HACCP In Food PDF

HACCP  A preventative approach to enable the production of consistently safe products:  Control of key steps (critical control points) which can eliminate or reduce the likelihood of a hazard occurring  Documentation that the system is working  Use of HACCP:  Together with the p...

HACCP  A preventative approach to enable the production of consistently safe products:  Control of key steps (critical control points) which can eliminate or reduce the likelihood of a hazard occurring  Documentation that the system is working  Use of HACCP:  Together with the prerequisite plan, it is the basis for successful implementation of a quality assurance system in the processing of food  Main objective is to ensure products are safe to consume  Monitoring and verification:  HACCP program compliance requires that establishments have systems in place to monitor and control the program and maintain records demonstrating due diligence  HACCP is important because… Systematic and scientific approach Implementation of HACCP can prevent foodborne outbreaks Proactive Focusing on the issues that are critical to food safety Can be integrated with other systems (ISO, TQM, 5s dll). Internationally recognized 3  HACCP is important because…  Demonstrates Management commitment on food safety issues  Pressure from government, customer and market  Export requirements  Pressure from media 4  1 Identify Hazards & Preventative Measures 2 Identify Critical Control Points 3 Establish Critical Limits 4 Establish a CCP Monitoring System 5 Establish Corrective Action Procedures 6 Establish Verification Procedures 7 Establish Documentation & Records 5  HACCP Pre-requisites (GMP) GMP elements based on MS1514:2009 : 1st Element -Design and Facilities 2nd Element-Control of Operation 3rd Element-Maintenance, Cleaning and Sanitation 6  HACCP Pre-requisites (GMP)  GMP elements based on MS1514:2009 (cont…) :  4th Element - Personal Hygiene  5th Element - Transportation and Distribution  6th Element - Product Information  7th Element - Training  8th Element - Internal Inspection  9th Elemen -Management Review  10th Element-Legal Requirements 7  HACCP Definitions  Hazard – any biological, chemical or physical property that may be expected to cause an unacceptable health risk to consumers if present in the product  Risk – an estimate of the likelihood of the occurrence of a hazard  Severity of risk – the seriousness of a hazard if not properly controlled, level of danger presented by a hazard (e.g., metal fragments vs. botulinum toxin)  Critical control point (CCP) – a specific point in a process where control can be applied to eliminate or reduce the risk of a hazard to an acceptable level  What is a Hazard?  Biological – bacteria, viruses and parasites  Chemical – natural toxins, and chemical contaminants (pollutants, pesticides, sanitizers)  Physical – glass, stones, metal  Not hazards: hair, filth, spoilage, etc., since no injury or illness is caused to the consumer  Foods may be divided into risk categories depending on their characteristics and potentially associated hazards  HACCP Study Requirements 1. A trained multidisciplinary HACCP Team – Typically 4-6 experienced personnel – Core disciplines include : Production, Engineering, QA/QC, Technical – Additional specialist knowledge – Ability to evaluate risk and make safety judgments 2. Product knowledge – Ingredient sensitivity – Recipe/intrinsic control factors – Process – Packaging / finished product state – Consumer target 3. Time – Realistic planning 10  What is a HACCP Plan? A formal document holding details of all that is critical to food safety management for a product or process -Process Flow Diagram - HACCP Plan Summary - Support documentation OR A document prepared in accordance with the principles of HACCP to ensure control of hazards which are significant for food safety in the segment of the food chain under consideration 11 (MS 1480: 2007)  Seven Principles of HACCP 1. Conduct a hazard analysis for each product 2. Identify critical control points (CCP’s) 3. Establish critical limits 4. Establish CCP monitoring requirements 5. Establish corrective actions when critical limits have been exceeded 6. Establish HACCP verification procedures 7. Establish effective record keeping  Twelve Steps to Implement HACCP As recommended by CFIA & Codex Alimentarius: 1. Assemble HACCP team 2. Describe product 3. Identify intended use 4. Construct process Flow Diagram and Plant Schematic 5. On-site verification of Flow Diagram and Plant Schematic 6. List hazards associated with each step - P1 7. Apply HACCP decision tree to determine CCP - P2 8. Establish critical limits – P3 9. Establish monitoring procedures - P4 10. Establish deviation procedures - P5 11. Establish verification procedures - P6 12. Establish record keeping/documentation for principles P1 to P6 (steps 6-11) - P7  Solid Foundation Required  Management commitment essential!  HACCP training for everyone on the team and eventually all employees  HACCP team assembly and initial tasks:  Description of intended use of product  Product to be consumed by any of the major risk groups? (Very young or old or people with health problems affecting their immune system)  Development and verification of the product flow diagram  HACCP Team: Selection & Duties  Team consists of individuals with different specialties:  Maintenance, QC, production, cleaning and sanitation, people involved in day to day plant operations  Team leader must be well-trained, have a reasonable scientific background, ability to motivate and work well with others  Team must have access to reliable technical information  Duties of the HACCP team:  Develop the HACCP plan  Verify the HACCP plan  Implement and continually revise plan to accommodate changes. The plan is a “living” document and will evolve with time!  Why the Team Approach?  No one person can be an expert on all processing operations as well as being an expert on all possible hazards  Team approach minimizes risk or missing something important  Encourages “ownership”  Describe The Product And Identify Intended Consumer Product description Identification of the intended use of the product and intended consumers 17  Product Description Raw material used Sensitive ingredients identified Rework material Important product characteristics, where appropriate Process type Packaging and labelling Shelf life and storage condition Handling and distribution 18  Identification of the Intended Use of the Product and Intended Customers Potential users and consumers shall be identified Consumer groups known to be especially vulnerable shall be indicated The intended use with regard to storage, preparation and where appropriate serving shall be described 19  Process Flow Diagram  Raw materials  Packaging  Process activities  Storage conditions (type & temperature)  Parameters for CCP  Temperature and time profile  Filter size  Pressure  Flow rate  Distribution  Re-work  Intermediate products 20 21 22 22  Process flow diagram Skimmed milk powder handling Skimmed milk powder arrival 25kg poly-lined sacks on wooden pallet Off load onto loading bay-fork lift truck Transfer to dry goods store-pallet truck Transfer onto plastic pallet-manual stacking Load into storage rack-captive fork lift truck Dry storage-< 25 C Transfer to debag into feed hopper ( pull string on bag to open ) 23 Gravity transfer to blender Validate Process Flow Chart To ensure accurate representation of the process at ALL times On site audit Process flow chart should be verified 24  Hazard Analysis Worksheet Identify Raw Materials/ Process Steps List the Potential Hazard/ Sources Significance of Hazard Preventive measures CCP/ Not CCP ? 25  What Are Hazards? A biological, chemical or physical agent in, or condition of, food with the potential to cause an adverse health effect. (MS 1480: 2007) 26  Type Of Hazards Microbiological – pathogenic bacteria, virus, fungi and mould, algae, protozoa, parasite Chemical – pesticides, heavy metals, natural occurrence toxins, additives, lubricants, etc. Physical – Items which are sharp and may cause injury, which are hard and may cause dental damage, and which could block airways and cause choking. Example : glass, rubber, screw, plastic 27  TYPE OF PATHOGEN Clearly  Specific organism Identify the  Resistant forms, e.g. spores, cysts  Toxin formers Nature of  Vegetative organisms the Hazard HAZARD  Presence MANIFESTATION  Contamination  Survival  Growth 28  Wide range of Pathogenic Bacteria- organisms Considerations Some are heat resistant Some can grow at chill temperatures Some can form toxins in foods React in different ways to Some can Some have a low the product’s intrinsic grow in the infective dose control factors e.g. pH , absence of aW oxygen 29  Other Microbiological Hazards-Considerations HAZARD TYPE SOURCES EXAMPLES Parasites/Protozoa Crytoporidium, Water, Meat Giardia Viruses Shellfish, Food SRSV, Hepatitis Handlers Algae Shellfish, Water Paralytic Shellfish Poisoning Crops, Nuts, Dried Mycotoxin (Chemical) Fungi Ingredients 30  Chemical Hazard-Examples PROCESS RAW MATERIALS PACKAGING CONTAMINANTS Pesticides/ herbicides Cleaning agents Plasticisers Heavy metal Lubricants and additives Natural toxins Refrigerants Ink/ adhesive Microbial toxins Allergens Pest control Metals Antibiotics Chemicals Hormone residues Microbial toxin Allergens Fumes 31  Control of Chemical Hazards Approved and legal chemicals (cleaners, sanitizers, hormones, pesticides) Use a safe level Letters of guarantee and vendor certification Proper procedures and rinsing (cleaners and sanitizers) Storage of feed (aflatoxin) Storage and labeling for ingredients and raw materials 32  Physical Hazards- Definition  Items which are sharp and may cause injury  Items which are hard and may cause dental damage  Items which could block airways and cause choking 33 How to Control Physical Hazards ? Separate and remove physical objects Filter or sieve (meat grinder) Water bath (vegetables) Metal detector (all foods) Good employee practices (jewelry) Good sanitation and quality control programs 34  Principle 1. Hazard Analysis  Hazard analysis: Identify steps in the process where significant hazards may occur  Must estimate both risk and severity of hazards  Risk assessment based upon experience, epidemiological data and technical information  Outside assistance often required for this step  Brainstorming, a potential tool  Identify preventive measures for each hazard to reduce probability of risk  What Is The Risk ? The likelihood of the hazard occurring HACCP requires control of any hazard that may be reasonably expected to occur ( Codex 1993) 36  Two – Dimensional Health Risk TOOLS Assessment Model (ILSI) Likelihood Of Occurrence High Sa Ma Significance of Mi Cr Hazards Medium Sa Ma Sa – Satisfactory Mi Ma Mi – Minor Ma – Major Low Sa Cr – Critical Mi Mi Mi Negligible Sa Sa Sa Sa Negli. Low Medium High Severity of Consequences 37  Significance Of Hazards Minor & Negligible (Not Significant)-No further consideration Major & Critical (Significant)-Followed by CCP Identification 38 MORE EXAMPLE….. HAZARD ANALYSIS CHART 40 HAZARD ANALYSIS CHART 41  Preventative Measures/ Control Measures- Definition Any action and/or activity that can be used to prevent or eliminate a food safety hazard or reduce it to an acceptable level (MS 1480 : 2007) 42 Preventative Measures/ Control Measures- Examples Factors Capable of Control  Process steps e.g. cooking, sieving  Use of approved suppliers  Controlled storage  Time management  Segregation  Application of effective cleaning schedule  Application of training procedures  Effective pest control Control, Not monitoring 43  Examples of Preventive Measures  Biological hazards:  Combination of heat x time to reduce / destroy pathogens  Low temperature preservation to control growth of pathogens or to kill parasites  Control water activity by drying or salt addition  Chemical / physical hazards:  Source control (e.g., vendor certification, raw material testing)  Production control (e.g., proper application of food additives; use of metal detectors, X-rays)  Principle 2. Identify the Critical Control Points (CCP’s)  A CCP is any point in a process which can be used to eliminate or reduce hazards to acceptable levels  a failure of some sort could make food unsafe if proper control is not exercised  Every significant hazard must have a corresponding CCP; if not, the process must be modified!  Sometimes a “decision tree” is used to determine if a process point is a CCP  Decision tree for hazard determination, raw material used & for each processing step Identification Of Critical Control Points What is a Critical Control Point ? How do we find them ? HACCP PRINCIPLE 2 46  What Is a CCP ? Definition A point, operational step or stage in the food chain at which control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level (MS 1480: 2007) 47 How Do We Identify CCPs ?  Team expertise and judgement  Tools  CCP decision trees - Raw materials - Process steps  Documentation  Answer record sheet  Software 48  RAW MATERIAL DECISION TREE Is there a hazard associated 1 With the raw material? NO Proceed to next raw YES material Are you or the customer (anybody) is going to process 2 this hazard out of product? NO Sensitive raw material YES High level of control required - CCP Is there a cross-contamination 3 risk to facility or the other products which will not be controlled? YES NO Proceed to next raw material Sensitive raw material High level of control required - CCP 49  Documenting Team Decisions… Provides Evidence Raw materials Q1 Q2 Q3 Sensitive Comments material? 50  TABLE OF DECISION TREE FOR RAW MATERIAL OF FROZEN CHICKEN NUGGET RAW Q1 (HAZARD) Q2 (PROCESS OUT Q3 (CROSS SENSITIVE COMMENT MATERIALS THE HAZARD?) CONTAMINATION) MATERIAL 1. FROZEN YES YES YES YES High Risk RM MINCE B-pathogen/ Will be cooked Pathogen still exist CHICKEN Salmonella through frying 2. EGGS YES YES YES YES High Risk RM B-pathogen/ Eggs will be Pathogen still exist Salmonella washed Product will be fried 3. WATER YES YES YES YES High Risk RM P- sediments/ Water will be Sediment still exist stones filtered YES B- pathogen/ YES Pathogen still exist YES High Risk RM waterborne Product will be fried  PROCESS STEP DECISION TREE Do preventative measure(s) MODIFY STEP, 1 exist for the identified hazard? PROCESS / PRODUCT YES NO YES IS CONTROL NECESSARY AT THIS NOT A NO CCP STOP * STEP FOR SAFETY? 2 Is the step specifically designed to eliminate or reduce the likely occurrence of the hazard to an acceptable level? NO YES Could contamination occur at or increase to 3 unacceptable level(s)? YES NO NOT A STOP * CCP Will a subsequent step or action eliminate or reduce the hazard 4 to an unacceptable level? YES NO CCP NOT A CCP STOP * 52 Documenting Team Decisions… Provides Evidence Process Q1 Q2 Q3 Q4 CCP Comments 53  TABLE OF DECISION TREE FOR PROCESS OF FROZEN CHICKEN NUGGET PROCESS Q1 Q2 Q3 Q4 CCP COM (PREVENTATIVEMEASURE (SPECIFICALLY DESIGN (CONTAMIN (SUBSEQUE MENT EXIST FOR HAZARD) TO ELIMINATE/ REDUCE ATION NT STEP TO HAZARD) OCCUR/ ELIMINATE/ INCREASE) REDUCE HAZARD) 1. FREEZING YES YES - - YES MINCED - Freezing and frying can -Freezing will control CHICKEN control pathogenic microbe growth of microbe YES (B) NO (B) YES (B) YES (B) NO -Heat treatment of product -the process aims to -pathogen -frying will will eliminate microbe eliminate Physical still exist eliminate hazard only pathogen 2. WATER FILTRATION YES (P) YES (P) - - YES -filtration of water will -the process is eliminate sediments/ stone specifically design to eliminate P hazard 3. WASHING YES YES - - YES EGG -washing to remove faeces -washing reduce on egg shells to reduce pathogenic microbe pathogenic microbe PROCESS Q1 Q2 Q3 Q4 CCP COMME (PREVENTATIVEM (SPECIFICALLY (CONTAMINATION (SUBSEQUE NT EASURE EXIST DESIGN TO OCCUR/ INCREASE) NT STEP TO FOR HAZARD) ELIMINATE/ REDUCE ELIMINATE/ HAZARD) REDUCE HAZARD) 4. Frying YES NO YES NO YES -high temp. -is design for cooking -potential of - Next process to reduce and reducing microbe pathogen survival frozen pathogenic storage will microbe only control growth pathogenic microbe 5. FREEZING YES YES - - YES STORAGE - Freezing can - Freezing for control control microbe growth growth of microbe (avoid danger zone) MORE EXAMPLE…..  Principle 2. CCP Decision Tree Q1: Does this step involve a hazard of sufficient risk and severity to warrant its control? Yes – go to Q2 No – Not a CCP Q2: Does a control measure for the hazard exist at this step? Yes – go to Q3 No – Is control of step necessary for safety? Yes – Modify the step process or product No – Not a CCP – Stop* Q3: Is control at this step necessary to prevent, eliminate or reduce the risk of the hazard to consumers? Yes – CCP No – Not a CCP – Stop* *Proceed to the next step in process flow Principle 2. CCPs are Product and Process Specific CCPs may change with differences in: Plant layout Formulation Process flow Equipment Ingredient selection Sanitation and support programs (prerequisite programs)  Principle 2. Examples of CCP’s  Cooking:  Obtain a specific time/temperature combination to destroy pathogens  Freezing:  Low temperature/time storage to destroy parasites or to reduce bacterial growth  Reception of raw materials:  Suppliers’ certificate (e.g., shellfish harvested from approved waters, packaging material free of toxic chemicals, drinking/potable water to be used in food processing )  Principle 2. CCP Decision Tree Table for IQF Shrimp Process Step/Hazard Q1 (hazard?) Q2 (control Q3 (control CCP measure necessary?) exist?) Receiving frozen shrimp yes No/no - No Bacterial pathogens Sulfiting agent yes No/no - No Thawing yes No/no - No –Bacterial pathogens Fresh Shrimp Thawing Cold storage Cooking Weigh/ Pack/Label  Principle 2. CCP Decision Tree Table for IQF Shrimp Process Step/Hazard Q1 (hazard?) Q2 (control Q3 (control CCP measure necessary?) exist?) Cold storage Yes No/No - No –Bacterial pathogens Cooker Yes Yes Yes Yes –Pathogen survival Weigh/ Pack/ Label No - - No Weigh/ Fresh Shrimp Thawing Cold storage Cooking Pack/Label CCP  CCP Log Sheet-Example Line / product : ……………… CCP Ref No: ……………………… Monitoring Procedure : ……… Date :……………………………… Monitoring Frequency : …….. Shift :……………………………… Target Levels : ………………. Corrective Action: ……………… Time Result Deviation? Action Taken Signature Reviewed by: Date: 62  Principle 3: Critical Limits “A criterion which separate acceptability from unacceptability” Key considerations * Must be measurable by test or observation * Criteria which must be met for each preventative measure at a CCP * Not necessarily the same as the existing processing parameters HACCP PRINCIPLE 3 63  Principle 3. Establish Critical Limits for Each Preventive Measure  Definition:  Critical limits are boundaries which cannot be exceeded if the hazard is to be prevented, eliminated or minimized- to make sure the CCP is under control  Research/ scientific data, regulatory requirement & guideline, experts  Examples:  Temperature of a pasteurizer to 80°C ± 2°C for 2 ± 0.5 min to control Listeria monocytogenes or Salmonella Typhimurium  3.5% ± 0.5 salt in water phase plus refrigeration to temperature < 5.0°C to control Clostridium botulinum in packaged cold-smoked salmon  Residual chlorine level in drinking water not less than 1 mg/L   Examples of critical limits: Eg: An acidified beverage that requires a hot fill and hold as the thermal process may have acid addition as the CCP. If insufficient acid is added or if the temperature of the hot fill is insufficient, the product would be underprocessed with potential for the growth of pathogenic spore-forming bacteria. The critical limits in this case would apply to pH and fill temperature CCP - Receipt of raw/frozen shrimp Maximum 100 ppm sulfites CCP - Cooked shrimp (Cooker) Cook at 100ºC for 3 minutes CCP - Dried shrimp (Dryer) Water activity 0.70 or less CCP - Canned Tuna (Retort) Fo = 6.0 CCP - Tuna butchering Histamine