KING ABDULAZIZ UNIVERSITY HAZARD ANALYSIS AND CRITICAL CONTROL

KING ABDULAZIZ UNIVERSITY HAZARD ANALYSIS AND CRITICAL CONTROL POINTS (HACCP) Dr. Areej Alkhaldy CLN 212 Food Safety and Hygiene Clinical Nutrition Department-2 nd year 26/04/2015

By the end of the lecture you will: Objective v Define the terms hazard and critical control point. v. Understand the purpose of Hazard Analysis Critical Control Point (HACCP). v Know the history of HACCP v Recognize the seven principles in the HACCP process. v Be aware of HACCP certificate provider. v Be familiar with some of the HACCP certified companies in Saudi Arabia.

What is the HACCP? HACCP is a system that identifies, assesses, and controls the biological, chemical, and physical hazards that are associated with food production or practice to prevent potential problems before they happen. • HACCP stands for ‘Hazard Analysis Critical Control Point’. • H Hazard Analysis of all hazards based on the • • product description, production process, and operational conditions. A Analysis C Critical Assessment of the likelihood of health hazards occurring and the identification of guiding points. C Control P Point

Why HACCP is important? v To controls potential hazards in food production. v. By monitoring and controlling major food risks, such as microbiological, chemical and physical dangers, the industry can better assure consumers that the products are safe.

History of HACCP • 1959 -1960: NASA wanted to produce food for astronauts to guarantee food safety. • 1963: World health organization issued HACCP principles in Codex Alimentarius ((Book of Food") is a collection of internationally recognized standards, codes of practice, guidelines and other recommendations relating to foods, food production and food safety). • 1973: NASA, American Army Laboratory and Pillsbury group company made a common project for astronauts in food production. • 1985: USA national science academy suggested that HACCP should be applied in food operations for food safety.

Cont. • 1973: HACCP becomes mandatory for low acid canned food regulations (p. H > 4. 6). • 1997: HACCP becomes mandatory for Seafood. • 1998: HACCP becomes mandatory for large meat and poultry manufacturers. • 1999: HACCP becomes mandatory for small meat and poultry manufacturers. • 1999: HACCP becomes mandatory for frozen dessert manufacturers. • 2000: HACCP becomes mandatory for very small meat and poultry manufacturers. • 2002: The juice HACCP regulation begins to be mandatory for processors, small businesses, and very small businesses.

HACCP Hazards v. Biological: harmful microorganisms Critical Control Point (CCP) v. Identifiable point in the production chain where a hazard may occur. v. Chemical: those either naturally occurring, intentionally added or unintentionally added). v. Physical: glass, stones, or metal v. Action is taken to prevent the hazard from occurring. v. This can either be a point, step or procedure at which control can be applied and is essential to prevent or eliminate a hazard or reduce it to an acceptable level.

HACCP plan • To develop a HACCP plan: 1. A team of individuals within the company. 2. Assistance from outside experts. • Conducts five preliminary steps. • Applies the seven HACCP principles.

Step 1: Collect the HACCP Resources/Assemble the HACCP Team • Gather as many materials and documents related to food safety as well as assemble a team to represent different sectors within the industry. • One HACCP coordinator with HACCP skills should be chosen. • Other members do not need HACCP skills to be on team. • The team should represent engineering, production, sanitation, and quality assurance. • Larger companies can have teams of seven or eight people while small companies may have teams as small as two or three people. • The HACCP coordinator should have responsibility for the whole HACCP program and be the team leader.

Step 2: Describe the Product and its Method of Distribution • The step can contain a short description of how the process happens and/or how the product is produced or prepared. • This will help to minimize the potential hazards that might occur. • To describe the product, the company should answer the following questions: • 1. Common Name/Description: • 2. Process Description: • 3. How is it to be used? • 4. Type of Package? • 5. Length of shelf-life; at what temperature? • 6. Where will it be used? • 7. Labeling instructions: • 8. Is special distribution control needed?

Step 3: Develop a Complete List of Ingredients and Raw Materials • The ingredients and raw materials will help to focus on potential hazards in the meat product produced. • Product and Ingredients • Product: • Meat Ingredients: • Non-Meat Ingredients: • Restricted Ingredients: • Packaging Materials: • Casing:

Step 4: Develop a Process Flow Diagram v. Make a process flow diagram that identifies steps used to prepare the product, from receiving through final shipment. v. After the flow diagram is created it should be confirmed by walking through the plant to make sure the steps listed on the diagram describe what happens in producing the product.

Step 5: Meet the Requirements for Sanitation • Good sanitation guarantees that a safe product is produced. • Maintaining good sanitation is an excellent foundation for building a HACCP plan. • It also shows that plant management can successfully implement the HACCP plan.

Seven principles of HACCP implementation • Hazard analysis • Determine the Critical Control Points (CCP) • Establish critical limits • Critical Control Point (CCP) monitoring • Corrective actions • Establish verification procedures • Record keeping procedures

1. Hazard Analysis The first step involves identifying any hazards that must be prevented, eliminated or reduced to acceptable levels. All potential hazards, from the receipt of raw materials to the finished product, must be considered. A hazard must be controlled if it is likely to occur, and/or likely to result in an unacceptable risk to consumers.

2. Determine the Critical Control Point (CCP) Identifying the Critical Control Point (CCP) at the steps to prevent or eliminate a hazard or to reduce it to acceptable levels.

3. Establish Critical Limits v A critical limit is a maximum or minimum value to which a biological, chemical or physical limit must be controlled at a CCP. v This is set in order to prevent, eliminate or reduce a hazard to an acceptable level.

4. Critical Control Point (CCP) monitoring v. A planned series of observations need to be taken to determine whether a CCP is within critical limits. v. This also helps to create an accurate record for future use in verification.

5. Corrective actions v Corrective actions to be followed when a hazard is identified in the food production. v The aim is to correct and eliminate the cause of the hazard and bring CCP back under control. v The cause of problem must be identified to prevent future recurrence.

6. Verification Procedures v Verification procedures are those activities, other than monitoring CCPs, that verify the HACCP plan and show the system is operating accordingly. v This is usually completed yearly or when a system fails or there is a major change in the product or process.

7. Record Keeping Procedures v. Documentation and record keeping help to show the effective application of HACCP. v. These records could be included in the development of the HACCP plan, CCP monitoring, corrective actions or verification activities. v. Four different types of HACCP records include: 1. HACCP plan and support documentation used in developing the plan. 2. Records of CCP monitoring. 3. Records of corrective actions. 4. Records of verification activities.

Review of HACCP v. The design and running of the HACCP structure should be reviewed whenever the food operation is changed. v. The system should be reviewed (e. g. once a year) even when there have been no changes.

My HACCP

HACCP in Administration of TPN Formula v. Steps to reduce formula contamination: 1. Before opening can of formula, carefully clean the can opener and lid. 2. Opened cans or mixed formula should be stored in clean, closed container. 3. Refrigerate unused portion of formula immediately. v. To reduce risk of bacterial infection: 1)Hang no more than 8 to 12 hours supply of formula for open system and 36 to 48 hours for closed one. 2) Discard any formula remaining after that time and add fresh formula using new feeding container and tube.

HACCP Certificate Provider

Contact • Dr. Areej Alkhaldy • E-mail: aalkhaldy@kau. edu. sa • Room: 1218 • Ext no: 23983