Hazard Analysis and Critical Control Points (HACCP) STENUM GmbH

Slides12 – HACCP What is HACCP?  Problems  Foodborne diseases  Market access – importance of food safety all along the food-chain  Solutions  Food safety system that focuses on preventing problems before they occur  Industry-led programme used to improve and verify food safety  Answer HazardDanger to health AnalysisInvestigation of the hazard CriticalCrucial for containment ControlHandling of conditions PointsPosition in the process

Slides12 – HACCP What is HACCP? Hazard Analysis and Critical Points Science-based, internationally accepted food safety system Focused on hazard identification and prevention Addresses chemical and physical hazards Can be applied to all segments of the food chain Source: Department of Food Science and Technology, Virginia Tech.

Slides12 – HACCP Why adopt HACCP?  A properly functioning HACCP system will result in the production of safer food.  Benefits:  Improved food safety  Increased market access  Protection against liability  Drive for continuous improvement  Enhanced process control

Slides12 – HACCP Where can HACCP be used? HACCP can be used in any food sector from production to retail Production Processing Transport Retail and food service

Slides12 – HACCP The seven principles of HACCP Conduct a hazard analysis Identify critical points Establish critical limits for each critical control point Establish critical control point monitoring requirements Establish corrective actions Establish record keeping procedures Establish procedures for verifying that the HACCP system is working as intended IIIIII IV VVIVII

Slides12 – HACCP ISO  Requirements for a food safety management system  4 elements  Interactive communication  System management  Prerequisite programmes  HACCP principles Source: Van Voorst Consult

Slides12 – HACCP Implementing HACCP 1.Preliminary Steps for the introduction of a HACCP System  Gathering the resources and information needed 2.Seven principles of HACCP in action  Completion of all steps will result in a properly functioning HACCP plan

Slides12 – HACCP Preliminary steps 1.Assemble the HACCP team  Group of people that will oversee the implementation and maintenance of the HACCP programme  Multi-disciplinary (i.e. production, sanitation, management, etc.)  Including a HACCP-trained person

Slides12 – HACCP Preliminary steps 2. Description of products and identification of intended use and consumers  Full description of the product(s) being manufactured under the programme  Product information assists with hazard analysis  Which group(s) will be consuming the food product  Where will the product be sold  How will it be prepared

Slides12 – HACCP Preliminary steps 3. Development and verification of process flow diagram(s)  The flow diagram should  Outline all processing steps  Include all processing steps  The plant schematic should  Outline where all of the processing steps occur  Display the movement of products, people and waste

Slides12 – HACCP Preliminary steps 4. Grouping of products  Decide whether products can be grouped using process categories  Slaughter – all species  Raw product – ground/not ground  Thermally processed – commercially sterile  Heat/not heat treated – shelf stable  Fully cooked – not shelf stable  Heat treated but not fully cooked – not shelf stable  Product with secondary inhibitors  Further categories for grouping can be commodity group, hazards, etc.  Products in the same process category may be covered by the same HACCP plan

Slides12 – HACCP Principle I  Conduct a hazard analysis  Evaluate information regarding potential hazards associated with the manufacturing process and ingredients  Determine which hazards are significant to food safety  Consider: Probability of occurrence Severity of consequences

Slides12 – HACCP What are hazards?  There are 3 types of hazards  Biological  Chemical  Physical  Do not forget cross-contamination  Microbiological, allergens

Slides12 – HACCP Biological hazards  Biological hazards can cause illness and include:  Bacteria: E.coli, Salmonella, Listeria, Campylobacter, Shigella  Viruses: cold viruses, Hepatitis A, Norwalk virus  Parasites: Giardia, Cryptosporidium, Trichinella, tapeworms  Yeasts and moulds  Any toxin produced by microbiological organisms is also a biological hazard

Slides12 – HACCP Chemical hazards  Chemical hazards can cause injury or poisoning and include:  Naturally occurring substances (e.g. allergens, plant specific toxins)  Excessive, intentionally added chemicals: antibiotics, pesticides, herbicides, fungicides, nitrates  Accidentally added chemicals: cleaning chemicals, paint, pest control chemicals

Slides12 – HACCP Physical hazards  Physical hazards are foreign objects that can cause injury:  Glass  Metal grindings, screws, nuts, bolts  Stones, pebbles  Needles  Hard plastic  Bones

Slides12 – HACCP Principle II  Identify Critical Control Points (CCPs):  A CCP is a point, step or procedure at which a control measure has to be applied to prevent, eliminate or reduce a food safety hazard  CCPs are not:  Necessarily located where the hazard occurs, they may be located at a subsequent step  Some hazards cannot be controlled by the operator

Slides12 – HACCP Principle III  Establish Critical Limits (CL) What is a critical limit?  The maximum and/or minimum value to which a parameter must be controlled at a CCP  The critical limit separates acceptability from unacceptability  The critical limit must be clearly defined and measurable

Slides12 – HACCP Principle IV  Establish monitoring procedures  Monitoring:  Is the process of conducting a planned sequence of measurements to determine if a CCP is under control  Monitoring results must be recorded If monitoring shows that critical limits are not met, then the process is out of control and the food may be unsafe.

Slides12 – HACCP Principle V  Establish corrective actions  Corrective actions are pre-determined measures that have to be implemented when monitoring indicates that a deviation has occurred.  Corrective actions must: Regain control of the process Locate and segregate affected product Determine disposal of affected product Prevent a recurrence

Slides12 – HACCP Principle VI  Establish verification procedures  Validation  Ensures that the HACCP plan is complete and valid  Ensures that the plan is effective in achieving expected food safety outcomes  Ongoing verification  Ensures that the HACCP plan is working effectively  Confirms that the plan is operating according to written procedures  Auditing  Overall review of the HACCP plan  To be performed whenever any changes occur that could affect the hazard analysis or alter the HACCP plan

Slides12 – HACCP Principle VII  Establish record keeping procedures  Record keeping must be complete and accurate and includes:  Documentation pertaining to all steps, including the HACCP principles  Appropriate record storage procedures  A log book to keep track of changes

Slides12 – HACCP HACCP system – Summary  HACCP systems consist of two elements  Prerequisite programmes Implemented prior to HACCP plans Control of the overall plant environment Control factors not directly related to food (e.g. water quality, transportation and storage, plant sanitation, employee training)  HACCP plans Implemented following pre-requisite programmes Tailored to a certain product or process Control factors directly related to food production