HACCP Generic Model: Pasteurized Honey

This HACCP generic model was developed for honey packing establishments using a honey pasteurizing establishment packaging creamed honey in glass jars with painted metal lids. This model was developed with the assumption that all prerequisite programs are in place and comply with the requirements of Agriculture and Agri-Food Canada.

The production line starts with honey in 50 gallon barrels being placed on a dump tank where the honey flows into the tank. Foreign debris is removed from the honey by a series of filters and a settling tank. The honey goes through a pasteurizer to destroy any yeasts present, to facilitate fine-mesh filtering, and to aid in mixing with the seed honey. The honey is packed into glass jars and capped mechanically with painted metal lids. It is stored under cool conditions to ensure the creaming of the honey.

Because of the pH level, the low water activity (a_w), the high sugar content, and the bacteriostatic composition of honey, very few biological hazards are associated with the product. Concern has been raised from one reported case of infant botulism in Canada in 1985, where a soother that was dipped in honey was found to contain 1,000 to 10,000 Clostridium botulinum spores/kg. It is reported that infant botulism can occur in infants up to 26 weeks of age and is caused by spores that germinate producing a toxin in the infant intestinal tract. Evidence suggests these spores are of a single serotype caused by a build-up of spores from a single source, contaminated dead bee larvae. Therefore, the contamination of the honey is likely to occur prior to extraction, and the honey producer has no control over this hazard. Physicians, public health nurses, and the school system are the key components in keeping the public informed of potential risks.

It is the opinion of the expert committee that the chemical and physical hazards that could exist are controllable. They are the result of the beekeeper's and the honey processor's production and handling practices; these hazards can generally be eliminated through the use of prerequisite programs. This includes the physical hazard of glass fragments. It was decided that, due to the traditional line speed and style of glass container, the hazard would be fully covered through prerequisite programs and glass breakage procedures.

Form 7 Physical Hazards Product Name: Pasteurized Honey List all Physical Hazards related to Ingredients, Incoming Material, Processing, Product Flow, etc.
Identified Physical Hazards	Controlled at
Incoming Materials
Raw Honey - Could contain metal and non-metal particles such as wood, stone, or glass
Glass Jars - Could contain glass fragments
Metal Lids - Could contain metal fragments
Seed Honey - Could contain metal fragments
Process Steps
#3 Dumping of Returns - Could add glass fragments when returned product is emptied
#9 Hot Room Dumping - Hazardous extraneous material from the barrel could be added during dumping
#12 Filtering - A damaged filter could allow contamination of product with hazardous extraneous material
#14 Holding - Hazardous extraneous material could fall into product in uncovered holding tank
#16 Filtering - A damaged filter could allow contamination of product with hazardous extraneous material
#17 Heating - Mixer blades could add metal fragments from abnormal contact or deterioration
#18 Grinding - Auger could add metal fragments from abnormal contact or deterioration
#19 Seed Injecting - Could add metal fragments from abnormal contact or deterioration of auger
#20 Heating - Could add metal fragments from abnormal contact or deterioration
#23 Jar Checking - Failure to detect abnormal or defective jars could result in glass fragments in product
#24 Metal Detecting - Improper sensitivity could result in metal fragments in product
#25 Jar Inverter/Air Blasting - Glass fragments could contaminate product if air pressure is not adequate
#29 Capping - Glass chards from containers breaking by closing machine could contaminate product


Date: ______________________	Approved by: ________________________

Form 8

Critical Control Points (CCPs) Determination

Product Name: Pasteurized Honey

Catergory and Identified Hazard
Determine if fully controlled by Prerequisite Program(s)
If YES = indicate Prerequisite Program and proceed to next identified hazard.
If NO = proceed to question 1 (Q1)

Q1. Could a control measure(s) be used by the operator at any process step?
If NO = not a CCP + identification on how this hazard will be controlled before and after the process
+ proceed to the next identified hazard
If YES = description + next question (Q2)

Q2. Is it likely that contamination with the identified hazard could occur in excess of the acceptable level or could increase to an unacceptabkle level?
If NO = not a CCP + proceed to the next identified hazard
If YES = next question (Q3)

Q3. Is this process step specifically designed to eliminate/reduce the likely occurence of the identified hazard to an acceptable level?
If NO = next question (Q4)
If YES = CCP + go to last column

Q4. Will a subsequent step eliminate the identified hazard or reduce likely occurence to an acceptable level?
If NO = CCP + go to last column
If YES = not a CCP + identify subsequent step + proceed to the next identified hazard

CCP Number
+ proceed to next identified hazard

Incoming Material: Raw Honey as Delivered

Biological Clostridium botulinum spores	No See Form 9
Chemical Antibiotic residues	Yes Receiving	Yes	N/A	Yes Step #1, Receiving
Chemical Phenol & pesticides	Yes Supplier specifications Product Testing	Yes	N/A	Yes Step #10, Product Testing
Chemical Contamination from chemical residues, inner coating and liner of barrels	Yes Receiving	Yes	N/A	Yes Step #1, Receiving
Physical Metal and non-metal such as wood, stone, glass	Yes Filtering	No Not likely to get through filter equipment

Incoming Material: Returned Honey as delivered

Biological

Clostridium botulinum spores

No
See Form 9

Incoming Material: Seed Honey as delivered

Biological Clostridium botulinum spores	No See Form 9
Chemical Non-listed coatings on pails container of seed honey	Yes Receiving	Yes	N/A	Yes Step #1, Receiving
Physical Could contain metal fragments	Yes Metal Detecting	Yes	N/A	Yes Step #24, Metal Detecting

Incoming Material: Glass Jars as delivered

Physical

Non-metal (glass) fragments

Yes
Air blasting/cleaning

Yes

N/A

Yes
Step #25, Jar inverter/air blasting

Incoming Material: Metal Lids as delivered

Chemical Non listed interior coating,sealing compound	Yes Receiving	Yes	N/A	Yes Step #1, Receiving
Physical Metal fragments	Yes Visual Inspection Supplier specifications	No

Process Steps

Process Step: #1 Receiving

Chemical

Reception of possibly unsafe (not listed) materials or reception of lids, raw honey and seed honey from non-contract suppliers without specifications could result in honey contaminated with harmful chemical residues

Yes
Receiving

Yes

CCP-1C

Process Step: #3 Dumping of Returns

Physical

Non-metal (glass)

Prerequisite programs

Process Step: #9 Hot Room Dumping

Physical

Addition of hazardous extraneous material

Prerequisite programs

Process Step: #10 Honey Testing

Chemical

Lack of or inadequate testing could result in product containing sulphathiazole and/or phenol residues

Yes
Product testing

Yes

CCP-2C

Process Step: #11 Hot Side Pasteurizing

Chemical

Caustic soda residues

Prerequisite programs

Process Step: #12 Filtering

Physical

Metal fragments and non-metal (wood,glass,stones)
A damaged filter could allow contamination of product with hazardous extraneous material

Prerequisite programs

Process Step: #13 Cold Side Pasteurizing

Chemical

Caustic soda residues

Prerequisite programs

Process Step: #14 Holding

Physical

Fall of hazardous extraneous material

Prerequisite programs

Process Step: #16 Filtering

Physical

Hazardous extraneous material (metal, wood, stone, glass)

Prerequisite programs

Process Step: #17 Heating

Physical

Metal

Yes
Metal detecting

Yes

Yes
Metal detecting

Process Step: #18 Grinding

Physical

Metal

Yes
Metal detecting

Yes

Yes
Metal detecting

Process Step: #19 Seed Injecting

Physical

Metal

Yes
Metal detecting

Yes

Yes
Metal detecting

Process Step: #20 Heating

Physical

Metal from mixer blades

Yes
Metal detecting

Yes

Yes
Metal detecting

Process Step: #23 Jar Checking

Physical

Non-metal (glass) fragments

Yes
Jar Inverter/air blaster

Yes

Yes
Step #25, Jar Inverter/air blasting

Process Step: #24 Metal Detecting

Physical

Metal

Yes
Metal detecting

Yes

CCP-3P

Process Step: #25 Jar Inverter, Air Blasting

Physical

Glass fragments

Yes
Air blasting

Yes

CCP-4P

Process Step: #29 Capping

Physical

Fragments of glass from breakage of glass bottles

Prerequisite programs


Date: ______________________	Approved by: ________________________

Form 7A Physical Hazards and Controls Product Name: Pasteurized Honey List all Physical Hazards related to Ingredients, Incoming Material, Processing, Product Flow, etc.
Identified Physical Hazards	Controlled at
Incoming Materials
Raw Honey - Could contain metal and non-metal particles such as wood, stone, or glass	N/A Not likely to get through filter equipment
Glass Jars - Could contain glass fragments	CCP-4P
Metal Lids - Could contain metal fragments	N/A Not likely to occur
Seed Honey - Could contain metal fragments	CCP-3P
Process Steps
#3 Dumping of Returns - Could add glass fragments when returned product is emptied	Prerequisite programs (Personnel, Premises)
#9 Hot Room Dumping - Hazardous extraneous material from the barrel could be added during dumping	Prerequisite programs (Equipment, Personnel, Transportation & Storage)
#12 Filtering - A damaged filter could allow contamination of product with hazardous extraneous material	Prerequisite programs (Equipment, Personnel)
#14 Holding - Hazardous extraneous material could fall into product in uncovered holding tank	Prerequisite programs (Sanitation, Equipment)
#16 Filtering - A damaged filter could allow contamination of product with hazardous extraneous material	Prerequisite programs (Equipment, Personnel)
#17 Heating - Mixer blades could add metal fragments from abnormal contact or deterioration	CCP-3P
#18 Grinding - Auger could add metal fragments from abnormal contact or deterioration	CCP-3P
#19 Seed Injecting - Could add metal fragments from abnormal contact or deterioration of auger	CCP-3P
#20 Heating - Could add metal fragments from abnormal contact or deterioration	CCP-3P
#23 Jar Checking - Failure to detect abnormal or defective jars could result in glass fragments in product	CCP-4P
#24 Metal Detecting - Improper sensitivity could result in metal fragments in product	CCP-3P
#25 Jar Inverter/Air Blasting - Glass fragments could contaminate product if air pressure is not adequate	CCP-4P
#29 Capping - Glass chards from containers breaking by closing machine could contaminate product	Prerequisite programs (Equipment including glass breakage procedures, Personnel)


Date: ______________________	Approved by: ________________________

Form 10

HACCP Plan

Product Name: Pasteurized Honey

Process Step/Incoming Material: #1 Receiving
CCP/Hazard Number: CCP-1C

Hazard Description

Critical Limits

Monitoring Procedures

Deviation Procedures

Verification Procedure

HACCP Records

Reception of possibly unsafe materials (not listed) or reception of lids, raw honey and seed honey from non-contract suppliers could result in honey contaminated with harmful chemical residues

Meets Food and Drug Regulations

Listed suppliers and types of barrels

Receiver to ensure raw honey is from producers with contractual specification regarding antibiotics

Lids are from approved supplier

Barrels and seed pails are correct type

Receiver will reject lot notify management and record rejected supplier.

QC will review records review contract specifications and carry out periodic random antibiotic residue testing

Supplier lists

Contract specifications

Lot receipt record

Lot reject record

Antibiotic test results

Deviation record

Process Step/Incoming Material: #10 Honey Testing
CCP/Hazard Number: CCP-2C

Hazard Description

Critical Limits

Monitoring Procedures

Deviation Procedures

Verification Procedure

HACCP Records

Excessive levels of Sulphathiazole and/or phenol residues

Meets Food and Drug Regulations

QC tests every batch

QC will notify production manager

Batch will be held for retest and investigation by QC

QC will annually test in- house lab against control samples from a private lab and review testing procedures

Batch Production Records

Batch Test Records

Primary Test Record

Deviation Record

Verification Record

Process Step/Incoming Material: #22 Metal Detecting
CCP/Hazard Number: CCP-3P

Hazard Description

Critical Limits

Monitoring Procedures

Deviation Procedures

Verification Procedure

HACCP Records

Improper sensitivity resulting in metal fragments in product

No metal fragments

4 times/day line operator tests the detector as described in test manual

If metal detector faulty operator will notify management and will hold product since last satisfactory check and investigate

Operator will recalibrate detector and notify QC

QC will check monitoring records weekly for:
proper times
proper procedures
signed records

Monitoring record with responsible signatures and comments

Metal detector deviation & action record

Operation manager verification records with responsible signatures and comments

Process Step/Incoming Material: #24 Jar Invertor/Air Blasting
CCP/Hazard Number: CCP-4P

Hazard Description

Critical Limits

Monitoring Procedures

Deviation Procedures

Verification Procedure

HACCP Records

Glass fragments in jars resulting from inadequate air pressure

No glass fragments

Minimum air blast pressure of 30 psi required

Air gauge monitored 4 times/day by line operator

Indicating light on when operating properly

If gauge reads < 30 psi operator will notify management, will stop line and hold product lot
since last satisfactory check, operator will rework product, reset air pressure and notify QC

QC will check monitoring records weekly (times and signatures) and will calibrate gauge semi annually

Monitoring record with responsible signatures and comments

Jar inverter/air blast deviation & action record with responsible signatures and comments

Verification records with responsible signatures and comments


Date: ______________________	Approved by: ________________________

Introduction
Form 1.	Product Description
Form 2.	List of Product Ingredients and Incoming Materials
Form 3.	Process Flow Diagram
Form 4.	Plant Schematic
Form 5.	Biological Hazards
Form 6.	Chemical Hazards
Form 7.	Physical Hazards
Form 8.	Critical Control Points Determination
Form 3A.	Process Flow Diagram with CCPs
Form 5A.	Biological Hazards and Controls
Form 6A.	Chemical Hazards and Controls
Form 7A.	Physical Hazards and Controls
Form 9.	Hazards not controlled by Operator
Form 10.	HACCP Plan
Annexe	HACCP Records (exemples)