FOOD HYGIENE

Unit 1: Food InspectionTopic: Introduction to HACCP

Lecture 7

Objectives At the end of the session, students should be able to:

– Outline correctly the weaknesses of the traditional approach to inspections

– Outline clearly the historical development of HACCP– State accurately the advantages of utilizing the HACCP

principles– Outline clearly the relationship between pre-requisite

programmes and the HACCP system– Define accurately specific terms related to HACCP– Identify correctly the 7 HACCP principles– List accurately the contents to be entailed in a HACCP plan– Outline clearly the role of regulators/PHI in ensuring

HACCP principles are utilized

Outline

• Tradition inspection• Overview of HACCP• Scope of the application of HACCP• Advantages of HACCP• Definition of terms• HACCP principles• HACCP plan• Role of the regulators

Questions to be answered

• Weaknesses of traditional approach to ensuring food safety

• History of HACCP• Scope of HACCP• HACCP principles and an example of each

principle

HACCP

• http://www.youtube.com/watch?v=7nbjd_TnU8o&feature=related

Traditional Inspection

• Inspection for compliance focussed on GMPs– Describe the methods, equipment, sanitary

operations, sanitary facilities, and controls for processed foods, personnel, grounds

• Good Agricultural Practices - GAPs• Standard Operating Procedures - SOPs• Sanitation Standard Operating Practices -

SSOPs

GMP for the 21st Century, FDA

Traditional Inspections

– Emphasis for prevention and control was based on inspections

• Frequency• Thoroughness

– Completeness, time of day, staff on duty, critical process – Could not provide the degree of food safety desired by

stakeholders

– Emphasis was primarily on aesthetics, sanitation of facilities and equipment, and habits of personnel

Traditional Inspection

• End Product Testing– Samples taken limited statistically

• Time & Cost required for testing• Lab results only identify the effect

– What about the causes?– What control measures would be required to

prevent a reoccurrence?

• Approach not very scientific

Quality Control programmes

Establish QC department• Conduct internal monitoring

– Physical– Chemical– Microbiological

• With a view to improve or ensure compliance

• Concerned about quality standards• Similar approach to the traditional inspection,

therefore weaknesses are the same– Very strong emphasis on final product testing

HACCP - History

• Developed in 1961– Pillsbury Company in cooperation with NASA – US Army Natick Laboratory

• Assure the safety of food products intended for space travel (pathogens and biological toxins)

• Limited total reliance on end product testing• The practical and proactive system of HACCP

evolved from efforts to understand and control food safety failures

History• Concept 1st presented publicly at 1971 US National

Conference on Food Protection• 1974 HACCP principle incorporated in US regulations for the

production of low-acid foods• By 1980 most major companies began adopting HACCP

principles in quality assurance programmes• Mandatory applications

– Fish & Seafood products – 1995 (FDA)– Meat & poultry industry – 1998 (USDA – FSIS)– Milk, Juice processing & packaging plants – 2001 (FDA)

History• Adopted by economies

– Europe, Canada, Australia, and New Zealand• High priority program under Codex Alimentarius

– the world food standards authority• created in 1963 by FAO and WHO to develop food standards,

guidelines and related texts such as codes of practice under the Joint FAO/WHO Food Standards Programme

• Today HACCP internationally accepted as an effective way to ensure product safety– Pressure from consumers; food trade

• Jamaica’s perspective???

History

• Structured and logical• Proactive/Preventative

• Designed to move away from final product testing

HACCP

• Hazard Analysis Critical Control Points– management system in which food safety is

addressed through the analysis and control of hazards from raw material production, procurement and handling, to manufacturing, distribution and consumption of the finished product

– Risk assessment tool used to guarantee safety and quality

– A system/framework which identifies, evaluates, and controls hazards which are significant for food safety

FSIS

HACCP• “The methodical and systematic application of the

appropriate science and technology to plan, control and document the safe production of foods”– Seeks to identify, assess and control hazards in foods

• Basic principle– “prevention rather than inspection”

• Common sense application of technical and scientific principles to food production process from farm to table

• Aim – to produce foods safely and be able to prove that it was produced safely

WHO

HACCP

• Stakeholders should have sufficient information concerning foods and related procedures– To identify where and how a hazard may occur

• Producers, processors, distributors, food handlers and consumers

Scope

• Powerful system which is applicable to a wide range of operations– Whether simple or complex

• It is used to ensure food safety at all stages of the food chain

• Manufacturers should not only investigate their own product and production methods– Distribution, retail operation and consumer

practices must also be considered

AGRICULTURAL IMPUTSFertilizers, pesticides, drug

PRMIARY PRODUCTIONFarmers, fishermen

PRIMARY PROCESSINGOn farm, dairies, abattoirs

Grain mill

SECONDARY PROCESSINGCanning, freezing, drying

brewing

FOOD DISTRIBUTIONNational/international

FOOD RETAILING

Supermarkets, shops

FOOD CATERINGRestaurants, schools

hospitals

DOMESTIC

PREPARATION

Food Chain

Scope

• Product and premises specific• Other systems exists that are common to all

premises– Necessary conditions to protect foods under its control– Traditionally relied on GMPs and GAPs

• Considered as pre-requisites to the development and implementation of an effective HACCP plan

• Ensures the integrity of the HACCP system

– Provide basic environmental and operating conditions necessary to produce safe, wholesome foods

Advantages of HACCP

• Greater degree of food safety assured

• Offset limitations in final product testing• Removes some of the subjectivity associated with conventional

inspection procedures– Know hazards, where likely to exist, project how they could occur, id.

where control must be exercised, decide where to conduct measurements

• Assists employees in coping with processing irregularities and equipment break down

• Final responsibility for food safety lies with company“Options limited based on Vision”

Complementary standards

ISO 9000 series • product quality standardsISO 22000 • a new standard that specifies the

requirements for a food safety management system.

• ISO 22000 incorporates all the elements of HACCP and of Good Manufacturing Practices (GMP)

Pre-requisite Programme

Cleaning & SanitizationPersonal HygienePreventative maintenanceRaw material controlPest ControlFacilitiesTrainingTraceability & Recall programmes

Food flow diagram

Conduct hazard analysis. Prepare flow diagram of steps in the processIdentify the hazard and specify control measures

Identify the CCPs in the process using a decision tree

Establish critical limits/target level to ensure that each CCP is under control

Establish monitoring requirements for CCP by scheduled testing or observations

Establish corrective action for each breach/ when monitoring indicates that a particular CCP is out of control

Establish procedures for verification that the HACCP system is working correctly

Establish effective record keeping procedures concerning all procedures and records applicable

STEP 1

STEP 7

• In an attempt to identify potential hazards, it is necessary to consider:

– The raw materials used– Processing procedures– The manner in which the product will be used

Step 1: Hazard Analysis

Step 1: Hazard Analysis

Identify PH foodsFoods that may contain poisonous substances,

pathogens or large numbers of spoilage micro organisms

Identify the potential source andspecific points of contamination

By analysis of each step in the food chain

Determine the potential for micro organisms to survive Or multiply during production, processing, distribution

Storage and preparation

Assess the risk and severity of hazards identified

Step 1: Hazard Analysis

• Procedure– Get information about the recipe– Get information about the process– Get information about the use of the food

• Holding temperature• Possibility for recontamination• Shelf life

• Prepare and serve without cooking• Preparing and cooking the same day• Preparing, cooking, holding, cooling, reheating and serving

Step 1: Hazard Analysis

Risk Assessment– Risk vs severity– Risk

• will the hazard always be present• how often will it be present

– Severity• Is it life threatening• Will many people become ill• Will there be extensive spoilage of the product

Risk vs Severity

Justifications

• What is the normal microbial load• Does the microbial population change during processing

until it reaches the consumer• Does the changes in the microbial population alter the

safety of the food• To what degree does the normal wear of the equipment

affect the likely occurrence of a physical hazard• Does the method of packaging affect the multiplication of

pathogens or formation of toxins• Is the food intended for the general pubic

– Infants, ages, immunocompromised– Institutional feeding vs home

Step 2: ID. CCP

• Find the points in the process where the identified hazards must be:– Prevented– Eliminated– Reduced to safe levels

– A decision tree is usually used• Depending on the process, there may be more than one CCP

– Cooking to destroy pathogens in chicken breast– Cooking and then reheating– Sealing of cans – cooking temp. and cooling temp– Milk – pasteurization temp and chilling temp.

Decision Tree used for CCP

Step 3: Establish Critical Limits

• For each CCP, establish a minimum or maximum limit that must be met in order to prevent or eliminate the hazard or reduce it to a safe level– Min limit -TT 74C for 15sec

• Can go a step further increase cooking time to 18 secs– Max limit – 4.4C for chilling

• additives, Aw

Step 4: Establish Monitoring procedures

• Once a critical limit has been established– Determine the best way to ensure it is not exceeded– Should be able to detect any deviation from specifications

and must provide the information in time for action to be taken

• Identify who to monitor• When to monitor• How to monitor• Device to be used• Calibration frequency

Visual observationSensory evaluation

Physical measurementsChemical testing

Microb testing

Step 5: Corrective Actions

• Identify the steps that must be taken when a critical limit is not met– These steps should be determined in advance– Should be noted on the log sheet used for

monitoring• Discard (sealing of cans)• Continue cooking (eg. Chicken)• Rewash (fruits for a salad)

Step 6: Verify system works

• Plan to evaluate on a regular basis• Ensure that the goals set were met

– Once per shift ( for chicken)– Temp logs reviewed weekly to identify pattern– Changes may be necessary

• Same chicken breast – Temp not being met towards the end of the week– Corrective action taken and was duly noted– What could be the problem

Step 7: Documentation

• Maintain HACCP Plan• Maintain all records obtained when:

– Monitoring activities were performed– Corrective actions taken– Verification activities– Equipment is validated/changed/modified– Information from suppliers– Training sessions

Development of HACCP plan

• Establish multi-disciplinary team– Line staff must be included

• Describe product• Identify intended use and consumer• Construct flow diagram• Onsite confirmation of flow diagram• Conduct hazard Analysis• Determine the CCP• Establish critical limits• Outline monitoring procedures• Establish corrective action• Establish verification procedures• Establish recording and documentation procedures• Implement the plan

Contents of a HACCP plan

• Listing of HACCP team and assigned responsibilities• Description of product and its intended use• Food flow diagram indicating CCPs• Hazards associated with each CCP and preventative measures• Critical limits• Monitoring system• Corrective action plan for deviations from critical limits• Procedures for verification of HACCP system• Record keeping procedures

HACCP Audits

• Systematic and independent examination to– determine whether activities and results comply

with the documented procedures– whether the procedures are implemented

effectively– suitable to achieve the objectives

Rationale – HACCP audit• The outcome of the audit is to have

established whether the manufacturer has– implemented a sound HACCP system – the knowledge and experience needed to

maintain it – the necessary support (or prerequisite)

programmes in place to assess adherence to GAPs, GHPs, GMPs

Components of HACCP Audit

• Assessment of the management commitment to support the system

• Assessment of the knowledge, competency and decision-making capabilities of the HACCP team members to apply the system and maintain it

• Assessment of performance of HACCP system

Types of Audits

• Internal HACCP audits– Internal/external resources

• External HACCP audits– Raw materials, processes

• Investigative audits

Frequency of audits• Frequency of HACCP audits should be based on:

– the risk category of the product being processed – the level of commitment of management and the

decision-making leverage of the HACCP team – the reputation of the company– previous safety and quality records– HACCP manual and implementation classification– training and qualification

Role of Government in HACCP

• Ensure appropriate application of the HACCP principle by food industry

• Facilitate HACCP implementation as deemed practical and necessary

• Provide leadership in food safety control by accepting and promoting HACCP– Enforcers and facilitators

• Regulations may be required• Voluntary compliance programme

– Dependent on legislative framework as well as the national, regional and global context

Role of the PHI

• Ensure that the HACCP plan is properly designed and implemented, and is operating effectively

• Enforcement activities should focus on the conceptual features of the HACCP system rather than only on the physical features emphasized by the traditional approach

• Advise and assist industry in the development of HACCP plans

• Facilitate training activities

Summary?

Assignment

• Choose a food item/product• Chart the food flow• Brain storm to identify the potential hazards

– For each hazard identified – justify– For each non-hazard – justify why not

• Determine CCP • Establish critical limit

– Decide on control methods