2024/25 HACCP: Hygiene & Food Safety - EGAS MONIZ SCHOOL PDF

For teaching purposes only! HACCP Hazard Analysis and Ricardo Assunção, DVM, PhD Critical Control Point Hygiene & Food Safety Integrated Master in Veterinary Medicine 2024/25 www.egasmoniz.com/pt...

For teaching purposes only! HACCP Hazard Analysis and Ricardo Assunção, DVM, PhD Critical Control Point Hygiene & Food Safety Integrated Master in Veterinary Medicine 2024/25 www.egasmoniz.com/pt For teaching purposes only! Objectives to be attained during this lecture: To recognize the main reasons to implement food safety systems as HACCP - Master’s Degree in Veterinary Medicine To understand the origins of HACCP and the main differences between inspection and prevention To identify the five preliminary steps to the HACCP principles WHY ARE THESE TOPICS IMPORTANT? 2  For teaching purposes only! Foodborne diseases → one of the largest public www.egasmoniz.com/pt health problems worldwide The proportion of the population who have increased susceptibility to foodborne illness is increasing (e.g. elderly community, the number of immunocompromised consumers, and the malnourished) - Changing lifestyles have resulted in a number of changes to our eating habits Master’s Degree in Veterinary Medicine More people now regularly eat out or snack on the move, which has led to an increased demand for food service establishments of varying standards Many people work outside the home and rely on processed foods for fast meal preparation; this has meant that knowledge of how to handle and prepare foods has decreased in recent years Increased mass production of foods has increased the potential for larger numbers of consumers to be affected in the event of an outbreak of foodborne disease Increased tourism has meant that people are exposed to foodborne hazards from other areas New foods/novel foods; different diets 3  For teaching purposes only! Foodborne diseases → one of the largest public www.egasmoniz.com/pt health problems worldwide Emerging pathogens (such as Cronobacter sakazakii) and increased awareness of the persistence and survival of pathogens in low moisture foods - Global sourcing of finished products and ingredients has increased the complexity of the supply chain and Master’s Degree in Veterinary Medicine made it more difficult to trace and recall in the event of a failure Increased testing capabilities combined with improved laboratory communication schemes mean that previously unidentified issues can both be detected and also linked together across states and countries to reveal an outbreak that would otherwise have gone unrecognized Without careful safety evaluation, changes could also result in unsafe practices that might contribute to foodborne disease 4 www.egasmoniz.com/pt For teaching purposes only! HACCP Hazard Analysis and Critical Control Point - Master’s Degree in Veterinary Medicine Tool that can be used to reduce the risk of a food safety failure Logical system of food control based on prevention Systematic approach to identify, assess, and control food hazards 5  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt Origins of HACCP Sara Mortimore, Carol Wallace (2013). HACCP: A Practical Approach https://doi.org/10.1007/978-1-4614-5028-3 6 For teaching purposes only! www.egasmoniz.com/pt For teaching purposes only! Origins of HACCP Original system pioneered by The Pillsbury Company working alongside NASA and the US Army Laboratories at Natick - Based on the engineering system: Failure, Mode and Effect Analysis (FMEA) Master’s Degree in Veterinary Medicine What could potentially go wrong at each stage in an operation together with possible causes and the likely effect Effective control mechanisms are then put in place to ensure that the potential failures are prevented from occurring HACCP looks for hazards, or what could go wrong, but in the product safety sense Preventative control measures are then implemented to ensure that the product is safe and cannot cause harm to the consumer 7 www.egasmoniz.com/pt For teaching purposes only! Origins of HACCP Developed originally as a microbiological safety system in the early days of the US manned space program (End of 1950s) - Vital to ensure the safety of food for the astronauts — imagine suffering foodborne illness Master’s Degree in Veterinary Medicine in a zero gravity environment! Preventative Food safety and system, with high quality systems level of food safety based on end- assurance → HACCP product testing system This could only fully assure safe products through testing 100 % of the product 8  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt Inspection versus Prevention Sara Mortimore, Carol Wallace (2013). HACCP: A Practical Approach https://doi.org/10.1007/978-1-4614-5028-3 9 For teaching purposes only! www.egasmoniz.com/pt For teaching purposes only! Inspection Desirably → 100% inspection Main difficulty when it is applied to biological and chemical hazards → impractical!!! Biological and chemical testing is nearly always destructive - Master’s Degree in Veterinary Medicine Sampling plans https://doi.org/10.1007/978-1-4614-5028-3 Sampling to detect a hazard relies on two key factors: Sara Mortimore, Carol Wallace (2013). HACCP: A Practical Approach 1. The ability to detect the hazard reliably with an appropriate analytical technique. 2. The ability to capture the hazard in the sample chosen for analysis. Ability to trap a hazard in a sample is dependent on a number of factors, including: 1. The distribution of the hazard in the batch. 2. The frequency at which the hazard occurs in the batch. 10  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt Inspection 11 Sara Mortimore, Carol Wallace (2013). HACCP: A Practical Approach https://doi.org/10.1007/978-1-4614-5028-3 For teaching purposes only! www.egasmoniz.com/pt For teaching purposes only! Benefits of HACCP HACCP is a very effective method of reducing risk of failure and maximizing product safety - Helps with prioritization in making informed judgments on food safety matters and removes bias (right personnel with the right Master’s Degree in Veterinary Medicine training and experience are making the decisions) Helps to demonstrate effective food safety management through documented evidence After the initial setting up of the system, can be extremely cost effective Enables food companies to meet their legal obligations to produce safe Almost always going to be an improvement in product quality → increased awareness of hazards in general + participation of people from all areas of the operation HACCP and food safety systems are a sound business investment (prevent higher costs with e.g. outbreaks) 12  For teaching purposes only! HACCP alone will not assure the production www.egasmoniz.com/pt of safe food! Prerequisite programs (PRPs) Basic conditions and activities that are necessary to maintain a HACCP - hygienic environment throughout the food chain suitable for Master’s Degree in Veterinary Medicine the production, handling and provision of safe end products and safe food for human consumption (ISO 22000: 2005, section 3.8) Good manufacturing practices (GMPs)/Prerequisite programs (PRPs) 13  For teaching purposes only! HACCP in the context of www.egasmoniz.com/pt EU Regulation Regulation (EC) No. 852/2004 on the Hygiene of Foodstuffs Article 5 - 1. Food business operators shall put in place, implement, and maintain a permanent procedure or procedures based on the HACCP principles. Master’s Degree in Veterinary Medicine 2. The HACCP principles referred to in paragraph 1 consist of the following: (a) Identifying any hazards that must be prevented, eliminated, or reduced to acceptable levels. (b) Identifying the CCPs at the step or steps at which control is essential to prevent or eliminate a hazard or to reduce it to acceptable levels. (c) Establishing critical limits at CCPs which separate acceptability from unacceptability for the prevention, elimination, or reduction of identified hazards. (d) Establishing and implementing effective monitoring procedures at CCPs. (e) Establishing corrective actions when monitoring indicates that a CCP is not under control. (f) Establishing procedures, which shall be carried out regularly, to verify that the measures outlined in subparagraphs (a) to (e) are working effectively. (g) Establishing documents and records commensurate with the nature and size of the food business to demonstrate the effective application of the measures outlined in subparagraphs (a) to (f). When any modification is made in the product, process, or any step, food business operators shall review the procedure and make the necessary changes to it. 14  For teaching purposes only! HACCP in the context of www.egasmoniz.com/pt EU Regulation Regulation (EC) No. 852/2004 on the Hygiene of Foodstuffs Article 5 - 3. Paragraph 1 shall apply only to food business operators carrying out any stage of production, processing, and distribution of food after Master’s Degree in Veterinary Medicine primary production and those associated operations listed in Annex I. 4. Food business operators shall: (a) Provide the competent authority with evidence of their compliance with paragraph 1 in the manner that the competent authority requires, taking account of the nature and si ze of the food business. (b) Ensure that any documents describing the procedures developed in accordance with this Article are up-to-date at all times. (c) Retain any other documents and records for an appropriate period. 15  For teaching purposes only! HACCP in the context of www.egasmoniz.com/pt EU Regulation Regulation (EC) No. 852/2004 on the Hygiene of Foodstuffs Annex 11 Chapter XII Training - Food business operators are to ensure: Master’s Degree in Veterinary Medicine 1. That food handlers are supervised and instructed and/or trained in food hygiene matters commensurate with their work activity. 2. That those responsible for the development and maintenance of the procedure referred to in Article 5(1) of this Regulation for the operation of relevant guides have received adequate training in the application of HACCP principles. 3. Compliance with any requirements of national law concerning training programs for persons working in certain food sectors. 16  For teaching purposes only! HACCP in the context of www.egasmoniz.com/pt EU Regulation Legislation now requires that all food business operators apply HACCP principles - to their operations and have appropriate training to do so Master’s Degree in Veterinary Medicine Small low-risk businesses range of food safety management systems acceptable from the implementation of Flexibility good hygiene practices (especially for small businesses) Large food manufacturing full requirements required 17 www.egasmoniz.com/pt For teaching purposes only! HACCP Plan Plan vs System A document prepared in accordance with the principles of HACCP to ensure control of hazards that are significant for food safety in the segment of the food chain - under consideration (Codex, 2009b) Master’s Degree in Veterinary Medicine formal document that pulls together the key information from the HACCP study and holds details of all that is critical to food safety management 18 www.egasmoniz.com/pt For teaching purposes only! Principles of HACCP System Principle 1. Conduct a hazard analysis. Principle 2. Determine the Critical Control Points (CCPs). - Principle 3. Establish Critical limits for control measures associated with each identified CCP. Master’s Degree in Veterinary Medicine Principle 4. Establish a system to monitor control of the CCP. Principle 5. Establish the corrective actions to be taken when monitoring indicates that a particular CCP is not under control. Principle 6. Establish procedures for verification to confirm that the HACCP system is working correctly. Principle 7. Establish documentation concerning all procedures and records appropriate to these principles and their application. 19  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt Development of HACCP Plan 20 For teaching purposes only!  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt Preliminary steps 21 For teaching purposes only! www.egasmoniz.com/pt For teaching purposes only! 1. Assemble HACCP Team It is important that HACCP is not carried out by one person alone but is the result of a multidisciplinary team effort Recommended core HACCP team: - Quality Assurance/Technical—providing expertise in microbiological, chemical, Master’s Degree in Veterinary Medicine and physical hazards, an understanding of risk and hazard significance assessment, and knowledge of measures that can be taken to control the hazards. Operations or Production—has responsibility for and has detailed knowledge of the day-to-day operational activities required in order to produce the product. Engineering—able to provide a working knowledge of process equipment and environment with respect to hygienic design and process capability. Additional expertise—may be provided both from within the company and from external consultancies. https://www.ranker.com/list/funny-teamwork-photos/nathandavidson Supplier Quality Assurance; Research and Development; Distribution/Logistics; Procurement; Microbiologist; Toxicologist; ; Statistical process control; HACCP experts 22  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt Team Work https://youtu.be/4duPBWzf46E?feature=shared 23 For teaching purposes only! www.egasmoniz.com/pt For teaching purposes only! 1. Assemble HACCP Team HACCP team leader Key role - A record sheet or minutes where it is Master’s Degree in Veterinary Medicine clear who is part of the HACCP team and proof of their HACCP training evidence (log sheets, minutes of team creation meetings and working meetings, proof of HACCP training, etc.) https://twitter.com/PoissonRougeUK/status/1004013531786809351 24  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt 1. Assemble HACCP Team https://www.memedroid.com/memes/detail/331634 25 For teaching purposes only!  For teaching purposes only! Full product description www.egasmoniz.com/pt 2. Describe the product Relevant safety information ✓ List of ingredients ✓ Materials used to prepare the product ✓ During preparation/processing/storage: can - ✓ Hazards associated with the product (raw contamination occur? By what routes? Master’s Degree in Veterinary Medicine material)? Which hazards? Biological/chemical? ✓ During preparation/processing: do you consider any ✓ Are substances used to preserve the product (e.g. steps that could inactivate microbiological hazards? preservatives)? ✓ Are storage and packaging conditions adequate? ✓ Physico-chemical characteristics (e.g. pH, aW) that ✓ How is the product distributed? Is it adequate? allow or inhibit microbial growth? Collecting & Systematizing information about the product 26  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt 2. Describe the product 27 Sara Mortimore, Carol Wallace (2013). HACCP: A Practical Approach https://doi.org/10.1007/978-1-4614-5028-3 For teaching purposes only!  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt 2. Describe the product 28 Sara Mortimore, Carol Wallace (2013). HACCP: A Practical Approach https://doi.org/10.1007/978-1-4614-5028-3 For teaching purposes only!  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt 2. Describe the product 29 Sara Mortimore, Carol Wallace (2013). HACCP: A Practical Approach https://doi.org/10.1007/978-1-4614-5028-3 For teaching purposes only! www.egasmoniz.com/pt For teaching purposes only! 3. Identify the intended use How will the product be used? Retail (consumer) or in food processing plants - What are the preparation and storage procedures? Master’s Degree in Veterinary Medicine Who are the target consumers? Do they include at-risk populations? 30  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt 3. Identify the intended use 31 Sara Mortimore, Carol Wallace (2013). HACCP: A Practical Approach https://doi.org/10.1007/978-1-4614-5028-3 For teaching purposes only! www.egasmoniz.com/pt For teaching purposes only! 4. Construct Flow Diagram Used as the basis of the hazard analysis Must contain sufficient technical detail for the study to progress Should be carefully constructed by members of the team as an accurate - representation of the process Master’s Degree in Veterinary Medicine Should cover all stages from raw materials to end product Identify the steps of the process, the interaction between them, in sequence Very important step!!! Can determine whether or not a hazard is considered at a stage in the process 32 www.egasmoniz.com/pt For teaching purposes only! 4. Construct Flow Diagram There is no established format → develop the diagram that best suits the process - Master’s Degree in Veterinary Medicine Steps usually considered: receipt of raw materials, preparation, processing,..., distribution, retail, consumer 33  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt 4. Construct Flow Diagram 34 Sara Mortimore, Carol Wallace (2013). HACCP: A Practical Approach https://doi.org/10.1007/978-1-4614-5028-3 For teaching purposes only!  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt 4. Construct Flow Diagram 35 Sara Mortimore, Carol Wallace (2013). HACCP: A Practical Approach https://doi.org/10.1007/978-1-4614-5028-3 For teaching purposes only! www.egasmoniz.com/pt For teaching purposes only! 5. Verify flow diagram on-site Why? - Master’s Degree in Veterinary Medicine 36 www.egasmoniz.com/pt For teaching purposes only! 5. Verify flow diagram on-site If it works in shifts → check on all shifts Adapt or correct the diagram if necessary - Master’s Degree in Veterinary Medicine Records → show the changes made and, if necessary, the reasons for the changes https://foodindustryexecutive.com/2022/11/a-multistage- approach-to-solving-the-labor-shortage-in-the-fb-industry/ 37  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt Development of HACCP Plan 38 For teaching purposes only! www.egasmoniz.com/pt For teaching purposes only! Objectives to be attained during this lecture: To recognize the main reasons to implement food safety systems as HACCP - Master’s Degree in Veterinary Medicine To understand the origins of HACCP and the main differences between inspection and prevention To identify the five preliminary steps to the HACCP principles WHY ARE THESE TOPICS IMPORTANT? 39  For teaching purposes only! HACCP Hazard Analysis and Ricardo Assunção, DVM, PhD Critical Control Point Hygiene & Food Safety Integrated Master in Veterinary Medicine 2024/25 www.egasmoniz.com/pt For teaching purposes only! Objectives to be attained during this lecture: To understand the 7 principles of the HACCP - Master’s Degree in Veterinary Medicine To be able to detail the main activities to implement HACCP To know the main documents to support the implementation of HACCP WHY ARE THESE TOPICS IMPORTANT? 41 www.egasmoniz.com/pt For teaching purposes only! HACCP Hazard Analysis and Critical Control Point - Master’s Degree in Veterinary Medicine Important part of food safety management HACCP completes any food safety management system by providing an approach that is: systematic science-based applicable throughout the food chain 42  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt 43 For teaching purposes only!  For teaching purposes only! Principle 1 www.egasmoniz.com/pt Conduct a Hazard Analysis The process of collecting and evaluating information on hazards and conditions - Master’s Degree in Veterinary Medicine leading to their presence to decide which are significant for food safety and therefore should be addressed in the HACCP plan (Codex, 2009b) 44  For teaching purposes only! Principle 1 www.egasmoniz.com/pt Conduct a Hazard Analysis Hazards that should be prevented, eliminated or reduced to acceptable levels to produce safe food should be identified and appropriately controlled - Specific hazards can be controlled by applying good hygiene practices and programmes Master’s Degree in Veterinary Medicine In other instances, control measures will need to be applied within the production or processing process, e.g. at Critical Control Points (CCPs) Crucial that you do not miss any hazards Input from a wide range of disciplines in your team, working from a comprehensive and validated process flow diagram 45 www.egasmoniz.com/pt For teaching purposes only! Principle 1 Conduct a hazard analysis - List all potential hazards Task 1 that are likely to occur and to identify the Master’s Degree in Veterinary Medicine associated with each step significant hazards Task 2 Identify any measures to control identified hazards 46  For teaching purposes only! Principle 1 www.egasmoniz.com/pt Task 1a) List all potential hazards Compiling the list of all potential hazards Hazards that may occur in each ingredient - and at each stage of the process Master’s Degree in Veterinary Medicine HACCP team should use the flow diagrams (HACCP Steps 4 and 5) to conduct this analysis 47  For teaching purposes only! Principle 1 www.egasmoniz.com/pt Task 1a) List all potential hazards Important aspects to support the identification of potential hazards: ingredients, additives, raw materials (considering their origins); food contact materials, surfaces, water and air; - how the product is prepared and sold; Master’s Degree in Veterinary Medicine the process that is applied (requiring a solid knowledge of the technological aspects and workflow, as well as following the process); how the product will be used (for example, chilled, refrigerated, as an ingredient); the standards the product should comply with (such as, export and import regulations, special customer requirements, etc.); the final consumer (considering, in particular, whether there any vulnerable groups among the consumers); and any processes that might be applied to control the hazard. 48  For teaching purposes only! Principle 1 www.egasmoniz.com/pt Task 1a) List all potential hazards Important steps when preparing the list of potential hazards: Identify the type of hazard (biological, chemical or physical) which is reasonably likely to occur in - each step of the process (considering all inputs in that step). Master’s Degree in Veterinary Medicine Hazards should be recorded clearly, providing specific information, including the type and name of the hazard and describing the source or reason for its presence (e.g. metal from broken blades from chopping, E. coli O157:H7 from faecal contamination during evisceration). The hazard analysis can be simplified by breaking down complex manufacturing operations and analysing steps in the multiple flow diagrams described in Step 4. 49  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt Principle 1 Task 1a) List all potential hazards 50 Sara Mortimore, Carol Wallace (2013). HACCP: A Practical Approach https://doi.org/10.1007/978-1-4614-5028-3 For teaching purposes only!  For teaching purposes only! Principle 1 www.egasmoniz.com/pt Task 1a) List all potential hazards Brainstorming = approach where all team members offer their ideas = - Master’s Degree in Veterinary Medicine 1. Naturally promotes lateral thinking as team members build on each other’s ideas 2. Allows team members to “think the unthinkable” 3. Overcomes the belief that there is always one correct solution to every problem https://www.mindmavericks.org/single- post/2014/12/31/brainstorming-literally-means-that 51  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt Principle 1 Task 1a) List all potential hazards 52 Sara Mortimore, Carol Wallace (2013). HACCP: A Practical Approach https://doi.org/10.1007/978-1-4614-5028-3 For teaching purposes only!  For teaching purposes only! Principle 1 www.egasmoniz.com/pt Task 1b) Conduct a hazard analysis and identifying significant hazards The potential hazards will be narrowed down to the most significant hazards associated with the food or the process under consideration - Master’s Degree in Veterinary Medicine Each potential hazard is evaluated based on the severity of the potential hazard and the likelihood of its occurrence. 53 www.egasmoniz.com/pt For teaching purposes only! Risk Regulation (EC) No 178/2002 function of the - probability of an adverse health effect Master’s Degree in Veterinary Medicine and the severity of that effect, consequential to a hazard 54  For teaching purposes only! Principle 1 www.egasmoniz.com/pt Task 1b) Conduct a hazard analysis and identifying significant hazards SIGNIFICANT HAZARD - Hazards that are of such a nature that their https://doi.org/10.1007/978-1-4614-5028-3 elimination or reduction to an acceptable Sara Mortimore, Carol Wallace (2013). Master’s Degree in Veterinary Medicine HACCP: A Practical Approach level is essential to the production of safe foods. (ILSI, 1999) A hazard that is likely to occur and that would cause an adverse health effect in the absence of control (Mortimore and Wallace, 1998) 55  For teaching purposes only! Principle 1 www.egasmoniz.com/pt Task 1b) Conduct a hazard analysis and identifying significant hazards Important questions to consider in deciding if the hazards are significant: - Master’s Degree in Veterinary Medicine How would the hazard affect a consumer? What is the severity of the hazard? Has the hazard occurred previously and is it likely to occur in the near future? 56  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt hazards Principle 1 Task 1b) Conduct a hazard analysis and identifying significant 57 Sara Mortimore, Carol Wallace (2013). HACCP: A Practical Approach https://doi.org/10.1007/978-1-4614-5028-3 For teaching purposes only!  For teaching purposes only! Principle 1 www.egasmoniz.com/pt Task 1b) Conduct a hazard analysis and identifying significant hazards Equal to or less than - 2 is not considered Master’s Degree in Veterinary Medicine significant for evaluation as a PCC https://www.vectorsolutions.com/resources/blogs/levels-of-a-risk-matrix/ 58  For teaching purposes only! Principle 1 www.egasmoniz.com/pt Task 1b) Conduct a hazard analysis and identifying significant hazards Severity High Equal to or less - H-R H-L H-M H-H 1000 than 1000 is not Master’s Degree in Veterinary Medicine Medium considered M-R M-L M-M M-H 100 significant for Low evaluation as a L-R L-L L-M L-H 10 PCC Low Medium High Remote 10 100 1000 Probability 59  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt hazards Principle 1 Task 1b) Conduct a hazard analysis and identifying significant 60 Sara Mortimore, Carol Wallace (2013). HACCP: A Practical Approach https://doi.org/10.1007/978-1-4614-5028-3 For teaching purposes only!  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt 61 Codex General Principles of Food Hygiene (CXC 1-1969). https://www.fao.org/fao-who-codexalimentarius/sh- proxy/en/?lnk=1&url=https%253A%252F%252Fworkspace.fao.org%252Fsites%2 52Fcodex%252FStandards%252FCXC%2B1-1969%252FCXC_001e.pdf For teaching purposes only!  For teaching purposes only! Principle 1 www.egasmoniz.com/pt Task 1b) Conduct a hazard analysis and identifying significant hazards Hazards considered - significant → will be considered in the HACCP Decision of the HACCP Subjectivity Master’s Degree in Veterinary Medicine plan Team (Decision tree) Significant hazards → controlled under HACCP Not significant hazards → controlled under other Programs 62  For teaching purposes only! Principle 1 www.egasmoniz.com/pt Task 2) Identify measures to control identified hazards CONTROL MEASURE: - Any action and activity that can be used to prevent or eliminate a food safety hazard or reduce it to an Master’s Degree in Veterinary Medicine acceptable level (Codex, 2009b) This is particularly important for the significant hazards but it is useful to consider control measure options for all hazards identified 63  For teaching purposes only! Principle 1 www.egasmoniz.com/pt Task 2) Identify measures to control identified hazards The HACCP team should: describe the control measures for each significant hazard (for example, GHP measures that - are in place or processes designed to eliminate each hazard); Master’s Degree in Veterinary Medicine identify the food safety outcomes or targets required; and provide evidence that demonstrates that the control measures are capable of controlling hazards to an acceptable level, if properly implemented (by validating the control measures). 64  For teaching purposes only! Principle 1 www.egasmoniz.com/pt Task 2) Identify measures to control identified hazards Even with effective control measures, a hazard can be present but may not pose a serious risk. A single significant hazard may need more than one control measure E.g., to control L. monocytogenes, a heat treatment may be needed to kill the organism in the food and cleaning and disinfection may be - needed to prevent the transfer of the organism from the processing environment. Master’s Degree in Veterinary Medicine A single control measure may address more than one significant hazard E.g., a heat treatment can control both Salmonella and E. coli O157:H7 when they are present as hazards in the food. Listing all the measures used to control hazards in each food production step will enable the HACCP team to determine whether the necessary controls are in place. Identify processing steps where controls are missing. Identify hazards that are not being effectively controlled, as measures may need to be adjusted, replaced or changed. 65  For teaching purposes only! Principle 1 www.egasmoniz.com/pt Conduct a Hazard Analysis - Master’s Degree in Veterinary Medicine 66  For teaching purposes only! Principle 2 www.egasmoniz.com/pt Determine Critical Control Points x Critical Control Point (CCP) A step at which control can be applied - Essential to preventing or eliminating a food Master’s Degree in Veterinary Medicine safety hazard or reducing it to an acceptable level 67  For teaching purposes only! Principle 2 www.egasmoniz.com/pt Determine Critical Control Points - Master’s Degree in Veterinary Medicine 68  For teaching purposes only! Principle 2 www.egasmoniz.com/pt Determine Critical Control Points Critical Control Points ≠ Control Points - https://doi.org/10.1007/978-1-4614-5028-3 Sara Mortimore, Carol Wallace (2013). Master’s Degree in Veterinary Medicine HACCP: A Practical Approach Control point any step at which a biological, physical or chemical factor can be controlled 69 www.egasmoniz.com/pt - Master’s Degree in Veterinary Medicine For teaching purposes only! If I lose control, is a health hazard likely to occur? 70  For teaching purposes only! Principle 2 www.egasmoniz.com/pt Determine Critical Control Points - Master’s Degree in Veterinary Medicine Decision Tree 71  For teaching purposes only! Decision Tree www.egasmoniz.com/pt Set of questions to help with the decision → is a control proxy/en/?lnk=1&url=https%253A%252F%252Fworkspace.fao.org%252Fsites%2 52Fcodex%252FStandards%252FCXC%2B1-1969%252FCXC_001e.pdf point a CCP? Codex General Principles of Food Hygiene (CXC 1-1969). https://www.fao.org/fao-who-codexalimentarius/sh- (only) a decision aid! - Master’s Degree in Veterinary Medicine There are different versions of HACCP CCP determination decision trees available as the format has been adapted to meet the needs and contexts of different sectors within the food industry (e.g. production, slaughter, storage). 72  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt point a CCP? Decision Tree (only) a decision aid! the decision → is a control Set of questions to help with 73 Sara Mortimore, Carol Wallace (2013). For teaching purposes only! HACCP: A Practical Approach https://doi.org/10.1007/978-1-4614-5028-3  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt 74 For teaching purposes only!  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt Principle 2 Determine Critical Control Points 75 Sara Mortimore, Carol Wallace (2013). HACCP: A Practical Approach https://doi.org/10.1007/978-1-4614-5028-3 For teaching purposes only!  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt 76 Sara Mortimore, Carol Wallace (2013). For teaching purposes only! HACCP: A Practical Approach https://doi.org/10.1007/978-1-4614-5028-3  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt 77 Sara Mortimore, Carol Wallace (2013). HACCP: A Practical Approach https://doi.org/10.1007/978-1-4614-5028-3 For teaching purposes only!  For teaching purposes only! Principle 3 www.egasmoniz.com/pt Establish critical limits for CCP Critical limits whether a CCP is in control - Can be used to separate acceptable Master’s Degree in Veterinary Medicine products from unacceptable ones Measurable or observable Use typically minimum and/or maximum values or critical parameters, such as Yes/No? temperature, time, moisture level, pH, aw, conveyor belt speed, etc. Should have scientific support 78  For teaching purposes only! Principle 3 www.egasmoniz.com/pt Establish critical limits for CCP Critical limit A criterion, observable or measurable, relating to - a control measure at a CCP which separates Master’s Degree in Veterinary Medicine acceptability from unacceptability of the food Operational limit A value that allows deviations to be prevented Stricter than the Critical Limit → allows the process to be adjusted BEFORE something happens... 79  For teaching purposes only! Principle 3 www.egasmoniz.com/pt Establish critical limits for CCP https://doi.org/10.1007/978-1-4614-5028-3 Sara Mortimore, Carol Wallace (2013). OPERATIONAL LIMITS (also HACCP: A Practical Approach - sometimes known as action or target levels): Master’s Degree in Veterinary Medicine Control criteria that are more stringent than critical limits, and that can be used to take action and reduce the risk of a deviation (Mortimore and Wallace, 1994) 80  For teaching purposes only! Principle 3 www.egasmoniz.com/pt Establish critical limits for CCP How to establish critical limits? → Two-part process: Specifying the critical limits; and - Validating the critical limits for each CCP. Master’s Degree in Veterinary Medicine obtain scientific evidence that the critical limits are effective in achieving the desired hazard control This requires both technological understanding of the process and scientific knowledge of the hazard 81  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt Principle 3 Establish critical limits for CCP 82 FAO Good Hygiene Practices (GHP) and Hazard Analysis and Critical Control Point (HACCP) Toolbox for Foods For teaching purposes only!  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt Principle 3 Establish critical limits for CCP 83 Codex General Principles of Food Hygiene (CXC 1-1969). https://www.fao.org/fao-who-codexalimentarius/sh- proxy/en/?lnk=1&url=https%253A%252F%252Fworkspace.fao.org%252Fsites%2 52Fcodex%252FStandards%252FCXC%2B1-1969%252FCXC_001e.pdf For teaching purposes only!  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt Principle 3 Establish critical limits for CCP 84 Sara Mortimore, Carol Wallace (2013). HACCP: A Practical Approach https://doi.org/10.1007/978-1-4614-5028-3 For teaching purposes only!  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt Principle 3 Establish critical limits for CCP 85 Sara Mortimore, Carol Wallace (2013). HACCP: A Practical Approach https://doi.org/10.1007/978-1-4614-5028-3 For teaching purposes only!  For teaching purposes only! Principle 4 www.egasmoniz.com/pt Monitoring CCP Monitoring of CCPs Scheduled measurement or observation of a - CCP relative to its critical limits Master’s Degree in Veterinary Medicine Personnel monitoring CCPs should be properly trained for the task and be capable of addressing any deviations 86  For teaching purposes only! Principle 4 www.egasmoniz.com/pt Monitoring CCP Purposes of monitoring CCP, according to National Advisory Committee on Microbiological Criteria for Foods (1997): - It is a means to determine if there is a loss of control and if a deviation has occurred at a CCP (in Master’s Degree in Veterinary Medicine which case, appropriate action must be taken); It tracks the operation and provides information on whether there is a trend towards loss of control, enabling action to be taken to bring the process back into control before a deviation occurs; and It provides documented records for use in verification procedures and audits. 87  For teaching purposes only! Principle 4 www.egasmoniz.com/pt Monitoring CCP Monitoring: Procedure & Frequency WHAT? - Master’s Degree in Veterinary Medicine HOW? WHEN? (WHERE?) WHO? Microbiological tests and samples are rarely an effective means of monitoring of a Critical Control Point 88  For teaching purposes only! Principle 4 www.egasmoniz.com/pt Monitoring CCP measuring a characteristic What will be monitored? of the product or of the process to determine Examples: - compliance with a critical Time or temperature of a thermal process limit Master’s Degree in Veterinary Medicine Humidity in a storage environment Cold-storage temperatures pH and aw levels Visual examination (for example, examining seals in a canning operation) Use of metal detectors to detect metal in products Use of detectors to examine glass containers for defects or cracks Verification of vendor’s certificates of analysis 89  For teaching purposes only! Principle 4 Monitoring should ideally provide quick results – in www.egasmoniz.com/pt time to make adjustments to ensure control of the Monitoring CCP process and prevent the violation of critical limits Monitoring procedures: In-line systems → critical factors are measured during the process: - Best type of monitoring as it is real-time Master’s Degree in Veterinary Medicine Continuous systems → critical data are continuously recorded (e.g. temperature recording chart) Discontinuous systems → observations are made at specified time intervals during the process. Off-line systems → samples are taken for measurement of the critical factors elsewhere Normally discontinuous (unless a continuous sampling device has been used) → sample taken may not be fully representative of the whole batch Monitoring method and frequency should make it possible to detect any failures before they fall outside the established critical limits, so that affected products can be isolated and evaluated in a timely manner 90  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt Principle 4 Monitoring CCP 91 Codex General Principles of Food Hygiene (CXC 1-1969). https://www.fao.org/fao-who-codexalimentarius/sh- proxy/en/?lnk=1&url=https%253A%252F%252Fworkspace.fao.org%252Fsites%2 52Fcodex%252FStandards%252FCXC%2B1-1969%252FCXC_001e.pdf For teaching purposes only!  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt Principle 4 Monitoring CCP 92 Sara Mortimore, Carol Wallace (2013). HACCP: A Practical Approach https://doi.org/10.1007/978-1-4614-5028-3 For teaching purposes only!  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt Principle 4 Monitoring CCP 93 Sara Mortimore, Carol Wallace (2013). HACCP: A Practical Approach https://doi.org/10.1007/978-1-4614-5028-3 For teaching purposes only!  For teaching purposes only! Principle 5 www.egasmoniz.com/pt Corrective Actions To respond effectively to deviations when they occur - Products affected by a deviation are potentially unsafe Master’s Degree in Veterinary Medicine Corrective actions → should ensure that control of the CCP and the process has been restored What happens to all potentially unsafe products? E.g. evaluated by experts, reprocessed, diverted to another use or possibly destroyed 94  For teaching purposes only! Principle 5 www.egasmoniz.com/pt Corrective Actions Corrective actions should: Correct the cause of the deviation to - Corrective actions have two parts ensure that the CCP is brought Master’s Degree in Veterinary Medicine 1. Identification: Recognize a deviation under control; as such and as early as possible Control any products that may be 2. Taking action: Corrective action should unsafe; and be taken by the operator