Refrigerated Salad Dressing - HACCP

I am writing a HACCP plan for a refrigerated salad dressing manufacturer. I need some guidance on how to look at the Hazard Analysis. We do use egg powder and mostly dry ingredients. We maintain pH ranges from 3.2 to 4.25. We do use fresh buttermilk and a variety of cheeses. If anyone can guide me in the right direction it would be appreciated.

Dear LMCxx,

Welcome to the forum ,

Here is a link to a previous thread (Nov 2008) with some similarity to yr request –

http://www.ifsqn.com...showtopic=11469
(the file originally enclosed by the starter seems to hv sadly been removed)

Appears that generic salad haccp plans are hard to find. Maybe somebody has more ides now ??

Rgds / Charles.C

added - one viewpoint of the likely haccp plan style can be got from -

haccp_retail_groups.png   87.88KB   73 downloads
(from http://www.hi-tm.com/ )

Thank you for your response!

I have looked at the previous post on salad dressings and it was not on the same lines as our production. We have fairly low pH ranges for refrigerated dressings and most of the ingredients are dry. We also make some dressings that are heated and some sauces that are heated between 165-205. I just need some direction or a sample plan as to how to determine the hazards and ccps. I have an idea about the ccp's but am not sure if they are accurate.

Thank you for your response!

I have looked at the previous post on salad dressings and it was not on the same lines as our production. We have fairly low pH ranges for refrigerated dressings and most of the ingredients are dry. We also make some dressings that are heated and some sauces that are heated between 165-205. I just need some direction or a sample plan as to how to determine the hazards and ccps. I have an idea about the ccp's but am not sure if they are accurate.

What are your ideas on the CCP's? From my experience of the forums here it is always useful if you have something to kick around and into shape.

Regards,
Simon

What are your ideas on the CCP's? From my experience of the forums here it is always useful if you have something to kick around and into shape.

Regards,
Simon

I am thinking that my refrigerated dressings should have a CCP dealing with pH. ALso, for the heated items should have a CCP dealing with temperature. I just need some basic guidance. We are a very small manufacture, but I do want to make it right.

Well from my small experience in the field and very roughly,
if you acidify your dressings then pH should be a CCP (max should be 4.1 since there are some strains of pathogens that can grow around there).
Also, if you heat treat (pasteurisation/ sterillisation) any ingedients for the salads (or the salads themshelves) then another CCP should be the time/ temperature of the heat treatment.
If you add any "dangerous" preservatives maybe you should consider if their weighting could be another CCP, and finally metal/ foreign body detection

Well from my small experience in the field and very roughly,
if you acidify your dressings then pH should be a CCP (max should be 4.1 since there are some strains of pathogens that can grow around there).
Also, if you heat treat (pasteurisation/ sterillisation) any ingedients for the salads (or the salads themshelves) then another CCP should be the time/ temperature of the heat treatment.
If you add any "dangerous" preservatives maybe you should consider if their weighting could be another CCP, and finally metal/ foreign body detection

We do use vinegar and ocassionally citric or malic acids. The highest pH is about a 4.3. Can you tell me which pathogens may be growing in this range? As I stated before, we use mostly powders (egg powder, etc.) and use liquid buttermilk with culture purchased from an outside vendor. As for the heated products, the ph's are usually no higher than 3.8. Those items would be more like BBQ sauces and wing sauces. Is there any table or paper that I may look at to get an idea of the pathogens and proper hold times?

As you are probably aware, there is an enormous range of recipes within the overall category of "salad dressings". The necessary HACCP control measures may vary accordingly.

I enclose an extract detailing the generic hazards of "mayonnaise and dressings" together with the typical control measures required. This is not yet a HACCP plan as such but illustrates the significant factors which would hv to be considered in a "typical" process flow.

mayonnaise_hazards.png   490.91KB   122 downloads

Rgds / Charles.C

As you are probably aware, there is an enormous range of recipes within the overall category of "salad dressings". The necessary HACCP control measures may vary accordingly.

I enclose an extract detailing the generic hazards of "mayonnaise and dressings" together with the typical control measures required. This is not yet a HACCP plan as such but illustrates the significant factors which would hv to be considered in a "typical" process flow.

mayonnaise_hazards.png   490.91KB   122 downloads

Rgds / Charles.C

Thank you! This is very helpful! We do use dry ingredients that have been pasteruized from the supplier. I am wondering if keeping a pH of less than 4.4 for refrigerated dressings is an adequate ccp? Also if I have COA's from the vendors stating pasteruization or appropriate testing, is this also a control measure?

We do use vinegar and ocassionally citric or malic acids. The highest pH is about a 4.3. Can you tell me which pathogens may be growing in this range? As I stated before, we use mostly powders (egg powder, etc.) and use liquid buttermilk with culture purchased from an outside vendor. As for the heated products, the ph's are usually no higher than 3.8. Those items would be more like BBQ sauces and wing sauces. Is there any table or paper that I may look at to get an idea of the pathogens and proper hold times?

There is legisaltion for milk pasteurisation 71.7 for 15 seconds. Your product is likely to be more viscous so this would need to be taken into consideration. Depending on your product composition you are going to need to validate your pH controls yourself at 4.3.

There has also been no mention of chemical and physical hazards. I would have thought filtration would be a CCP?

Regards,

Tony

Regret this topic not my direct area of expertise so I can only offer chunks from the literature.

It does appear that a pH level of 4.5 is at the high end of the normally quoted figures. I presume this number is given for the industrial situation where it is assumed that proper safety challenge/validation tests will also be made associated with the specific process. For example, see this (taken from same source as previous post - mic. orgs. in foods 6) -

safety_aspects.png   133.31KB   39 downloads

This technical discussion may also be of interest -

safety_egg_yolk_based_mayonnaise.PDF   120.89KB   168 downloads

Rgds / Charles.C

There is legisaltion for milk pasteurisation 71.7 for 15 seconds. Your product is likely to be more viscous so this would need to be taken into consideration. Depending on your product composition you are going to need to validate your pH controls yourself at 4.3.

There has also been no mention of chemical and physical hazards. I would have thought filtration would be a CCP?

Regards,

Tony

We do not produce the milk here. We purchase it from an outside supplier. As far as the physical hazards, I think I have a good handle on that. It's the hazards dealing with the product itself that has slowed me to a crawl.

Regret this topic not my direct area of expertise so I can only offer chunks from the literature.

It does appear that a pH level of 4.5 is at the high end of the normally quoted figures. I presume this number is given for the industrial situation where it is assumed that proper safety challenge/validation tests will also be made associated with the specific process. For example, see this (taken from same source as previous post - mic. orgs. in foods 6) -

safety_aspects.png   133.31KB   39 downloads

This technical discussion may also be of interest -

safety_egg_yolk_based_mayonnaise.PDF   120.89KB   168 downloads

Rgds / Charles.C

The good thing for us is that we use dry eggs and they are tested by the supplier for salmonella. We do not use fresh eggs or whole eggs.

We do not produce the milk here. We purchase it from an outside supplier. As far as the physical hazards, I think I have a good handle on that. It's the hazards dealing with the product itself that has slowed me to a crawl.

From your previous post:

As for the heated products, the ph's are usually no higher than 3.8. Those items would be more like BBQ sauces and wing sauces. Is there any table or paper that I may look at to get an idea of the pathogens and proper hold times

I am a little confused. Do you heat treat your products as a control?

Regards,

Tony

There is legisaltion for milk pasteurisation 71.7 for 15 seconds. Your product is likely to be more viscous so this would need to be taken into consideration. Depending on your product composition you are going to need to validate your pH controls yourself at 4.3.

There has also been no mention of chemical and physical hazards. I would have thought filtration would be a CCP?

Regards,

Tony

The chemical and physical hazards are being addressed at the same time. I am just having more issues with the ccps for biological. We also do not make our own milk here. We purchase from outside vendor.