Cook Chill Reduced Oxygen Packaging HACCP Plan Guidance
A cook chill packaging process is one in which cooked foods are placed into oxygen impermeable packaging while still hot and the package is sealed to complete the oxygen barrier. Food processed in this manner is in Reduced Oxygen Package (ROP) and requires a Hazard Analysis Critical Control Point (HACCP) plan.
A HACCP plan is a written document that identifies where hazards might occur in the food production process and puts into place stringent actions to prevent hazards from occurring. It details a complete food safety management system following HACCP principles in combination with prerequisite programs. This guideline may be used as a tool when creating a cook chill HACCP plan
Preliminary HACCP Steps
- Assemble the HACCP team. Select people with specific knowledge and expertise about the process and product(s). The team is responsible for planning, developing and implementing the HACCP plan. It is important to include personnel who routinely make the product(s).
- Develop a complete list of ingredients and raw materials used in the product(s).
- Develop a complete list of equipment and material that will be used to produce the product(s).
- Develop a process flow by listing all steps of the process used to produce the product(s). Steps can include, but are not limited to receiving, cold holding before ROP, cooking, packaging, cooling, cold holding of ROP product(s) at the processing facility, transport to outlets, cold holding of ROP at outlets, reheating, hot holding, and removal from the package. There are several types of process flows to choose from including diagrams, narratives, lists, charts, and tables.
- Conduct a hazard analysis by evaluating the steps of the process flow and identifying the food safety hazards
- Use a Hazard Analysis Worksheet to document the biological, chemical, and physical hazards in the process
- The following organisms are common biological hazards that may be required to be controlled depending on ingredients used: Listeria monocytogenes, Campylobacter jejuni, Yersinia enterocolitica, Salmonella spp., Staphylococcus aureus, Clostridium perfringens, Clostridium botulinum, Bacillus cereus, Shigella spp., E. coli O157:H7, Hepatitis A, Norovirus, Cryptosporodium, Trichinella (if pork is included in the plan).
- A hazard must be controlled if it is reasonably likely to occur and is likely to result in an unacceptable risk to consumers. A Critical Control Point (CCP) is a step at which controls can be applied and a food safety hazard can be prevented, eliminated, or reduced to acceptable levels. CCPs will vary depending on the steps used to produce the product. Identify all CCPs on the process flow.
- The HACCP Worksheet is used to provide details (critical limit, monitoring, corrective action, verification, records/documentation) for all designated CCPs from the process flow.
- In the example below, a separate table is used for each CCP. The following tables include details of necessary information for two of the required CCPs on the HACCP Worksheet. The minimum required CCPs for a cook chill HACCP plan include cooking, bagging, cooling, and cold holding. Note: CCPs are dependent on the facilities process; therefore, additional CCPs may be required.
- Develop a HACCP worksheet, including details for all identified CCPs
- Sample Cook Chill HACCP Worksheet
- Blank HACCP Worksheet
Phone: (702) 759-0500
Updated on: May 21, 2019