HACCP Food Safety System PDF

Unit 7 - The Hazard Analysis Critical Control Point (HACCP) System  What is HACCP? Hazard Analysis and Critical Control Point System, as defined by the Codex Committee on Food Hygiene Powerful food safety management technique Based on 7 HACCP Principles Structure...

Unit 7 - The Hazard Analysis Critical Control Point (HACCP) System  What is HACCP? Hazard Analysis and Critical Control Point System, as defined by the Codex Committee on Food Hygiene Powerful food safety management technique Based on 7 HACCP Principles Structured, preventative system that achieves safety through hazard identification and control Needs to be supported by prerequisite programmes  Hazard Analysis and Critical Control Point (HACCP) Hazard Analysis and Critical Control Point (HACCP) is a systematic preventive approach to food safety and pharmaceutical safety that addresses physical, chemical, and biological hazards as a means of prevention rather than finished product inspection. Objective of HACCP – To monitor and protect food from contamination  The Need for Safety & Quality Control in Food Production Need to reevaluate the food safety system due to the following challenges: New germs that can cause foodborne illness The changing nature of global food supply New techniques for processing and serving food Changing eating habits of consumers A growing number of people at increased risk of foodborne illness Major incidents of food-borne illness or health scares Worldwide; may involve several countries May involve biological, chemical or physical hazards Many different causes: – Contaminated raw materials – Mishandling – Change of product formulation – Cross contamination – Inadequate maintenance – Wrong addition of ingredients Direct and indirect costs  Examples Year Country Food Number ill Cause Cost (£) 1985 USA Mexican style 147 Listeria Reported soft cheese 47 deaths monocytogenes lawsuit 400 million 1985 UK Infant dried milk 76 Salmonella 22 million 1 death 1987 Switzerland Soft cheese 30 deaths Listeria 880 000 monocytogenes 1988 UK Hazelnut 27 Clostridium Companies yoghurt 1 death botulinum went out of business 1994 USA Ice cream 224 000 Salmonella ? no deaths Enteritidis 2007 UK Cadbury Salmonella 20 million+ Schweppes Montevideo 2008 USA Peanut butter 500 Salmonella 2,100 different 8 deaths Typhimurium products recalled  Traditional Methods of Food Safety & Quality Assurance End- product testing for assurance of safety Codes of practice for food production (GMP/GHP etc.)  End Product Testing Based on observation and testing of samples Not effective at detecting defective batches Can give false sense of security Expensive Ineffective use of resources Detects problems once they have occurred  Codes of Practice Tend to be general rather than product specific – Management – Design of plant and equipment – Facilities and operations – training in personal hygiene – Cleaning and disinfection procedures Essential but not sufficient Guidelines can be vague – `use appropriate cleaning procedures’ – `inspect as often as necessary’ Often fail to identify which are the most important requirements for product safety  Advantages of HACCP over Traditional Inspection Methods 1. Traditional: react to problems and correct hazardous conditions after they happen. HACCP: anticipate and control problems before they happen. 2. Traditional: provide a description of an establishment’s conditions at the time of evaluation only. HACCP: describes the overall condition of an establishment by tracking food handling practices over a period of time. 3. Traditional: focus on aesthetic/visual or non critical factors. HACCP: based on controlling time, temperature, and specific factors that are known to contribute to foodborne disease outbreaks.  HACCP Define the process Identify and hazards that may occur Identify the points critical to product safety Manage these points effectively Verify that the system is working properly Objective of HACCP: To monitor and protect food from contamination.  More emphasis on how food is handled during storage, preparation, and service. proper food handling techniques, good personal hygiene, proper control of food temperatures etc.  Less emphasis on general sanitation.  Origins of HACCP Developed in 1960s as a microbiological safety programme in the early days of the US manned space programme Original system drawn up by the Pillsbury Company working with NASA and the US army laboratories at Natick NASA asked Pillsbury to design & manufacture the first foods for space flights – to ensure food sent to space was safe. Apollo 11 Digital Picture This system looks at what could Library HTML Design by Brian W. Lawrence. possibly go wrong (critical failure areas) before implementing control measures – i.e. eliminating them from the system.  The Seven Principles of HACCP 1. Conduct a hazard analysis. 2. Identify the Critical Control Points (CCP) in food preparation. 3. Establish Critical limits (thresholds) which must be met at each identified Critical Control Point. 4. Establish procedures to monitor CCPs. 5. Establish the corrective action to be taken when monitoring indicates that a Critical Limit has been exceeded. 6. Establish procedures to verify that the HACCP system is working. 7. Establish effective record keeping that will document the HACCP system.  What is a HACCP Plan? A written document which is based upon the principles of HACCP and which specifies the procedures to be followed. HACCP needs to be supported by prerequisite programmes  Prerequisite Programmes Apply across the site to generally applicable activities Often called ‘Good Manufacturing Practices’ (GMP) Provide a sound foundation for HACCP Allow the HACCP plan to be focussed on the management of critical food safety hazards.  Prerequisite Programs (examples) Training and personal hygiene – illness reporting – protective clothing – hair, jewellery – hand washing Premises – building and machinery design – cleaning and maintenance – pest control – waste and drainage control – chemical hazards control – Glass and foreign object control  Prerequisite Programmes….contd Product – raw material control – product design Process Control – HACCP, QA checks Distribution – protect food from contamination – protect food from damage likely to make it unsafe – temperature control Retailer – proper storage – product trace and recall Consumer – product information on storage and handling HACCP Plan - Describe the product and intended use Scope Which product? Which process? Whole process or module? Start and end points? Type of Hazard to be considered Microbiological Chemical Physical  HACCP Plan - Describe the product and intended use Principal raw materials Recipe: intrinsic control factors in food pH, water activity etc. Principal process technologies heating drying high pressure fermentation Packaging and finished product state Target consumer group Abuse possibilities  HACCP Plan - Construct a process flow chart Develop a flow chart to follow the flow of food from start to finish. Identify “high-risk” activities that occur during the process. Ask: What can be done to control the “high-risk” activities to reduce the risk of foodborne illness? For each step in the process flow chart: Identify the potential hazards Assess the risk to establish significant hazards Identify effective control measures  Construct a process flow diagram Raw Raw Raw material material material 1 2 3 Mixing Heating Cooling Filling Storage Distributi on  Principle 1. Conduct a Hazard Analysis Identify hazards that might be introduced to food by certain food production practices or the intended use of the product. Potentially hazardous foods  Meats  Dairy products  Poultry, eggs  Cooked foods such as beans, pasta, rice, potatoes  Cut cantaloupe and raw seed sprouts  What is a Hazard? Hazards: biological, chemical, or physical agent with the potential to cause an adverse health effect - introduced into food by people, poor food-handling practices, and/or contaminated equipment. Biological hazards - Look for steps in the production process where food may become contaminated and microorganisms may survive and multiply. Chemical hazards - proper handling and storage of chemicals to prevent the possibility of chemical contamination. - purchasing of food items and additives from approved sources. Physical hazards - may accidentally enter food during production and service. Identify potential sources and provide safeguards.  Risk Estimate During Hazard Analysis Step What is Risk? The probability or likelihood that a condition or conditions will lead to a hazard, causing an adverse health effect. Factors that Influence Risk: type of customers served, types of foods on the menu, nature of the organism, past outbreaks, size and type of food production operations, extent of employee training. The severity of a hazard is defined by the degree of seriousness of the consequences, should it become a reality. A significant hazard is a hazard that is of such a nature that its elimination or reduction to an acceptable level is essential to the production of safe foods Hazards that pose little or no risk, or are unlikely to occur, need not be addressed by the HACCP system.  Establishing Preventive Measures During Hazard Analysis Preventive Measures Controlling the temperature of the food Cross-contamination control Good personal hygiene practices Prevent, minimize, or eliminate an identified health hazard Avoiding the danger zone for potentially hazardous foods.  Temperature and Time: preventive measures used most often in HACCP. Principle 2. Identify Critical Control Points (CCPs) What is a critical control point (CCP)? A step where control can be applied and is essential to prevent, eliminate or reduce a food safety hazard to an acceptable level Provides: A kill step that will destroy bacteria, or A control step that prevents or slows down the rate of bacterial growth.  Critical Control Points (CCPs) Examples of CCPs: Cooking, reheating, and hot-holding Chilling, chilled storage, and chilled display Receiving, thawing, mixing ingredients, and other food-handling stages Product formulation (i.e., reducing the pH of a food to below 4.6 or the A w to 0.85 or below) Purchasing seafood, modified atmosphere packaged (MAP) foods, and ready-to-eat foods from approved sources. Most commonly used CCPs Cooking, cooling, reheating, and hot-/cold-holding cooking, reheating ➤ kill step cooling, hot-holding, cold-holding ➤ control step Standard Operating Procedures (SOPs) vs CCPs SOPs more difficult to measure, monitor, and document, therefore not considered CCPs. CCPs are Operations that Involve:  Simplified HACCP flow diagram for pasteurised milk Raw milk monitored for Bacteria from Receipt of milk microbial counts and faeces and milking antibiotics equipment Possible growth of bacteria Holding tank Temperature control pasteurisation CCP 72C 15 sec Cooling Cool to 6C within 90 min Post pasteurisation Filling and contamination packaging Germination and growth of spore Storage and formers distribution  How do you identify critical control points (CCPs)? Team expertise and judgement CCP decision trees  Raw material CCP decision tree Is there a hazard Question associated with this NO Procee 1 raw material? d YES Are you or the Sensitive raw customer going to NO Question material High level process this hazard 2 of control out of the product? CCP YES Is there a cross Question NO Procee contamination risk* 3 d that cannot be controlled? Sensitive raw material High YES level of control CCP  Flow diagram for hazard analysis: chocolate chip ice cream Skimme Liquid d milk Chocolat packagi Air Cream sugar powder Water Stabiliser Vanill e chips ng a Blend Homogenis e pasteurise Age Freeze Fill Harden Storage Q1 Is there a hazard Q2. Are you or the Q3. Is there a cross associated with this customer going to contamination risk raw material? process this hazard out that cannot be of the product? controlled? Raw Q1 Q2 Q3 CCP? HACCP Team notes material Skimmed Y Y N N Q1 is yes because of Salmonella milk but later heat process will Powder control. No cross contamination because full segregation from post process area Foreign N - - N Foreign material not usually material associated with SMP because milk filtered immediately before drying Antibiotic Y N - Y Antibiotic residues may carry residues through to final product. Not removed by heat, so raw milk supply must be monitored as part of Supplier Quality Assurance (SQA) Q1 Is there a hazard Q2. Are you or the Q3. Is there a cross associated with this customer going to contamination risk raw material? process this hazard out that cannot be of the product? controlled? Raw Q1 Q2 Q3 CCP? HACCP Team notes material Cream Y Y N N Hazard from vegetative pathogens most likely from post- process contamination, but Q2 is yes and Q3 is no for same reasons as SMP Chocolate Y N - Y Hazard from Salmonella. No chips subsequent heat process. Eaten without further preparation. High level of control necessary. SQA. Chemical- Y N - Y Hazard could occur during pesticide growing cocoa and raw material residues in storage. Q2 is no, so important chocolate that hazard is controlled by the supplier (SQA) N.B. In practice you should consider microbiological, chemical and physical hazards for each raw ingredient  Process step CCP decision tree Is there a hazard at NO Not a Question this process step? CCP 1 YES Modify Can this hazard be process Question NO step or controlled 2 product Is control at YES this step Not a necessary for NO YES CCP safety? Is this step Question specifically YES CCP 3 designed to eliminate the hazard or reduce it to acceptable NO levels?  Process step CCP decision tree continued Is this step Question specifically YES CCP 3 designed to eliminate the hazard or reduce it to acceptable NO levels? Could Question contamination NO Not a CCP 4 occur or increase to unacceptable levels? YES Will subsequent Question processing NO CCP eliminate risk or 5 reduce it to an acceptable level? YES Not a CCP Q1 Is Q2. Can Q3. Is this Q4. Could Q5. Will there a this step contamination subsequent hazard at hazard be specifically occur or processing this controlled designed to increase to eliminate the process ? eliminate the unacceptable hazard? step? hazard? levels? Process Q1 Q2 Q3 Q4 Q5 CCP HACCP Team notes step Pasteurising Y Y Y Y Pasteurisation specifically designed to kill vegetative pathogens Cooling Y Y Y Y Rapid cooling essential to prevent spore outgrowth.