1. FOOD SAFETY & HYGIENE BASED ON HACCP regulationsBy
Ramadan Badran

2. Objectives At the end of the session, you 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

3. 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

4. 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

5. 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

6. 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

7. 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?

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

9. 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.

10. Food flow diagram

11. 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

12. 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

13. 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

14. 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

15. 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

16. 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

17. 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.

18. Decision Tree used for CCP

19. 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

20. 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

21. 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)

22. 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

23. 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

24. 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

25. 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

26. 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