FT2024_PRP PDF - Pre-requisite Programs

PRE-REQUISITE PROGRAMS (PRP) Prof. Dr. Ir. Liesbeth Jacxsens Dr. Lotta Kuuliala Department of Food Technology, Safety and Health Ghent University LEARNING GOALS ̶ Key definitions Codex Alimentarius GMP/GHP PRP HACCP ̶ PRPs...

PRE-REQUISITE PROGRAMS (PRP) Prof. Dr. Ir. Liesbeth Jacxsens Dr. Lotta Kuuliala Department of Food Technology, Safety and Health Ghent University LEARNING GOALS ̶ Key definitions Codex Alimentarius GMP/GHP PRP HACCP ̶ PRPs in the fish industry Basic requirements to produce in a safe and hygienic way DEFINITIONS Food safety The condition of the foodstuffs in all stages of production, processing and distribution, required to guarantee protection of consumer's health, also taking into account normal circumstances of use and information available for the foodstuffs concerned (Baert et al., 2011) ̶ Absence of biological, chemical or physical hazards in concentrations/ quantities that can cause adverse health effects ̶ Assurance that there will be no harm to the consumer when the food is used as intended 3 DEFINITIONS Food hygiene All conditions and measures necessary to ensure the safety and suitability of food at all stages of the food chain (General Principles of Food Hygiene - Codex Alimentarius, 2017) ̶ Pre-requisite to achieve food safety 4 DEFINITIONS Codex Alimentarius A collection of internationally recognized standards, guidelines and codes of practice related to food and food production, adopted by the Codex Alimentarius Commission ̶ General Principles of Food Hygiene CAC/RCP 1-1969 Reference document for the production of safe food Reference document for legislation and voluntary quality standards First version: 1969 Revision 4: from 2003 DEFINITIONS Good Manufacturing Practices (GMP) and Good Hygienic Practices (GHP) Package of preventive practices and conditions to ensure the safety of the food produced. GHP underline more the need for hygiene, GMP stress correct work methodologies. (Commission Notice EC. 2016/C278) ̶ Keep the contamination level as low as possible ̶ Prevent the development of micro-organisms (MOs) ̶ Reference document : Codex Alimentarius DEFINITIONS ̶ The most important GPs 1. Cleaning and disinfection 2. Pest control 3. Water/air 4. Temperature control 5. Personnel 6. Structure/infrastructure 7. Technical maintenance 8. Waste management 9. Control of raw material 10. Work methodology DEFINITIONS Pre-requisite programs (PRP) Every specific and documented activity or facility that is implemented corresponding to the Codex General Principles of Food Hygiene, GMP and the legislation, with the purpose to create general preventive control measures that are necessary for the production and processing of safe foods in all stages of the food chain ̶ PRP covers GHP, GMP and legislation More than a working instruction, a plan or a regulation General control measures → regular verification of effectiveness DEFINITIONS ̶ Most important legal provisions for PRPs General hygiene requirements in Annex I of Regulation (EC) No 852/2004 for primary production and associated operations General hygiene requirements in Annex II of Regulation (EC) No 852/2004 for activities after primary production further on in the production chain Specific hygiene requirements for food of animal origin laid down in Annex III of Regulation (EC) No 853/2004 ̶ Commission Notice EC. 2016/C278 PRPs are obligatory in all food businesses (incl. primary production) PRPs are worked out proportionate to size and nature of the business o Sector-specific guides to good hygiene practices are developed and approved by the competent authorities Non-exhaustive list of PRPs + examples of implementation DEFINITIONS ̶ Non-exhaustive list (company-dependent) of PRPs proposed in Commission Notice 2016/C278 PRP 1 : Infrastructure PRP 2 : Cleaning and disinfection PRP 3 : Pest control PRP 4 : Technical maintenance and calibration PRP 5 : Physical and chemical contaminations from production environment PRP 6 : Allergens PRP 7: Waste management PRP 8: Water and air control PRP 9: Personnel PRP 10: Raw materials (supplier selection/specifications) PRP 11: Temperature control of storage environment PRP 12: Working methodology (PRP 13: Product information and consumer awareness, added in EFSA opinion small retail (EFSA_BIOHAZ ,2017) ) DEFINITIONS Hazard Analysis Critical Control Points (HACCP) An auto-control system which identifies, evaluates and controls hazards which are significant for food safety consistent with the HACCP principles (Commission Notice 2016/C278) ̶ Critical Control Point (CCP): 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 ̶ Further courses: Prof. L. Jacxsens DEFINITIONS Relations GP-PRP-HACCP GP General hygiene measures that need to be taken (can be sector-specific or not) PRP Transform these hygiene measures in a practically manageable, effective and company-specific surveillance system HACCP Systematic analysis of the hazards that are specific for the company Overview of 14 PRPs PRP 1 : Cleaning and desinfection PRP 2 : Pest control PRP 3 : Water/air quality PRP 4 : Temperature control PRP 5 : Personnel (hygiene, training, medical screening) PRP 6 : Structure and infrastructure  PRP 7 : Technical maintenance and calibration PRP 8 : Waste management PRP 9 : Control of raw material PRP 10 : Traceability, recall PRP 11 : Allergen policy PRP 12 : Physical and chemical contamination PRP 13 : Management of product information PRP 14 : Work methodology PRP 1: CLEANING AND DISINFECTION Purpose ̶ General aim: keep vermin outside + avoid MO accumulation ̶ Cleaning: remove dirt → visually clean (MOs can still be present) ̶ Disinfection: kill the present MOs Cleaning and disinfection plan ̶ What? How? When? Who is responsible? ̶ Registration of executed activities ̶ Cooling elements and evaporators must be included in the plan Dirt + condensation → MO accumulation PRP 1: CLEANING AND DISINFECTION Material ̶ Disinfectants and detergents Disinfectants: approved by the ministry of public health (in BE) Detergents: free choice (but not corrosive + no odour) For every used product: safety filling cart and instructions for use Storage in a separate room ̶ Cleaning material No cause of contamination Resistant against corrosion and chemicals Cleaning material needs to be cleaned and disinfected Separate cleaning materials for sanitary facilities, low care zone and high care zone PRP 1: CLEANING AND DISINFECTION Execution ̶ 5 steps 1) Removal of visual dirt (brush, water) 2) Cleaning with water and detergent 3) Rinsing with potable water 4) Disinfection 5) Rinsing with potable water Control ̶ Visual inspection ̶ Microbiological inspection: swab, contact plates, last rinsing water ATP-BIOLUMINESCENCE MEASUREMENT PRP 2: PEST CONTROL Insects and rodents ̶ Source of pathogens ̶ Damaging of packaging material and raw materials Prevention ̶ Exterior walls may contain as few cracks and chinks as possible ̶ Pipes and grids not accessible from outside ̶ Exterior windows need an insect screen ̶ Loading and unloading gate needs to be closed immediately ̶ Company + surroundings need to be clean ̶ Not used apparatus + rooms need to be clean ̶ Avoid the prolonged stay of water PRP 2: PEST CONTROL Pest control plan ̶ Enumeration of traps (inside vs. outside) ̶ Maintenance of insect killers ̶ Make a file ̶ Determine the cause ̶ Closed storage of insecticides and rodenticides ̶ … PRP3: WATER/AIR Water ̶ Potable water for the preparation of foodstuffs and for C&D ̶ Non-potable water → separate pipe lines and identification ̶ Indicate the water supply on a plan ̶ Water analysis Air ̶ Airflow can be a pathway for MOs → filters must be controlled and cleaned ̶ Aseptic filling → sterile filtration ̶ No combustion gases of engines in the production area ̶ Formation of condensation should be avoided ̶ Ventilators should be cleaned at a regular basis PRP 4: TEMPERATURE CONTROL PRP 4: TEMPERATURE CONTROL PRP 4: TEMPERATURE CONTROL Rooms ̶ Control and registration of temperature ̶ Control of temperature and humidity → limit the growth of psychrotrophs ̶ Freezing of products in a separate freezer ̶ Cold and frozen storage rooms: C&D on a regular basis (extra attention for evaporators) ̶ Do not exceed the cooling area capacity PRP 4: TEMPERATURE CONTROL Transport ̶ Control and registration of temperature Product temperature ̶ Measure on a regular basis Calibration ̶ Apparatus for temperature measurements needs to be calibrated on a regular basis PRP 5: PERSONNEL Personnel health ̶ Medical examination ̶ Control of hands and face for skin infections ̶ Report illness → possible transfer ̶ First-aid kit ̶ Sticking plasters: blue color – metal strip Source: ARDO Hygienic handling of foods ̶ After treatment of raw products: wash hands, replace towels and work clothing ̶ Avoid contact between hands and cooked products ̶ Replace gloves (for RTE food) on a regular base PRP 5: PERSONNEL Personal hygiene ̶ Hand washing Removal of transient MOs, not residents With drinking water and soap Dry with clean towel When? o Before work o After using the lavatory, coughing and sneezing o After the treatment of raw products o When they are filthy through another treatment ̶ Hair covers S. aureus Put on before entering the work area PRP 5: PERSONNEL Personal hygiene ̶ Clothing and jewellery Clothing can be replaced at regular times and cleaned profoundly No visible jewellery, nail polish, exaggerated use of make-up, perfume or deodorant Personal possessions: not in the production area No pockets ̶ Eating/drinking/smoking Not in production area or clothing room ̶ Training Hygiene training Job training PRP 5: PERSONNEL Food defense ̶ Access control + minimize number of visitors Source: ARDO (https://ardo.be/en/ardo-corporate) PRP 6: STRUCTURE/INFRASTRUCTURE Location and surroundings ̶ Design phase Proximity of potential sources of contamination Sufficiency and quality of water supply Waste water removal Adequacy of power supply Availability of transport ̶ Climate (temperature, humidity) ̶ Other -: shoots, woody regions, busy motor-roads, companies working with highly contaminated products +: paved roads & parking places with good drainage PRP 6: STRUCTURE/INFRASTRUCTURE Building ̶ Arrangement of rooms, areas and processes Prevent cross-contamination o Separation of ‘low risk’ vs. ‘high care’ area Low risk o Handling of contaminated raw materials High care o Any area where contaminants may contaminate final products PRP 6: STRUCTURE/INFRASTRUCTURE Building ̶ Structural components Floors o Designed for easy cleaning, waterproof, non-absorbent, washable material (stone, asphalt, tiles), not too smooth (slippery) o Angles between floors and walls: sealed and covered o Slope towards drains Walls o Washable to a certain height o Smooth without crevices o Joints between walls or ceilings and wall: sealed Windows o Preferably without windows o If necessary, avoid dirt and dust accumulation o Openings: removable screens for insects and vermin PRP 6: STRUCTURE/INFRASTRUCTURE Building Ceilings o Not often cleaned, no contact with food o Prevent dirt and dust o Air circulation: prevents mold growth o No absorbent material o Fungicidal paints Doors o Tight fitting (against rodents, insects, dust) o Smooth non-absorbent surfaces o Automatic opening and closing (cross-contamination by touching) Pipelines o Smooth surface o Preferably vertical; above the ceiling when horizontal PRP 6: STRUCTURE/INFRASTRUCTURE Building ̶ Control of environment and measures to protect the product Lighting o Adequate lighting: permit recognition of gross soiling o Should not significantly alter colors o Protection with plastic shield or treated with coating ✓ Global light intensity: 400 lux ✓ At inspection points: 600 lux ✓ In storage depots: 250 lux Effluent disposal o Avoid cross contamination through waste water pipes o Two separated waste pipes (low and high risk) o If not possible, flow away from ‘high care’ to ‘low care’ o Shut-off valves o Odor traps in drains o Culverts: removable grid (take off only for cleaning) PRP 6: STRUCTURE/INFRASTRUCTURE Building Storage depots and recipients o Raw materials and packaging materials: protection against microbial or other contamination o No dusty rooms o Single-use packaging materials: plastic + paperboard o Re-use of used recipients: no microbial, chemical or organoleptic changes Integrity of structural components and apparatus o Nothing can contain mold spots, rust or flakes of paint Storage of toxic materials o Only food additives which are allowed in the product o Other toxic compound: not in contact with food or packaging PRP 6: STRUCTURE/INFRASTRUCTURE Building ̶ Sanitary facilities Clothes changing facilities o Obliged o Clean, neat, not used for smoking or as refectory o Cupboards: one part for normal and one for work clothing o Special rack for cleaned work clothing Toilets o Should not open directly into food handling areas o Doors close automatically o Avoid flushing handles with hand contact (foot pedals) o Obliged to wash hands afterwards PRP 6: STRUCTURE/INFRASTRUCTURE Building Hand washing facilities o Situated so that employees must pass them when returning to processing areas o Cold + hot flowing water o Reservoir of soaps and decontamination products o Towels for single use o Roller towels: if they roll automatically and if used parts are separated physically from the clean part o Hot air blowers: only in rooms were food products are absent o Non-hand-operable taps PRP 6: STRUCTURE/INFRASTRUCTURE Equipment ̶ Cleanability Durable, non-toxic materials resistant to corrosion or physical damage Smooth surfaces Wood and cast iron: prohibited Stainless steel is preferable Rubber compounds: limited operational life → frequent inspection and replacement Sample ports: minimize contamination and easy to clean and disinfect between uses PRP 6: STRUCTURE/INFRASTRUCTURE Equipment ̶ Monitoring devices Necessary for CCPs Present + efficient use Examples o Cold storage room with thermometer and recorder o Fermenter with pH-meter o Brine baths with salinometers ̶ Installation and layout Optimum cleaning and disinfection o Sealed with the floor or at least 15 cm above it o Sealed with the wall or adequate space between PRP 7: TECHNICAL MAINTENANCE ̶ Maintenance plan is necessary ̶ Reparations need to be carried out as soon as possible No temporary solutions with rope, tape, … ̶ Prevention Parts that deteriorate with time (e.g. seals) need to be replaced on a regular basis ̶ Technical maintenance must meet hygiene rules Personal hygiene Equipment should be cleaned and disinfected afterwards No foreign objects left behind ̶ Calibration: schedule + registration + status labelling PRP 8: WASTE MANAGEMENT ̶ Waste removal without contamination of water and food ̶ Spoiled food products need to be removed immediately ̶ Garbage cans: good condition, washable, non-absorbent material ̶ Following points must be considered: Different waste types Waste collection Responsible persons Waste storage Waste removal PRP 9: CONTROL OF RAW MATERIAL Classification ̶ ‘Raw materials’ can be divided in four groups: Raw materials in the narrow sense Auxiliary materials (e.g. coloring agents, preservatives) Ingredients (e.g. intermediate products) Packaging materials and food contact materials Objective ̶ Good products can only be made with good raw materials ̶ Raw materials of a good quality need to be handled in a proper way to avoid quality deterioration PRP 9: CONTROL OF RAW MATERIAL Purchase policy ̶ Supplier selection Clear agreements / specifications Audits need to be carried out ̶ Supplier evaluation Commercial delivery quality Delivery quality with respect to food hygiene Other aspects of delivery quality o Relationship based on long-lasting business contact o Certified quality management system o Possibility for regular supplier audits ̶ List of suppliers with an order of preference PRP 9: CONTROL OF RAW MATERIAL Reception of materials ̶ Control of the goods at receipt Raw, auxiliary and packaging material Clear working instructions Limited control vs. exhaustive control o Compliance with the order? o Compliance with the specifications? o Shelf-life? o Temperature? o Label information? o Packaging? o Odor, texture, …? → Complaint, blockade, refusal ̶ Hygienic condition of the vehicle and driver PRP 9: CONTROL OF RAW MATERIAL Storage ̶ Aim: no quality deterioration or contamination ̶ Important during storage Storage conditions Shelf-life Use the FIFO-principle (First In First Out) No packages can be open or uncovered Packages are never placed on the ground Pallets and racks are never placed directly against a wall Separate storage room for waste PRP 10: TRACEABILITY, RECALL ̶ Clear procedures need to be available Traceability Recall Returned goods Rejections/ non-conform products PRP 11: ALLERGENS ̶ 14 allergens recognized and should be clearly labelled (FIC Reg. 1169/2011) Cereals containing gluten Crustaceans and products thereof Egg and products thereof Fish and products thereof Peanut and products thereof Soybeans and products thereof Milk and products thereof (including lactose) Nuts and products thereof Celery and products thereof Mustard and products thereof Sesame seeds and products thereof Sulfur dioxide and sulfites (at concentrations of more than 10mg/kg or 10mg/L in terms of the total SO2 which are to be calculated for products as proposed ready for consumption or as reconstituted according to the instructions of the manufacturers) Lupin and products thereof Molluscs and products thereof PRP 11: ALLERGENS ̶ Allergen risk management: preventing adverse reactions in food-allergic consumers without unnecessarily limiting their food choices Which allergens? How to keep allergens out of the company? When certain allergens are used: cross-contamination risk (air, contact materials, personnel, carry-over from batches, media,…) ̶ Preventive measures to prevent cross-contamination Closed packages Separated recipients and materials Intermediated cleaning and disinfection Production order Specific measures Level 1: research and development: Different steps of Allergen -product formulation management on company level -impact of process on proteins ? Level 2: Selection raw materials/ingredients: -specifications: presence of allergens -allergen management of supplier : risk estimation of presence of hidden allergens -database of (hidden) allergens per product Level 3: Production: -identification of possible cross-contamination routes -preventive measures to control cross-contaminations e.g. segregation, cleaning procedures -management of re-work Level 4: Consumer awareness: -legal direct allergens -hidden allergens : ‘may contain’ labeling based on qualitative or quantitative data Level 5: Validation and verification: -sampling and analysis to demonstrate preventive measures and allergen risk management is effective (=validation) -time to time sampling and analysis, internal auditing, people performance to demonstrate allergen risk management is working properly (=verification) PRP 12: PHYS/CHEM CONTAMINATION ̶ Describing how the contamination with physical and chemical hazards is controlled in the company Contamination from environment, working methodology, …. ̶ Physical hazards = foreign objects Glass, hard plastic, metal, wood Intrinsic (e.g. fish bones) versus extrinsic (e.g. stones, metal,…) Major source of customer complaints USDA o Adulterated: 7-25 mm + RTE (or minimal preparation) o Possibly adulterated (FDA review): 7-25 mm + processing; 25 mm Preventive measures and detection/removal o D/R systems: metal detection, magnets, optical sorting,… o Separation systems: air/liquid separation systems o Glass checklist ̶ Chemical hazards Cleaning or disinfection products, oil, ink,… PRP 12: PHYS/CHEM CONTAMINATION ̶ Knife and pen policy Registration/identification of all knives No cutter knives Only metal detectable pens Source: ARDO (https://ardo.be/en/ardo-corporate) PRP 13: MANAGEMENT OF PRODUCT INFO Preparation methods ̶ Recipes = big secret ̶ Recipes and preparation methods determine not only the organoleptic characteristics of the product, but also its shelf- life and safety ̶ How do you need to handle the preparation methods? Who can change them? Who distributes them in the company? Which staff members can have knowledge of them? Inform the HACCP-team when a method is changed PRP 13: MANAGEMENT OF PRODUCT INFO Label information ̶ A lot of information (law + additional information) ̶ How do you need to handle this information? Who designs the label? Who verifies all necessary legal information? Is there consultation with the client? Who keeps the label register up to date? End product specifications ̶ Information of the end products ̶ Necessary to estimate which dangers can occur during the production or can be present in the end product PRP 14: WORK METHODOLOGY ̶ Avoid an extra contamination and MO growth ̶ Maintain good quality of raw materials, intermediary products and end products and achieve a constant quality ̶ Work instructions need to be followed! KISS: Keep It Straight Simple ̶ Examples Do not leave the packaging material in the machine Tidy up broken glass immediately and report it Do not leave inspection places unmanned behind Place products that need to be cooled immediately in a cooled room Fill in the forms in a correct way