Lecture 03 food safety and quality control 2024.pdf

Food Safety and Quality Control Dr. Muhammad CERTIFIED FOOD PhD, MBA, MSc Naseem Khan SAFETY PROFESSIONAL  2 What is Quality? ATTRIBUTES...

Food Safety and Quality Control Dr. Muhammad CERTIFIED FOOD PhD, MBA, MSc Naseem Khan SAFETY PROFESSIONAL  2 What is Quality? ATTRIBUTES are used to describe QUALITY… examples:  Beauty,  Goodness,  Freshness,  Expensiveness etc because different people perceive these attributes differently, the use of attributes to describe quality is IMPRECISE. Quality, therefore needs to be defined. Food & Dairy Microbiology  3 What is Quality? According to the Oxford Dictionary, quality is defined as being  ‘the degree of excellence of a thing;  relative nature or kind or character of a thing;  class or grade of something determined by this; Food & Dairy Microbiology  4 What is Quality? “Quality is never an accident; it is always the result of high intention, sincere effort and intelligence” Food & Dairy Microbiology  5 Quality Defined: ISO 9000:2000 Degree to which a set of inherent characteristic fulfils requirements (3.1.1)  Characteristic – distinguishing feature, i.e. physical, sensory, temporal or functional etc (3.5.1)  Requirement –need or expectation that is stated or implied or obligatory, i.e. custom or common practice for you! (3.1.2) Food & Dairy Microbiology  6 Who defines Quality - the Q Lens Lens of the people organisation products processes results outcomes benefits Lens of the customer Food & Dairy Microbiology  7 Food Safety No health hazards observed after consuming the food ! Food & Dairy Microbiology  Consumer 8 Safety Public health Industry Food & Dairy Microbiology  9 Biological Chemical pathogenic Hazards Histamine Heavy metals bacteria(Salmonella Vibrio cholerae) Pesticides viruses Antibiotics worms Dyes Mycotoxin Physical Bolts and nuts Metal Fragments Sand Food & Dairy Microbiology  10 Brief history of HACCP  HACCP was developed by Pillsbury for the NASA space program in the 1970’s  Codex Alimentarius (FAO) has developed it for international use  Canada refined it in 1992 as the Food Safety Enhancement Program (FSEP) Food & Dairy Microbiology  11 GLOSSARY OF HACCP TERMS  Control: To manage the condition of an operation to establish the state wherein correct procedures are being followed and critical limits or target levels are being met.  Control Measure: Those actions and activities that can be used to eliminate hazards or reduce their impact or occurrence to acceptable levels.  Corrective Action: The action taken when monitoring at a CCP indicates a potential loss of control or when a critical limit is not met.  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.  Critical Limit: A value which separates acceptability from unacceptableness. Food & Dairy Microbiology  12 GLOSSARY OF HACCP TERMS  HACCP Plan: The written document which is based upon the principal activities of HACCP and which indicates the procedures to be followed to assure the control of a specific process or procedure.  Hazard: A biological, chemical or physical agent or condition with the potential to cause harm.  Hazard Analysis: The process of collecting and interpreting information to assess the risk and severity of potential hazards.  Monitor: To conduct a planned sequence of observations or measurements of a control parameter to assess whether a CCP is under control.  Risk: An estimate of the likely occurrence of a hazard Food & Dairy Microbiology  13 GLOSSARY OF HACCP TERMS  Severity: The seriousness of a hazard.  Step: Any location or stage in food production and/or manufacture (including raw materials), their receipt and/or production, harvesting, transport, formulation, processing/manufacture, storage, etc. as identified in the flow diagram.  Target Levels: Values which are used to assure that critical limits are met.  Verification: The use of methods, procedures, or tests in addition to those used in monitoring to determine if the HACCP system is in compliance with the HACCP plan, and/or whether the HACCP plan needs modification and revalidation Food & Dairy Microbiology  14 Hazard Analysis Critical Control Point (HACCP ) system  Codex Definition  “ A system which identifies, evaluates and controls hazards which are significant for food safety ” (Codex 1999) Food & Dairy Microbiology  Food safety management systems 15 Conventional HACCP based Process Line Process line S F S F CCP GMP GMP Hygiene/ sanitation control (SSOP) Hygiene/ sanitation control (SSOP) End line product Inspection & testing Continuous monitoring & CCP control Food & Dairy Microbiology  16 HACCP SSOP GMP Food & Dairy Microbiology  17 Sanitation Standard Operating Procedure (SSOP) Eight Key sanitation conditions and practices  Safety of water  Condition and cleanliness of food-contact surfaces  Prevention of cross-contamination  Maintenance of hand-washing,  hand-sanitizing and toilet facilities  Protection from adulterants  Labelling, storage and use of toxic compounds  Employee health conditions  Exclusion of pests Food & Dairy Microbiology  18 Food & Dairy Microbiology  19 This is management of risk ! Food & Dairy Microbiology HACCP applied !!  20 Food Safety Prevention of hazards in foods  Physical  Biological  Chemical  Allergens Food & Dairy Microbiology  HACCP - Answers 3 questions 21 H azard WHAT hazards can enter the product? A nalysis Where do these C ritical hazards occur? C ontrol How can we control P oint or eliminate these hazards? Food & Dairy Microbiology  22 HACCP  Science based  Step wise process:  Identifies hazards  Installs preventative measures to eliminate or reduce hazards in foods  Proactive rather than reactive  Risk based Food & Dairy Microbiology  23 HACCP  Does not rely on end product testing  hazards not be evenly distributed and can be missed in sampling  need to test large quantities  product would need to be destroyed or reworked Food & Dairy Microbiology  24 HACCP  Starts from the beginning of the process  Receiving of ingredients, packaging  through process steps  to final product and shipping Food & Dairy Microbiology  25 Components  Pre- requisite program  Hazard analysis Food & Dairy Microbiology  26 Prerequisites  Foundation to a HACCP program  Includes Good Manufacturing Practices  Addresses food safety at all stages from receiving to shipping Including indirect hazards Food & Dairy Microbiology  27 Prerequisite program  Premises  Transportation and Storage  Equipment  Personnel/Training  Sanitation and Pest Control  Recall  Allergen Control  Supplier Quality Assurance Food & Dairy Microbiology  28 Premises  Outside property and building  Design, construction & maintenance  Lighting  Ventilation  Waste disposal  Inedible areas  Employee & sanitary facilities  Water/Steam/Ice Food & Dairy Microbiology  29 Transportation and Storage  Food Carriers  Temperature Controls  Receiving and Storage  Incoming ingredients and packaging  Non-Food Chemicals  Finished Product Storage Food & Dairy Microbiology  30 Equipment  Design and installation  Maintenance and Calibration Food & Dairy Microbiology  31 Personnel  Trained for their job  Understand food safety Food & Dairy Microbiology  32 Sanitation and Pest Control  Sanitation  Equipment and Utensils  Floors  Locker rooms  Lunch rooms  Washrooms  Pest control Food & Dairy Microbiology  33 Recall  Product identification  Locating product  Returning product Food & Dairy Microbiology  34 Allergen control  Identification of Allergens  Control of allergens  Special handling  Segregate  Special sanitation procedures  Rework  Proper labelling Food & Dairy Microbiology  35 Supplier Quality Assurance  Vendor approval process  Product specifications  Inspect incoming materials Food & Dairy Microbiology  36 Sequence of 12 Steps 1. Assemble HACCP team 2. Describe product 3. Identity intended use 4. Construct process flow and plant schematic 5. On site verification of flow and schematic 6. List hazards associated with each process step (principle #1) Food & Dairy Microbiology  37 Sequence of 12 steps 7. Apply HACCP decision tree to determine CCP’s (Principle #2) 8. Establish critical limits (Principle #3) 9. Establish monitoring procedures (Principle #4) 10. Establish deviation procedures (Principle #5) 11. Establish verification procedures (Principle #6) 12. Establish record keeping/documentation for principles 1 - 6 (Principle #7) Food & Dairy Microbiology  38 Food & Dairy Microbiology  39 HACCP team People chosen that have expertise in different areas:  Production  Shipping  Quality Assurance  Sanitation  Maintenance  Sales Food & Dairy Microbiology  40 Product Description  Product Name(s)  Important Product Characteristics  How it is to be used  Packaging  Shelf Life  Where it will be sold  Labelling Instructions  Special Distribution Control  Specific Ingredients Food & Dairy Microbiology  41 Define the processing steps Packaging Storage and Receiving Preparation and Storage Distribution Holding Labelling Food & Dairy Microbiology  42 Construct Plant Schematic Food & Dairy Microbiology  43 Determine hazards  Look at each input- ingredients  Determine possible hazards  How are they controlled? Food & Dairy Microbiology  44 CCPs  Critical control points  Place where you can prevent, remove or reduce a hazard  if there is not step in the process that can eliminate or reduce the hazards- use labelling, cooking instructions to inform how control can be achieved Food & Dairy Microbiology  45 CCPs Example  Metal detector  Metal is a hazard in our facility  Not fully controlled by any prerequisite program  Metal detectors specifically designed identify product containing metal  That product can be removed  No other step will remove the metal Food & Dairy Microbiology  46 What is your role? What is your role?  Monitor  Look, smell, measure  Record  Corrective actions  Verify  Monitor people doing activity  Take corrective actions when necessary  Complete records properly Food & Dairy Microbiology  47 Fish in the hold (box or hold) Unloading onto the dock Process flow Washing diagram Deliver to the auction hall / pier Landing and distribution Auctioning of fish in fishery Cutting Re-loading harbor Consumer Re-icing Transport Consumer Food & Dairy Microbiology  Hazard analysis & identification in 48 fishery harbor  Identify and analyze possible hazards in each steps of the flow diagram considering following categories 1. Chemical hazards (eg: Histamine) 2. Microbial hazards (eg: Microbial growth) 3. Physical hazards (eg: Sand)  Control measures Time and temperature monitoring Food & Dairy Microbiology  49 Example of hazards and controls Hazards Control measures  Pathogenic bacteria (Salmonella) Use potable water contamination of fish by washing  Microbial growth Monitoring chlorine levels (contamination by water leak)  Growth of pathogenic bacteria Time and temperature in fish  Histamine Time and temperature  pathogenic bacterial cross contamination personal hygiene  contamination by toxic chemicals Good handling practices Food & Dairy Microbiology  50 VERIFED PROCESS FLOW CHART  Pulp Processing Industry Food & Dairy Microbiology  51 Virtual Visit to Food Industry Food & Dairy Microbiology  52 THANK YOU Food & Dairy Microbiology