Risk assessment of vacuum-packed pouched tuna chunks during industrial processing using ISO 22000 and HACCP systems

Risk analysis was conducted during processing of Vacuum-Packed Pouched Tuna Chunks using HACCP systems. The hazards likely to occur and their levels of severity and chances of occurrences were identified. Critical control points, critical limits, control and preventive measures, corrective actions for non-conformances and verification procedures were evaluated and documented. ISO 22000 Analysis Worksheet was also employed for determination of some prerequisite programmes (PrPs) and compared with the HACCP decision tree table for determination of Critical Control Points (CCPs). The PrPs were the main difference between the two systems. The major hazards identified were the probable contamination with spoilage and pathogenic microorganisms - Listeria monocytogenes, Clostridium botulinum, Salmonella and Staphylococcus aureus; foreign materials - metal residues and sand; chemical contaminants - heavy metals, histamine and cleaning detergent residues, before, during and after processing. Using the HACCP decision tree, eight CCPs were identified, namely: fish receipt (CCP 1), frozen storage (CCP 2), racking and staging (CCP 3), metal detection (CCP 4), vacuum sealing (CCP 5), thickness rolling (CCP 6), retorting (CCP 7) and bulk incubation/seal testing (CCP 8). The incorporation of PrPs in the ISO 22000 made the system more flexible by reducing the number of CCPs (8 in the HACCP system) to 4 without compromising safety of the product.