1. FEDIAF Guide to Good Practice
for the Manufacture of Safe Pet Food
TRAINING PACKAGE
Module III
Hazard Analysis and Critical Control Points

2. Food Safety Management SystemCI
Review
measure
CI = Continuous Improvement
HACCP
Food safety management
Prerequisites (GMP)

3. Food Safety Management System
Food safety management system consists of a prerequisite programme and a HACCP system
Senior management commitment as first condition
Components of the HACCP system:
Implemented within the quality management system
HACCP team leader and personnel trained and skilled
Specific to the application, practical and effective
Reviewed regularly and validated
CCPs and OPRPs identified, controlled, monitored and recorded

4. Pre-Requisite Programmes
Prerequisite programmes are basic conditions and activities (good practices)
Examples:
Exterior/Interior conditions
Cleaning
Storage conditions
Handling of toxic materials
Training
Pest control
Calibration
Supplier control
Good Laboratory Practice
etc
Food and Non food grade Lubricant storage
Calibration status

5. 3. HACCP - definitions What is HACCP?
Hazard Analysis and Critical Control Points is
a technique that identifies, evaluates and
controls hazards significant for food safety
What is a hazard?
A biological, chemical or physical agent in, or
condition of, food or feed with the potential to
cause an adverse health effect
What is pet food safety?
Assurance that, when eaten according to its
intended use, the pet food will not harm the animal

6. Examples of food borne hazards
Bacteria:
Aeromonas, Clostridium perfrigens,
Clostridium botulinum, Campyloabcter,
pathogenic E.coli, Listeria monocytogenes,
Salmonella, Staphylococcus aureus…
Viruses:
Hepatitis A, Rotavirus,
Norwalk-like viruses…
Physical:
Metal, Glass…
Parasites:
Trichinella spiralis, Taenia,
Fasciola hepatica…
Chemicals:
PCBs, Dioxins, Heavy metals,
Pesticides, Veterinary Drugs,
Mycotoxins, Melamine, Toxins…

7. Ex.: decision tree to determine inspection plans based on the source
Feed material/Ingredient/ Additive/packaging/Wet product/Finished Products
EU/EFTA origin or of third country with equivalent safety/hygiene standards?
Is your supplier a trader? no
Third country origin with occurrence or doubts as to safety/hygiene concerns?
yes
Trader does not separate supplies
Trader separates supplies
Does supplier has the quality assurance system in place ?
Follow frequency for Low Risk ( A)
Follow frequency for Medium Risk ( B)
Follow frequency for High Risk (C)
As a principle, materials outsourced from a supplier identified as having a level of risk A using the Decision Tree shall have a lighter inspection plan than ones rated as B, and the latter shall be lighter than a supplier with a risk rated C.
A table of undesirables and the relevant references can be found in Annex 3 of the guide
Occurance in RASFF can be an indicator of increased risks

8. HACCP principles Step 0 Implement Pre-requisite Programmes
Codex Principle 1
Conduct a hazard analysis
Assemble HACCP Team
Describe product
Identify intended use
Construct Flow diagram
Confirm flow diagram on site
List all potential hazards
Consider control measures
Codex Principle 2
Determine the Critical Control Points (CCPs) and Operational Pre-Requisite Programs (OPRPs)
Use decision tree to determine CCPs and OPRP’s
Codex Principle 3
Establish critical limits
Establish action and critical limits for each CCP and OPRP
Codex Principle 4
Establish CCP monitoring procedures
Establish monitoring systems for each CCP and OPRP
Codex Principle 5
Establish corrective action plans
Establish the corrective action to be taken when monitoring indicates that a particular CCP or OPRP is not under control
Codex Principle 6
Establish verification procedures
Establish procedures for verification to confirm that the HACCP system is working effectively
Codex Principle 7
Establish documentation and recordkeeping systems
Establish documentation concerning all procedures and records appropriate to these principles and their application
Establish Validation
Validation of control measures

9. HACCP study What is a risk?
Probability of causing an adverse health effect caused
by the occurrence and severity of a hazard in food
Risk assessment to identify hazards:
Occurrence/severity of hazards and adverse effects
Qualify/quantify hazards
Micro-organisms growth
Toxins, chemicals or physical agents
Conditions leading to the above
Clostridium botulinum

10. Ex.: decision tree to identify CCPs and OPRPs (1)Q1
Do preventative control measure(s) exist for the identified hazard (including control measures upstream)? No
Modify steps in the process or product
Yes
Point, step or procedure at which control can be applied and is essential to prevent or eliminate hazards or reduce it to an acceptable level
Is control at this step necessary for safety?
Yes No
Not a CCP
Stop*
Critical Control Point Q2
Is the step specifically designed and essential to eliminate or reduce the likely occurrence of a hazard to an acceptable level by it self?
Yes
Is control measure at this step essential, in combination with other control measures, but out of control does not automatically implicate there is an immediate food safety risk?
Is the step specifically designed to eliminate or reduce the likely occurrence of a hazard to an acceptable level? No
OPRP No Q3

11. Ex.: decision tree to identify CCPs and OPRPs (2)Q3
Could contamination occur, with identified hazard(s) in excess of acceptable level(s), or could this increase to unacceptable levels?
Point, step or procedure at
which control can be applied and is essential to prevent or eliminate hazards or reduce it to an acceptable level
Yes No
Not a CCP
Stop* Q4
Will a subsequent step eliminate identified hazard(s) or reduce likely occurrence to acceptable levels?
Critical Control Point
Yes No
OPRP

12. HACCP examples: wet pet food
The following is an example of an HACCP outcome when applied to wet pet food e.g: cans, trays, pouches.
It is not intended to be complete. Manufacturers should use this for guidance only
Critical Control Point/OPRP depending on your HACCP
Hazard to be controlled
Typical Control Method
Transport / storage
Contamination or deterioration (e.g. temp)
Assurance and inspection programme
Raw Materials conform spec
Incorrect or contaminated raw materials (e.g. SRM)
Supplier Assurance programme and incoming inspection
Processing
Microbial growth due to incorrect processing
Monitoring time and temperature inspection, shelf-life control
Metal detection
Metal contamination (e.g. fish hooks)
Permanent magnets, electric metal detection device
Filling
Microbial growth due to under-sterilisation (caused by overfilling of chunks)
100% inspection by headspace control/weight control
Gravy addition
Seaming / Sealing
Growth micro-organisms (e.g. product inclusion in seal, damaged flanges)
Seam / seal control
Sterilisation
Microbial growth due to under-sterilisation (e.g. due to low initial temperature, low sterilisation time or low sterilisation temperature) which leads to a F0 less than 3
Calibration and monitoring
Cooling
Microbiological ingress during cooling (e.g. due to lack of Chlorine)
Calibration and monitoring (of dosing equipment and water quality)
Handling of primary package
Contamination or deterioration due to loss of packaging integrity
Visual control

13. HACCP examples: semi-moist
Critical Control Point/OPRP depending on your HACCP
Hazard to be controlled
Typical Control Method
Transport / storage
Contamination or deterioration (e.g. temp)
Assurance and inspection programme
Raw Materials conform specification
Incorrect or contaminated raw materials (e.g. SRM)
Supplier Assurance programme and incoming inspection
Addition of preservatives
Microbiological growth
Monitoring / inspection
Processing
Microbial or mould growth (e.g. due to high Aw)
Aw monitoring / inspection, shelf-life control
Filling
Microbial growth due to condensation (caused by too high filling temperature) and risk moulding
Monitoring / inspection filling temperature and external temperature
Metal detection
Metal contamination
Electric metal detection device
Handling of primary package
Contamination or deterioration due to loss of packaging integrity
Visual control

14. HACCP examples: dry pet food
Critical Control Point/OPRP depending on your HACCP
Hazard to be controlled
Typical Control Method
Transport / storage
Contamination or deterioration (e.g. humidity)
Assurance and inspection programme
Raw Materials conform spec.
Incorrect or contaminated raw materials (e.g. SRM)
Supplier Assurance programme and incoming inspection
Heating
Bacterial growth caused by lethality too low, e.g. low time/temperature (less than 90°C) of product during extrusion/pressing/baking)
Control of temp/time and monitoring/ inspection, shelf-life control
Processing
Microbial or mould growth (e.g. due to high Aw)
Aw, moisture, monitoring / inspection, shelf life control
Filling
Microbial growth due to condensation (caused by too high filling
temperature)
Monitoring / inspection filling Temperature and external temperature
Metal detection
Metal contamination
Permanent magnets, electric metal detection device
Storage of product
Microbial or mould growth
Aw/Warehouse assurance program
Handling of primary package
Contamination or deterioration due to loss of packaging integrity
Visual control

15. HACCP examples: chews
Critical Control Point/OPRP depending on your HACCP
Hazard to be controlled
Typical Control Method
Transport / storage
Contamination or deterioration (e.g. temp))
Assurance and inspection programme
Raw Materials conform spec.
Incorrect or contaminated raw materials (e.g. SRM)
Supplier Assurance programme and incoming inspection
Processing
Growth of spoilage bacteria in process (e.g. High number of Salmonella due to poor processing conditions; Aw, time and temperature, cross contamination)
Monitoring / inspection, shelf-life control
Bag Filling
Condensation (due to high filling temperature)
Monitoring / inspection filling temperature and external temperature
Metal detection
Metal contamination
Permanent magnets, electric metal detection device
Handling of primary package
Contamination or deterioration due to loss of packaging integrity
Visual control

16. HACCP examples: frozen
Critical Control Point/OPRP depending on your HACCP
Hazard to be controlled
Control Method
Transport / storage
Contamination or deterioration (e.g. temp))
Assurance and inspection programme
Raw Materials conform spec.
Incorrect or contaminated raw materials (e.g. SRM)
Supplier Assurance program and incoming inspection
Processing
Growth of spoilage bacteria in process (e.g. High number of Salmonella due to poor processing conditions; AW, time and temperature, cross contamination)
Monitoring / inspection, shelf life control
Metal detection
Metal contamination
Permanent magnets, electric metal detection device
Cooling / Freezing
Microbiological ingress during cooling
Storage, transport, including point of sales
Contamination or deterioration, Growth of micro-organisms
Warehouse assurance and inspection program, temperature monitoring
Handling of primary package
Contamination or deterioration due to loss of packaging integrity
Visual control

17. HACCP examples: fresh / chilled
Critical Control Point/OPRP depending on your HACCP
Hazard to be controlled
Control Method
Transport / storage
Contamination or deterioration (e.g. temp)
Assurance and inspection programme
Raw Materials conform spec.
Incorrect or contaminated raw materials (e.g. SRM)
Supplier Assurance program and incoming inspection
Processing
Growth of spoilage bacteria in process (e.g. High number of Salmonella due to poor processing conditions, AW, time and temperature, cross contamination )
Monitoring / inspection, shelf life control
Filling
Microbiological ingress
Temperature monitoring / inspection / shelf life control
Metal detection
Metal contamination
Permanent magnets, electric metal detection device
Cooling / Chilling
Microbiological ingress during cooling
Storage, transport, including point of sales
Contamination or deterioration, Growth of micro-organisms
Warehouse assurance and inspection program, temperature monitoring , shelf life control
Handling of primary package
Contamination or deterioration due to loss of packaging integrity
Visual control

18. HACCP examples: small pets
Critical Control Point/OPRP depending on your HACCP
Hazard to be controlled
Typical Control Method
Transport / storage
Contamination or deterioration (e.g. humidity)
Assurance and inspection programme
Raw Materials conform spec.
Incorrect or contaminated raw materials (e.g. SRM)
Supplier Assurance programme and incoming inspection
Cooling of raw materials
Contamination or deterioration, growth of micro-organism
Transport assurance, temperature monitoring, shelf life control
Heating
Bacterial growth caused by lethality too low, e.g. low time/temperature (less than 90°C) of product during extrusion/pressing/baking)
Control of temp/time and Monitoring / inspection, shelf-life control
Mixing
Homogeneous basic produkt
Manufacturer´s declaration, personal training, visual control
Processing
Microbial or mould growth
Aw, moisture monitoring / inspection, shelf life control, personal hygiene
Metal detection
Metal contamination
Permanent magnets, electric metal detection device
Storage of product
Aw/Warehouse assurance program
Handling of primary package
Contamination or deterioration due to loss of packaging integrity
Visual control, personal training