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

2. 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

3. 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

4. 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

5. HACCP

6. 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

7. 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

8. 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

9. 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

10. 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

11. 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)

12. 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???

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

14. 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

15. 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

16. 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

17. 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

18. 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

19. 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

20. 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?

21. 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)

22. 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.

23. Food flow diagram

24. 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

25. 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

26. 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

27. 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

28. 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

29. Risk vs Severity

30. 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

31. 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.

32. Decision Tree used for CCP

33. 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

34. 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

35. 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)

36. 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

37. 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

38. 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

39. 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

40. 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

41. 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

42. 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

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

45. 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

46. 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

47. 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

48. Summary?

49. 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