A case study on implementing a HACCP plan in the production process of 3D-printed beef puree

Abstract Despite the growing demand for 3D-printed foods, the need for research to ensure the safety and regulatory compliance of 3D-printed meat products remains. This study aims to establish a Hazard Analysis Critical Control Point (HACCP) plan for 3D-printed beef products that are ready to heat and have modified textures designed for dysphagia treatment. The potential food safety hazards (i.e. biological, chemical, allergen, and physical) at each processing step were identified and evaluated based on their significance according to a hazard risk assessment matrix. Seven critical control points (CCPs) were identified, namely, (1) pressure cooking the beef puree, (2) cooling the cooked beef puree, (3) blending the cooked beef puree, (4) cartridge filling, (5) 3D printing, (6) metal detection of vacuum-packed 3D printed beef puree, and (7) labelling of the final product. CCP1-CCP5 are due to biological hazards, while CCP6 and CCP7 are due to physical and allergen hazards, respectively. Subsequently, control measures, critical limits, monitoring procedures, corrective actions, verification activities, and records were established according to the HACCP principles based on international food standards and the Food Standard Australia New Zealand (FSANZ). Nonetheless, this HACCP plan serves as a valuable reference model for commercial-scale 3D meat printing in various settings and jurisdictions while also supplementing the safety protocols for home-style 3D printing.