HACCP Plan for MarNuggets

Group 4: Amanda Burgett Emily Ennis Joshua Harris Uriel Franco Eleanor Hellard Andrea Urrutia Company Name and Description · Company name: MarNuggets Poultry · Firm Address: 455 Farm North Drive, Celina TN 38551 · Product: Marinate Raw chicken nuggets · Company Size: The company is made up of 250 employees with three shifts a day. There is a morning shift for receiving, a mid-day for processing, and a night shift for processing and cleaning/sanitizing. · Target Marked: Commercial Fast Food used Product Description

• Labelling instructions: Must be refrigerated until cooked. At a high temperature of -18C.

• Shelf life of 14 days

• Bite size pieces of freshly marinated boneless chicken breast

• Grilled juicy nuggets and have excellent taste

• Where is it distributed: Restaurants

· Type of package: 228g in 1 bag (17.5cm X 17.5cm) of HDPE, in a pelletized cardboard box of 46.19cm long x 26.82cm width x 29.21cm high at -18C Process Flow Diagram:

Flow Diagram Description: Raw material reception: In this stage they will receive the raw material for the nuggets and marinate for the processing industry MarNugget. At the same time, we can find the first Critical Control Point (CCP). In which a visual review will be made for the detection of physical hazards and temperature measurements will be made to ensure the cold chain in the raw chicken breast. Dry ingredients storage: In this area all the dry ingredients will be stored according to the temperature and humidity correct for the preservation and prevention of bacterial growth. The area has to be clean with good ventilation to control humidity and prevent the growth of mold and bacteria. Cool ingredients storage: All the frozen chicken breasts have to be stored according to the correct temperature to maintain the cold chain from the reception before start processing. Mixing process: Inside the High Shear Mixer machine, the chicken breast meat is mixed with some seasonings and chicken skin for flavoring. Cut-up Process: Using a cleaver or a poultry shears, cut the breast quarter crosswise in half to produce two equal sections. Cutting the breast quarter in half will produce 10 pieces of chicken when both halves have been cut. Using a cleaver or a poultry shears, cut the breast quarter crosswise in three equal sections. Marination and Tumbling Process: The chicken nuggets will move through the industrial injector machine to inject the marinate. Refrigeration Process: The nuggets travel down the assembly to the spiral and tunnel freezers. The nuggets pass from a temperature of 31 to 25°F. Weighing Process: The nuggets are weighing in an industrial scale (+/- 2lb) according to the final product weight. Packaging Process: The nuggets pass the conveyor belt move though the systematic packaging line machine (HDPE), after this pass though the pelletized box packaging machine and the last one is the label machine. Storage: The nuggets in the box package are stored in a freezing room at -18°C to maintain the integrity of the food and prevent the growth of pathogenic microorganisms. Shipment Process: The final products have to be shipped according to the production date to avoid the accumulation of old products in the freezing rooms. Has to continue with the cold chain until the cold trailer. It’s necessary to use pallets to move the boxes of nuggets to cold transporter roads. The temperature has to be monitored.