Model 2.. Preparation of a PQC Program for Fat-Content-per-Serving Labeling for Meat and Non-Meat Products
Scales/ Meters
- Establish verification procedures to ensure that all scales/meters used in the formulation and analytical testing of the product are accurate. The procedure should include checks against a standard weight or measurement.
Lotting
- Define lot and sublot.
- Establish a standardized procedure for identifying the lot throughout the process.
Formulation
- Establish a procedure to verify the formulation of each lot/ sublot in compliance with the approved label formulation.
- Establish tolerances for non-restricted ingredients.
- No ingredient in the formulation should be substituted for another. Fat content of the meat portion (ground beef, ground pork, or products with a declared fat limit on the label)
- Establish a statistically sound sampling procedure for each lot/ sublot of the meat portion.
- Identify the analytical method used, such as an AOAC method. Weight Control (serving and component).
- Establish a statistically sound sampling procedure to ensure that each portion and component of the product with in a lot/ sublot is checked against the label transmitted.
- Raw weights—The weight is checked on all portions and components on finished raw and cooked products.
- Cooked weights—Cooked weights are checked and compared with the portion size stated on the transmittal and on the Child Nutrition (CN) label. Weights also are checked for precooked components of products against information on the label transmittal.
- The sampling plans and tolerances should be based on generally recognized statistical process control methods and should ensure that the process is in control and that applicable product or label limits are being met.
- Each CN product should have its own lot average.
Batter and Breading (if applicable)
- Establish a procedure to verify that the batter/ breading application does not exceed regulatory limits, label declarations, or product standards. The monitoring procedure should identify the following:
- pre-batter/ breading application weight
- sample size
- sample frequency
- post-batter/ breading application weight
- Post-batter/ breading weight should be determined at the end of the application procedure and before further processing. Note: Model also can be used in developing the following PQC programs:Batter and Breading; FES Labeling Content for Meat and Non -Meat Products; Precooked Breakfast Sausage Yield; Control
Model 3. Low Temperature Rendering for the Production of Partially Defatted Chopped (P.C.) Beef/ Pork, Fat-Reduced Species, and Partially Defatted Beef/ Pork Fatty Tissue
Raw Materials Control
- Define a lot and sublot
- If producing P.C. beef/pork or fat-reduced species, establish a statistically based sampling procedure to ensure the lot is in compliance with raw material requirements (12 percent lean).
Heat Processing
- Identify processing temperature (minimum and maximum).
- Identify the target processing time, which is the time the product is subjected to the target.
- Establish procedures for monitoring processing temperatures and times.
Cooling and Freezing Controls
- Identify the cooling and freezing temperatures for the finished product.
- Identify the amount of time the cooling and freezing process will take to reach established temperatures.
Microbiological
- If the cooling/ freezing process (starting from the time heat is applied until the product is 40 degrees F for less) exceeds 30 minutes, a microbiological sampling procedure should be developed. The following sampling procedures and limits have been used in PQC programs in the past, and current regulations permit their continued use.
- Using a statistically based sampling plan , select two samples per lot from the raw material and finished products.
- Test samples for total plate count, coliforms, E. coli, and C. Perfringens.
- Demonstrate that the process does not increase the product’s microbial load by 1 log or more.
- Sampling can be reduced to one per lot when control has been demonstrated in three consecutive lots.
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