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Imitation Crabmeat

Generic HACCP Plan

Updated: 1/30/97
  1. Product Description
  2. Flow Diagram
  3. Potential Hazards
  4. Hazard Analysis Worksheet
  5. HACCP Plan Form
  6. Daily Metal Detector Record

1. Product Description

Aquatic Product Raw Material: Frozen surimi made from Pacific whiting ( Merluccius spp.) or pollock ( Theragra chalcogramma )
Raw material harvest Area: Oregon/Alaska
Raw material received: Directly from processor
Finished Product: Ready-to-eat imitation crabmeat sticks
Food additives, ingredients, processing aids: Flours, seasonings
Shipping: Shipped by commercial carrier
Intended use: Ready-to-eat fully-cooked imitation seafood product
Intended consumers: General public

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2. Flow Diagram

Surimi   Flours   Liquid
seasonings 		 
|   |   |  
Receiving   Receiving   Receiving Frozen surimi, flours, seasonings received at loading platform
|   |   |  
Freezer   Dry storage   Refrigerated storage Freezer at or below 0°F; refrigerated storage at or below 40°F; dry storage at ambient temperature
|   |   |  
Thaw   Weigh   Measure Thawing equipment, scale, measuring utensils
|   |   |  
|   Mix <– <–––        Mechanical mixing equipment
|   |      
       ––> –> Chop     Mechanical chopping equipment
    |      
    Mix     Mechanical mixing equipment
    |      
    Pump and extrude     Mechanical pumping and extrusion equipment
    |      
    Cook     Radiant heat and steam cooker
    |      
    Cool      
    |      
    Slit     Mechanical slitter
    |      
    Roll     Roller
    |      
    Cut and Wrap     Mechanical cutter and wrapper
    |      
    Package     Hand pack into trays
    |      
    Weigh     Scale
    |      
    Vacuum wrap     Vacuum wrapper
    |      
    Check weigh     Scale
    |      
    Pasteurize     Pasteurizer
    |      
    Cool     Cold water bath
    |      
  Freezer <––> Cooler   Freezer at or below 0°F; cooler at or below 40°F
  |   |    
  Ship   Ship   Ship with commercial carrier

Return to Index

3. Potential Hazards

  1. Potential species-related hazards: (FDA's Draft Hazards and Controls Guide)
    1. None
  2. Potential process-related hazards: (FDA's Draft Hazards and Controls Guide)
    1. Pathogen Survival Through Cooking
    2. Cross-Contamination
    3. Temperature Abuse During Processing of Cooked Products and Raw Molluscan Shellfish
    4. Pathogen Survival During Pasteurization
    5. Recontamination after Pasteurization
    6. Temperature Abuse During Final Cooling (Pathogens)
    7. Temperature Abuse During Finished Product Storage (Pathogens)
    8. Temperature Abuse During Distribution (Pathogens)
    9. Metal Inclusion
    10. Food and Color Additives
 Return to Index

4. Hazard Analysis Worksheet

(1)
Ingredient/ Processing Step 		(2)
Potential Hazard Introduced or Controlled 		(3)
Is the Potential Hazard Significant (Reasonably Likely to Occur - Yes/No) 		(4)
Justification for Inclusion or Exclusion as a Significant Hazard (Consider the likelihood that the hazard would or would not be introduced, or intensified, or a hazard from a previous step can be controlled 		(5)
Preventive Measure(s) for the Significant Hazard from Column 3 (Existing plus additional, if needed) 		(6)
Critical Control Point (Yes/No)
Receiving BIOLOGICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
CHEMICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
PHYSICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
Storage BIOLOGICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
CHEMICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
PHYSICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
Thaw, weigh, measure BIOLOGICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
CHEMICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
PHYSICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
Mix BIOLOGICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
CHEMICAL
Food and color additives 		 
No 		 
Ingredients and additives are not a food safety hazard 		 
N/A 		 
No
PHYSICAL
Metal inclusion 		 
Yes 		 
Mechanical mixing equipment 		 
Metal detector at check weigh 		 
No
Chop BIOLOGICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
CHEMICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
PHYSICAL
Metal inclusion 		 
Yes 		 
Mechanical Chopping equipment 		 
Metal detector at check weigh 		 
No
Mix BIOLOGICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
CHEMICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
PHYSICAL
Metal inclusion 		 
Yes 		 
Mechanical mixing equipment 		 
Metal detector at check weigh 		 
No
Pump and extrude BIOLOGICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
CHEMICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
PHYSICAL
Metal inclusion 		 
Yes 		 
Mechanical pumping and extrusion equipment 		 
Metal detector at check weigh 		 
No
Cook BIOLOGICAL
Pathogen survival 		 
No 		 
Not a pathogen kill step 		 
N/A 		 
No
CHEMICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
PHYSICAL
Metal inclusion 		 
Yes 		 
Mechanical cooker parts 		 
Metal detector at check weigh 		 
No
Cool BIOLOGICAL
Cross-contamination 		 
No 		 
Controlled at pasteurization 		 
N/A 		 
No
Pathogen growth No Minimum time period N/A No
CHEMICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
PHYSICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
Slit BIOLOGICAL
Cross-contamination 		 
No 		 
Controlled at pasteurization 		 
N/A 		 
No
Pathogen growth No Minimum time period N/A No
CHEMICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
PHYSICAL
Metal inclusion 		 
Yes 		 
Mechanical slitter 		 
Metal detector at check weigh 		 
No
Roll BIOLOGICAL
Cross-contamination 		 
No 		 
Controlled at pasteurization 		 
N/A 		 
No
Pathogen growth No Minimum time period N/A No
CHEMICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
PHYSICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
Cut and wrap BIOLOGICAL
Cross-contamination 		 
No 		 
Controlled at pasteurization 		 
N/A 		 
No
Pathogen growth No Minimum time period N/A No
CHEMICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
PHYSICAL
Metal inclusion 		 
Yes 		 
Mechanical cutting equipment 		 
Metal detector at check weigh 		 
No
Package BIOLOGICAL
Cross-contamination 		 
No 		 
Controlled at pasteurization 		 
N/A 		 
No
Pathogen growth No Minimum time period N/A No
CHEMICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
PHYSICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
Weigh BIOLOGICAL
Cross-contamination 		 
No 		 
Controlled at pasteurization 		 
N/A 		 
No
Pathogen growth No Minimum time period N/A No
CHEMICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
PHYSICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
Vacuum wrap BIOLOGICAL
Cross-contamination 		 
No 		 
Controlled at pasteurization 		 
N/A 		 
No
Pathogen growth No Minimum time period N/A No
CHEMICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
PHYSICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
Check weigh BIOLOGICAL
Pathogen growth 		 
No 		 
Minimum time period 		 
N/A 		 
No
CHEMICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
PHYSICAL
Metal inclusion 		 
Yes 		 
Mechanical processing equipment 		 
Metal detector 		 
Yes
Pasteurize BIOLOGICAL
Pathogen survival 		 
Yes 		 
Inadequate pasteurization may not kill pathogens 		 
Use established process 		 
Yes
CHEMICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
PHYSICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
Cool BIOLOGICAL
Recontamination after pasteurization 		 
No 		 
Package prevents recontamination 		 
N/A 		 
No
Pathogen growth Yes Temperature abuse may allow pathogen growth Cool to 40°F or below within 4 hours Yes
CHEMICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
PHYSICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
Cooler BIOLOGICAL
Recontamination after pasteurization 		 
No 		 
Package prevents recontamination 		 
N/A 		 
No
Pathogen growth Yes Temperature abuse may allow pathogen growth Hold at 40°F or below Yes
CHEMICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
PHYSICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
Freezer BIOLOGICAL
Recontamination after pasteurization 		 
No 		 
Package prevents recontamination 		 
N/A 		 
No
Pathogen growth No Temperature too low for pathogen growth N/A No
CHEMICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
PHYSICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
Ship BIOLOGICAL
Recontamination after pasteurization 		 
No 		 
Shipped by commercial carrier 		 
N/A 		 
No
Pathogen growth No Shipped by commercial carrier N/A No
CHEMICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
PHYSICAL
None 		 
No 		 
N/A 		 
N/A 		 
No
Reviewed by:
Date:

Return to Index

5. HACCP Plan Form: Imitation Crabmeat

(1)
Critical Control Point (CCP) 		(2)
Hazard 		(3)
Critical Limits of the
Preventive Measures 		Monitoring (8)
Corrective Actions 		(9)
Records 		(10)
Verification
(4)
What 		(5)
How 		(6)
Frequency 		(7)
Who
Check weigh Metal inclusion Perform no processing without a metal-detection device Packaged product Metal detector Each package Automatic reject Destroy or reprocess Metal detector record Daily record review; Metal detector calibration
Pasteurize Pathogen survival Heat to internal temperature of 177.8°F for 5 minutes Time or Temperature recorder Continuous Processing supervisor Reprocess Recorder chart Daily record review
Time Measure chain speed Daily before processing Processing supervisor Reprocess Process log Daily record review
Temperature Temperature recorder Continuous Processing supervisor Reprocess Recorder chart Daily record review
Cool Pathogen growth Cool to 40°F or below within 4 hours Temperature Temperature recorder Continuous Processing supervisor Destroy Recorder chart Daily record review; thermometer calibration
Cooler Pathogen growth Less than 4 hours above 40°F Temperature Temperature recorder Continuous Processing supervisor Destroy Recorder chart Daily record review; thermometer calibration
 
Reviewed by:
Date:

Return to Index

6. Daily Metal Detector Record

Date:
Processing line:
 
CALIBRATION CHECK
Time Results Comments Initials
  Pass ____ Fail ____    
 
REJECT RECORD
Time No. of packages
rejected 		Disposition
of packages 		Comments Initials
         
         
         
         
         
Reviewed by:
Date:

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The author is Robert J. Price, Extension Specialist, Seafood Products, Food Science & Technology, University of California, Davis, CA 95616-8598

UCSGEP 96-2W; April 1996

This work is sponsored in part by NOAA, National Sea Grant College Program, Department of Commerce, under grant number NA36RG0537, project number A/EA-1, through the California Sea Grant College Program, and in part by the California State Resources Agency. The U.S. Government is authorized to reproduce and distribute reprints for governmental purposes.

Affirmative Action Statement

Send comments to rjprice@ucdavis.edu
Sea Grant

Updated: 07/18/07

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Pamela D. Tom, SeafoodNIC Director
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Sea Grant Extension Program
Food Science & Technology Department
University of California
One Shields Avenue, Davis, CA 95616

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