HACCP - Dry-Cure Meat PDF
HACCP - Dry-Cure Meat PDF
HACCP - Dry-Cure Meat PDF
Food Control
journal homepage: www.elsevier.com/locate/foodcont
a r t i c l e i n f o a b s t r a c t
Article history: This work provided a HACCP plan for mycotoxigenic hazards associated with dry-cured meat production
Received 19 May 2010 facility. Mycotoxigenic hazards that could emerge at each stage of the production were described.
Received in revised form Pathogenic yeasts, toxic secondary metabolites of toxigenic moulds were identified as the potential
12 August 2010
hazards. Smoking and the dry-ripening stages of production were the critical control points identified.
Accepted 3 September 2010
Critical limits for the critical control points were set based on scientific premises and recommendations
set by legislative authorities. The status of the critical limits at the identified critical control points need
Keywords:
to be monitored, verified and recorded.
Dry-cured meat products
HACCP
Ó 2010 Elsevier Ltd. All rights reserved.
Mycotoxigenic hazards
1. Introduction food (Orriss & Whitehead, 2000). GMPs are practices and proce-
dures performed by food processors in order to keep the safety of
Hazard Analysis Critical Control Point (HACCP) is a scientific the food products. GMPs may refer to the hygienic conditions of the
approach to assess hazards associated with food production and people, equipment, process and the environment in the production
establish control systems to ensure food safety (FAO, 1997). It is process (Food Product Association (FPA), 2006). SOPs are written
a preventative system, that takes the whole chain of food produc- descriptions of specific tasks to be carried in a particular food
tion into consideration before biological, chemical and/or physical processing activity. They are used in conjunction with GMPs to
hazards affect the safety of food products (FAO, 1997; Food Product support a HACCP system (Food Product Association (FPA), 2006).
Association (FPA), 2006). The system focuses on assessing hazards Even if the HACCP system has been successfully applied in the
associated with a particular food production, identifying produc- food industry, there are food safety hazards that were not given
tion stages where the hazards occur and design control mecha- significant attentions. This is especially true with regard to myco-
nisms (Ropkins & Beck, 2000). HACCP system is intended to address toxigenic hazards associated with animal food products. The term
hazards that their elimination or reduction to acceptable levels is “mycotoxigenic hazards” is used in this manuscript to describe
essential to the production of safe food (FAO, 1997; Orriss & pathogenic yeasts, toxic secondary metabolites of toxigenic moulds
Whitehead, 2000; Ropkins & Beck, 2000). that contaminate food products and affect food safety. Most HACCP
An effective HACCP system should be built on a solid foundation plans in food processing activities, such as the production of
of prerequisite programs, such as good manufacturing practices cheeses and dry-cured meat products, considered mainly bacterial
(GMP) and standard operational procedures (SOP) (FAO, 1997; Food agents (Arvanitoyannis & Mavropoulos, 2000; Barbuti & Parolari,
Product Association (FPA), 2006). These programs provide the basic 2002), even if such food products get often contaminated with
conditions that are necessary for the production of safe, wholesome mycotoxigenic hazards. In earlier studies the potential pathogenic
yeasts and toxigenic moulds in the production processes
of Norwegian dry-cured meat products were reported with
a recommendation for effective intervention measures to minimize
* Corresponding author. Tel.: þ47 23216244; fax: þ47 23216202.
E-mail address: [email protected] (I. Skaar).
the occurrence of potential food safety hazards (Asefa, Gjerde et al.
0956-7135/$ e see front matter Ó 2010 Elsevier Ltd. All rights reserved.
doi:10.1016/j.foodcont.2010.09.014
832 D.T. Asefa et al. / Food Control 22 (2011) 831e837
2009; Asefa et al., 2010; Asefa, Møretrø et al. 2009). Hence, the set by the critical limits to guarantee the safety of the products.
findings were used to develop a HACCP plan specifically for the Verification and records systems were proposed to determine the
mycotoxigenic hazards associated with the Norwegian dry-cured effectiveness and tractability of the HACCP plan.
meat production processes.
3. Results
2. Methods
3.1. The HACCP team
The tasks outlined in Codex Alimentarius (FAO, 1997) were fol-
lowed to develop a HACCP plan for mycotoxigenic hazards that Multidisciplinary HACCP team led by the quality manager of the
includes the following seven principles of HACCP. dry-cured meat production facility was established. The team
members were experts in mycology, food microbiology; veterinary
Conduct hazard analysis (HA) medicine, meat science and have extensive experience in food
Identify critical control points (CCP) safety research activities, HACCP systems for a range of food
Establish critical limits (CL) production activities, risk assessment procedures and food safety
Monitor each CCP management systems. The team obtained the flow diagram from
Establish corrective action the producer and described the products with their intended use.
Establish verification procedures
Establish record keeping 3.2. Dry-cured meat production processes and the flow diagram
The steps outside of the dry-cured meat production facility were The production processes of two smoked dry-cured hams and
excluded as the existence of effective control systems is expected. one unsmoked Norwegian speciality called “Fenalår” (dry-cured leg
Tree diagram was used to identify each potential mycotoxigenic of lamb) were considered. The only difference between the hams
hazard at each processing stage and determine whether the stage is and fenalår production processes are the use of thawed meat and
a CCP or not (Fig. 1). For the CCP identified reliable control mech- the absence of smoking in the later case (Fig. 2). In the processes,
anism and corrective actions established to fulfil the requirements fresh and thawed meat pieces were deboned in the trimming room
and transferred to the salting room. Before the addition of salt, the
3.4. Hazard analysis, critical control points (CCP), critical limits (CL)
meat pieces are pressed and kept in elastic nets. The pressed meat
and corrective actions identified for each stage of production
are dipped in a brine solution before they go through smoking,
drying, washing, dry-ripening, sorting and packing production
In general, the mycotoxigenic hazards identified in the
processes respectively. The final products are for direct consump-
production processes were pathogenic yeasts and toxic secondary
tion with no further processing. The products have the shelf life of
metabolites of toxigenic moulds (Asefa, Gjerde et al. 2009; Asefa,
eight months at refrigeration temperature and their composition is
Møretrø et al. 2009).
described in Table 1.
3.4.1. Hygienic quality of raw meat at reception
3.3. The status of the prerequisite programmes The mycological hazards associated with fresh and thawed meat
are pathogenic yeasts. (Asefa, Møretrø et al. 2009; Bisbe et al., 1987;
Even though the producer follows standard good manufacturing Nunez et al., 2000). Yeasts like Candida zeylanoides were frequently
practices (GMP), some deviations were observed as indicated in isolated from the fresh and frozen meats delivered by different
(Asefa et al., 2010) and were shortly described below. The pressing slaughter houses (Asefa, Møretrø et al. 2009). Our previous works
process at the salting room, spore concentration in the air of salting, indicated that subsequent processing activities such as salting,
brining and smoking rooms and the activity in the sorting room brining, smoking and drying, retarded the growth of pathogenic
were identified as important factors facilitating the contamination yeasts and facilitated their replacement by non-pathogenic, but
of products by fungi, specifically moulds. important yeasts like Debaryomyces hansenii (Asefa, Møretrø et al.
Visual observation revealed that most of the dry-cured meat 2009; Martin, Cordoba, Aranda, Cordoba & Asensio, 2006; Martin,
products contaminated with toxigenic moulds were those that Cordoba, Benito, Aranda & Asensio, 2003; Nunez, Rodriguez,
have cracks on the surface due to improper pressing activity (Asefa Cordoba, Bermudez & Asensio, 1996). Hence, this stage did not
et al., 2010). The cracks seem to create hiding spots for mould fulfil the criteria to be a CCP. The traces of toxic fungal secondary
spores, suitable microclimate for mould growth and possibly for the metabolites in fresh or thawed meat originated from contaminated
subsequent production of toxic secondary metabolites. Hence, feeds are the potential important chemical hazards at this stage
reducing crack formations through a good GMP can minimise the (Mahmoud, Abou El-Alla & Sayed, 2001). The risk can only be
risk of mould growth and the potential production of toxic minimised by demanding for documentation that indicates the
secondary metabolites on the products. The indoor air had poor animals slaughtered had received good animal husbandry practice.
If so the animals would receive safe and quality feed which in turn
Table 1 is important for the quality and safety of the meat. Current regu-
Composition of the products. latory programs such as Food Act of Norway (The Ministry of Health
Parameter Level and Care Services in Norway, 2004), are expected to reduce the
Water activity (aw) 0.84e0.90 occurrence and transfer of natural chemical contaminates in use for
Salt 6e8% animal production to the consumers.
NaNO3 (E250) 0.02%
Protein 28 gm/100 gm 3.4.2. Trimming
Fat 13e14 gm/100 gm
Antioxidant Sodium ascorbate (E301)
The production activity at this stage is deboning. Pathogenic
yeasts like C. zeylanoides, are still the potential hazards that could
834 D.T. Asefa et al. / Food Control 22 (2011) 831e837
occur (Asefa, Møretrø et al., 2009; Bisbe et al., 1987). However, they The occurrence of toxigenic moulds usually prevails at the
do not compromise the safety of the products as subsequent drying and ripening stages of production (Asefa et al., 2010; Nunez,
salting, brining, smoking and drying production process control Rodriguez, Bermudez, Cordoba & Asensio, 1996). Hence the dry-
and will be replaced by important non-pathogenic yeasts as dis- ripening process was identified as an important critical point at
cussed earlier (Asefa, Møretrø et al., 2009; Martin et al., 2006; which potential mycotoxigenic food safety hazards can emerge
Martin et al., 2003; Nunez et al., 1996). Moulds were not isolated (Table 2).
frequently at this stage and the potential production of toxic
metabolites that could raise a food safety hazard is minimum. 3.4.5.1. Hazard characterisation. Secondary toxic metabolites such
as penicillin, Ochratoxin A, cyclopiazonic acid, verrucosidin and
3.4.3. Salting and brining aflatoxins which can be produced by toxigenic moulds associated
Bone free meat is treated with excess salt (NaCl) after pressing with dry-cured meat products (Chiavaro et al., 2002; Iacumin et al.
and netting processes. The meat was treated with curing salts like 2009; Mintzlaff, Ciegler & Leistner, 1972; Monaci, Palmisano,
sodium nitrate (NaNO3) at refrigeration temperature. Pathogenic Matrella & Tantillo, 2005; Nunez et al., 2000; Papagianni,
yeasts are still the mycotoxigenic hazards identified but the Ambrosiadis & Filiousis, 2007; Petzinger & Weidenbach, 2002)
potential hazards could be controlled by the subsequent brining, are the important food safety hazards identified.
smoking and drying processes (Asefa, Møretrø et al. 2009; Martin The toxic secondary metabolites that could be produced on food
et al., 2006; Martin et al., 2003). Salt lowers the water activity of products vary with the types of toxigenic moulds growing on them.
the products by diffusing into the center of the meat. It inhibits Isolates of P. nalgiovense dominated on the dry-cured meat products
microbial growth on the products there by enhances durability and of the production facility studied and most of them have the ability
safety (Blesa et al., 2001). to produce penicillin (Asefa et al., 2010). Hence, penicillin is
considered as the important food safety hazard that could occur.
3.4.4. Smoking Research finding in other countries proved that toxic secondary
The meat was exposed to cold smoking (20e30 C) in order to metabolites of toxigenic moulds could be produced and accumu-
facilitate a faster surface drying process and inhibit microbial lated on dry-cured meat products (Iacumin et al., 2009; Laich,
growth. This process was identified as the first critical control point Fierro, Cardoza, & Martin, 1999; Monaci et al., 2005; Nunez,
(CCP1) as it minimizes the potential food safety hazards that could Westphal, Bermúdez, & Asensio, 2007; Toscani et al., 2007). If
arise from pathogenic yeasts. penicillin is produced on the products, the level should not expose
the consumers to a point that exceeds the maximum tolerable
3.4.4.1. Hazard characterization. The pathogenic yeasts, such as C. weakly intake (TWI) set by the legislative authorities, which in
zeylanoides, that were frequently isolated in the earlier production Norway is 4 ug/kg of the body weight (Grønningen, 2008) (Table 3).
processes were the hazards to be controlled and their growth was Similarly, if moulds capable of producing Ochratoxins A are
completely inhibited by smoking process (Asefa, Møretrø et al., contaminating the dry-cured meat products, the level should not
2009). The process facilitates the proliferation of important expose the consumers to a point that exceeds the maximum
yeasts like D. hansenii in the late production stages by minimizing tolerable weekly intake (TWI) of 100 ng/kg of body weight
the potential competition that could arise from the pathogenic (Norwegian Institute of Public Health, 2008).
yeasts.
3.4.5.2. Critical limits. Moulds’ ability to produce toxic secondary
3.4.4.2. Critical limits. Time and temperature specifications metabolites is highly affected by the water activity of the substrate
described in the flow diagram (Fig. 2), i.e., 2e4 days of light (Gqaleni, Smith, Lacey & Gettinby, 1997; Nunez et al., 2000). It is
smoking and a temperature of 20 C are working well and can be possible to reduce the production and accumulation of toxic
used as the critical limits. Temperature and time of smoking should secondary metabolites by controlling the level of water activity and
be recorded properly. adjusting the drying and ripening temperatures. A significantly
higher verrucosidin production by P. polonicum was reported at
3.4.4.3. Verification. Samples should be taken at fixed intervals, if a water activity of 0.99 in comparison to the water activities of 0.97
possible frequently, for mycological analysis in order to verify the and 0.95 (Nunez et al., 2000). The production of aflatoxin by A.
effectiveness of this process to control pathogenic yeasts and flavus was reported to reduce by 50e60% as the water activity
perform corrective actions in case of deviation. However, further dropped from 0.99 to 0.95 (Gqaleni et al., 1997). A temperature
research that increases our understanding about the effect of range from 20e30 C was reported as optimum for the production
smoking on fungal growth is needed. of high amount of toxic secondary metabolites range, given a higher
water activity is in place (Gqaleni et al., 1997; Nunez et al., 2000).
3.4.5. Dry-ripening Hence any attempt to reduce the potential production of myco-
The drying process is a critical step in ensuring product safety as toxins should consider water activity. A drying process that lowers
it affects the microbiological and chemical aspect of the product. the water activity of the products faster to a level near to 0.9
The meat undergoes a carefully controlled and monitored surface- minimises the risk of the production of toxic secondary metabolites
drying process using air. The ripening process starts right after the tremendously. Mycotoxins production by toxigenic moulds was not
drying process, but interrupted only by the washing process. At the observed at a water activity of 0.9 (Gqaleni et al., 1997).
ripening process the dehydrating process continues while lipolysis The team used these research findings and set critical limit for
and proteolysis activities that are responsible for sensory qualities water activity of the products at 0.92 at the end of the drying
(Toldra, 2002) of the products are initiated. A good temperature and process and 0.9 at the end of the ripening process. The critical limit
humidity control in the drying chamber is required throughout the for the drying and ripening temperature proposed by the team was
process. The drying and ripening rooms at the production facility 20 C and the drying and ripening rooms should have a relative
have a temperature range of 12e16 C and a relative humidity of humidity lower than 75%. The producer has a lower drying and
70%e80%. With the exclusion of the washing process, the team ripening temperature (Fig. 2), and it is important to follow up the
considered the drying and ripening processes as one whole process level of the temperature and relative humidity are consistent
and named it “dry-ripening stage of production”. through out the drying and ripening processes.
D.T. Asefa et al. / Food Control 22 (2011) 831e837 835
Table 2
Mycotoxigenic hazards in dry-cured meat production processes.
3.4.5.3. Verification. Frequent visual inspections can be performed 3.4.6. Sorting and packaging
by the staffs in the production facility and samples of dry-cured Products with visible moulds were sorted out from those
meat products with safety concerns can be taken for the analysis of without before packing. This is an important control point and can
the occurrence of toxigenic moulds. Such analysis can be used as be used for verification of the identified CCPs to produce quality
tools of decision to perform the analysis of the occurrence of and safety (Table 2 and 3). A quality control system that facilitates
potential toxic secondary metabolites. Temperature, relative the analysis of toxic secondary metabolite on selected products
humidity, water activity, types of moulds on the products and representative for the batch should be in place. This has to be done
results of toxic secondary metabolite analysis are some of the for products with and without visible mould growth and if toxins
important records to be documented. are found, the concentration should not exceed the acceptable level
The maximum tolerable weekly intake values set by the legisla- set by the legislative authorities (Grønningen, 2008; Norwegian
tive authorities could serve as tools to verify the effectiveness of the Institute of Public Health, 2008).
critical limits to reduce or eliminate occurrence of toxic secondary Before the actual packing process of sliced products, 3e4 pieces
metabolites. of unsliced dry-cured meat products are allowed to be vacuum
Table 3
The HACCP plan for mycotoxigenic hazards in dry-cured meat production processes.
CCP2
Products contaminated eaw < 0.9 eControl the aw eFacilitate a correct drying eCheck aw of the products eaw records
with toxigenic moulds eZero tolerance for eControl performance and ripening temperature eTemperature check in eBatch records
and production and crack formation on of pressing machine in eHold all suspected the drying chamber eMaintenance and
accumulation of toxic product surfaces salting room products and test eQC audits performance records
secondary metabolites eTemperature lower eControl the drying eaw below 0.9 eRandom sampling to eResults of
than 20 C and ripening temperature eZero tolerance for crack control the type of moulds laboratory analysis
formation while pressing growing on the products
the meat periodically and if toxigenic
test selected products for the
occurrence of potential toxic
secondary metabolites
Fig. 3. Modified Flow diagram with critical control points (CCP) and control points in the production of dry-cured meat products.
packed in order to facilitate an even distribution of salt through out Asefa, D. T., Gjerde, R. O., Sidhu, M. S., Langsrud, S., Kure, C. F., Nesbakken, T., et al.
(2009a). Moulds contaminants on Norwegian dry-cured meat products. Inter-
the products. The vacuum packaging reduces the ability of fungi to
national Journal of Food Microbiology, 128(3), 435e439.
grow further and become reasons for food safety hazards. It should Asefa, D. T., Kure, C. F., Gjerde, R. O., Omer, M. K., Langsrud, S., Nesbakken, T., &
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3.4.7. Validation of the HACCP plan and record keeping Asefa, D. T., Møretrø, T., Gjerde, R. O., Langsrud, S., Kure, C. F., Sidhu, M. S., et al.
Initial validation of this HACCP plan is necessary to determine its (2009b). Yeast diversity and dynamics in the production processes of Norwe-
effectiveness to keep the identified hazards at an acceptable level. gian dry-cured meat products. International Journal of Food Microbiology,
133(1-2), 135e140.
In addition, a systematic revalidation should be performed by Barbuti, S., & Parolari, G. (2002). Validation of manufacturing process to control
reviewing the HACCP plans, and recording properly the identified pathogenic bacteria in typical dry fermented products. Meat Science, 62(3),
CCPs, critical limits, deviations registered, corrective actions per- 323e329.
Bisbe, J., Vilardell, J., Valls, M., Moreno, A., Brancos, M., & Andreu, J. (1987). Transient
formed, verifications performed via random sampling and analysis fungemia and Candida arthritis due to Candida zeylanoides. European Journal of
followed by continuous maintenance. Clinical Microbiology & Infectious Diseases, 6(6), 668e669.
Blesa, E., Alino, M., Barat, J. M., Grau, R., Toldra, F., & Pagan, M. J. (2001). Micro-
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4. Conclusion salting stage as affected by partial replacement of NaCl by other salts. Meat
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Summaries of hazards, CCP and the HACCP plan are indicated in Chiavaro, E., Lepiani, A., Colla, F., Bettoni, P., Pari, E., & Spotti, E. (2002). Ochratoxin A
determination in ham by immunoaffinity clean-up and a quick fluorometric
Tables 2 and 3 with critical limits and corrective actions. However, method. Food Additives and Contaminants, 19, 575e581.
the successful implementation of this HACCP plan depends on the FAO. (1997). Hazard analysis and critical control point (HACCP) system guidelines for
correction of the deviations in the prerequisite programs. The basic its application. CAC/RCP 1e1969, Rev 3.
Food Product Association (FPA). (2006). HACCP: A systemic approach to food safety.
conditions and activities that maintains good hygienic and Washington, D.C.: FPA.
production practices and reduce product contamination by fungi Gqaleni, N., Smith, J. E., Lacey, J., & Gettinby, G. (1997). Effects of temperature, water
should be in place. The full commitment of the management and activity, and incubation time on production of aflatoxins and cyclopiazonic acid
by an isolate of Aspergillus flavus in surface agar culture. Applied and Environ-
the employees is also required. The commitment of the manage-
mental Microbiology, 63(3), 1048e1053.
ment to convey a positive message at all levels of the operation in Grønningen, D. (2008). Restmengder av legemidler og forurensninger i levende dyr og
both words and actions are important. Training of personnel at the animalske næringsmidler. Oslo, Norway: National Veterinary Institute.
Iacumin, L., Chiesa, L., Boscolo, D., Manzano, M., Cantoni, C., Orlic, S., et al. (2009).
two CCPs (Fig. 3) about the importance of food safety hazards is
Moulds and ochratoxin A on surfaces of artisanal and industrial dry sausages.
important for the effective implementation of this HACCP plan. Any Food Microbiology, 26(1), 65e70.
concerns or weaknesses in these should be addressed to ensure Laich, F., Fierro, F., Cardoza, R. E., & Martin, J. F. (1999). Organization of the gene cluster
product safety. for biosynthesis of penicillin in Penicillium nalgiovense and antibiotic production
in cured dry sausages. Applied and Environmental Microbiology, 65(3), 1236e1240.
Mahmoud, A. L. E., Abou El-Alla, A. A., & Sayed, A. M. (2001). Mycoflora and natural
Acknowledgements occurrence of mycotoxins in some meat products and livers of poultry and
imported bulls. Pakistan Journal of Biological Sciences, 4(5), 611e613.
Martin, A., Cordoba, J. J., Aranda, E., Cordoba, M. G., & Asensio, M. A. (2006).
We wish to thank all the operators at the dry-cured meat Contribution of a selected fungal population to the volatile compounds on dry-
production facility, staffs of Section of Mycology and Section of cured ham. International Journal of Food Microbiology, 110(1), 8e18.
Food and Feed Microbiology at the National Veterinary for their Martin, A., Cordoba, J. J., Benito, M. J., Aranda, E., & Asensio, M. A. (2003). Effect of
Penicillium chrysogenum and Debaryomyces hansenii on the volatile compounds
support while developing the plan. This work was financed by the during controlled ripening of pork loins. International Journal of Food Microbi-
Norwegian research council and Stranda Spekemat AS. ology, 84(3), 327e338.
Mintzlaff, H.-J., Ciegler, A., & Leistner, L. (1972). Potential mycotoxin problems
in mould-fermented sausage. Zeitschrift fur Lebensmitteluntersuchung und
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