Food safety , OPRP, CCP.pptx

Industrial food safety, difference between CCP and OPRP

1. Training Module on Food Safety, OPRP & CCP

2. Overview In the food manufacturing sector or even in food service, it has been realised by business owners that in order to compete in business they have to offer the best quality products as well as safe and wholesome food.

3. What is Food Safety ? Is a scientific discipline describing handling, preparation, and storage of food in ways that can prevent food borne illness. This includes a number of routine activities that should be followed to avoid potentially severe hazards. FOOD SAFETY considerations include practices relating to: Food Labelling Food Additives Pesticide Residues Food Hygiene

4. FOOD LABELLING A panel found on the package of food which contains a variety of information about the nutritional value. It also includes the production date, best before or expiry date, serving size, number of calories, grams of fat, etc. This information is very helpful for people who are trying to restrict consumers about their intake, chemical reactions, etc.

5. FOOD ADDITIVES Substances that are added to food to preserve flavour, incorporate colour or enhance its taste and appearance.

6. PESTICIDE RESIDUES Refers to the pesticides that may remain on the food crops after harvesting. These chemicals may have allergic reactions or may affect human health severely.

7. FOOD HYGIENE Unhygienic food can transmit disease from one person to another. Ex. Flies sitting on food items Also, food can serve a medium of growth for bacteria that can cause food poisoning. Ex. dysentery, loose motions 5 key principles of food hygiene : 1. Prevent food contamination with pathogens spreading from people, pets and pests 2. Separate the raw and cooked foods to prevent contaminating the cooked foods. 3. Cook for appropriate temperature to kill pathogens 4. Store food at proper temperature. 5. Use safe and potable water, good quality raw materials.

8. Food Hygiene : 4’C

9. Food Safety Hazards

10. 1. Physical Hazards Usually results from accidental contamination and poor food handling practices. This may include- Glass pieces Human hair Nails Nail polish Jewellery ornaments Metal pieces from worn out utensils Stones Wood Dust/Sand

11. 2. Chemical Hazards Can occur at any point during harvesting. Toxic chemicals used for - Pest control Mopping floors Sanitising food contact surfaces May even come in contact with food and may result in contamination. Machine grease coming in contact with food. Overdose of additives / intentionally added chemicals.

12. 3. Biological Hazards Occurs when food gets contaminated by micro-organisms present in air, water, soil, animals, human body, faecal matter, etc. M/o that cause food borne illness include bacteria, virus and parasites.

13. Food Spoilage Signs of spoilage Off odours Discolouration Slime/ Stickiness Mould growth Change in texture – dry or spongy Unusual taste Production of gas Puffed cans Prevention of spoilage/ Preservation Cooking at high temperature Low temp, refrigeration, freezing Dehydration, ex: soup Chemicals, ex: salt, sugar Vacuum packing Irradiation

14. What if the food is NOT safe ? - Food Poisoning Food Poisoning is an acute illness, which usually occurs within 1 to 36 hours of eating contaminated or poisonous food. Symptoms usually last from 1 to 7 days and include one or more of the following : Abdominal pain Diarrhoea Vomiting Fever Collapsing

15. Food poisoning may be caused by: Bacteria Moulds (mycotoxins) Chemicals such as insecticides, cleaning agents and weed killers Heavy metals such as lead, copper, mercury Poisonous plants such as deadly nightshade Poisonous fish or shellfish

16. Allergy v/s Intolerance What is allergy ? A reaction of the immune system to a normally harmless substance. This substance may be – Food proteins Latex House dust mites Pollen grains Drugs What is food allergy ? Allergic reaction & immunological response of body to the food. Body protects itself by release of histamine. What is food intolerance ? The body when cannot tolerate large amounts of offending food shows adverse reactions to food that does not involve the immune system. Intolerances are more common than food allergies. Some causes- Lack of milk digestive enzyme : lactose intolerance Food additives : sulphites, MSG Toxins Contaminants

17. Food Allergens Avoidance of these food is the only protection….

18. Allergic Reactions

19. Why is Allergen management important in a food industry ? Food allergies are life-threatening and there is no cure Successful management is through avoidance of food Consumer’s life is at risk from eating formulated foods (hidden ingredients) Awareness, education and communication can prevent deaths and improve quality of life of food- allergic consumers.

20. Responsibilities of Food Handler Avoid cross – contamination Wash hands thoroughly after handling known allergens Keep the allergen materials separate from non-allergen materials with proper identification Follow a thorough sanitation program to prevent cross- contamination Keep all ingredients closed when not in use Use only specific equipments and utensils for handling food allergens. Oils used for cooking allergenic foods (ex. Peanuts, cashews, etc) shall not be used subsequently for cooking products that are not allergenic. Cleaning of machines to be done effectively after running allergenic products Do not use compressed air for cleaning as airstream may cross contaminate the adjacent equipments or carry allergens to clean areas. No food and drinks must be allowed inside the production premises Train the contractual people and other personnel on allergen management If any lack of facilities for allergen management, immediately report to site FSQA officer.

21. What else comes under the umbrella of Food Safety ? Personal hygiene of food handlers Good Warehouse Practices (GWP) – Good infrastructure and facilities with maintained floors, walls and ceilings Policies for workmen related to hair, jewellery, nails, clean clothing Person entering should not be ill /sick/ wounded No smoking Good Manufacturing Practices (GMP) Cleaning and Sanitation Food Allergens

22. Cleaning and sanitation Cleaning : Physical and chemical process of removing dirt, leftover food, soil from product contact surface. Sanitation : Chemical treatment to remove and kill bacteria and other germs. 5 step cleaning technique

23. Food Safety Management System FSMS is a network of inter-related elements that combine to ensure that food does not cause adverse human health effects. These elements include programs, plans, policies, procedures, practices, goals, objectives, methods, controls, roles, responsibilities, documents, records and resources.

24. HACCP Hazard Analysis and Critical Control Points As per CODEX guidelines, HACCP is a systematic approach to the identification, evaluation , and control of food safety hazards based on the following 7 principles: Conduct a hazard analysis. Determine the critical control points. Establish critical limits. Establish monitoring procedures. Establish corrective actions. Establish verification procedures. Establish documentation and record – keeping procedures.

25. VACCP Vulnerability Assessment and Critical Control Points Used to identify vulnerabilities for a food business due to food fraud. Systematic prevention of any potential adulteration of food, whether intentional or not by identifying the vulnerable points in a supply chain. HACCP VACCP

26. TACCP Threat Assessment and Critical Control Points TACCP is similar to VACCP TACCP is performed for ideological rather than economic reasons Intentional contamination of food products Sabotage of the supply chain Using food or drink items for terrorism or criminal purposes - Bioterrorism

27. OPRP Definition: Control measure or combination of control measures applied to prevent or reduce a significant food safety hazard to an acceptable level, and where action criterion and measurement or observation enable effective control of the process and/or product  Now what each of those words means ? =>  Action criterion:  measurable OR observable specification for the monitoring of an OPRP  =>  Measurement:  a process to determine a value =>  Observation:   a process to determine a status  Action criteria is a specification (rules) to be followed for observing or measuring the OPRP which means that OPRP can be observed only , this term is relevant to OPRPs only. Ex: Sanitation Effectiveness

28. CCP Definition: Step in the process at which control measure is applied to prevent or reduce a significant food safety hazard to an acceptable level, and defined critical limit and measurement  enable the application of corrections. In the definition of CCP we have seen words like Critical Limit and measurement Now what each of those words means? =>  Critical Limit:  measurable value which separates acceptability from unacceptability, relevant to CCP only. =>  Measurement:  a process  to determine a value W e must have a value to be measured for any CCP and we should keep in our mind that the word observation is not mentioned in the definition of CCP  Example : Cooking, pH level, metal detector  

29. Q&A A panel is found on the package that contains info about the product and its nutritional facts. What is it called ? What is food poisoning ? How long does it last ? What is the 4 C principle in food hygiene ? Give 2 examples of food additives. What is the difference between food allergy and food intolerance ? What does TACCP stand for ? What shall be an integral step in any process flow diagram – CCP or OPRP ?