THE HACCPSYSTEM Hazard Analysis Critical Control Point System

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, 3 rd 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, immunecompromised, 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 Adapted from: HACCP A Practical Approach, 3 rd Edition, Sara Mortimore and Carol Wallace Retailers

Governmental Regulation of HACCP § HACCP is not governed by international legislation § Each country has own food safety regulation which may include HACCP § European Union, 1 st of January 2006: Regulation (EC) No. 852/2004 on the Hygiene of Foodstuffs, Article 5

International Standardisation § Codex 2009 b: Primary international reference standard for HACCP § ISO 22000 (2005): Certification standard for HACCP (based on Codex 2009 b)

HACCP Success Structure External Pressure Resource Availability Education and Training Management Commitment Adapted from: HACCP A Practical Approach, 3 rd 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, 3 rd 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, 2009 b) § 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 2009 b)

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 O 157: H 7 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 § p. H 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, 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 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, 3 rd Edition, Sara Mortimore and Carol Wallace

Hazard Significance Severity High Significant Hazard Medium Low Medium High Likelihood of Occurrence Adapted from: HACCP A Practical Approach, 3 rd 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, 3 rd Edition, Sara Mortimore and Carol Wallace

PRPs – the Foundation of HACCP PRPs Adapted from: HACCP A Practical Approach, 3 rd Edition, Sara Mortimore and Carol Wallace Focus on: raw materials, product and processes Focus on: Production environment, facility, programs and people

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, 2009 b) 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, 3 rd 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/veterinar y_checks_and_food_hygiene/f 84001_en. htm