Unit 1: Food Inspection Topic: Introduction to HACCP Lecture 7 FOOD HYGIENE Unit 1: Food Inspection Topic: Introduction to HACCP Lecture 7

Objectives At the end of the session, students should be able to: Outline correctly the weaknesses of the traditional approach to inspections Outline clearly the historical development of HACCP State accurately the advantages of utilizing the HACCP principles Outline clearly the relationship between pre-requisite programmes and the HACCP system Define accurately specific terms related to HACCP Identify correctly the 7 HACCP principles List accurately the contents to be entailed in a HACCP plan Outline clearly the role of regulators/PHI in ensuring HACCP principles are utilized

Outline Tradition inspection Overview of HACCP Scope of the application of HACCP Advantages of HACCP Definition of terms HACCP principles HACCP plan Role of the regulators

Questions to be answered Weaknesses of traditional approach to ensuring food safety History of HACCP Scope of HACCP HACCP principles and an example of each principle

HACCP http://www.youtube.com/watch?v=7nbjd_TnU8o&feature=related

Traditional Inspection Inspection for compliance focussed on GMPs Describe the methods, equipment, sanitary operations, sanitary facilities, and controls for processed foods, personnel, grounds Good Agricultural Practices - GAPs Standard Operating Procedures - SOPs Sanitation Standard Operating Practices -SSOPs GMP is a system for ensuring that products are consistently produced and controlled according to quality standards appropriate to their intended use and as required by the product specification. GMP for the 21st Century, FDA

Traditional Inspections Emphasis for prevention and control was based on inspections Frequency Thoroughness Completeness, time of day, staff on duty, critical process Could not provide the degree of food safety desired by stakeholders Emphasis was primarily on aesthetics, sanitation of facilities and equipment, and habits of personnel

Traditional Inspection End Product Testing Samples taken limited statistically Time & Cost required for testing Lab results only identify the effect What about the causes? What control measures would be required to prevent a reoccurrence? Approach not very scientific

Quality Control programmes Establish QC department Conduct internal monitoring Physical Chemical Microbiological With a view to improve or ensure compliance Concerned about quality standards Similar approach to the traditional inspection, therefore weaknesses are the same Very strong emphasis on final product testing

HACCP - History Developed in 1961 Pillsbury Company in cooperation with NASA US Army Natick Laboratory Assure the safety of food products intended for space travel (pathogens and biological toxins) Limited total reliance on end product testing The practical and proactive system of HACCP evolved from efforts to understand and control food safety failures Every batch of food developed had to be tested; this proved very time consuming and inefficient. HACCP evolved because of the need to understand and control food safety failures

History Concept 1st presented publicly at 1971 US National Conference on Food Protection 1974 HACCP principle incorporated in US regulations for the production of low-acid foods By 1980 most major companies began adopting HACCP principles in quality assurance programmes Mandatory applications Fish & Seafood products – 1995 (FDA) Meat & poultry industry – 1998 (USDA – FSIS) Milk, Juice processing & packaging plants – 2001 (FDA)

History Adopted by economies Europe, Canada, Australia, and New Zealand High priority program under Codex Alimentarius the world food standards authority created in 1963 by FAO and WHO to develop food standards, guidelines and related texts such as codes of practice under the Joint FAO/WHO Food Standards Programme Today HACCP internationally accepted as an effective way to ensure product safety Pressure from consumers; food trade Jamaica’s perspective???

History Structured and logical Proactive/Preventative Designed to move away from final product testing

HACCP Hazard Analysis Critical Control Points management system in which food safety is addressed through the analysis and control of hazards from raw material production, procurement and handling, to manufacturing, distribution and consumption of the finished product Risk assessment tool used to guarantee safety and quality A system/framework which identifies, evaluates, and controls hazards which are significant for food safety FSIS

HACCP “The methodical and systematic application of the appropriate science and technology to plan, control and document the safe production of foods” Seeks to identify, assess and control hazards in foods Basic principle “prevention rather than inspection” Common sense application of technical and scientific principles to food production process from farm to table Aim – to produce foods safely and be able to prove that it was produced safely WHO

HACCP Stakeholders should have sufficient information concerning foods and related procedures To identify where and how a hazard may occur Producers, processors, distributors, food handlers and consumers

Scope Powerful system which is applicable to a wide range of operations Whether simple or complex It is used to ensure food safety at all stages of the food chain Manufacturers should not only investigate their own product and production methods Distribution, retail operation and consumer practices must also be considered

Food Chain AGRICULTURAL IMPUTS PRMIARY PRODUCTION DOMESTIC PREPARATION Fertilizers, pesticides, drug PRMIARY PRODUCTION Farmers, fishermen DOMESTIC PREPARATION PRIMARY PROCESSING On farm, dairies, abattoirs Grain mill FOOD RETAILING Supermarkets, shops SECONDARY PROCESSING Canning, freezing, drying brewing FOOD DISTRIBUTION National/international FOOD CATERING Restaurants, schools hospitals

Scope Product and premises specific Other systems exists that are common to all premises Necessary conditions to protect foods under its control Traditionally relied on GMPs and GAPs Considered as pre-requisites to the development and implementation of an effective HACCP plan Ensures the integrity of the HACCP system Provide basic environmental and operating conditions necessary to produce safe, wholesome foods

Advantages of HACCP Greater degree of food safety assured Offset limitations in final product testing Removes some of the subjectivity associated with conventional inspection procedures Know hazards, where likely to exist, project how they could occur, id. where control must be exercised, decide where to conduct measurements Assists employees in coping with processing irregularities and equipment break down Final responsibility for food safety lies with company “Options limited based on Vision” Histamine poisoning/scromboid – where is the hazard likely to occur?

Complementary standards ISO 9000 series product quality standards ISO 22000 a new standard that specifies the requirements for a food safety management system. ISO 22000 incorporates all the elements of HACCP and of Good Manufacturing Practices (GMP)

Pre-requisite Programme Cleaning & Sanitization Personal Hygiene Preventative maintenance Raw material control Pest Control Facilities Training Traceability & Recall programmes HACCP plan more effective as focus can be placed directly on the production operation. Support for hazards being Not reasonably likely to occur. Justification for not adding a particular potential hazard to theHACCP Plan.

Food flow diagram

STEP 1 Conduct hazard analysis. Prepare flow diagram of steps in the process Identify the hazard and specify control measures Identify the CCPs in the process using a decision tree Establish critical limits/target level to ensure that each CCP is under control Establish monitoring requirements for CCP by scheduled testing or observations Establish corrective action for each breach/ when monitoring indicates that a particular CCP is out of control Establish procedures for verification that the HACCP system is working correctly STEP 7 Establish effective record keeping procedures concerning all procedures and records applicable

Step 1: Hazard Analysis In an attempt to identify potential hazards, it is necessary to consider: The raw materials used Processing procedures The manner in which the product will be used Egg for cooking vs to be used in punches

Step 1: Hazard Analysis Identify PH foods Foods that may contain poisonous substances, pathogens or large numbers of spoilage micro organisms Identify the potential source and specific points of contamination By analysis of each step in the food chain Every time a new ingredient is added or the processes are changed then the food flow will look different. Not an overnight event Determine the potential for micro organisms to survive Or multiply during production, processing, distribution Storage and preparation Assess the risk and severity of hazards identified

Step 1: Hazard Analysis Procedure Get information about the recipe Get information about the process Get information about the use of the food Holding temperature Possibility for recontamination Shelf life Prepare and serve without cooking Preparing and cooking the same day Preparing, cooking, holding, cooling, reheating and serving

Step 1: Hazard Analysis Risk Assessment Risk vs severity Risk Severity will the hazard always be present how often will it be present Severity Is it life threatening Will many people become ill Will there be extensive spoilage of the product

Risk vs Severity

Justifications What is the normal microbial load Does the microbial population change during processing until it reaches the consumer Does the changes in the microbial population alter the safety of the food To what degree does the normal wear of the equipment affect the likely occurrence of a physical hazard Does the method of packaging affect the multiplication of pathogens or formation of toxins Is the food intended for the general pubic Infants, ages, immunocompromised Institutional feeding vs home

Step 2: ID. CCP Find the points in the process where the identified hazards must be: Prevented Eliminated Reduced to safe levels A decision tree is usually used Depending on the process, there may be more than one CCP Cooking to destroy pathogens in chicken breast Cooking and then reheating Sealing of cans – cooking temp. and cooling temp Milk – pasteurization temp and chilling temp.

Decision Tree used for CCP

Step 3: Establish Critical Limits For each CCP, establish a minimum or maximum limit that must be met in order to prevent or eliminate the hazard or reduce it to a safe level Min limit -TT 74C for 15sec Can go a step further increase cooking time to 18 secs Max limit – 4.4C for chilling additives, Aw

Step 4: Establish Monitoring procedures Once a critical limit has been established Determine the best way to ensure it is not exceeded Should be able to detect any deviation from specifications and must provide the information in time for action to be taken Identify who to monitor When to monitor How to monitor Device to be used Calibration frequency Visual observation Sensory evaluation Physical measurements Chemical testing Microb testing

Step 5: Corrective Actions Identify the steps that must be taken when a critical limit is not met These steps should be determined in advance Should be noted on the log sheet used for monitoring Discard (sealing of cans) Continue cooking (eg. Chicken) Rewash (fruits for a salad)

Step 6: Verify system works Plan to evaluate on a regular basis Ensure that the goals set were met Once per shift ( for chicken) Temp logs reviewed weekly to identify pattern Changes may be necessary Same chicken breast Temp not being met towards the end of the week Corrective action taken and was duly noted What could be the problem Product audits, end product testing incubation tests

Step 7: Documentation Maintain HACCP Plan Maintain all records obtained when: Monitoring activities were performed Corrective actions taken Verification activities Equipment is validated/changed/modified Information from suppliers Training sessions

Development of HACCP plan Establish multi-disciplinary team Line staff must be included Describe product Identify intended use and consumer Construct flow diagram Onsite confirmation of flow diagram Conduct hazard Analysis Determine the CCP Establish critical limits Outline monitoring procedures Establish corrective action Establish verification procedures Establish recording and documentation procedures Implement the plan Product name2Raw material and ingredients used3Parameters influencing safety (aw, pH, salt%, etc.)4Processing5Packaging and packaging material6Storage conditions and shelf life7Conditions during distribution8Intended use and consumer9Labelling instructions

Contents of a HACCP plan Listing of HACCP team and assigned responsibilities Description of product and its intended use Food flow diagram indicating CCPs Hazards associated with each CCP and preventative measures Critical limits Monitoring system Corrective action plan for deviations from critical limits Procedures for verification of HACCP system Record keeping procedures

HACCP Audits Systematic and independent examination to determine whether activities and results comply with the documented procedures whether the procedures are implemented effectively suitable to achieve the objectives

Rationale – HACCP audit The outcome of the audit is to have established whether the manufacturer has implemented a sound HACCP system the knowledge and experience needed to maintain it the necessary support (or prerequisite) programmes in place to assess adherence to GAPs, GHPs, GMPs

Components of HACCP Audit Assessment of the management commitment to support the system Assessment of the knowledge, competency and decision-making capabilities of the HACCP team members to apply the system and maintain it Assessment of performance of HACCP system

Types of Audits Internal HACCP audits External HACCP audits Internal/external resources External HACCP audits Raw materials, processes Investigative audits

Frequency of audits Frequency of HACCP audits should be based on: the risk category of the product being processed the level of commitment of management and the decision-making leverage of the HACCP team the reputation of the company previous safety and quality records HACCP manual and implementation classification training and qualification

Role of Government in HACCP Ensure appropriate application of the HACCP principle by food industry Facilitate HACCP implementation as deemed practical and necessary Provide leadership in food safety control by accepting and promoting HACCP Enforcers and facilitators Regulations may be required Voluntary compliance programme Dependent on legislative framework as well as the national, regional and global context

Role of the PHI Ensure that the HACCP plan is properly designed and implemented, and is operating effectively Enforcement activities should focus on the conceptual features of the HACCP system rather than only on the physical features emphasized by the traditional approach Advise and assist industry in the development of HACCP plans Facilitate training activities

Summary?

Assignment Choose a food item/product Chart the food flow Brain storm to identify the potential hazards For each hazard identified – justify For each non-hazard – justify why not Determine CCP Establish critical limit Decide on control methods