Food Safety and HACCP Presenter Trevor Larson What

Food Safety and HACCP Presenter: Trevor Larson

What is HACCP ? n n n Hazard Analysis Critical Control Point Food Safety Management System - preventative - systematic - structured Safety through Hazard Identification & Control

How does HACCP work? n n n Define how the process works Identify what can go wrong-the hazards Identify control points critical to product safety Manage these points effectively Verify

Developments in HACCP n International acceptance q ICMSF n 1988 produced the first international publication n Covered microbiological hazards only q NACMCF and Codex Elementarius (WHO) n Published approaches based on seven principles n Codex Alimentarius accepted as international standard

International Acceptance General Principles of Food Hygiene n primary production n design and facilities n control of operation n maintenance and sanitation n personal Hygiene n transportation n product information and consumer awareness n training

National Developments n n SANS 10049 (SABS 049: 2001) Regulation 918 of 1999 SABS 0330 : 1999 Regulation 908 of 2003

The Codex Principles n n n n 1. 2. 3. 4. 5. 6. 7. Identify hazards and preventative measures Identify Critical Control Points (CCP’s) Establish Critical Limit Establish a CCP monitoring system Establish corrective action procedures Establish verification procedures Establish documentation and records

Why use HACCP n n n Management of product safety Prevention of product safety incidents Limitations of traditional quality control External pressures Many benefits Effective product management

Benefits of HACCP n n n Preventative system Systematic Increases confidence Cost effective control system Effective use of resources

Benefits of HACCP n n n Internationally accepted Strengthens quality management systems Facilitates regulatory inspection / external audit Demonstrates management commitment Helps demonstrate “due diligence”

PREREQUISITE PROGRAMMES n n Required prior to HACCP development Universal steps Simplifies HACCP plans Also referred to as GAP’S, GMP’S, SSOP’S

Prerequisite Programs TQM HACCP GAP’S / GMP’S / SSOP’S

Good Agricultural Practices (GAP’S) n n n Water Organic and inorganic fertilizers Animal exclusion Pest control Worker health and safety Harvesting

Premises n n Outside property Building Sanitary facilities Water / steam / ice quality program

2. Transportation and storage n n n Food carriers Temperature control Storage of incoming materials, non-food chemicals and finished product

3. Equipment n n n General equipment design Equipment installation Equipment maintenance and calibration

4. Personnel n n Training Hygiene and health requirements

5. Sanitation and pest control n n Sanitation program Pest control program

6. Recalls n n n Traceability Recall procedures Distribution records

HOW TO DO A HACCP STUDY ASSEMBLE A HACCP TEAM DEFINE THE TERMS OF REFERENCE DESCRIBE THE PRODUCT AND INTENDED USE CONSTRUCT A PROCESS FLOW DIAGRAM VALIDATE A PROCESS FLOW DIAGRAM IDENTIFY HAZARDS & PREVENTATATIVE MEASURES

HACCP STUDY (CONT. ) IDENTIFY CRITICAL CONTROL POINTS IDENTIFY CRITICAL LIMITS (TARGET LEVELS) IDENTIFY MONITORING PROCEDURES ESTABLISH CORRECTIVE ACTIONS ESTABLISH VERIFICATION PROCEDURES ESTABLISH RECORDS AND DOCUMENTATION

1. Assemble a HACCP Team Form 1 Product: Facility: Date: HACCP Team Leader HACCP Team Members

2. Define the terms of reference Form 2 Starting Point End Point Hazards to be covered

3. Product description and intended use Form 3 1. Product name(s) 2. Important product characteristics 3. How it is to be used 4. Type of packaging 5. Shelf life 6. Where it is to be sold 7. Labeling instructions 8. Distribution 9. Consumer target groups

4. Construct a process flow diagram Form 4 Product:

5. Validate the process flow diagram n n Checked for accuracy and completeness On-site inspection

6. Identify hazards and preventative measures Form 5 (1) Incoming material (2) Potential hazard (3) Significance of the hazard (4) Justify decision in column 3 (5) Preventative measures (6) Is this step a critical control point

Identify hazards and preventative measures Form 5 (1) Process Step (2) Potential hazard (3) Significance of the hazard (4) Justify decision in column 3 (5) Preventative measures (6) Is this step a critical control point

Definition of a hazard n A biological, chemical or physical property which may cause a food to be unsafe for consumption

Biological Hazards q q Bacteria Moulds Viruses Parasites

Chemical Hazards n n n Raw materials q Pesticides q antibiotics Process contaminants q Cleaning agents q lubricants Packaging q Ink q adhesives

Physical Hazards n n n Sharp items causing injury Hard items causing dental damage Items causing air blockages / choking

Identification of Critical Control Points : HACCP Principle 2 n n What is a Critical Control Point? How do we find them?

What is a CCP? n n n A point, step or procedure where control can be applied and a hazard can be prevented, eliminated or reduced to acceptable levels Essential for safety Kept to a minimum to ensure correct focus

How are CCPs identified n n n Team expertise and judgment CCP decision trees Software

CCP Decision Tree n n Incoming material and process steps Category and identified hazard q q q Determine if fully controlled by prerequisite programs. If yes, indicate the prerequisite program and proceed to next identified hazard If no, proceed to Question 1

CCP Decision Tree (cont. ) n Q 1. Do preventative measures exist for the identified hazard q q If no, not a CCP and proceed to next identified hazard If yes, describe and proceed to next question

CCP Decision Tree (cont. ) n Q 2. Is the process step specifically designed to eliminate/reduce the likely occurrence of the identified hazard to an acceptable level? q q If no, proceed to next question If yes, CCP and proceed to last column

CCP Decision Tree (cont. ) n Q 3. Could contamination with the identified hazard occur in excess of acceptable levels or could these increase to unacceptable levels q q If no, not a CCP and proceed to the next identified hazard If yes, proceed to next question

CCP Decision Tree (cont. ) n Q 4. Will a subsequent step eliminte the identified hazard or reduce the likely occurrence to acceptable level? q q n If no, CCP and proceed to the last column If yes, not a CCP, identify the subsequent step and proceed to the next identified hazard CCP number

Controlling CCPs : HACCP Principles 3, 4 and 5 n n n Establish critical limits and target levels Establish monitoring procedures Establish corrective action procedures

HACCP Control Chart n n Used to build up the day to day control requirements for each CCP identified Documents information relating to identified CCPs only

Critical limits or Target Levels: HACCP Principle 3 n n Definition: A value which separates acceptable from unacceptable Must be measurable Criteria must be met for each preventative measure at a CCP A target level is control criteria which is more stringent than Critical Limits

Establish monitoring procedures: HACCP Principle 4 n n Monitoring is the measurement or observation at a CCP that the process is operating within the critical limits (or target levels) It must be able to detect loss of control

Establish corrective action procedures : HACCP Principle 5 n n Corrective action is taken when monitoring indicates that there is a deviation from a critical limit Correction following deviation q Adjust the process q Destroy non-complying product q Re-work

Completing the HACCP Control Chart : HACCP Principle 6 and 7 n n Establish verification procedures q To verify that the system is working q To determine compliance with the HACCP Plan Establish records and documentation procedures q Objective evidence of all actions and results