Transcript haccp - Flypoint

THE HACCP-SYSTEM
Hazard Analysis Critical Control Point System
A Summary
What is HACCP?
„A holistic approach to food safety
management programs, incorporating
best practice facility and equipment
design, as well as structured
management systems“
HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace
Where did HACCP come from?
 Developed as a microbiological
safety system
 Pioneered by Pillsbury Company,
NASA and US Army Laboratories
 Based on Failure Mode and Effect
Analysis (FMEA)
Why use HACCP?
Product safety cannot be tested in
Proven system to manage food safety
Foodborne diseases are a public health problem



 Increase in susceptible population (elderly, immune



compromised, malnourished)
Changing lifestyles (eating-out, processed food,
tourism)
Emerging pathogens
Increase in complexity of supply chain
Improved laboratory testing schemes
7 Principles of HACCP
1.
2.
3.
4.
5.
6.
7.
Conduct a hazard analysis
Determine the Critical Control Points (CCPs)
Establish Critical Limits
Establish a system to monitor control of the CCP
Establish the corrective actions to be taken when
monitoring indicates that a particular CCP is not
under control
Establish procedures for verification to confirm that
HACCP is working correctly
Establish documentation concerning all
procedures and records appropriate to these
principles and their application
According to: Codex Alimentarius Commission and NACMCF
Applicability of HACCP within Supply Chain
Wholesalers
Primary
Producers
Foodservice
Caterers
Sea Food
Primary
Producers
Land Crops
Human
Processing
Animal
Feeds
Consumers
Primary
Producers
Meat, Dairy,
Poultry, Eggs
Retailers
Adapted from: HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace
Governmental Regulation of HACCP
 HACCP
is
not
governed
by
international legislation
 Each country has own food safety
regulation
which
may
include
HACCP
 European Union, 1st of January 2006:
Regulation (EC) No. 852/2004 on the
Hygiene of Foodstuffs, Article 5
International Standardisation
 Codex 2009b:
Primary international reference
standard for HACCP
 ISO 22000 (2005):
Certification standard for HACCP
(based on Codex 2009b)
HACCP Success Structure
External Pressure
Resource
Availability
Education and
Training
Management
Commitment
Adapted from: HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace
Key Stages in HACCP Development
 Planning & Preparation
 HACCP studies & HACCP plan
development
 Implementation of HACCP plan
 Maintenance of HACCP system
HACCP System Structure

Linear HACCP plans
 Applicable to each product or process
individually
 For simple operations with few product types

Modular HACCP plans
 Flexible approach
 Applicable to basic operations or modules

Generic HACCP plans
 Based on framework approach
 For simple operations
HACCP & Continuous Improvement
Verification
Monitoring and
Corrective/Preventive
Actions
Improvement
Planning and Realisation
of Safe Products
Implementation
HACCP Plan
Development
Hazard
Analysis
Establishing PRPs
Adapted from: HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace
PRPs – Prerequisite Programmes
„Universal steps or procedures that control the
operational conditions within a food
establishment allowing for environmental
conditions that are favourable for the
production of safe food“ (CFIA, 1998)
 „Procedures including good manufacturing
practices that address operational conditions
providing the foundation for the HACCP
system“ (NACMCF, 1997)
 „Practices and conditions needed prior to and
during the implementation of HACCP and
which are essential for food safety“ (WHO,
1998)

Hazards – Significance & Control
Hazard... Any factor present in the product that causes illness or
harm to the customer. The basis for every HACCP system
A biological, chemical or physical agent in, or
condition of, food with the potential to cause
an adverse health effect (Codex, 2009b)
 Significant hazard

 „Hazards
that are of such a nature that their
elimination or reduction to an acceptable level is
essential to the production of safe foods“ (ILSI, 1999)

Control measures
 „Any actin or activity that can be used to prevent or
eliminate a food safety hazard or reduce it to
acceptable level“ (Codex 2009b)
Biological Hazards
 Macro-biological
 Insects
 Micro-biological
 Direct: invasion of humans
 Indirect: via toxins
Biological Hazards - Bacteria
Pathogenic Gram-negative bacteria











Salmonella enterica
Escherichia coli
Campylobacter jejuni
Vibrio parahaemolyticus
Vibrio vulnificus
Shigella spp.
Yersinia enterocolitica
Cronobacter sakazakii
Habitat: animal intestines
Control: heat processing, segregation of raw and
cooked foodstuffs, good hygienic practices
Biological Hazards - Bacteria

Pathogenic Gram-positive bacteria
 Clostridium botulinum
 Clostridium perfringens
 Bacillus cereus
 Staphylococcus aureus
 Listeria monocytogenes
Biological Hazards - Viruses
 Hepatitis A and Norovirus
 Source: Shellfish
 Very small and thus difficult to
detect
 But easily to be inactivated by
heat
Biological Hazards – Parasites & Protozoa

Pathogenic flatworms, tapeworms, flukes
 Taenia saginata
 Trichinella spiralis
 Clonorchis sinensis
Source: infected flesh (pork, beef, fish, game)
 Prevention: good animal husbandry, veterinary
inspection, heating, freezing, drying
 Encysted larvae:

 Toxoplamsa gondii
 Giardia intestinalis
 Cyclospora cayetanensis
 Cryptosporidium parvum
Biological Hazards - Prions








Transmissible agents
Misfolded cellular proteins
Initiation of abnormal folding of normal
protein in brain
Formation of plaques
Destruction of brain cells
BSE (Bovine Spongiform Encephalopathy)
Scrapie (Sheep disease)
Creutzfeldt-Jakob Disease (Human)
Emerging Pathogens















Listeria monocytogenes
Escherichia coli O157:H7
Cronobacter spp.
Prions
Expected: Continued emergence of new foodborne microbial
pathogens
Drivers:
Changes in land use or agricultural practices
Changes in human demographics and society
Poor population health
Hospitals & medical procedures
Pathogen evolution (antibiotics)
Contamination of food sources or water supplies
International travel
Failure of public health programmes
Climate change
Control of biological Hazards

Intrinsic factors
 pH and acidity
 Organic acids
 Preservatives
 Water activity
 Ingredients

Process Technologies
 Thermal processes
 Fermentation
 Drying
 Freezing
 Irradiation
Chemical Hazards
 Not
well understood – lack of
toxicological expertise
 Contamination can happen at
any stage
 Chronic (carcinogenic) or acute
(allergenic reaction) effects for
customer
Chemical Hazards - Mycotoxins
Secondary metabolites of certain fungi
Long-term carcinogenic effect or short-term
acute toxic effects
 Affected food: cereals, nuts, dried fruit, coffee,
cocoa, spices, beans, fruit, etc.
 Very stable


 Aflatoxins
 Aspergillus flavus
 Patulin
 Penicillium spp.
 Deoxynivalenol
 Fusarium spp.
 Fumonisins
 Fusarium spp.
Chemical Hazards – Cleaning Chemicals
 Most common potential
contaminant
 Use of non-toxic and food-grade
chemicals
 PRP: Design & management of
cleaning procedures
Chemical Hazards - Pesticides










Insecticides
Herbicides
Fungicides
Wood preservatives
Masonry biocides
Bird & animal repellents
Food storage protectors
Rodenticides
Anti-fouling paints
Industrial/domestic hygiene products

Consider cross-contamination at any stage
Allergens & Food Intolerances
Immune mediated
 Non-immune mediated (majority)
 Allergens:

 Peanuts, tree nuts, eggs, milk products, shellfish,
fish, soya, wheat (Big 8 allergens)
 Lactose intolerance: 70% of population are
lactase deficient
 HACCP must consider cross-contamination
 PRP: general control of allergens
Chemical Hazards









Toxic/heavy metals
Nitrites, nitrates, N-nitroso compounds
Polychlorinated Biphenyls
Dioxins and Furans
Polycyclic aromatic hydrocarbons
Plasticizers & packaging migration
Veterinary residues
Melamine & cyanuric acid
Chemical additives
Physical Hazards

Can enter at any stage

Glass
Metal
Stones
Wood
Plastic
Pests
Intrinsic material (bones in meat/fish, nut shells)






Hazard Significance
Risk Evaluation Categories
Likelihood of
Occurrence
Hazard Severity
High
Highly probable. Known history in the
sector.
Medium
Could occur. Minimal history within
the sector –but has happened.
Low
Unlikely to occur. No known examples
High
Life threatening or long-term chronic
illness
Medium
Injury or intolerance. Not usually life
threatening
Low
Minor effect. Short duration
Adapted from: HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace
Hazard Significance
Severity
High
Significant
Hazard
Medium
Low
Low
Medium
High
Likelihood of Occurrence
Adapted from: HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace
PRPs – HACCP Support Network
Good
Distribution
Practice
Good
Manufacturing
Practice
Statistical
Process
Control
Supplier
Quality
Assurance
Good
Laboratory
Practice
HACCP
Preventative
Maintenance
Sanitary
Design and
Sanitation
Incident
Management
Quality
Management
Systems
Education
and
Training
Adapted from: HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace
PRPs – the Foundation of HACCP
HACCP
PRPs
Focus on:
raw materials,
product and
processes
Focus on:
Production
environment,
facility, programs
and people
Adapted from: HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace
The HACCP Plan





“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)
A formal document
Pulls together key information from HACCP
study
Details of all that is critical to food safety
Developed by HACCP team
Logic Sequence for HACCP Application
Step
Action
Step 1
Assemble HACCP team
Step 2
Describe product
Step 3
Identify intended use
Step 4
Construct Flow Diagram
Step 5
On-site confirmation of Flow Diagram
Step 6
List all potential hazards, conduct hazard analysis, and
consider control measures
Step 7
Determine critical control points (CCPs)
Step 8
Establish critical limits for each CCP
Step 9
Establish a monitoring system for each CCP
Step 10
Establish corrective actions
Step 11
Establish verification procedures
Step 12
Establish documentation and record keeping
References - Book
HACCP - A Practical Approach, 3rd Edition
Sara Mortimore and Carol Wallace,
Springer 2013 (ISBN: 978-1-4614-5027-6)
http://www.springer.com/food+science/book/978-1-4614-5027-6
References – Websites
Codex Alimentarius


National Advisory Committee on Microbiological
Criteria for Foods (NACMCF)




http://www.fsis.usda.gov/about/NACMCF/index.asp
World Health Organisation (WHO)


http://www.codexalimentarius.org/
http://www.who.int/topics/food_safety/en/
EU legislation
http://europa.eu/legislation_summaries/food_safety/ve
terinary_checks_and_food_hygiene/f84001_en.htm