HACCP LEC2

Learning Outcomes for Modules

• Learning outcomes include stating HACCP principles, identifying relevant elements, identifying regulatory agencies, and evaluating HACCP systems.
• Learning outcomes also include designing hygiene protocols and contamination controls, designing HACCP systems using control measures, and prescribing corrective actions.

Learning Outcomes - Lecture 2

• At the end of the lecture, the student, should be able to classify leading food safety hazards, understand control measures, and understand the importance of product descriptions in HACCP design.
• Also able to design food hygiene protocols, HACCP systems, and corrective actions for critical control points.

Assessment of Module

• Continuous assessment accounts for 40% of the overall grade and will be online on March 8, 2024.
• Final exam in May 2024 will contribute to the remaining 60% of the overall grade
• A minimum of 30% must be achieved in both the final exam and the continuous assessment overall to pass
• The pass grade is 40% overall.

Categories of Leading Food Safety Hazards

• Biological hazards include micro-organisms.
• Physical hazards are a leading category of food safety concerns
• Chemical hazards are a leading category of food safety concerns
• Allergens are often managed through prerequisite programs and separate risk assessments.
• Radiological hazards are associated with dried ingredients and are addressed separately from standard hazard analysis.

Biological Food Safety Hazards

• Micro-organisms of importance to the food industry are: Salmonella spp, E.coli and E.coli 0157:H7, Campylobacter spp, Cl. Botulism, CI. Perfringen, B. cereus and other Bacillus spp, Staph. aureus, Listeria monocytogens.
• Microbiological risks and controls are covered in the Food Microbiology module.

Physical Food Safety Hazards - Introduction

• About 80% of foreign body ingestions occur in children under three
• Of those ingestions, 1% to 5% result in some kind of foreign body injury

Classification of Physical Food Safety Hazards

• Physical food safety hazards can be broken down into two categories: intrinsic and extrinsic.
• Intrinsic foreign materials are materials or objects that are an integral part of a component of a product. Example: gristle in a beef burger.
• Extrinsic foreign materials are materials that are a foreign component of a product. Example: glass in a hash brown.

Physical Food Safety Hazards - Introduction

• Leading physical hazards during processing include: glass, perpex, wood, metal, aluminium foil slivers, hard plastic, plastic film, cardboard, paper, hair, fibre, bone, gristle, EVM (Extraneous Vegetative Material), and other miscellaneous foreign material.

Physical Food Safety Hazards – Two Categories

• Intrinsic physical safety hazards are recognised hazards that are part of the raw material that we do not want to find in a finished product including gristle, onion skins and pepper seeds
• Extrinsic physical safety hazards are recognised hazards that are foreign to all raw materials and should not be in the finished product Including glass, metal, wood, and Beef gristle in a vegetarian product

Physical Food Safety Hazards – Glass – Practical Controls

• Wherever possible, glass and brittle plastics should be replaced with sustainable alternatives.
• Replace Perspex rulers with metal rulers.
• Replace glass windows with Perspex in internal office windows.
• Where this is not possible, a protective sheet can be affixed to glass windows so that in the event of glass shattering all fragments may still be held in place.
• Perspex covers can be placed over all fluorescent light tubes.
• Shatterproof light tubes can be used on Electrical Fly Killing (EFKs) Units.
• Incoming inspection checks should be performed for any glass alternatives
• Following safe working practices, where SOP's for the handling of glass must be in place,
• Glass breakage procedures including a 10m cleanup procedure must be implemented

Physical Food Safety Hazards – Glass – Practical Controls

• Best practice dictates that glass, hard plastic and brittle plastics must be treated with equal caution.
• Wherever possible glass/perpex/brittle plastic should be of a colour that is different to the food material
• A register of all glass, perpex and brittle plastic must be maintained for the entire production site
• Scheduled routine audits must be carried out on all register items

Physical Food Safety Hazards – Glass – Risk Assessment

• The frequency of assessment is based on risk assessment.
• Assessment timelines include assessing documented items daily, monthly, and every three months depending on area

Physical Food Safety Hazards – Glass – Risk Assessment

• An audit must record the condition of glass items e.g. intact, broken, damaged but not working.
• Any issues raised must be investigated to establish if the glass breakage procedure has been followed and if not, whether product has been put at risk.
• A risk assessment must be completed to determine how quickly repairs must be made.

Physical Food Safety Hazards – Glass Breakage Control Measures

• A detailed procedure must be in place for the management of glass and hard breakages.
• Include stopping of production, restriction of movement, Quarantine, report to management, clean up, and safe removal and repair or replacement
• Include, checking PPE is is good condition, completion on an incident log, a sample of the broken glass, and the determination of corrective action.
• All production / hygiene managers and engineers must be trained to understand and apply the glass breakage procedure.

Physical Food Safety Hazards – Metal

• All modern food processing equipment is mainly made of stainless steel which can experience wear and tear and fail if care is not taken
• Tools can also be a contamination risk especially if maintenance isn't controlled properly
• Other product will be packaged with metal including bag clips, cans and foil

Physical Food Safety Hazards – Metal

• Knives are commonly used in production for meat and veg preparation
• Controls should be in place including reconciliation of numbers and inspection of condition
• Knife control must be in place for Knife, blade, scissors and needles which should be company issue, captive, identified and registered

Physical Food Safety Hazards – Metal

• No snap blade knives must be used and knives must only be used for the intended task
• Equipment must be accounted for and the condition checked and recorded (minimum start and end of production).
• All broken parts must be accounted for and corrective actions taken.

Physical Food Safety Hazards – Metal

• Knife sharpening must take place away from production areas and equipment must be returned in a clean condition.
• shadow boards are acceptable for used knives

Physical Food Safety Hazards – Metal

• Best practice includes knives being individually numbered for tracking.
• Safe knife sharpening is acceptable
• Where sharpening devices are fixed, they must be within butchery areas and not a contamination risk

Physical Food Safety Hazards – Metal – Engineering Activities

• Engineering activities must be controlled with inspections to avoid compromising product safety or quality.
• Start up checks of equipment are important to prevent contamination.
• In both cases, accountability of parts is vital in engineering actions

Physical Food Safety Hazards – Metal – Engineering Activities (cont.)

• Potential transfer of metal contamination from engineering areas must be suitably controlled (e.g swarf mats).
• When purchasing small items, where possible they must be metal detectable at level of detection on site
• Wire brushes and scourers must be in good condition and stored away from the production process or below product height when not in use

Physical Food Safety Hazards – Metal – Engineering Activities (cont.)

• Mobile engineering work stations must not be used in open food areas
• Areas where wire brushes are used must be inspected.
• PPM programs must be used which cover all critical equipment

Physical Food Safety Hazards – Metal – Engineering Activities (cont.)

• Systems must be in place to record maintenance work.
• All work undertaken must follow timescales and standards for engineering and fabrication.
• Areas must be included in pest control.

Physical Food Safety Hazards – Metal – Engineering Activities (cont.)

• Food containers must not be placed which could pose a risk.
• Wherever possible engineering must take place away for product.
• Areas which have direct access must be restricted.

Physical Food Safety Hazards – Metal – Engineering Activities (cont.)

• Welding needs to be adequately cleaned and safe hygienic screening used
• Captive tools or tool cleaning must take place in relevant areas.

Physical Food Safety Hazards – Metal – Engineering Activities (cont.)

• Electrical items must be sterilised and waterproof.
• Use tools must be in a metal lockable box with inventory.

Physical Food Safety Hazards – Metal – Engineering Activities (cont.)

• All GMP must comply with all safety and risk standards.
• A list of compliant contractors should be listed, with permit to work systems in place.

Physical Food Safety Hazards – Metal – Engineering Activities (cont.)

• Check cleaning and follow production.
• Final sign of must only take place with engineer and PA or QA

Physical Food Safety Hazards – Metal – BRC

• Staples, paper clips and similar must not be used in potential product hazard areas.
• Plastic sleeves should be used.

Physical Food Safety Hazards – Metal – Foreign Body Detection and Removal Equipment

• To eliminate risk from hazards there should be systems in place such as X-ray inspection and metal detection

Physical Food Safety Hazards – Metal – Foreign Body Detection and Removal Equipment

• a documented assessment in association with HACCP should be present such as filters and sieves

*Physical Food Safety Hazards – Metal – Foreign Body Detection and Removal Equipment

• magnets and optical sorters are helpful.
• other physical separation equipment should be used

Physical Food Safety Hazards – Metal – Foreign Body Detection and Removal Equipment

• A comprehensive assessment is needed to track HACCP.

Physical Food Safety Hazards – Metal – for Metal Detection and Removal Equipment

• Detection setting should be calibrated so only specified authorized employees can alter them.

Physical Food Safety Hazards – Metal – Foreign Body Detection and Removal Equipment

• Regular checks with industry-standard detection is important across a range of products.

Physical Food Safety Hazards – Foreign Body Detection and Removal Equipment

• Site data checks help reduce the risk of a failure

Physical Food Safety Hazards – Foreign Body Detection and Removal Equipment

• Implement detection procedures.

Physical Food Safety Hazards – Metal - Other good practices

• system monitoring tests must consider startup and shutdown.
• changes in machine settings or following downtime and specified customer requirement

Physical Food Safety Hazards – Metal - Other good practices

• the testing method to isolate contaminants. -the location in which there are risks for contamination.

Physical Food Safety Hazards – Metal - Other good practices

• All metal detection should be ferrous, non-ferrous and stainless steel sensitive with appropriate personnel and standards kept to a high measure.

Physical Food Safety Hazards – Metal - Other good practices

• Detectors with conveyor belts should audibly have a alarm.

Physical Food Safety Hazards – Metal - Other good practices

• A data capture system is needed to track packs including tests on the numbers of rejects.

Physical Food Safety Hazards – Metal - Other good practices

• foreign body detection must be fully operational with the same temperature to minimise risk for testing with equipment on par with other best practices measures.

Physical Food Safety Hazards – Metal - Other good practices

• The worst places must be tested and in line systems calibrated from data driven assessments.

*Physical Food Safety Hazards – Meta Metal

• all metal detectors must be tested fully with calibrated metal.

Physical Food Safety Hazards – Plastics and other FM

• There should be procedures to prevent damage.

Physical Food Safety Hazards – Plastics and other FM

• checks should take place when the raw materials and product is at its most vulnerable including at decanting.

Physical Food Safety Hazards

• portable items could be in sensitive area must be handled with diligence and precision.

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• Food for the factory should also be of high quality at PPE standard.

Physical Food Safety Hazards – Plastics and other FM

• plastic and product should also be checked and sealed at a regular high standard.

Physical Food Safety Hazards – Plastics and other FM

There should be standards for plastic and checks on all product that is packed An alternative may not be the best source of product at a critical point.

Physical Food Safety Hazards – Other FM -plastics

The type, grade color and quality as it can be affected with exposure across use cases including washing, impact and temperature.

Physical Food Safety Hazards Plastics

Avoid the cross over of containers.

Physical Food Safety Hazards Plastics

Items such as pens must be 1 piece and also checked at high standard Use plastic sleeve

This lesson covers safety standards for wood use in food production. It focuses on the conditions for wood maintenance, concerns about direct contact with food, and the use of wooden pallets. Risk management and steps for handling damaged equipment are also addressed.