reorientation on hazard analysis critical control...

HAZARD ANALYSIS AND CRITICAL

CONTROL POINT

(HACCP)

MARJORIE PAJE

Background on the Implementation of Food Safety

Program

WTO-SPS Agreement in 1994 encouraged member countries to adopt

international standards, and in the case of food safety, it names the

Codex Alimentarius Commission Standards.

Codex Alimentarius Commission is an international standards setting body

created in 1962 by FAO WHO.

Codex Alimentarius (Latin, meaning Food Law or Code) is a collection of

International Food Standards adopted by the Commission and

presented in a uniform manner.

Meat Safety Laws

I. Constitutional Basis of Food Safety

II. Law, Rules and Regulations

A. CA 82 (1936)

B. PD 7 (1972) & IRR (NMIC AO #6 s. 1975)

C. RA 7160 (1991) & IRR (EO #137 s. 1993)

D. RA 7394 (1993) & IRR (DA-AO #9 s. 1993)

E. RA 9296 (2004) & 10536 (2013) & Revised IRR (DA-DC #1 s. 2014)

F. RA 10611 (2013) & IRR (JDA-DOH AO # 2015—0007 s. 2015)

G. OTHER LAWS:

1. PD 533

2. PD 856 & IRR

3. RA 8485 & 10631 (2013) & IRRs

4. Environmental Laws

Guidelines/Official Issuances/Legal Basis Code of Food Hygiene (CAC/RCP 1969) Code of Meat Hygiene (CAC/RCP 58-2005) DA A.O. No. 9 Series of 2003- Mandatory Application of HACCP in all “AAA” MEs DA A.O. No. 21 Series of 2004- Mandatory Application of GMP in all NMIC “AA” MEs RA 9296 and its IRR (DA-AO No. 28 Series of 2005)as ammended on RA 10536 Sec 15- Power to Enforce Hygiene Requirements Sec 43- Sanitation Sec 44- Product Quality & Safety Standards & Quality

Why implement the principles of food

hygiene?

(CODEX)

To avoid the adverse human health and

economic consequences of food borne

illnesses, food borne injury and food spoilage.

Roles of Government, Industry and Consumers

Government:

a. Protect consumers adequately from illness or injury

caused by food.

b. Provide assurance that food is suitable for human

consumption

c. Maintain confidence in internationally traded food

d. Provide health education programmes which

effectively communicate the principles of food

hygiene to industry and consumers.

Roles of Government, Industry and Consumers

Industry: (CODEX)

a. Provide food which is safe and suitability for

consumption

b. Ensure that consumer have clear and easily-

understood information

c. Maintain confidence in internationally traded food

Consumers should recognize their role by following relevant

instructions and apply appropriate food hygiene measures

WHAT IS HACCP

HACCP is the acronym for Hazard Analysis and

Critical Control Point. It is a food safety system

developed by the food industry that examines

every step in a food operation, identifies

specific hazards, implements effective control

measures and monitoring procedures

HACCP is • A systematic approach

• Proactive

• A team effort

HACCP is not

• A common sense technique

• A Living, dynamic system

• An One- off paper exercise

• One person’s responsibility

• Pilsbury, NASA and US Army Lab, Natick- Principal object was to develop safe

food for astronauts

• Based on engineering system- Failure Modes and Effect Analysis( FMEA )

• 1960- 1980 Quality Assurance principles widely adopted by Food

Industry( Prevention )

• 1980’s major international food scares

• Preventative Food Safety System was needed

• HACCP now fully recognized and used internationally in trade, insurance and

regulation.

Origin of HACCP

History

HACCP Code adopted in 1969, revised in 1979, 1985, 1997, 2003

• Legislation and Regulatory organizations recommend or demand it.

• Customers require it

• Consumers expect safe food

• It provides manufacturers with

self- confidence

• It is verifiable and auditable

Why HACCP ?

assurance brand protection

• It produces evidence( assurance ) which can be used in litigation

• It is recognized by insurance companies

• Systematic approach to food safety

• Proactive preventive management system

• Complements and strengthens Quality management systems( QMS ).

• Can be integrated with QMS

• Helps to demonstrate due diligence

Advantages/Benefits of Using HACCP ?

• Internationally recognized approach

• Fewer rejects

• Cost effectiveness

• Increased confidence/ customer satisfaction

• Improves Teamwork Understanding and motivation

• Risk management Tool

• Brand protection

Definition of Terms

CCP Decision Tree: A sequence of questions to assist in determining whether a control point is a CCP.

Control: (a) To manage the conditions of an operation to maintain compliance with established criteria.

(b) The state where correct procedures are being followed and criteria are being met.

Control Measure: Any action or activity that can be used to prevent, eliminate or reduce a significant hazard.

Control Point: Any step at which biological, chemical, or physical factors can be controlled

Corrective Action: Procedures followed when a deviation occurs.

Criterion: A requirement on which a judgment or decision can be based.

Critical Control Point: A step at which control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level.

Critical Limit: A maximum and/or minimum value to which a biological, chemical or physical parameter must be controlled at a CCP to prevent, eliminate or reduce to an acceptable level the occurrence of a food safety hazard.

Deviation: Failure to meet a critical limit.

HACCP: A systematic approach to the identification, evaluation, and control of food safety hazards.

HACCP Plan: The written document which is based upon the principles of HACCP and which delineates the procedures to be followed.

HACCP System: The result of the implementation of the HACCP Plan.

HACCP Team:

The group of people who are responsible for developing, implementing and maintaining the HACCP system.

Hazard: A biological, chemical, or physical agent that is reasonably likely to cause illness or injury in the absence of its control.

Hazard Analysis: The process of collecting and evaluating information on hazards associated with the food under consideration to decide which are significant and must be addressed in the HACCP plan.

Monitor: To conduct a planned sequence of observations or measurements to assess whether a CCP is under control and to produce an accurate record for future use in verification.

Prerequisite Programs: Procedures, including Good Manufacturing Practices, that address operational conditions providing the foundation for the HACCP system.

Severity: The seriousness of the effect(s) of a hazard.

Step: A point, procedure, operation or stage in the food system from primary production to final consumption.

Validation: That element of verification focused on collecting and evaluating scientific and technical information to determine if the HACCP plan, when properly implemented, will effectively control the hazards.

Verification: Those activities, other than monitoring, that determine the validity of the HACCP plan and that the system is operating according to the plan.

HACCP SUPPORT

PROGRAMS

Steps or procedures that control the inplant environmental conditions that

provide a foundation for safe food production.

4. Training

• Good Manufacturing Practices(GMPs)

key issues dealt with under HACCP Support Programs generally covers;

HACCP Support Programs

1. Cleaning

2. Calibration

3. Pest Control

• Sanitation Standard Operating procedures(SSOP)

5. Product Identification & Traceability

6. Approved suppliers

7. GMP,SSOP, Codes of Practice

GMP/SSOP provide the basic foundation for the

development of a HACCP System

HACCP

GMP

SSOP

12 STEPS (CODEX GUIDELINES) FOR THE

IMPLEMENTATION OF SEVEN (7 ) HACCP PRINCIPLES

1. Assemble the HACCP Team

2. Describe the Product

3. Identify the Intended Use

4. Construct a Process Flow Diagram

5. On - site verification of the Process Flow Diagram

6. Conduct Hazard Analysis (Principle 1)

7. Determine Critical Control Points (Principle 2)

8. Establish Critical Limits for each CCP (Principle 3)

9. Establish a monitoring system for each CCP (Principle 4)

10. Establish Corrective Action (Principle 5)

11. Establish Verification Procedures (Principle 6)

12. Establish Record Keeping and Documentation (Principle 7)

FOOD SAFETY HAZARDS

Types of Hazards:

1. Physical

2. Chemical

3. Biological

1. EXAMPLES OF PHYSICAL HAZARD

Natural or man made

Feathers, hair, rodents’ droppings, metal, glass,

rock, sand, paint flakes, jewelry, button,

cigarette butts, band aid, writing pen caps,

carcass ID tags, needles

SOURCES OF PHYSICAL HAZARDS

Contaminated raw materials

Design of facilities and equipment

Faulty production procedure

Improper employee practices

PREVENTION AND CONTROL OF PHYSICAL

HAZARDS

Applying GMP

Using appropriate ingredients and supplies

specifications

Obtaining letter of guarantee/certificate of analysis

from all suppliers

Able to identify types and sources of physical hazards

Able to determine CCP

Training of employees in Good Hygienic Practices

2. CHEMICAL HAZARDS

a. Naturally occurred- ex. Mushroom, some tapioca species, bamboo shoots, and some fish specie

b. Commercially added- ex. Pesticides, herbicides, colouring, additives, flavour, enhancer

C. Unintentionally added- ex. Cleaners, sanitizers, lubricants, and other hazardous chemicals

3. EXAMPLES OF MICROBIOLOGICAL HAZARDS

a. Pathogenic bacteria- ex. E. coli, Salmonella sp., Vibrio

chlolerae, Listeria monocytogenes

b. Virus- Hepatitis A virus, Norwalk virus

c. Toxins- ex. Fish and shell fish toxins, algal toxin,

Clostridium botulinum, Staphylococcus aureus

d. Parasites - ex. Flatworms, tapeworms and flukes

And protozoa like Giardia which causes dysentery

Factors affecting Microbial Growth Food- Meat/blood

Acidity- most microorganisms like to grow in near neutral conditions

Time- at an ideal time bacteria will double in number in every 20 minutes

Temperature- bacteria grow ideally at body temperature of 37.5 C; also grow at temperature higher or lower , ex. Salmonella- 37 C, Clostridium perfringenes-43-47 C, Listeria monocytogenes- 2 C,

Oxygen- important to their growth (aerobic)

Moisture- water activity value for bacteria- 0.91-amount of water available for growth

HOW TO IMPLEMENT HACCP

Using the 12 steps

Based on the application of seven (7) principles

Key elements

- common sense

- knowledge of products and process

- understanding of HACCP

HACCP Plan - The written document which is based upon the principal activities of HACCP and which delineates the procedures to be followed to assure the control of a specific process or procedure.

*SECURE MANAGEMENT COMMITMENT AND UNDERSTANDING

Apply the 12 steps (CODEX Guidelines) for the Implementation of Seven (7 ) HACCP Principles

1. a. HACCP Team – multidisciplinary to include representatives from, production, quality assurance, engineering, product development/R & D, store/distribution, purchasing, receiving, HR, finance, management (plant proprietor)

Responsibilities:

- Organizing and documenting HACCP

- Reviewing deviation from critical limits

- Internal auditing of HACCP Plans

- Communicating , educating and training employees in the operation of HACCP system

Team Leader : coordinate HACCP team meetings; records of all HACCP documentations; schedule of internal audits; report deviation of requirements

b. Scope should describe which segment to be included in the food chain


2. Product description includes

a. summary of food product manufactured at factory and formulation (composition, packaging, storage conditions)

b. Method of distribution- ex. Frozen, refrigerated, and shelf life

Apply the 12 steps (CODEX Guidelines) for the

Implementation of Seven (7 ) HACCP Principles

3. Intended use and consumers- consider consumer

susceptibility

- Based upon normal use of the food by end users or

consumers

- (General public, infants, aged, immuno

compromised individual, sick)



4. Construct Process flow diagram

-done by the HACCP team

-flow diagram covers all the steps in the operation

- include product recycle/rework, storage and

distribution conditions



5. On-site confirmation of the flow diagram

-verifying for accuracy and completeness

- on-site inspection of the facility, equipment and

operation to be done by people with knowledge

and expertise on the operation (HACCP Team)



6. List all the potential hazards associated with each step,

conduct hazard analysis, and consider any measures to

control identified hazards (Principle 1)

Responsible : HACCP Team

Hazard analysis- likely occurrence and severity of their adverse

health effects

control measures- any action or activity than can be used to

prevent or eliminate a food safety hazard or reduce it to an

acceptable label

Example of hazard analysis (each step )

Process Step

Number

Process Step Hazard Cause/Sourc

e

12 Issuance

(dispatch

area)

Biological Temperature

abuse

Example of control measure

Process step

Number

Process

Step

Hazard

Possible cause

Control Measure

8 Final

Chilling

Survival of

possible

biological

hazards (E.

coli,

Salmonella sp)

due to….

Maintain Chilling

temperature at 0.2C

to attained ICT below

or equal to 4C with

chlorine

concentration of at

least 30-50ppm



7. Determine Critical Control Point (Principle 2)- a

point, step or procedure at which control can be

applied and a food safety hazard can be

prevented, eliminated or reduced to acceptable

levels.

-Use CCP Decision Tree



8. Establish critical limit (Principle 3)

Critical limits must specified and validated for each

CCP. Criteria could be temperature, time moisture

level, pH, Water activity, available chlorine and

sensory parameters such as appearance and

texture

(ex. Chilling temperature, freezing)


9. Establish monitoring system for each CCP (Principle 4)

- a system to monitor control of CCP- (tracking)

- employ scheduled testing or observation

- Procedures to monitor critical limits

-type of monitoring- what

-method of monitoring- how

-frequency of monitoring- when

- personnel for monitoring- who

The 5 keys of monitoring

- WHAT

- HOW

- WHERE

- WHEN

- WHO


10. Establish corrective actions (Principle 5)- must be developed

for each CCP in the HACCP System in order to deal with deviation when they occur.

- to be taken when monitoring indicates that a particular CCP is not under control

-One or more corrective actions may be required for each CCP

- Results , decisions communicated and understood clearly

-Procedures to be detailed on a “CCP Log Sheet and signed off by the operator. Deviation and product disposition must be documented in the HACCP record keeping



11. Establish verification procedures (Principle 6)

-Verification, its frequency and auditing methods,

procedure and tests including random sampling

and analysis can be used to determine HACCP

system is working. Frequency of verification-for

confirmatory.


12. Establish Documentation and Record Keeping (Principle 7)- Efficient and accurate record keeping is essential. Documentation and record keeping should be appropriate to the nature and size of operation

- Records are integral part of HACCP Plan

- Authority to records and access or location of records must be clearly defined.

Documentation examples:

- Hazard analysis

- CCP determination

- Critical limit determination

Record examples:

CCP monitoring activities; Deviations and associated corrective actions; verification procedures performed; modifications of HACCP plan

REFERENCE: CAC/RCP1-1969, REV. 4-2003

GENERAL PRINCIPLES OF FOOD HYGIENE

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