HACCP lec3

Learning Outcomes for Module

• Understanding HACCP principles in GMP within the food industry is a key learning objective.
• Identifying the relevant elements of a HACCP program is a learning outcome.
• Identifying the regulatory agencies and requirements for a HACCP program is part of the module.
• Evaluating and auditing a HACCP system is a learning objective.
• Designing protocols and procedures for food hygiene and contamination controls is a learning aim.
• Designing a documented HACCP system with appropriate control measures at critical points is targeted.
• Identifying and prescribing corrective actions for failures at critical control points is a learning outcome.

Learning Outcomes – Lecture 3

• There is a classification of leading allergen food safety hazards.
• It is important to understand control measures used by the food industry to control allergen hazards.
• It is important to understand the importance of risk assessments in allergen food safety risks management.

Assessment of this module

• The final exam in May 2025 accounts for 60% of the overall grade.
• A minimum score of 30% must be achieved in both the final exam and overall coursework.
• The passing grade for the module is 40%.

Legislation on Food Allergens

• EC Directive 13/2000, amended by Directive 68/2007, lists scheduled allergens that must be declared on food products in the EU.
• There are 14 categories of scheduled allergens.
• EC Directive 1169/2011, amending Directive 68/2007, requires allergens to be listed in bold print on product ingredients lists for customer information.

14 Scheduled Food Allergens

• The 14 scheduled allergens include: Peanuts, Tree Nuts, Milk and Milk Derivatives, Gluten, Egg and Egg Derivatives, Soya and soya Derivatives, Lupin and lupin Derivatives, Fish and fish derivatives, Molluscs and mollusc derivatives, Crustaceans and crustacean derivatives, Sesame Seed and sesame seed derivatives, Celery and celery derivatives, SO2, and Mustard and mustard derivatives.

Food Allergens

• An allergic reaction to peanuts usually occurs within minutes.
• Symptoms of an allergic reaction to peanuts may range from mild to severe and include: skin reactions (hives, redness, swelling)
• Other common allergy symptoms include: itching or tingling sensations in or around the mouth and throat, and digestive problems: diarrhea, stomach cramps, nausea or vomiting.
• Tightening of the throat can occur
• Anaphylaxis is a life-threatening reaction and peanut allergy is the most common cause of food induced anaphylaxis
• Signs and symptoms of Anaphylaxis include: constriction of airways, swelling of the throat that makes it difficult to breathe, severe drop in blood pressure (shock), rapid pulse or even feeling dizzy.

BRCQS Standard and Food Allergens

• BRC Standard -Clause 5.3.1 requires sites to assess raw materials for allergen presence and likelihood of contamination.
• Raw material assessment requirements include review of the raw material specifications, and additional information from suppliers (questionnaires to understand allergen profile).
• Raw material assessment must establish supplier approval and the risk of raw materials
• Raw material specifications, including flavorings, additives, carriers, and processing aids, must be agreed upon with each supplier to prevent cross-contamination.
• Additional allergen information should be obtained from suppliers, if needed.
• A risk assessment must consider the risks associated with ingredients and manufacturing sites.
• The identification and listing of all allergen-containing materials handled on-site is necessary, including raw materials, processing aids, and development ingredients
• All materials containing allergenic substances must be listed in a single reference document, including non-food materials like wheat-based pest control baits.
• There is a need to maintain and communicate up-to-date allergen lists.

Prevention of Cross-Contamination

• Identifying routes of contamination ensures documented policies and procedures are in place.
• This identifies and documents policies for handling of raw materials and ensures contamination is avoided with raw, intermediate and finished goods
• This shall include consideration of physical state and identification of potentional points through the flow process
• A physical state of the allergent must be considered, for example a powder may contaminate compared to liquid
• Risk of cross-contamination should be assessed at each step
• To ensure safe product, suitable controls must be identified to reduce or eliminate cross contamination.
• Procedures must be established for the management of allergenic materials to prevent cross-contamination.
• Methods include physical or time segregation, which may involve storage, processing or packing
• Methods include the use of separate or additional clothing when handling allergenic materials.
• The use of dedicated equipment must be used for processing.
• Having an effective system in place for scheduling production can reduce allergenic incidents
• Dust control systems are put in place to keep airborne
• Effective waste handling and control must be implemented using allergen kits
• There are restrictions on food brought on site by staff, visitors and contractors for catering.
• Rework practices include implementing procedures to rework operations
• Specific documentation is required to show if rework used and to prevent risk

Labeling to prevent allergenic incidents

• A warning should be considered on labels if the product is at risk of cross-contamination
• This shows if the allergen cannot be prevented and is based on risk assessment or national guidlines
• Warning Labels that are justifiable show where controls cannot prevent cross-contaminaton.
• Label warning must be considered on location of list, statement and colour used
• It should be fully labelled in proximity with clear colours and highlighting

Documentation

• A claim is made regarding the suitability of a food must be documented where processes are validated, if there are any processes that cause hypersensitive conditions
• Demonstration of product that controls where allergens can be found
• Adequate cleaning and process must be applied to processes
• A documentation of processes must happen in the company

Cleaning

• Cleaning tools or procedures must reduce contamination and levels of allergens
• Tools must be checked for correct use
• tools should be identiable and specific for allergens and affectively cleaned
• The area should be inspected for cleaning effectiveness
• Additional validaiton is needed

Personal and Production Dept Best Practice

• Personnel including engineers/ contractors must have sufficient training when dealing with allergens.
• There must be an effective system in place that includes checks at line start up etc
• There should be clear allergy risk assessment with raw materials, ideally signed through all parties
• There must be signage at ground level to show materials and allergens
• The Production department should be aware and implement production plans
• To prevent airborne contaminations Swab validation for cleaning is required.
• Also use Dedicated kits for allergen control
• The packing department must have signs and approved text relevant to the process