See discussions, stats, and author profiles for this publication at: https://www.researchgate.net/publication/270272832 Risk assessment of vacuum-packed pouched tuna chunks during industrial processing using ISO 22000 and HACCP systems Article  in  International Food Research Journal · June 2013 CITATIONS READS 0 244 4 authors, including: Emmanuel Ohene Afoakwa Henry Mensah-Brown University of Ghana University of Ghana 141 PUBLICATIONS   2,053 CITATIONS    22 PUBLICATIONS   76 CITATIONS    SEE PROFILE SEE PROFILE Some of the authors of this publication are also working on these related projects: FISH SMOKING SYSTEMS IN GHANA: IMPLICATIONS ON FOOD SAFETY AND NUTRITION View project POST-HARVEST LOSS INNOVATION LAB (PHLIL) PROJECT View project All content following this page was uploaded by Emmanuel Ohene Afoakwa on 16 January 2015. The user has requested enhancement of the downloaded file. International Food Research Journal 20(6): - (2013) Journal homepage: http://www.ifrj.upm.edu.my Risk assessment of vacuum-packed pouched tuna chunks during industrial processing using ISO 22000 and HACCP systems 1*Afoakwa, E. O, 2Mensah-Brown, H., 1Budu, A. S. and 3Mensah, E. 1Department of Nutrition & Food Science, University of Ghana, Legon-Accra, Ghana 2Department of Food Process Engineering, University of Ghana, Legon-Accra, Ghana 3Myroc Food Processing Company Limited, Tema, Ghana Article history Abstract Received: 1 April 2013 Risk analysis was conducted during processing of Vacuum-Packed Pouched Tuna Chunks Received in revised form: using HACCP systems. The hazards likely to occur and their levels of severity and chances 14 June 2013 of occurrences were identified. Critical control points, critical limits, control and preventive Accepted: 16 June 2013 measures, corrective actions for non-conformances and verification procedures were evaluated Keywords and documented. ISO 22000 Analysis Worksheet was also employed for determination of some prerequisite programmes (PrPs) and compared with the HACCP decision tree table for HACCP determination of Critical Control Points (CCPs). The PrPs were the main difference between ISO 22,000 the two systems. The major hazards identified were the probable contamination with spoilage Food safety and pathogenic microorganisms - Listeria monocytogenes, Clostridium botulinum, Salmonella Food control and Staphylococcus aureus; foreign materials - metal residues and sand; chemical contaminants Canned fish - heavy metals, histamine and cleaning detergent residues, before, during and after processing. Critical control points Using the HACCP decision tree, eight CCPs were identified, namely: fish receipt (CCP 1), Hazard analysis frozen storage (CCP 2), racking and staging (CCP 3), metal detection (CCP 4), vacuum sealing (CCP 5), thickness rolling (CCP 6), retorting (CCP 7) and bulk incubation/seal testing (CCP 8). The incorporation of PrPs in the ISO 22000 made the system more flexible by reducing the number of CCPs (8 in the HACCP system) to 4 without compromising safety of the product. © All Rights Reserved Introduction was expensive, destructive and generally focused on finding solutions after problems had occurred. It The fish processing industry observes strict therefore became necessary to identify an approach safety and hygiene standards to meet regulatory that was preventive, hence the establishment of the requirements and ensure final product quality and HACCP system. safety. In addition, certain quality measures are Although the application of HACCP begun put in place to prevent and control the occurrence in 1959, it was formally introduced to the public of these hazards and the measures include Hazard in 1971 and was adopted by food industries in the Analysis Critical Control Points (HACCP), Good 1980’s (Luning et al., 2002). Since then, it has been Manufacturing Practices (GMP’s) and Good Hygienic applied in several food industries to ensure the safety Practices (GHP’s). and quality of industrially processed foods. HACCP is defined as “a system that identifies, In 2005, ISO developed a new food safety evaluates, and controls hazards which are significant standard, the ISO 22000 – ‘Requirements for Food for food safety” (UNCTAD/WTO, 2002). It identifies Chain Organizations’ (Blanc, 2006). The new all possible hazards that could occur in all the standard, ISO 22000; incorporates management processes in the food manufacturing chain and finds systems and food safety practices (HACCP and Pre- preventive measures to ensure that the processes requisite programs) in the development of protocols are controlled. The basis of HACCP was first for guaranteeing food product safety (Arvanitoyannis developed in the 1960’s by the Pillsbury Company and Varzakas, 2009). ISO 22000 provides additional in collaboration with the National Aeronautics and control in hazard prevention due to its focus on Space Administration (NASA) in an effort to develop Prerequisite Programmes and integration of all a safe food product that could be used under zero parties directly and indirectly involved in the food gravity conditions by astronauts (Pearson and Dutson, chain (Blanc, 2006). 1995). The main challenge was to guarantee the The Company under study is a tuna processing safety of the food products. Although conventional and packing establishment licensed by the European quality control was being practiced at that time, it Commission (EC) through the Ghana Standards *Corresponding author. Email: eoafoakwa@gmail.com / eafoakwa@ug.edu.gh Tel: +233 (0) 244 685893 / +233 (0) 203505696 1884 Afoakwa et al./IFRJ 20(6): Authority (GSA) for the export of canned and provides assurance of the product safety and therefore pouched tuna products to member states. The minimizes the amount of testing required (Silliker, company exports mainly to the European Union and 1995). is a member of industries in the Free Zone enclave in HACCP was first presented to the general public Ghana. The company produces sterilized tuna fish in in 1971 at the United States’ National Conference of cans and pouches. The production line includes tuna Food Protection (Department of Health, Education flakes, chunks and solid pack, each in either brine and Welfare (DHEW, 1972). In 1973 it was applied or vegetable oil. The company began production of to low acid canned food (FDA, 1973) and in 1987 canned tuna in 2002 and pouched tuna in 2007. it was developed for application in the fish and As part of the company’s objective to produce seafood processing industry (Pearson and Dutson, and supply high quality and safe products, it adopted 1995). The HACCP system is defined as a result of the HACCP system for all its product lines. Although implementation of an HACCP plan which is a written HACCP provides an effective system for assuring document that is based on the principles of HACCP food safety, it is often accompanied by many CCPs and that delineates procedures to be followed (Luning some of which require intense monitoring but still et al., 2002). deliver much less than HACCP promises. Prerequisite programmes incorporated in ISO 22000 have been Developing a HACCP plan shown to reduce the number of CCPs, making the Several articles have been published, which safety management system more flexible without describe the HACCP principles and procedures for compromising the product quality and safety. development and implementation of an HACCP plan The objective of this study was to apply the (ICMSF, 1989; MFSCNFPA, 1993a, b; European principles of HACCP and ISO 22000 as a means Commission, 1996; Codex Alimentarius Commission, of providing preventive, advantageous strategies 1997; Leaper, 1997; NACMCF, 1992, 1998). There for minimizing food safety hazards while ensuring is a 12-stage procedure for the development and utmost product quality during the production of introduction of an HACCP plan, which includes five Vacuum-Packed Pouched Tuna Chunks in a food preliminary steps of HACCP and seven HACCP processing factory. principles. The five preliminary steps of HACCP as The HACCP system outlined by the National Advisory Committee on The HACCP system was developed in 1959 for Microbiological Criteria for Foods (NACMCF) to the North American Space Agency (NASA) space help in developing an HACCP plan are: program as a preventive system of food control. Step 1: Assembling an HACCP Team, Step 2: Most quality assurance programmes, which existed Description of the product and its distribution, Step at the time, were based on what the quality assurance 3: Identification of intended use and consumers, Step manager believed was a good program (Pearson 4: Development of process flow diagram (Leaper, and Dutson, 1995). There was no uniformity or 1997), and (Luning et al., 2002) and Step 5: On-site standardization and therefore companies could not verification of the flow diagram. provide the assurance required that the products were Luning et al. (2002) stated that the seven HACCP safe enough to be consumed. The old systems also principles which make up the sixth to twelfth steps resulted in the destruction of large amounts of product of the 12-stage procedure for development and for testing since such a high amount was necessary to introduction of the HACCP plan are: arrive at a statistically reasonable level of confidence Principle 1: Hazard analysis, Principle 2: Critical in the product (Pearson and Dutson, 1995). The Control Points (CCPs) identification (Pearson and HACCP system was therefore created to achieve Dutson, 1995), Principle 3: Establishment of critical such high confidence in safety with significantly less limit(s) (FAO, 1997) and (Luning et al., 2002), testing. Principle 4: Establishment of monitoring systems As a preventive system, HACCP focuses on (FAO, 1997), Principle 5: Establishment of corrective control over the raw materials, the process, the actions, Principle 6: Establishment of procedures environment, personnel, storage, and distribution for verification and Principle 7: Establishment of beginning as early in the system as possible (FDA, documentation and record keeping. 1994). It aims to identify possible problems before they occur and establish control measures at stages Shortfalls of HACCP in production that are critical to product safety. This HACCP plans unlike GMP’s do not cover all kind of control, along with good record-keeping areas of sanitary control in a food operation. Whereas Afoakwa et al./IFRJ 20(6): 1885 all GMP requirements are equal from a regulatory subcategories: infrastructure and maintenance perspective, and span all areas of the food processing programmes and operational pre-requisite operation, HACCP narrowly focuses on specific areas programmes. Infrastructure and maintenance where hazards might be introduced. For example, dust programmes are used to address basic requirements is filth under GMPs, and its presence on equipment of food hygiene and accepted good practice of a more is a violation. However, under HACCP, control of permanent nature, whereas operational pre-requisite dust is a sanitary step but is not critical, because programmes are used to control or reduce the impact its presence is an unlikely safety hazard. Secondly, of identified food safety hazards in the product or the HACCP is a dedicated safety programme (i.e. solely processing environment (Faergemand and Jersperson, focuses on safety issues), which cannot include 2004). Arvanitoyannis and Varzakas (2008) noted quality points without a dilution of critical areas the main differences of ISO 22000 compared with (Arvanitoyannis and Varzakas, 2008). It is therefore HACCP and detailed the main advantages of ISO evident that, HACCP cannot exist as a stand-alone 22000 over HACCP elsewhere Arvanitoyannis and programme. Thus to achieve safety and quality, Varzakas (2008) and BSI (2010). HACCP should be supported by a strong foundation of prerequisite programmes (Sperber, 1998). Tuna Prerequisite programmes are written, implemented Tuna fish belongs to the family Scombridae procedures that address operational conditions and (Collette and Nauen, 1983). The family Scombridae provide the documentation to help an operation run is composed of 15 genera comprising 49 species more smoothly to maintain a comprehensive food- of epipelagic marine fishes, which includes the safety assurance programme (Arvanitoyannis and Mackerels, Spanish mackerels, Bonitos and Tunas Varzakas, 2008). (Collette and Nauen, 1983). Tunas are extremely valuable commercially especially yellow fin (Thunnus ISO 22000 approach albacores), skipjack (Katsuwonus pelamis), big-eyed As food safety hazards may be introduced (Thunnus obesus), frigate (Auxis thazard), eastern at any stage of the food chain, adequate control little tuna (Euthynnus affinis), and bullet tuna (Auxi throughout the supply chain is essential. Based srochei) (Industry Profile, 2001). Several industrial on this, in 2005, ISO developed a new food safety methods of processing tuna have been developed. standard, the ISO 22000 – ‘Requirements for Food These include canning, cold smoking, curing, and Chain Organizations’. ISO 22000 is an international more recently, thermal processing in retort pouches. standard that defines the requirements of a food safety management system covering all organizations in Flexible retort pouches the food chain from “farm to fork” (BSI, 2010), as The retort pouch is a flexible laminate that can food safety is a joint responsibility that is principally be thermally processed in a way similar to that in assured through the combined efforts of all the parties which traditional cans are processed to produce shelf participating in the food chain (Faergemand and stable food products. Simpson (2008) noted that the Jersperson, 2004). The standard combines generally development of the pouch began in the United States recognized key elements to ensure food safety along in early 1950’s, by the U.S. Army Natick Development the food chain, including: Interactive communication, Center for military use. Reynolds Metal Company System management, Control of food safety hazards and Continental Can Company were the first civilian through pre-requisite programmes and HACCP plans, companies to be granted approval by the FDA for Continual improvement and updating of the food the production of retort pouches in 1977 (Simpson, safety management system (BSI, 2010). Basically, it 2008). During the 1980’s, low-acid foods thermally is a combination of the management systems of ISO sterilized in retort pouches were successfully 9001 and food safety practices (HACCP and Pre- marketed in Japan and Europe (Simpson, 2008). requisite programmes). ISO 22000 dynamically combines the HACCP Advantages of retort pouches principles and application steps with prerequisite Retort pouches offer many more advantages for programmes, using the hazard analysis to determine food manufacturers, consumers, and retailers than the strategy to be used to ensure hazard control by conventional metallic cans. Farber and Todd (2000) combining the prerequisite programmes and the and Simpson (2008) have noted that the several HACCP plan (Faergemand and Jersperson, 2004). advantages of retort pouches to include among The standard further clarifies the concept of pre- others; requisite programmes. These are divided into two (i) Their flat geometry which provides a small 1886 Afoakwa et al./IFRJ 20(6): cross-sectional dimension that enables rapid heat Physical hazards transfer during thermal processing which results in Physical hazards associated with fish include energy savings with improvement of organoleptic intrinsic physical hazards which are in the food by attributes and nutritional quality, (ii) The lightweight nature e.g. bones in fish, technical faults during and reduced storage space of empty pouches before harvesting, transportation and processing which processing resulting in lower transportation and might cause contamination with physical material storage costs for manufactures, (iii) The relatively (foreign bodies) such as metal, glass or plastic in raw low thickness and weight facilitate transportation and materials or finished products. storage by consumers packaging of more products in less space, (iv) Retort pouches are more convenient Chemical hazards to use (e.g., safe to open, minimum requirement for Chemical hazards associated with processing opening tools, etc) and (v) Saves shelf space during tuna can be divided into three categories including retail display. intrinsic (chemicals which are already in fish production during post-harvest handling and storage) Hazards associated with tuna processing e.g. histamine and heavy metals such as mercury, Several hazards have been identified with and technical faults during processing which might the production of vacuum-packed tuna; from the contaminate the food with chemicals. These include handling of the raw material (tuna), processing, detergent residues, packing materials containing through to storage and distribution. Some of these poisonous material in contact with the fish, cleaning hazards lead to the spoilage of the fish whereas agents, metals dissolving in the product and others result in pathogen proliferation in the fish, maintenance materials such as diesel from forklifts predisposing prospective consumers to severe and fishing vessels, lubricants from machine parts, illnesses and even death. These hazards are classified etc. (Sonneveld, 2004). into microbiological, chemical and physical hazards. Histamine Microbiological hazards Histamine is a chemical formed in certain fish, Tuna is a low acid food made up of 70% water, especially scombroid fish, when it starts to decompose. 23% protein, 1% lipid, less than 0.5% carbohydrate Histidine, a naturally occurring amino acid, is and 1.2 to 2.5% ash (Lund et al., 2000). The converted into histamine by an enzyme produced relatively high pH and compositional attributes by certain bacteria (CFIA, 2002; FDA, 2009). (high moisture and protein content) of tuna make it Histamine, in small doses, is necessary for the proper a suitable medium for microbial growth. Tuna tissues functioning of the human immune system. However, also contain high levels of free non-protein nitrogen histamine may trigger severe allergic reactions (called (NPN) compounds, which are readily available to scombroid poisoning) when consumed in high doses support post-mortem bacterial growth (Lund et al., (CFIS, 2002; FDA, 2009). 2000). The growth of these microbes could either The presence of high levels of histamine always lead to spoilage of the fish product or cause disease indicates that decomposition has occurred, even if (infections or intoxication). the decomposition is not obvious (CFIA, 2002). Several types of microorganisms have been Toxic amounts of histamine can form before a fish found to be associated with fish during post-harvest smells or tastes bad. Histamine, once formed in fish handling, processing, storage and distribution of cannot be destroyed or eliminated by heat treatment the fish. These include Clostridium botulinum, or freezing (Surak and Wilson, 2007; FDA, 2009). Listeria monocytogenes, Clostridium perfrigens, Formation of the toxin can however be controlled Staphylococcus aureus, Salmonella spp., Shigella through proper chilling from harvest to process, and spp., Campylobacter spp., Aspergillus spp. and utilizing a detailed knowledge of the temperature Penicillium spp. (Hussain et al., 1989; Garrett et al., history (Surak and Wilson, 2007). 1997). Whether the contamination of microorganism will become a hazard or not depends on several Heavy metals factors during the production or processing of Heavy metals are metals which have a high atomic the raw materials. These factors are related to the mass including mercury, cadmium, arsenic, and lead. hygienic environments during production, presence Heavy metals are usually toxic in low amounts and are of inhibition or destruction step during processing therefore a potential health hazard (IUFoST, 2008). and the conditions in the product/material regarding Heavy metals mostly arise indirectly in fish from the possible microbiological growth (Sonneveld, 2004). environment (water) in which it lives. As such, once Afoakwa et al./IFRJ 20(6): 1887 they become incorporated into the fish they cannot safety, and hence it is imperative that it be carried out be removed. Control of raw materials is, therefore, under strict control. Prior to filling it is important to the only mechanism for ensuring that levels do not ensure that the pouch is free from contamination and become unsafe (IUFoST, 2008). defects, as these would affect the integrity of the final product. During filling it is important to maintain a Critical operations in processing of pouched tuna constant fill weight and/or temperature. This is because in processes where target F0 values are recognized as Freezing of the fish close to the minimum for safety from botulism (e.g. Once harvested, the change in natural F0 = 2.8 to 3.0 min), even small variations in fill environment, death, handling and exposure to temperature or fill weight can have significant effects atmospheric micro flora and physical conditions on the adequacy of the thermal process (FAO, 1988). trigger the onset of spoilage and deterioration. Also, filling should not contaminate the seal areas of Generally, the rates at which both autolytic and the pouch as this will result in imperfect sealing and microbial spoilage take place are dependent upon the impair the sterilization process (Sen, 2005). temperature at which the fish is stored. Deteriorative processes are retarded at reduced temperatures and, Vacuum Sealing/thickness control of Pouches when the temperature is low enough, spoilage can The effective sealing of the filled pouch is an almost be stopped (Hall, 1997). extremely important operation: the post process The purpose of freezing fish is to lower the contamination of a heat-processed product is temperature even further thus slowing down spoilage dependent upon a secure (hermetic) closing seal such that when the product is thawed after cold storage (CCFRA, 2006). Prior to sealing, it is an absolute it is virtually indistinguishable from fresh fish (Hall, necessity to deaerate the filled pouch (a process 1997). Because handling conditions immediately called vacuum packing). If air is left in the sealed after catching are responsible for the rapid loss of the pouch, it may result in the following problems: (i) “as-fresh” quality, the quality of thermally processed During thermal processing, the air would inflate fish suffers whenever the raw material is temperature and burst the pouch (Sen, 2005) and (ii) It would abused and/or physically damaged between catching impair the heat transfer, cause under sterilization and and thermal processing. later be reflected by swelling of the pouch. Vacuum sealing assists uniform heat transfer during thermal Precooking processing (Sen, 2005). According to Sen (2005), the Precooking involves subjecting the raw material residual air in the pouch should not exceed 2% of (tuna) to a relatively severe heat treatment (usually the volume of the pouch content. Both air removal steam) at a specified temperature, pressure and time and sealing is done in one operation and is normally (Da-Wen, 2006). The precooking time depends on effected in an automatic line. It is also important the size and species of the tuna, quality of the raw that the pouches have a uniform thickness to ensure material, and the temperature along the backbone uniform sterilization of all the products as excessive (Da-Wen, 2006). Precooking serves a number of pouch thickness could cause under sterilization. functions: (i) To partially dehydrate the flesh and prevent release of those fluids during retorting which Thermal processing (retorting) would otherwise collect in the container (FAO,1988); Thermal processing involves, heating the packed (ii) To remove excess natural oils, some of which have product such that every location in the container a strong flavour (Dagoon, 2005); (iii) To coagulate would receive a pre-designated minimum thermal fish protein and loosen meat from the bones (FAO, treatment. The key objective of this heat treatment 1988); (iv) To develop desirable textural and flavour is to ensure commercial sterility of the product, such properties in the final product (Dagoon, 2005; FAO, that all pathogenic and spoilage microbes capable 1988). of growing under normal storage and handling Pre-cooking conditions affect yield and sensory conditions are destroyed (Da-Wen, 2006). quality it is important that they are regulated. Among the spore-forming organisms, C. Excessive treatment tends to reduce yields, whereas botulinum types A and B are the most heat resistant, inadequate pre-cooking means that the purpose of the constituting a potential health hazard (Da-Wen, 2006). treatment is not achieved (FAO, 1988). For low-acid products with pH values greater than 4.5, such as packaged fish, the anaerobic conditions Filling of pouches are ideal for growth and toxin production by C. Filling of pouches can be critical to product botulinum (Da-Wen, 2006). Therefore, its destruction 1888 Afoakwa et al./IFRJ 20(6): is the critical parameter used in heat processing. The Start destruction of C. botulinum is normally achieved through application of a heat process that has a F Tuna receipt 0 value equivalent in lethal effect to not less than Frozen storage (-12 to -18oC) 3 minutes at 121.1oC, resulting in product that is commercially sterile (CCFRA, 2006). Waste water Chlorinated Sizing/washing/thawing/racking (-4 to 2oC) Retort pouches are processed in a specially water (1ppm) adapted retort called over-pressure retorts (Hall, Pre-cooking (95oC at 0.3 bar) 1997; Sen, 2005; CCFRA, 2006). Pressure developed Waste water inside the pouch during thermal processing is very Cooling (40oC) high. Although sealed pouches can withstand high Cleaning (< 40oC) Flakes sorting external pressure, a small positive internal pressure even to the order of 0.1 kg/cm2 resulting from the Offal Cutting difference between internal and external pressures may result in bursting of the seal. It is for this reason Metal detection that, while heat processing, it is necessary to introduce 22pp an additional compensating pressure into the retort in order to prevent bursting of the pouch or weakening Pouches Filling tuna into pouches the seal (Gopakumar, 1993). media Media dispensing Methodology Wiping of seal area and Vacuum sealing Application of HACCP in the processing of tuna The 12-stage procedure for the implementation Thickness Rolling & Coding of an HACCP plan described earlier was adopted to o the processing of tuna to produce vacuum pouched Retorting (117/118 C) at 1.5 bar tuna chunks. A preliminary visit to the factory was carried out over a three week period to gain Water-cooling familiarity with the various operations involved in Air-cooling processing, as well as the processing plant layout. During the visit, staff and personnel were observed Bulk Incubation/ Seal testing and interviewed concerning the existing GHP’s and GMP’s. The already established factory HACCP Labeling and Secondary packaging team was involved in the application of HACCP to the processing of tuna. Storage Description of product and its distribution End As part of the HACCP plan a full description of the product, which included all relevant safety Figure 1. Flow chart for processing of vacuum-packed information, was drawn up and this included the pouched tuna chunks following aspects: oil is 2 years; vi. Instructions for use and storage i. Composition and physical features of the final by consumers - after opening the pouched product, product - tuna are packed in water or vegetable oil any unused contents should be placed and covered and are either seasoned with salt, vegetable broth or in a food container, then stored in a refrigerator and xanthan gum depending on the specification by the used within 2 days; vii. Intended use and consumers customer; ii. Method of packaging - a four-layer - The intended use is ready-to-eat product, without laminate retort pouch is used a packaging material; further cooking, in a variety of fillings, salads and iii. Storage conditions - the product is stored under sandwiches or with minimal preparations into other ambient temperature (room temperature) of between dishes by the general population who are not allergic 25 to 28oC; iv. Method of distribution - Labeled to tuna or any of the stated ingredients. secondary packaged products are loaded into container trucks, transported to the harbour and are then shipped Process description to the country of destination; v. Shelf life - the target The process flow diagram (Figure 1), for the shelf life of the products both in brine and vegetable processing of vacuum-packed pouched tuna was Afoakwa et al./IFRJ 20(6): 1889 verified as required by HACCP implementation Sizing/Washing/Thawing/Racking plan. The tuna received is inspected for good quality, Fish selected for processing are thawed to reduce unloaded, weighed and put in the cold store. The tuna precooking time. Thawing involves bringing down is then sized, thawed and racked for pre-cooking. the fish from cold storage, reweighing and transferring After pre-cooking the tuna is cooled and cleaned to to the thaw area. The fish backbone temperature is remove blood meat, bones, scales and offal. Cleaned then checked and recorded and the fish are arranged loins are then cut, passed through a metal detector, according to sizes (sizing) on pre-cooker baskets and weighed and filled into pouches. Media (brine or racks, a process called racking. The arrangement of oil) at 50°C is added in appropriate amounts and the fish by sizes in the racking process is done to vacuum-sealed according to seal specification. ensure effective heat transfer during pre-cooking Sealed pouches are passed through thickness roller such that smaller fish do not get over cooked. and placed on retort racks for retorting. Retorted Actual thawing involves placing racked fish under pouches are cooled and incubated for 14 days after running water within a temperature range of 23oC to which labeling and secondary packing is done and 29oC. The optimum temperature is 25oC. Thawing is the product is dispatched for shipment. done until fish attains a temperature range of -4 to 2oC. Above this temperature range, histamine levels in the Pre-processing operations fish begin to increase. By thawing, fish is washed at All preparatory operations prior to sterilization the same time, removing any traces of sand and other heat treatment used in food production are pre- foreign materials which may have been introduced processing operations (Hall, 1997) and in the case during harvesting and handling. of vacuum pouched tuna chunks they include fish receipt and cold storage, thawing, racking, pre- Pre-cooking cooking, cleaning, cutting, sorting, metal detection, Depending on species, size and backbone filling, sealing and coding. temperature, thawed fish are subjected to heat treatment within a temperature range of 93oC to Fish receipt and cold storage 95oC, at 0.3 bar pressure, until the desired backbone Tuna is purchased from fishing vessels officially temperature range of 55oC to 57oC is reached. approved by the Ghana Standards Authority in Precooking involves loading pre-cooker with racks Tema, Ghana. Tuna purchased for processing include of fish, setting the chamber temperature to 95oC and skipjack, yellow fin and big eye tuna which weigh heating it for the specified time. Once the precooking between 1.36 kg to 10 kg. The tuna, before purchased, has been completed, the front racks are removed is inspected by quality assurance personnel for and random backbone temperatures are taken (i.e. good quality. It is then unloaded into scows (large 3-5 pieces per rack). If the average reading is within containers), weighed and transported to the company’s or above the target temperature range the cooker cold store (-12 to -18°C). The factory is about 8 km is unloaded. If the average is less than the target, away from the fishing harbour and has a good access the racks are pushed back into the pre-cooker and road and it takes 15 min to transport frozen tuna from additional cook time is given. the vessel unloading site to the factory. Upon arrival Precooking reduces initial microbial load, at the factory, the following quality control measures deactivates certain enzymes and facilitates subsequent used in fish collection are undertaken: processes such as cleaning. Following precooking, a. Backbone temperatures of randomly sampled fishes fish are sprayed continuously with potable water are checked to ensure that it meets the company’s (cooling) until fish backbone temperature reaches a specification of -12oC to -18oC. Conformance to desired temperature range of 31oC to 40oC. After this this temperature range prevents the onset of fish stage, the cooled fish are distributed to fish cleaners deterioration and development of histamine. for cleaning. b. The following attributes are inspected for fresh fish received for processing: (i) Bright, shiny and firm skin Cleaning with transparent mucus, (ii) Bright and bulging eyes Cleaning involves de-heading, de-boning, skin with crystal clear cornea, (iii) Bright red or pink gills, and scale removal, degutting and removal of belly (iv) No skin discoloration and (v) No foul smell. portion and blood meat. These parts of the fish are c. Plastic scows are preferably used by the company removed and disposed of because they are generally for fish collection to minimize introduction of metallic considered unusable for processing. Skin and blood chips (which usually occurs when metallic scows are meat removal ensures uniformity in colour of the used) into the fish. product for presentation purposes. Cleaning also 1890 Afoakwa et al./IFRJ 20(6): involves polishing of the loins. This involves breaking policy to sterilize to an absolute minimum F0 value of of fish into two halves along the dorso-ventral axis. not less than 3. However, the company targets an F0 Each half is further broken into two longitudinal value of 6 minutes for precautionary reasons. halves called the loins. The loins are polished by rubbing them against the palm. This process generates Post processing operations flakes of fish flesh. However rubbing is done gently All operations after the sterilization heat to prevent generating excess flakes and breaking the treatments are post processing operations and these loins. The belly portions are washed, mixed with the include cooling, incubation, labeling and storage. generated flakes and undergo further processing to be used in subsequent preparations. Cooling/ bulk incubation After thermal processing, the pouched products Cutting/ sorting and metal detection are cooled with water to a temperature of 45 - 50°C. Loins are arranged on trays, inspected to ensure The pouches are dried with clean rugs, air cooled to they are devoid of bones and cut into pieces suitable room temperature and then subsequently stored in a for packaging. They are then passed through a metal warehouse for 14 days (a process referred to as bulk detector to check for metallic contamination and incubation) to quarantine the product and ensure that sent for pouch packaging. Flakes are also sent to there are no defects in the product. the sorting room, where blood meat and bones are removed. This is done under low temperatures (17oC Labeling/secondary packaging/storage - 20oC) and quickly to prevent histamine build-up. Pouches with no defects are labeled for The flakes are thereafter passed through the metal identification purposes, packed into boxes (secondary detector and sent for pouch packaging. package) and stored in a warehouse at ambient conditions (25oC to 28oC) until ready to be shipped. Pouch filling/sealing/coding/thickness rolling Prior to filling, pouches are thoroughly inspected On-site verification of flow diagram to ensure that they do not have any defects such as The operation process was inspected to verify punctures and scratches. Pouches inspected and that each step in the flow diagram was an accurate confirmed to be devoid of defects are filled with fish representation of the actual situation. (solids and flakes) according to client specifications. Percentage composition of media (brine or oil) of Hazard analysis acceptable temperature is added from a measuring Hazard analysis was conducted by undertaking jug to each filled pouch and vacuum-sealed according three-stage activities comprising; composing a list to seal specification. Vacuum sealing removes air of all potential hazards (physical, chemical and from the package which when left will reduce the microbiological) that are reasonably likely to occur efficiency of heat penetration. The sealed pouches during processing, evaluating potential hazards then pass through a rolling machine, which controls based on severity and likely occurrence and lastly the thickness (excessive pouch thickness could cause designating preventive or control measures to be under sterilization) and ensure uniformity in pouch applied for each hazard. thickness, after which they are coded and placed on ii. Determining pre-requisite programmes using ISO retort racks for thermal processing. 22000 approach Determination of pre-requisites programmes Thermal processing (retorting) (PrPs) was done by employing ISO 22000 Analysis Thermal processing involves, heating the packed Worksheet (Arvanitoyannis and Varzakas, 2008; product such that every location in the container 2009). would receive a pre-designated minimum thermal iii. Determining the CCPs in the production line using treatment. Retort pouches are processed in specially both HACCP and ISO 22000 approach adapted retorts called over pressure retorts at a CCPs according to HACCP were determined temperature of 117oC - 118oC and a pressure of 1.5 using HACCP decision tree. CCPs according to ISO bar. The duration of the process depends on a variety 22000 were determined by comparative analysis of factors such as, type and size of the product and between CCPs according to HACCP and determined container. In order to determine the adequacy of the pre-requisite programmes. heat process, F0 charts are plotted frequently. F value iv. Establishing a monitoring system for pre- 0 is a measure of the effective sterilization of a heat determined Critical Control limits. This was done process. For low acid canned foods produced, it is the by designing documents and schedules for the Afoakwa et al./IFRJ 20(6): 1891 measurement and/or observation of CCP relative to agents like chlorine and soap under the cleaning their critical limits and assigning people with relevant processing step has an associated assessment of 1 knowledge to evaluate and sign the monitoring data. because likelihood of occurrence is low (because v. Applying a systematic problem-solving approach proper cleaning protocols are followed) and severity for corrective action is low (because it does not pose serious health risks), This was done by determining and correcting the whiles microbial contamination associated with fish cause of non-compliance (non-conformance) and receipt has a risk assessment of 16 because fish has recording the corrective action taken. a high occurrence of contamination with spoilage and pathogenic microorganisms which are of severe Results and Discussion health and quality concern. The major hazards identified in the production of The scope of this project included undertaking a the pouched tuna were of microbiological, chemical Hazard analysis, determining Critical Control Points and physical origin as indicated in Table 1. The most (CCPs) and Prerequisite Programmes (PrPs), and the predominant chemical hazard that was identified was development of a monitoring system for the Critical histamine contamination (caused by the action of Control Points. The comparison between application microorganisms coupled with favourable temperature of HACCP and ISO 22000 was also made. The results which was present in seven processing steps, namely; of these activities are presented in Tables 1 to 5. fish receipt, frozen storage, sizing and thawing, Table 1 shows the hazard analysis worksheet racking and staging, cooling, cleaning and flakes identifying the different hazards at each processing sorting. stage, their causes, their preventive and control Physical hazards were identified in only four measures, when and by whom follow up will be processing steps - fish receipt, cutting, metal detection given to the control and preventive measures. The and media preparation. The most dominant physical last column Document/system makes reference to hazard was the presence of metal chips/residues, the document in which the control and preventive which have severe impact on the safety and quality measures are stipulated. Step 0 makes reference to of the product. Out of the four processing steps that the prerequisite, which is also subject to the Hazard had physical hazards, the hazard associated with fish Analysis and Risk Assessment. receipt had the highest risk assessment value of 16 due Table 2 presents an ISO 22000 analysis to its high severity and occurrence. Compared to the worksheet for the determination of prerequisite physical and chemical hazards, the microbiological programmes for pouched tuna processing and Table hazards were present/identified in almost every 3 shows the determination of Critical Control Points processing step and in each instance, were associated (CCPs) according to the decision tree diagram. with a high-risk assessment value. This is because the Table 4 summarizes the findings of the previous two raw material (fish) is highly susceptible to microbial tables displaying the CCPs according to HACCP contamination because it serves as an excellent and ISO 22000 taking into account the effect of substrate for microbial growth. The microorganisms, implementation of prerequisite programmes in the through their metabolic activities or presence cause industrial processing of pouched tuna. Finally, Table 5 food infections, spoilage or intoxications which are shows the monitoring system developed for the CCPs, of severe health concern. including their preventive measures, critical limits, corrective actions, assignment of responsibilities and Critical control point determination verification procedures. The CCP Decision Tree is a tool used to determine the right CCPs for each processing stage in HACCP. Hazard analysis Table 3 shows the HACCP decision tree as applied In Table 1, the different processing steps are to the processing of vacuum-packed pouched tuna each associated with different risk assessment and the resulting CCPs.The requirements for ISO values, which range widely from the least 1 to the 22000 assume the determination of the prerequisite highest 16. The risk assessment values are obtained programmes (Table 2). The questions frequently by multiplying the occurrence and severity values asked for each processing step involve questions and it serves to choose, among the hazards listed regarding the adequacy of the technical infrastructure for a food, those that are likely enough or severe and preventative maintenance, the feasibility for enough to warrant preventive action (Varzakas and their evaluation, their contribution in the control Arvanitoyannis, 2009). For instance, a hazard such as of recognizable food safety hazards, whether the contamination of product with cleaning and sanitizing effectiveness of the remaining control measures 1892 Afoakwa et al./IFRJ 20(6): Table 1. Hazard analysis worksheet Afoakwa et al./IFRJ 20(6): 1893 Table 1 continued: 1894 Afoakwa et al./IFRJ 20(6): Table 1 continued: NR = Number, CAT = Category, O = Occurrence, S = Severity, RA = Risk Assessment 1 = lowest rank and 4 = highest rank in the occurrence and severity columns The Figure presented in the risk assessment column is the product of the occurrence and severity values. Table 2. ISO 22000 analysis worksheet for the determination of prerequisite programmes for Vacuum Pouched Tuna processing Processing step Are the technical infrastructure and preventive Is it feasible to Do they contribute in the control of Does the effectiveness of the remaining Is it a prerequisite maintenance program adequate? evaluate them? recognizable food safety hazards? control measures depend on them? program? Fish receipt Yes Yes No No No Frozen storage Yes Yes No No No Sizing and Thawing Yes Yes No Yes Yes Racking and staging Yes Yes No Yes Yes Precooking Yes Yes No Yes Yes Cooling Yes Yes No Yes Yes Cleaning Yes Yes No Yes Yes Flakes sorting Yes Yes No _ Yes Cutting Yes Yes No Yes Yes Metal detection Yes Yes No No No Empty pouch receipt _ _ _ _ - Filling tuna into pouches Yes Yes No Yes Yes Media preparation and dispensing Yes Yes No No Yes Vacuum sealing Yes Yes No No Yes Thickness control Yes Yes No Yes Yes Retorting Yes Yes No No No Water/air cooling Yes Yes No No Yes Bulk Incubation/ Seal testing Yes Yes No _ Yes Labeling and Secondary packaging _ _ _ _ _ Storage _ _ _ _ _ Afoakwa et al./IFRJ 20(6): 1895 Table 3. Decision tree table Processing step Cause of hazard Q1. Do preventive control Q2. Is the step specifically designed Q3. Could contamination with Q4. Will a subsequent step Is this step a critical measures exist? to eliminate or reduce the likely identified hazards(s) occur in eliminate identified control point? occurrence of hazard to an excess or could this increase to hazards(s) or reduce likely acceptable level? unacceptable levels? occurrence to acceptable levels? Fish receipt Microbiological hazard Yes Yes _ _ CCP 1 Chemical hazards Yes Yes _ _ CCP 1 Physical hazards Yes No Yes Yes Not CCP Frozen storage Microbiological hazards Yes Yes _ _ CCP 2 Chemical hazards Yes Yes _ _ CCP 2 Sizing and Thawing Chemical hazards Yes No No Not CCP Racking and staging Chemical hazards Yes No Yes No CCP 3 Precooking Chemical hazards Yes No No _ Not CCP Cooling Chemical hazards Yes No No _ Not CCP Cleaning Microbial hazards Yes No Yes Yes Not CCP Chemical hazards Yes No No _ Not CCP Flakes sorting Chemical hazard Yes No No _ Not CCP Cutting Metal residues and Microbial contamination Yes No Yes Yes Not CCP Metal detection Physical hazards Yes Yes _ _ CCP 4 Empty pouch receipt No known hazard _ _ _ _ _ Filling tuna into pouches Microbiological hazards Yes No Yes Yes Not CCP Media preparation and dispensing Microbiological hazards Yes No No Yes Not CCP Chemical hazards Yes No No _ Not CCP Physical hazards Yes No No _ Not CCP Vacuum sealing Microbiological hazards Yes Yes _ _ CCP 5 Thickness control Microbiological hazards Yes Yes _ _ CCP 6 Retorting Microbiological hazard Yes Yes _ _ CCP 7 Water/air cooling No known hazards _ _ _ _ _ Bulk Incubation/ Seal testing Microbiological hazards Yes Yes _ _ CCP 8 Labeling and Secondary packaging No known hazards _ _ _ _ _ Storage No known hazard _ _ _ _ - Table 5. Monitoring system CCP Step Why Preventive Set value Frequency of Title of Corrective action Registration Responsibility Verification measures Tolerances checking Procedure and / or Critical limits working Instruction 1 Fish receipt Microbial spoilage -Purchase fish vessels Frozen tuna Every delivery Working Reject lot if backbone Suppliers delivery Quality Assurance -Daily review of resulting in officially approved by the backbone batch instructions, temperature exceeds 9oC report Manager records by the QA histamine formation Ghana Standards Board temperature < -9oC. Reference form and if histamine content manager. -Fish from each batch should Histamine content < exceeds 20ppm -Proficiency be tested according to defined 20ppm testing for sampling plan for histamine histamine should content be undertaken at least 4 times each year with the Ghana Standards board 2 Frozen storage Microbial spoilage Correct operation and 100% -12°C to -18°C Every hour Working Stop freezing and check Non conformance Quality Assurance Review of records resulting in recording instructions, cause of non compliance report Manager by QA manager histamine formation Reference form 3 Metal Metal pieces present All fish must pass through the Metal detector set up Every batch of Working Isolate contaminated Non conformance Quality Assurance Daily metal detection in fish could cause metal detector prior to filling using test pieces. loins and flakes instructions, loins and flakes and then report Manager detector harm to consumer into pouches Fe=2.0mm Reference form inform QA manager for monitoring report Non-Fe = 2.5 mm re-check and reject must be reviewed Stainless steel = 4.77 contaminated portion an countersigned mm by QA manager 4 Retorting Under sterilization -Monitoring of process All thermal Each Working Refer to process Non conformance Production Manager Daily review of all will lead to growth temperature and time. processes must be sterilization instructions, deviation and alternative report records including of spoilage and -Check all instruments for within -5°C to +1°C batch Reference form procedure instructions. process deviation pathogenic apparent serviceability and of scheduled Document all actions on records by QA microorganisms calibration prior to startup temperature and not sheet. Notify Q. A/Prod. manager less than process Manager and time Maintenance Supervisors required 1896 Afoakwa et al./IFRJ 20(6): depends on them. These questions lead to the answer industrial processing of common octopus (Octopus of a programme being prerequisite or not. vulgaris) – Part I. International Journal of Food Using the HACCP decision tree, eight CCPs Science and Technology 44: 58-78. were obtained for the process and using the ISO Blanc, D. 2006. ISO 22000: From intent to implementation. 22000 worksheet, the number of CCPs was reduced ISO Management Systems Report, May-June 2006. to four. This is presented in Table 4. Certain CCPs pp. 1-5. Bremer, P. J., Fletcher, G. C. and Osborne, C. 2004. according to HACCP were not CCPs according Staphylococcus aureus. New Zealand Institute for to ISO 22000 because they were found to be Crop & Food Research Limited. Christchurch, New prerequisite programmes in the processing line. Zealand. pp. 1- 4 For example, Racking and staging was identified to Bremer, P. J., Fletcher, G. C. and Osborne, C. 2003. be a prerequisite programme and hence not a CCP Salmonella in seafood. New Zealand Institute for according ISO 22000 because the histamine hazard Crop and Food Research Limited, Christchurch, New associated with this step is effectively controlled by Zealand. pp. 1-2. strict adherence to process time schedules. British Standards Institution (BSI) 2010. ISO 22000 Food safety. Retrieved from http://www.bsigroup.com/en/ Conclusion Assessment-and-certification-services/management-systems/Standards-and-Schemes/ISO-22000/ on April 12, 2012. The major hazards identified in the production Campden and Chorleywood Food Research Association of the Vacuum-Packed Pouched Tuna Chunks Group (CCFRA) 2006. Guidelines on good were the probable contamination with spoilage manufacturing practice for heat processed flexible and pathogenic microorganisms (such as Listeria packaging. Guideline No.50. Chipping Campden monocytogenes, Clostridium botulinum, Salmonella Gloucestershire GL55 6LD UK. Pp 2. and Staphylococcus aureus), foreign materials Canadian Food Inspection Agency (CFIA) 2002. Food (such as metal residues and sand), and chemical safety facts on scombroid poisoning. Retrieved from contaminants (such as heavy metals, histamine and http://www.inspection.gc.ca/english/fssa/concen/ cleaning detergent residues) before, during and after cause/histame.shtml on June 10, 2012. processing. However, effective control, preventive Central Visayas Information Sharing Network, Philippines 2001. Industry Profile: Canned Tuna. Retrieved from maintenance systems and verification procedures http://www.cvis.net.ph/cvisnet/Indusprof/canned_ could be implemented to ensure the safety and quality tuna.htm on April 12, 2012. of the product from fish reception through to the final Codex Alimentarius Commission 1997. Codex product. Alimentarius, A Joint FAO/WHO Food Standards Using the HACCP decision tree, eight CCPs Programme. General Requirements (food hygiene) were identified which were fish receipt (CCP 1), Supplement Volume 1b, 2nd ed. Rome, Italy. frozen storage (CCP 2), racking and staging (CCP Collette, B. B. and Nauen, C. E. 1983. FAO. Species 3), metal detection (CCP 4), vacuum sealing (CCP catalogue. Vol.2. Scrombids of the world. Pp. 137. 5), thickness rolling (CCP 6), retorting (CCP 7) and Craven, K. E., Ferreira, J. L., Harrison, M. A. and Edmonds, bulk incubation/seal testing (CCP 8). Using the ISO P. 2002. Journal of Official Analytical Chemists 85: 1025-1028. 22000 approach, which incorporates Prerequisite Dagoon, J. 2005. Agriculture and fishery technology. Rex programmes, four (4) CCPs were identified, making Bookstore Inc, Manila. pp 188. the system more flexible without compromising Da-Wen, S. 2006. Thermal food processing: New the safety of the product. The CCPs removed were technologies and quality issues. CRC Press, Boca racking and staging, thickness rolling, vacuum Raton. Pp. 236-237. sealing and bulk incubation and the remaining CCPs Department of Health, Education and Welfare 1972. according to ISO 22000 were fish receipt, frozen Proceedings of 1971 National Conference on Food storage, metal detection and retorting, which were Protection. Department of Health, Education & identified as most critical to the finality and safety of Welfare, US Government Printing Office, Washington, the Vacuum Packed Pouched Tuna. DC.Early, R. 1997. Putting HACCP into practice. International Journal of Dairy Technology 1: 7 – 13. References European Commission 1996. Guide for introduction of system in pursuance of Article 3 of Directive Al-Baali, A. G. and Farid, M. M. 2006. Sterilization of 94/43/EEC on the Hygiene of Foodstuffs in a Small food in retort pouches. Springer Publishers. New and Medium sized business in the Food Industry. York. pp. 9-10. III/5087/96-5087EN1. Arvanitoyannis, I. S. and Varzakas, T. H. 2009. Application Farber, J. M. and Todd, E. C. D. 2000. Safe handling of of ISO 22000 and comparison with HACCP on foods. Marcel and Dekker, Inc. publishers, New York. Afoakwa et al./IFRJ 20(6): 1897 Pp 341 FAO 1988. Manual on fish canning. FAO fisheries technical paper - 285. Retrieved from http://www.fao. org/docrep/003/t0007e/T0007E00.htm on April 22, 2011. FAO 1997. Hazard Analysis and Critical Control Point (HACCP) system and guidelines for its application. Annex to CAC/RCP 1-1969, Rev. 3. Retrieved from http://www.fao.org/docrep/005/y1579e/y1579e03.htm April 12, 2010. FDA 1973. Acidified foods and low-acid foods in hermetically sealed containers. Code of US Federal Regulations, Title 21, 1, Parts 113 and 114 (renumbered since 1973). FDA, Washington, DC. FDA 1994. Food and safety assurance program; Development of hazard analysis critical control points; proposal rule. Federal Register, August 4. 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