FOOD HYGIENE

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FOOD HYGIENE

• Unit 1 Food Inspection
• Topic Introduction to HACCP
• Lecture 7

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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

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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

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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

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• HACCP
• http//www.youtube.com/watch?v7nbjd_TnU8ofeature
  related

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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 for the 21st Century, FDA
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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

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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

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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

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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

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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)

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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
• Jamaicas perspective???

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History

• Structured and logical
• Proactive/Preventative
• Designed to move away from final product testing

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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
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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
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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

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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

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Food Chain
AGRICULTURAL IMPUTS 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
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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

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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

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Complementary standards

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

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Pre-requisite Programme
Cleaning Sanitization Personal
Hygiene Preventative maintenance Raw material
control Pest Control Facilities Training Traceabil
ity Recall programmes
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Food flow diagram
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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
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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

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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
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
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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

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Step 1 Hazard Analysis

• Risk Assessment
• Risk vs severity
• Risk
• 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

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Risk vs Severity
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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

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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.

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Decision Tree used for CCP
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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

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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
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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)

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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

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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

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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

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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

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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

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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

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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

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Types of Audits

• Internal HACCP audits
• Internal/external resources
• External HACCP audits
• Raw materials, processes
• Investigative audits

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(No Transcript)
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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

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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

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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

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Summary?
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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