HACCP System-Part I PDF, Abu Dhabi University, Fall 2024-2025

HACCP System-Part I Chapter 36 – Food Safety and Management College of Health Sciences Food Safety and Management EHS 310 Fall 2024-2025  Outline 1. What is HACCP? 2. Where HACCP can be Used? 3. HACCP Objective 4. Hazard Analys...

HACCP System-Part I Chapter 36 – Food Safety and Management College of Health Sciences Food Safety and Management EHS 310 Fall 2024-2025  Outline 1. What is HACCP? 2. Where HACCP can be Used? 3. HACCP Objective 4. Hazard Analysis 5. Critical Control Point A- Biological Hazards B- Chemical Hazards C- Physical Hazards 6. Why Adopt HACCP? 7. HACCP Program A- cGMPs B- HACCP Plan C- Documentation Program  Overview Learning Outcomes After studying this chapter, you should be able to: Understand the purpose of Hazard Analysis Critical Control Point (HACCP). Define the terms hazard and critical control point. Understand how HACCP assists the food industry. Recall the seven principles in the HACCP process. Demonstrate development and application of HACCP.  1. What is HACCP? H azard WHAT hazards can enter the product? A nalysis Where do these C ritical hazards occur? C ontrol How can we control or P oint eliminate these hazards?  1. What is HACCP? H azard Danger to health A nalysis Investigation of the hazard C ritical Crucial for containment C ontrol Handling of conditions P oint Position in the process  1. What is HACCP? HACCP Is a proactive process of consecutive actions to ensure food safety to the highest degree through IDENTIFICATION AND CONTROL. as defined by the Codex Alimentarius Through the identification and control of any points or procedure in a Commission is a specific food system, from receiving through service, where loss of control may result in an unacceptable health risk. system that identifies, evaluates, and controls Is a preventive approach that addresses biological, chemical and hazards which are physical hazards through anticipation and prevention. significant for food Focuses on the entire process. safety (CAC (Codex Alimentarius Commission), 2003). Is a self-control/self-inspection system.  1. What is HACCP? It is based on two concepts: 1- Prevention How and where food safety hazards may exist and how to prevent them 2- Documentation To verify that potential hazards have been controlled  1. What is HACCP? HACCP Is a documented process of 7 principles. Uses the approach of controlling critical points in food handling. Increases buyers’ confidence.  1. What is HACCP? HACCP HACCP was originally designed by the Pillsbury Company, together with the National Aeronautics and Space Administration (NASA) and the US Army Laboratories at Natick. They developed the HACCP system to ensure the safety of food for astronauts. The system was promoted by international organizations such as the World Health Organization and applied on a voluntary basis in certain food industries. In 1993, the Codex Alimentarius Commission recognized the HACCP system as a powerful tool to improve food safety and established the Codex guidelines for the Application of the HACCP system. In 1995, with the establishment of the World Trade Organization and the coming into force of the Agreement on Sanitary and Phytosanitary Measures (WTO/SPS), the work of Codex, i.e., its standards, guidelines, and recommendations (including the Codex document on the Hazard Analysis and Critical Control Point system and Guidelines for its application) became the international reference or the “yardstick” for national requirements in food safety.  1. What is HACCP? The program focuses on safety and not quality. It should be considered separate from or supplement to quality assurance. HACCP may be used by food companies to make sure they do not break the law by putting consumers at risk when producing food. 2. Where HACCP can be Used?  3. HACCP Objective The objective of HACCP is to: Establish the maximum or minimum value to which a physical, chemical or biological food hazard must be controlled at a critical control point to prevent, eliminate or reduce to an acceptable level, the occurrence of the identified safety hazard.  4. Hazard Analysis Hazard: The potential to cause harm. All food ingredients, food and processes are analyzed for three types of hazards: - Biological - Chemical - Physical Hazards may be a cause or a factor in food safety.  4. Hazard Analysis Sources of Hazards: ✓Workers ✓Ingredients and materials ✓Equipment ✓Processes ✓Building  5. Critical Control Point CCP: A point, step or procedure at which control can be applied and a food safety hazard can be prevented, eliminated, or reduced to acceptable levels prior to this point. Examples of a CCP: - Freezer - Fryer - Metal detector - Label  5. Critical Control Point Critical limit: A value which separates acceptability from unacceptability.  5. Critical Control Point A- Biological Hazards: How do they become a problem in food? Uncontrolled conditions: - Inadequate cleaning - Inappropriate facilities - Uncontrolled temperatures - Overcrowding of storage - Product exposed to moisture Inadequate destruction: - Ineffective sanitation, programs, and training - Inadequate heat treatment  5. Critical Control Point A- Biological Hazards: Controlling Biological Hazards Temperature control - Keep out of the Danger Zone (4 C-60 C) - Keep frozen food below -18 C Atmosphere control Nutrient control Moisture control Prerequisite programs (to be discussed later)  5. Critical Control Point B- Chemical Hazards: How do they become a problem in food? Contamination from: - Other food - Residues - Equipment and utensils Uncontrolled conditions: - Inappropriate or lack of SOPs - Inappropriate storage facilities - Lack of specifications and quality control - Overcrowding of storage  5. Critical Control Point B- Chemical Hazards: Controlling Chemical Hazards Appropriate SOPs Appropriate prerequisite programs  5. Critical Control Point C- Physical Hazards: Injurious Extraneous Matter (IEM) - Risk is based on hardness, sharpness, size or shape. Examples of IEM: - Metal - Glass - Stones - Jewellery - Wood - Plastic  5. Critical Control Point C- Physical Hazards: How do they become a problem in food? Contamination from: - Misuse of packaging - Broken glass - Ingredients - Pellets - Physically damaged product Uncontrolled conditions: - Inappropriate or lack of SOPs - Inappropriate storage facilities - Lack of specifications and quality control  5. Critical Control Point C- Physical Hazards: Controlling Physical Hazards Magnets Metal detectors X-ray Appropriate SOPs Appropriate prerequisite programs  6. Why Adopt HACCP? A properly functioning HACCP system will result in the production of safer food. Benefits: - Improved food safety - Increased market access - Protection against liability - Drive for continuous improvement - Enhanced process control  7. HACCP Program A HACCP program has three components: A- GMP (Prerequisite Programs) B- HACCP Plan C- Verification Program  7. HACCP Program Now on to the prerequisite programs ….  7. HACCP Program A- cGMPs-The Building Blocks for HACCP The current Good Manufacturing Practices (cGMPs) regulations were set by the FDA to provide criteria that all human foods be free from adulteration. Emphasis is placed on the prevention of product contamination from direct and indirect sources.  7. HACCP Program What are GMPs? GMPs are the minimum sanitary and processing requirements necessary to ensure the production of wholesome food. They are broad and general in nature. GMPs should be selected and adopted before HACCP is implemented.  7. HACCP Program What are cGMPs? cGMPs are usually written for such areas: - Personnel (cleanliness, training, disease control, education) - Buildings and facilities - Equipments and utensils - Production and process control (inspection, storage, cleaning) - Records and reports (suppliers, processing, production, distribution) - Defect action levels - Miscellaneous (visitor rules) Without the application of cGMPs, an effective HACCP plan can’t be conducted.  7. HACCP Program SSOPs-The Cornerstones of HACCP Plan cGMPS must be applied in the development of Sanitation Standard Operating Procedures (SSOPs). ✓SOPs: “Detailed, written instructions to achieve uniformity of the performance of a specific function”. ✓SSOPs: detail a specific sequence of events necessary to perform a task to ensure sanitary conditions. SSOPs and cGMPS are interrelated. They follow very similar rules.  7. HACCP Program Examples of SSOPs Rinse surfaces with warm water. Wash and scrub as necessary using an approved cleaner as directed in the SSOP. Sanitize using an approved sanitizer as directed in the SSOP.  7. HACCP Program Where GMPs should be applied? A- Premises: Outside property: - Free of debris and refuse - Proper roadways and drainage Building: - Permit cleaning - Prevent entrance and harbourage of pests - Prevent entrance of environmental contaminants - Sound construction and good repair  7. HACCP Program Where GMPs should be applied? A- Premises: Sanitary facilities: - Washrooms, lunchrooms, and change rooms - Handwashing and sanitizing facilities - Equipment cleaning and sanitizing facilities Water quality and supply program  7. HACCP Program Where GMPs should be applied? B- Receiving/Storage: Receiving of raw materials, ingredients, food products and packaging: - Specifications and conformance - Food and packaging must be inspected on arrival. - Reject product not meeting specification. - All frozen and refrigerated foods must be put into proper storage immediately. - Store food in such a manner as to avoid cross-contamination  7. HACCP Program Where GMPs should be applied? B- Receiving/Storage: Storage: - Temperature and humidity controls of: ❑ Raw materials ❑ Ingredients ❑ Food products ❑ Packaging of finished food products, of damaged and or returned goods, and of non-food chemicals  7. HACCP Program Where GMPs should be applied? B- Receiving/Storage: Storage: Store all perishable foods below 4 oC. Store all frozen food at or below -18 oC. Follow the FIFO (First In First Out) rule. Keep all food 15 cm off the floor and 46 cm between rows. Store products according to instructions. Code all cases for easy ID, store accordingly.  7. HACCP Program Where GMPs should be applied? C- Equipment Performance and Maintenance: Equipment design Equipment installation Equipment maintenance Equipment calibration Preventative maintenance  7. HACCP Program Where GMPs should be applied? D- Personnel Training: Manufacturing controls Hygienic Practices: - Communicable disease - Injuries - Washing of hands - Personal cleanliness and conduct - Controlled access  7. HACCP Program Where GMPs should be applied? E- Hygiene: Use hair restraints Garments, aprons, and shoes must be cleaned and changed as necessary.  7. HACCP Program Where GMPs should be applied? F- Sanitation: A- Sanitation Program - Adequacy - Adherence B- Pest Control Program - Adequacy - Adherence  7. HACCP Program Where GMPs should be applied? F- Sanitation: A- Sanitation Program Areas that must be included in a cleaning program: Food storage areas, equipment, and work surfaces Toilet and handwashing facilities Lockers, dressing rooms, and lunchroom facilities Storage of clean and soiled linens, clothing and cleaning cloths Garbage and refuse disposal materials and areas Storage of cleaning compounds (poisonous and toxic materials) Floors, walls, and ceilings Ventilation Lighting Receiving area Entrance/parking lot  7. HACCP Program Where GMPs should be applied? F- Sanitation: B- Pest Control Program Eliminate entry ways Eliminate habitats and food supplies Destroy or catch those that gain entry Regular inspections Sound well-documented pest control program  7. HACCP Program Where GMPs should be applied? F- Sanitation: B- Pest Control Program Remember: 1 fly leads to 900 1 cockroach leads to 30-40 1 moth leads to 400 1 beetle leads to 375 1 rodent leads to 30 Pesticides and rodentcides can only be applied by certified technicians.  7. HACCP Program Where GMPs should be applied? F- Sanitation: B- Pest Control Program Remember: 1 fly leads to 900 1 cockroach leads to 30-40 1 moth leads to 400 1 beetle leads to 375 1 rodent leads to 30 Pesticides and rodentcides can only be applied by certified technicians. Questions? Thank you