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The HACCP method in mineral water bottling Partner P5 - CSEI Catania

Dr. Chiara COPAT – University of CataniaDr. Caterina LEDDA – University of Catania

Hazard and risk: What is it?

Hazard analysis: Identify all possible hazards potentially created by a product, process or application SENSATION

Risk assessment: It is the next step after the identification of potential hazards. Risk in this context is the probability and severity of the hazard becoming reality MATHEMATICS / A NUMBER

Hazard analysis: What is it?

Objectives:Tool for safety practitioners to:

• identify possible hazards,• provide an evaluation of the risks, • prompt alternative design solutions to

mitigate or control the risks to an acceptable level

Hazard Management Process• Identify the hazards: health, safety, and

environmental hazards• Assess the risks: injury, illness, damage,

productivity loss…• Evaluate risks: Likelihood x Consequence

(Severity). • Hazards can be ranked from high to low risk• Control the risks• Monitor and Review

What to consider?

• The number of times tasks which could result in an incident are undertaken

• The number of people performing the task(s) • The likelihood of the incident occurring while

the task is being performed • If it (the incident) occurs, what will happen?

Caution:

Any unidentified hazard will not be addressed by safety measures and will not be detected during testing

Hazards not identified during this analysis can create substantial risk to users of the design

Hazard Analysis and Critical Control Points

HACCP

• System for food safety management

(including bottled water)

• Internationally recognized and recommended

• A stepwise process which:

- Identifies hazards

- Installs preventive measures to eliminate or reduce hazards

• A proactive (before) rather than reactive (after) system

• A risk-related and based system

What is an HACCP system?

HACCP Importance

By reducing major food risks - microbiological, chemical

and physical - the industry can better guarantee that its

products are as safe as good science and technology allow

By reducing food/water borne risks, public health protection

is strengthened

How to perform a HACCP Study?

HACCP studies involves a logical

sequence of tasks ...

Assemble a HACCP Team • By involving a team of people, a greater diversity of skills

and knowledge appropriate to the system will be available• It is counselled to create a team with some external people

Define the Terms of Reference • Identify the process (e.g. the production and supply of

water) • Identify the limits of the study • All hazards (microbiological, chemical and physical)

must be considered as a whole, or will each type of hazard be considered individually?

• Each process stage is studied individually (e.g. ozonation, filling, capping...)

Describe the Product and Identify the Intended Use

Draw up a full description of the production system, including information on water composition and the method of distribution as well as the materials used in the production:

• Raw materials: water, CO2 and added minerals (depending on the type)

• Authorised water treatments• Materials in contact with the product (filling line and containers:

bottles, cans...) • Storage conditions and methods of distribution• Theoretical/legal expiry date

Identify the consumer/s target group/s for the product

The intended use shall be based on the composition and

expected uses of the product

In specific cases, people that can be affected (e.g. infants,

special diets) should be considered

Flow Diagram Draw a flow diagram of all aspects of the factory/procedure

considering: • Source and its protection• Water operation • Raw materials• Processing • Packing (all steps)• Storage • Distribution • Retailer• Point of consumption (drinking)

1. Step – process identified in the flow diagram; Hazard - potential source of harm

or adverse health effect/s on a person or persons; Risk - the likelihood that a

person may be harmed or suffer adverse health effects if exposed to a hazard;

Control Measures (CM)

2. Critical Control Point Yes/Not (CCP Y/N)

3. Control Limits (verification) (C Limits)

4. Monitoring:

5. Corrective Actions (CA)

6. Verification

7. Documentation

The HACCP team shall list all hazards reasonably expected to occur at each step according to: - Scope from primary production, processing, manufacture and distribution until the point of consumption- Each process step identified in the flow diagram shall be assessed for the introduction or presence of a hazard

The HACCP team shall next conduct a hazard analysis to identify which hazards are of such a nature that their elimination or reduction to acceptable levels is essential to the production of safe bottled / packaged water.

PRINCIPLE 1

List All Hazards Associated With Each Step And Consider Any Control Measures To Control The Hazard

The identification of a Critical Control Point (CCP) in the HACCP system is facilitated by the application of a Decision Tree (next). Application of the Decision Tree determines if the step is a "critical" control point for the identified hazard

If a hazard has been identified at a step where control is necessary for

safety and no control measure exists at that step, or at any other step, then the product or process must be modified at that step, or an earlier or later stage, to include a control measure

PRINCIPLE 2

Identify the Critical Control Points

Critical limits shall be specified and validated for each CCP. Details

of the establishment of critical limits shall be recorded

These critical limits shall be measurable

Criteria often used include: measurements of time, temperature,

concentration of disinfecting agent (not in the water), pH, absence

of metals, microbiological limits, sensory parameters e.g. visual

appearance and texture, etc.

In some cases more than one critical limit will be elaborated at a

particular step

PRINCIPLE 3

Establish Critical Limits for each CCP

Monitoring is a planned sequence of observations or measurements of a CCP target level and tolerance

Typical monitoring methods include visual evaluations, physical measurements (e.g. temperature), chemical analysis, and microbiological assessment

Records and documents associated with monitoring CCPs must be signed by the person(s) doing the monitoring and by a responsible reviewing official of the company

If monitoring is not continuous, then the amount of frequency of monitoring must be sufficient to guarantee the CCP is under control

PRINCIPLE 4 Establish a Monitoring System for each CCP

Specific corrective actions must be developed for each CCP in order to deal with any

deviation. The action must ensure the CCP is brought under control and include

details of what to do with the affected product

Monitoring and auditing should be carried out to determine if the system is

working correctly. Examples include a review of the HACCP system and

its records, review of deviations, checks to ensure CCPs are under

control, validation of established critical limits, etc.

PRINCIPLE 5 Establish Corrective Actions

PRINCIPLE 6 Validate the HACCP System

In order to be efficient and effective, keeping of records is essential

Each process step as documented in the flow diagram must be detailed in the HACCP chart

and the controls, monitoring, corrective actions, etc. determined accordingly. This will

ensure that the hazards at each process step are duly considered and controlled

These records must be reviewed periodically e.g. annually or when there is a significant

change in operation

PRINCIPLE 7

Establish Record Keeping and Documentation

SAMPLE HACCP CHART