instance those where abscesses are present, be
removed and destroyed.
Factory personnel must not remove any diseased parts until they have been seen by the inspector otherwise, they may mask
a general condition which should result in the whole carcass being condemned. Any instructions from the inspector to
remove and destroy certain parts are obeyed.

➢ DEBONING, SIZING AND PACKAGING

 After the carcass dressing, and there’s an order, the carcass is normally taken for further processing, deboning and sizing
where specialized staff cut the carcass based on the need to the customers after which the meats are packaged, vacuumed
sealed, batched and labeled as required then taken immediately in the chillers.
Here the staff take precaution when handling the meat, since they might introduce bacteria to the final products, they
therefore have protective equipment like the Hairnets, Hand Gloves, Overcoats and Gumboots. The Sizing and deboning
knives are kept in sanitizing solution every after use.
➢ REFRIGERATION AND STORAGE
Carcasses are taken into the cooler as soon as possible to dry as quick as possible. The object of refrigeration is to retard
bacterial growth and extend the shelf-life. Chilling meat postmortem from 10°C down to 0°C and keeping it cold will give a
shelf-life of up to three weeks, provided high standards of hygiene were observed during slaughter and dressing.
Carcasses are then placed in the cooler immediately after weighing. They must hang on rails and never touch the floor. After
several hours the outside of a carcass will feel cool to the touch, but the important temperature is that deep inside the
carcass. This is measured with a calibrated probe thermometer, and used as a guide to the efficiency of the cooling.
The rate of cooling at the deepest point will vary according to many factors including the efficiency of the cooler, the load,
carcass size and fatness. As a general guide a deep muscle temperature of 6–7° C is achieved in 28 to 36 hours for beef, and
24 to 30 hours for sheep carcasses. Failure to bring down the internal temperature quickly will result in rapid multiplication
of bacteria deep in the meat resulting in off-odors and bone taint. High air speeds are needed for rapid cooling but these will
lead to increased weight losses due to evaporation unless the relative humidity (RH) is also high. However, if the air is near to
saturation point (100 percent RH) then condensation will occur on the carcass surface, favoring Mould and bacteria growth.
A compromise between the two problems seems to be an RH of about 90 percent with an air speed of about 0.5 m/second.
Condensation will also occur if warm carcasses are put in a cooler partially filled with cold carcasses. The cooler should not be
overloaded beyond the maximum load specified by the manufacturers and spaces should be left between carcasses for the
cold air to circulate. Otherwise, cooling will be inefficient and the carcass surface will remain wet, favoring rapid bacterial
growth forming slime.
Once filled, a cooler is closed and the door opened as little as possible to avoid sudden rises in temperature. When emptied,
it is thoroughly washed before refilling. Personnel handling carcasses during loading and unloading operations follow the
strictest rules regarding their personal hygiene and clothing and should handle carcasses as little as possible.
➢ DISTRIBUTION.
Chilled meat is kept cold until it is sold or cooked. If the cold chain is broken, condensation forms and microbes grow rapidly.
The same rules about not overloading, leaving space for air circulation, opening doors as little as possible and observing the
highest hygiene standards when handling the meat apply. An ideal storage temperature for fresh meat is just above its
freezing point, which is about - 1°C.
The expected storage life given by the International Institute of Refrigeration of various types of meat held at these
temperatures is as follows:
Type of meat Expected and storage life at - 1°C Beef up to 3 weeks (4–5 with strict hygiene), Lamb 10–15 days.
Under commercial conditions, meat temperatures are rarely kept at - 1°C to 0°C, so actual storage times are less than
expected. The times would also be reduced if RH were greater than 90 percent.
Meat should be placed in the refrigerator immediately following receipt. Any parts which show signs of Mould growth or
bacterial slime should be trimmed off and destroyed. Hands must be thoroughly washed after handling such trimmings and
knives must be sterilized in boiling water. The refrigerator should be thoroughly cleaned after finding such meat and should
also be cleaned on a regular basis.
Carcasses, quarters and large primals should not be cut into smaller portions before it is necessary as this will expose a
greater surface area for bacteria to grow. Freshly cut surfaces are moist and provide a better medium for bacterial growth
than the desiccated outer surfaces of cuts that have been stored for some time.

An accurate thermometer is placed in the refrigerator and checked regularly. The temperature should remain within a
narrow range (0° to + 1°C).
Vehicles for transporting meat and carcasses is considered as an extension of the refrigerated storage. The objective is to
maintain the meat temperature at or near 0°C. Meat is chilled to 0°C before loading. Meat is then hanging on rails, not on the
floor. If stockinette’s are put on carcasses they are cleaned. Meat trucks carry nothing other than meat.
The refrigeration is usually produced by injecting liquid nitrogen or carbon dioxide (CO2) into the compartment or by blowing
air over CO2 chunks (dry ice). The temperature in these vans is set and controlled to minimize the temperature rise and to
avoid condensation on the meat surface.
Insulated vans without refrigeration are refrigerated by adding dry ice. While this is a reasonably good alternative to the
refrigerated truck it does not allow the temperature to be controlled.
Uninsulated vans and open trucks are not considered as suitable transport for meat, particularly in hot climates. In addition
to the temperature abuse, condensation will occur when the meat goes back into refrigeration, and in open trucks the meat
is exposed to attack from insects. Loading and unloading is therefore done quickly. If there are any unavoidable delays then
dry-ice blocks is placed in the partly filled van.