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

2. Food Safety Management System CI Review measure HACCP Food safety management Prerequisites (GMP)

3. Food Safety Management System Food safety management system consists of a prerequisite programme and a HACCP system Components of the system:  Senior management commitment  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 identified, controlled, monitored and recorded

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

5. 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… Parasites: Trichinella spiralis, Taenia, Fasciola hepatica… Chemicals: PCBs, Dioxins, Heavy metals, Pesticides, Veterinary Drugs, Mycotoxins, Toxins… Physical: Metal, Glass…

6. HACCP principles Step 0 Implement Pre-requisite Programmes 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 Conduct a hazard analysis Consider control measures Principle 2 Determine the Critical Control Points (CCPs) Use decision tree to determine CCPs Principle 3 Establish critical limitsEstablish action and critical limits for each CCP Principle 4 Establish CCP monitoring procedures Establish monitoring systems for each CCP Principle 5 Establish corrective action plans Establish the corrective action to be taken when monitoring indicates that a particular CCP is not under control Principle 6 Establish verification procedures Establish procedures for verification to confirm that the HACCP system is working effectively Principle 7 Establish documentation and recordkeeping systems Establish documentation concerning all procedures and records appropriate to these principles and their application

7. HACCP study 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 Probability of causing an adverse health effect caused by the occurrence and severity of a hazard in food What is a risk? Clostridium botulinum

8. Ex.: decision tree to identify CCPs Preventative control measures exist? Modify steps in process Is control necessary? Not a CCP Is the step designed to eliminate or reduce the likely occurrence of a hazard to an acceptable level? Stop* Contamination occurs with identified hazard(s) in excess of acceptable level(s)? Not a CCP Elimination of identified hazard(s) or reduction to acceptable levels? Critical Control Point Stop* Not a CCP Yes Q1 Yes No Yes No Yes No Stop* Q4 Q3 Q2 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

9. HACCP examples: wet pet food Critical Control PointHazard to be controlledTypical Control Method Receiving raw materials conform spec. Incorrect or contaminated raw materialsSupplier Assurance + inspection Metal detectionMetal contamination (e.g. fish hooks)Permanent magnets, electric metal Seaming / SealingRe-contamination by pathogensSeam / seal control SterilisationMicrobial growth due to under-sterilisation (Fc0 < 3) Monitoring Time and Temperature CoolingRe-contamination of pathogens due to contaminated cooling water Monitoring free and active Chlorine in cooling water

10. HACCP examples: semi-moist Critical Control PointHazard to be controlledTypical Control Method Receiving raw materials conform spec. Incorrect or contaminated raw materialsSupplier Assurance + inspection Addition of preservativesPathogen growthMonitoring / inspection ProcessingPathogen or mould growth (due to high Aw) Aw Monitoring, monitoring of the right recipe FillingMicrobial growth due to condensation (high filling temp.) + risk moulding Monitoring / inspection filling temp. and external temp. Metal detectionMetal contaminationElectric metal detection device

11. HACCP examples: dry pet food Critical Control PointHazard to be controlledTypical Control Method Receiving raw materials conform spec. Incorrect or contaminated raw materialsSupplier Assurance + inspection Extrusion/ pressPathogen growthControl of temp/time or Monitoring density as a indicator of the cooking step ProcessingPathogen or mould growth (high Aw)Monitoring Aw, moisture, FillingMicrobial growth due to condensationMonitoring / inspection filling temp. and ambient temperature Metal detectionMetal contaminationPermanent magnets (only Ferrous), electric metal detection device Storage of productPathogen or mould growthWarehouse assurance program

12. HACCP examples: chews Critical Control PointHazard to be controlledTypical Control Method Receiving raw materials conform spec. Incorrect or contaminated raw materialsSupplier Assurance + inspection Storage of raw Materials conform spec. Deteriorated raw materialsStocking silo assurance programme and inspections Dosing and mixing of ingredients Incorrect proportion of ingredients and additives Calibration and capability assessment of dosing and mixing ProcessingGrowth of Pathogenic bacteria in process (e.g. Salmonella due to Aw, time and temp., cross contamination) Monitoring / inspection, shelf-life control Bag FillingCondensation (high filling temp.)Monitoring / inspection filling temp. Metal detectionMetal contaminationPermanent magnets, electric metal detection device

13. HACCP examples: frozen Critical Control PointHazard to be controlledControl Method Receiving raw materials conform spec. Incorrect or contaminated raw materialsSupplier assurance + inspection ProcessingGrowth of pathogenic bacteria (Salmonella due to AW, time and temp., cross contamination) Monitoring / inspection, Metal detectionMetal contaminationPermanent magnets (only Ferrous, electric metal detection device Cooling / FreezingMicrobiological ingress during coolingMonitor airflow/temperature Storage, transport, including point of sales Contamination or deteriorationWarehouse assurance and inspection, temp. monitoring

14. HACCP examples: fresh / chilled Critical Control PointHazard to be controlledControl Method Receiving raw materials conform spec. Incorrect or contaminated raw materialsSupplier Assurance + inspection ProcessingGrowth of pathogenic bacteria in process (Salmonella due to AW,time and temp., cross contamination) Monitoring / inspection, Metal detectionMetal contaminationPermanent magnets (only Ferrous), electric metal detection device Cooling / ChillingMicrobiological ingress during coolingMonitor airflow/temperature Storage, transport, including point of sales Contamination or deteriorationWarehouse assurance and inspection, temp. monitoring, shelf life control