haccp in fish processing sectorcacfish.eurofish.dk/presentations/11-ferrahi-fao-haccp.pdf · 2019....

HACCP IN FISH PROCESSING SECTOR

Ferrahi SARACOGLU (MSc)

Government Provided Staff

Fisheries and Aquaculture Expert

Food and Agriculture Organization of

the United Nations (FAO) Subregional Office For

Central Asia (SEC)

[email protected]

Office : (+90) 312 207 5000/6466

Mobile : (+90) 542 473 0407

REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY

Outline• Introduction

• What is the HACCP System?

• History

• Why we need HACCP in Fish Processes

• What is the hazards

• HACCP Principles

• HACCP Implementation to The Fish Processes

• Prerequisite Programs


Introduction▪ According to data published in 2015 by FAO, 17 percent of the world supply of animal proteins derived from Fish.

▪ With capture fishery production relatively static since the late 1980s, aquaculture has been responsible for the continuing impressive growth in the supply of fish for human consumption.

▪In per capita terms, food fish consumption grew from 9.0 kg in 1961 to 20.2 kg in 2015, at an average rate of about 1.5 percent per year.

▪The highest per capita fish consumption, over 50 kg, is found in several small island developing States (SIDS), particularly in Oceania, while the lowest levels, just above 2 kg, are in Central Asia and Caucasus

▪Fish is an exceptionally important component of the human diet and an enormous industry exists to provide a huge variety of consumer products in which fish is a major component.


What Is The HACCP?

HACCP

PROACTIVE

EFFECTIVE

RISK ASSESMENT

BASED

FULLY DOCUMENTE

D

SYSTEMATIC

SCIENCE BASED


Food Safety And Quality Pyramid


Continuous

Quality Improvement

HACCP

Prerequisite Programs

Management Commitment

TrainingEducation

History


1950

1951: Dr Deming and others developed total quality

management (TQM) systems

19701960 200019901980

1961: NASA and Pillsbury first developed HACCP

(3 Principles)

1971: HACCP Presented at 1th National Food

Safety Conference

1974: A regulation for low acid canned food was published by FDA and HACCP

became mandatory.

1980: WHO/ICMSF Published a report on

HACCP

1983: WHO Europe recommended HACCP

1985: National Academy of

Science recommended

HACCP

1992: NACMCF issues a revised documents, The first document

with 7 principles

of HACCP.

1993: Codex AlimentariusComission published first

guideliness

1994: HACCP was introduced into EU

Legislation.

1986: FAO Fishery Industries Division

(FAO/FII) adopted the HACCP approach to

fish quality assessment

1995: FDA NACMCF issues a revised

documents, The first document with 7

principles of HACCP.

1997: FDA issued its final rule to mandate HACCP

for use in seafood

processing plants.

2005: ISO 22000 Food Safety Management

System formed.

Why We Need HACCP?


Prevention Cure

Risky

Cheap

Safe Time Consuming

Expensive

Difficult

Healthy

Easy

Advantages Of The HACCP▪It focuses on those critical points in food processing and handling required for safe food production

▪Science based and systematic allowing for the specific identification of food safety hazards

▪Requires the implementation of measures to control these hazards where significant

▪Employs the principle of risk assessment allowing prevention to be based on the control program rather than inspection and testing

▪Better use of resources

▪Standardization of hazard management allowing for easier auditing and inspection by second and third parties


HACCP Implementations In Fish Processing

Stunning

Grading

Scaling Washing

Beheading

Gutting Filleting

Skinning

Meat-Bone Seperating


Preliminary Processing Of Fish

Implementation Steps of HACCP


Step 1: Assemble HACCP Team▪Gather as many materials and documents related to food safety as well as assemble a team to represent different sectors within the industry.

▪One HACCP coordinator with HACCP skills should be chosen.

▪The team should represent engineering, production, sanitation, and quality assurance.

▪Larger companies can have teams of seven or eight people while small companies may have teams as small as two or three people.

▪The HACCP coordinator should have responsibility for the whole HACCP program and be the team leader

▪Obtain management commitment


Step 2:Describe Product▪ Product name (common name) or group of product names (the grouping of like products is acceptable as long as all hazards are addressed)

▪ Important end-product characteristics: properties or characteristics of the food under review that are required to ensure its safety (e.g. pH/preservatives)

▪ How the product is to be used (i.e. ready-to-eat/further processing required, heated prior to consumption)

▪ Type of package, including packaging material and packaging conditions (e.g. modified atmosphere)

▪ Shelf-life, including storage temperature and humidity if applicable

▪ Where the product will be sold (e.g. retail, institutions, further processing)

▪ Labelling instructions (e.g. handling and usage instructions)

▪ Special distribution control (e.g. shipping conditions)


Step 3: Identify Intended Use▪Describe the normal expected use of the food

▪Who are the customers?

▪Who might misuse or abuse the product?

▪Ensure clear instructions on the label.


Step 4: Construct Flow Diagram


▪A flow diagram is a graphical representation of the process steps involved in making the food product and is developed by the HACCP team. It should be comprehensive and cover all the steps in the processes and the defined scope of the HACCP study.

Fresh Fish Flow Diagram Example


Receiving*

Storage*Scale

HeadWash

Fillet

Skin

RinseFillet/

Candle/ Bone*

Weight/ Pack/ Label

Refrigerated Storage*

Shipping

* Denotes that one or more CCPs have been identified

Step 5: Verification of Flow Diagram

▪After the flow diagram has been drawn up, the multidisciplinary team should confirm it on site during operating hours.

▪Any observed deviation must result in an amendment of the original flow diagram to make it accurate.



7 Principles of HACCP

Conduct A Hazard Analysis

1

Determine The Critical Control Points (CCPs)

2

Establish Critical Limits

3

Establish Monitoring Procedures

4

Establish Corrective Actions

5

Establish Verification Procedures

6

Establish Record keeping and Documentation

Procedures 7

Step 6: Conduct a Hazard Analysis-Principle 1▪ List all potential hazards associated with each step

▪Conduct a hazard analysis

▪Determine whether there are hazards that are reasonably likely to occur

▪Identify preventive measures to control the identified hazards


Potential HazardsHazard: A biological, chemical or physical agent in, or condition of,food with a potential to cause an adverse health effect (Codex,2009b)


Agents

▪Bacteria

▪Viruses

▪Moulds

▪Parasites

▪Toxins

▪Chemicals & Allergens

▪Foreign material

Adverse Health Effects

▪ Choking

▪ Vomiting

▪ Fever

▪ Kramps

▪ Chronic Infections

▪ Damage of Organs

▪ Cancer

▪ Death

Biological Hazards


▪Foodborne biological hazards include microbiological organisms such as bacteria, viruses, fungi and parasites.

▪These organisms are commonly associated with humans and with raw products entering the food establishment.

▪Many of-these microorganisms occur naturally in the environment where foods are grown.

▪Most are killed or inactivated by cooking, and numbers can be minimized by adequate control of handling and storage practices (hygiene, temperature and time)


Chemical Hazards

▪ Inorganic chemicals: arsenic, cadmium, lead, mercury, selenium, sulphites (used in shrimp processing)

▪ Organic compounds: polychlorinated biphenyls, dioxins, insecticides (chlorinated hydrocarbons). Thisis a very diverse group with a wide range of industrialusers. Unfortunately the chemical stability allow themto accumulate and persist in the environment

▪ Processing related compounds: nitrosamines and contaminants related to aquaculture (antibiotics, hormones).

Physical Hazards


▪ Physical hazards include any potentially harmful extraneous matter not normally found in food. The extraneous matter found in fish products can be divided or classified as:

▪ Non-food safety hazards (e.g. filth)▪ Food safety hazards (e.g. glass, metal, wood,

bones, stones, hard plastic).

▪ The Codex guidelines define a critical control point (CCP) as "a step at which control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level".

▪ The determination of a CCP in the HACCP system can be facilitated by the application of a decision tree such as that included in the Codex Hazard Analysis and Critical Control Point (HACCP) sys-tem and guidelines for its application which indicates a logical reasoning approach.

▪ The application of the decision tree should be flexible according to the type of operation (production, slaughter, processing, storage, distribution or other).


Step 7: Determine Critical Control Points-Principle 2

Decision Tree


Step 8: Establish Critical Limits For Each CCP Principle 3

▪Critical Limit is a criterion which separates acceptability from unacceptability.

▪Critical limits are criteria, which must be met if control is to be achieved. These are based on experience, regulations, literature searches, microbiological data, etc.

▪Targets set at each critical control point which guarantees to eliminate or reduce the hazard to a safe level

▪Critical limits can be values of : pH, temperature, time, Maximum residue limits, Maximum levels (of contaminants), Limits in microbiological criteria, Level of cleanliness, Levels of chlorine, overpressure etc.


Step 9 : Establish a Monitoring System For Each CCPPrinciple 4

▪The Codex Hazard Analysis and Critical Control Point (HACCP) system and guidelines for its application defines monitoring as "the act of conducting a planned sequence of observations or measurements of control parameters to assess whether a CCP is under control".

▪To measure the performance level of the system's operation at the CCP (trend analysis)

▪To determine when the performance level of the system results in a loss of control at the CCP, e.g. when there is deviation from a critical limit

▪To establish records that reflect the performance level of the system's operation at the CCP to comply with the HACCP plan


Monitoring Document Example


Critical Control Point

Monitoring Step Monitoring Frequency

Critical Limits Action on Deviation

Storage Temperature Verify required storage temperature is met. Prior to production start and in afternoon

Maintain products between 0 0C and 3 0C

When internal temperature exceeds 3 0C,product is culled by a supervisor for decomposition

Multiple Use of Storage Area

Confirm Processed and raw fish are separated by a divider.Confirm that no chemicals or cleaners are in storage unit.

Daily No mixing processed and raw fish products.No chemicals or cleaners in storage unit.

Confirm if stored product is contaminated and cull as required.Remove chemical/cleaners. Check product for contamination.

Product Inspection Inspect each lot for decomposition and required identification.Confirm proper icing of unprocessed fish.

Each Monday and Thursday

Each lot to be adequately identified (receipt date or production date and source).All unprocessed fish to be layered and covered with ice.

Assign lot identity.Re-ice products when required.

Rotation of Stock All product is checked determine length or storage.Confirm stock (raw and finished) is rotated on a first –in first- out basic.

Weekly Use dressed fish for production within 5 days.Ship finished product within 3 days.Rotation system is adhered to.

Ensure passed product is immediately processed or shipped.Modify rotation system.

Notify supplier for all noted deviations.All corrective actions to be recorded and signed by supervisor.

Step: Product and Refrigerated Storage FRESH FISH

Step 10 : Establish Corrective Actions- Principle 5▪The Codex Hazard Analysis and Critical Control Point (HACCP) system and guidelines for its application defines corrective action as "any action to be taken when the results of monitoring at the CCP indicate a loss of control".

▪For each CCP, corrective actions have to be planned in advance by the HACCP team, so that they can be taken without hesitation when monitoring indicates a deviation from the critical limit.

▪Corrective actions should ensure that only safe products reach the consumer

▪Actions to be taken when the results of monitoring at the CCP indicate a loss of control

▪Corrective action procedure include; deviation, identification deviation, isolated of affected products, evaluation of affected products and all procedure records.


Step 11 : Establish Verification Procedure –Principle 6

▪Verification procedures are intended to check the effectiveness of the HACCP system

▪The HACCP team should specify the methods and procedures to be used for determining if the HACCP is working correctly.

▪Methods for verification may include in particular:▪ random sampling and analysis

▪ reinforced analysis or tests at selected critical points

▪ intensified analysis of intermediate or final products

▪ surveys on actual condition during storage, distribution and sale and on actual use of the product

▪Verification procedures include;▪ HACCP plan validation

▪ HACCP system audits

▪ Equipment calibration


Example Verification Procedures

Verification Procedures Minimum Frequency

Verification schedule Annually

Prerequisite program verification In the beginning and annually thereafter

Validation of critical limits and HACCP system Before and during HACCP system implementation

Revalidation of HACCP plan Annually or upon significant change

Observation and interview of CCP monitor Quarterly/monitor/CCP

CCP monitoring record review Daily

Equipment calibration According to HACCP plan

Others records review Monthly

HACCP system verification Annually


Step 12: Establish Documentation and Record Keeping – Principle 7

▪Four types of records should be kept as part of the HACCP programme:▪ Support documentation for developing the HACCP plan

▪ Records generated by the HACCP system

▪ Documentation of methods and procedures used

▪ Records of employee training programmes

▪HACCP system records are kept to demonstrate adherence of the HACCP system with the HACCP plan. These records are used to demonstrate control at CCPs in the food process. The records generated by the HACCP system include all activities and documentation required by the plan, as follows.▪ Monitoring records for all CCPs

▪ Deviation and corrective action records

▪ Verification/validation records

▪ Training records


Step 12: Establish Documentation and Record Keeping – Principle 7

▪ Efficient and accurate record keeping is essential to the application of a HACCP system. HACCP procedures should be documented. Documentation and record keeping should be appropriate to the nature and size of the operation.

▪Documentation examples are: ▪ Parasite Control Form

▪ Packaging Control Form

▪ Metal Dedector Control Form

▪ Record examples are: ▪ CCP monitoring activities;

▪ Deviations and associated corrective actions;

▪ Modifications to the HACCP system


Prerequisite ProgramsPrerequisite Program: A programme that is required prior to the application of the HACCP system to ensure that a fish and shellfish processing facility is operating according to the Codex Principles of Food Hygiene, the appropriate Code of Practice and appropriate food safety legislation.


Prerequisite Programs▪The application of HACCP does not stand alone in a food processing facility. The plan must be built on other food safety programs.

▪Sanitation standard operating procedures (SSOPs)▪ Good Manufacturing Practices (GMP)

▪ Sanitation

▪ Personal hygiene

▪ Employee training

▪ Recall procedure

▪ Supplier Control

▪ Chemical Control

▪ Receiving, Storage and Shipping

▪ Pest control


haccp in fish processing sectorcacfish.eurofish.dk/presentations/11-ferrahi-fao-haccp.pdf · 2019....

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