Salmonella is controlled by monitoring that the correct time and temperature is maintained. This could be validated by periodically testing the finished product for Salmonella.
This Process Preventive Control form shows the peanut butter process roasting step with the potential verification activities added.
Verification of Process Preventive Control – Roasting example
| PROCESS PREVENTIVE CONTROLS | ||||||||
|---|---|---|---|---|---|---|---|---|
| PRODUCT: | PAGE 1 of ___________ | |||||||
| FACILITY: | ISSUE DATE: | |||||||
| ADDRESS: | ||||||||
| Process Control | Hazard | Critical Limits | Monitoring | Corrective Action | Verification | |||
| What | How | How often | Who | |||||
| Roasting | Non- sporeforming pathogens, such as Salmonella | Minimum roasting time: 25 minutes | Length of roast cycle | Measure time-in to time-out with stop watch and metal test unit run through oven | Beginning of shift and after any adjustment | Roaster operator | If roasting is interrupted, product is held and evaluated to determine if it can be reprocessed. If a processing parameter was not met, reprocess batch using alternate validated process; identify root cause and determine actions needed to address it; conduct training as needed to prevent recurrence. Also, segregate and evaluate product, rework or discard as appropriate. | Operator verifies the roaster bed depth, temperature and roasting time are accurate and operating properly during the processing run once each day during morning shift. QA manager reviews and initials records within a week of preparation and compares performance with past results to determine trends. Maintenance manager ensures that roster and monitoring equipment are calibrated. Finished product tested for Enterobacteriaceae once every 2 weeks. Salmonella is analyzed if hygiene Enterobacteriaceae counts are found to be out of specification. |
| Bed depth ≤2 inches | Bed depth leveling bar height | Leveling bar height is set at 2 inches high at oven inlet | Check at startup and end of day | |||||
| Oven temperature ≥300 degrees F (≥149 degrees C). *Note: to achieve 5 log reduction of Salmonella | Oven air temperature | Recording thermometer at the coldest locations (i.e., inlet and outlet of oven) | Continuous with visual check of recorded data at startup and once per day at each location | |||||
Another important verification for peanut food processes is for metal detection. Metal is often identified as a potential hazard in the process that must be addressed separately from other less harmful foreign material. Here is an example documentation for metal detection.
Verification of Process Preventive Control for metal
| PROCESS PREVENTIVE CONTROLS | |||||||||
|---|---|---|---|---|---|---|---|---|---|
| PRODUCT: | PAGE 1 of ___________ | ||||||||
| FACILITY: | ISSUE DATE: | ||||||||
| ADDRESS: | |||||||||
| Process Control | Hazard | Critical Limits | Monitoring | Corrective Action | Verification | Records | |||
| What | How | How often | Who | ||||||
| Metal detection | Metal inclusion | Metal detector present and operating | All of the product passes through an operating metal detector | Visual examination that the detector is on and reject device is working | Beginning, middle and end of shift | Production employee | If the product is processed without metal detection, hold it for metal detection. Correct operating procedures to ensure that the product is not processed without metal detection | Pass X mm ferrous and Y mm non-ferrous and stainless standard wands through detector at start-up, middle and end of shift to assure equipment is functioning. Review Metal Detector Log and corrective action and verification within 7 working days | Metal Detector Log Manufacturer’s Validation Study that determined detector settings and sensitivity standards Corrective action records |
| No metal fragments that would cause injury of choking are in the product passing through the metal detector | Reject product for the presence of metal fragments | Examine product rejected by electronic metal detector to determine why it was rejected | When product is rejected | Production employee | If metal is found in product, segregate product, inspect back to the last good check, rework or discard product depending on metal type and prevalence. Identify source of the metal and fix damaged equipment if relevant | ||||
Calibration should be performed on equipment and instruments used to monitor or verify parameters in the Food Safety Plan to assure that the equipment is collecting accurate information. For the peanut process, calibration for roasting means assuring that the time, temperature, and bed depth are correctly measured and applied.
Periodic verification may also include targeted sampling and laboratory testing of ingredients, in-process materials, and finished products. Peanut or peanut butter finished product can be tested for Salmonella. Another example of targeted testing may be checking for pesticide residue in peanuts used for further processing.
Environmental monitoring or testing for specific microorganisms on surfaces that come into contact with peanuts during processing as well as on equipment, floors, and drains – helps to verify that sanitary controls are working. This monitoring should be scheduled and performed on a routine basis.
Periodically, a manager should analyze the entire peanut processing food safety system to verify that it works. This can be done on a schedule (for example, every three years), or when significant changes in the product or process are made. New information about potential hazards may trigger you to reassess. This analysis would include reviewing the hazard analysis and trends indicated in records.
