Presentation- Introduction & Principle1 - Hazard Analysis.pptx

Introduction to HACCP

1. Definition of HACCP History of HACCP 7 principles of HACCP Preparatory Stages of HACCP HACCP TEAM Flow Diagram

2. Hazard Analysis and Critical Control Points (HACCP) is a systematic approach to hazard identification, risk assessment and control

3. Hazard Analysis Critical Control Points (HACCP) is an internationally recognized standard and method of identifying and managing food safety related risk. It demonstrates that an organization can provide to customers, the public, and regulatory agencies assurance that a food safety program / management system has been established and is being well managed . HACCP is a management system standard / set of Principles / set of Guidelines in which food safety is addressed through the analysis and control of biological, chemical, and physical hazards from raw material production, procurement and handling, storage, to manufacturing, distribution and including the consumption of the finished product. .  

4. It originated in the 1960s, when the US National Aeronautics and Space Administration (NASA), the Pillsbury Company, and the U.S. Army Laboratories collaborated to ensure safe food for upcoming space expeditions. In the early 1970s, a safety incident with baby food manufactured at Pillsbury resulted in the company implementing a secure product safety system to minimize the likelihood of another product recall. Pillsbury then collaborated with U.S. Food and Drug Administration to create and present the first training courses designed to educate producers on this new quality framework. Since then, the HACCP principles have become the basis of international food safety policies and regulations worldwide.

5. 01 Conduct Hazard Analysis 02 Determine Critical Control Points 03 Establish Critical Limits 04 Establish Monitoring Procedures 05 Establish Corrective Actions 06 Establish Verification Procedures Establish record Keeping and Documents 07 7 PRINCIPLES

6. PRINCIPLE 1 - WHAT DOES HACCP INVOLVE ?

7. Monitoring , verification , validation plus your emergency response plan. These can only be formulated after conducting a hazard analysis. These require, monitoring verification and validation

8. PRINCIPLE 1 - WHAT DOES HACCP INVOLVE ? OPERATIONAL PREREQUISITES Most prerequisites are general in nature and their purpose is to ensure the general hygiene conditions of the food business. However, some prerequisites may be identified through the HACCP study as being critical to food safety to control a specific hazard. These are referred to as “Operational Prerequisites” or “OPR” and they should be carefully identified and managed.  PREQUSITE PROGRAMS Pest Control. Lack of pest activity in a facility is the key indicator of a successful pest control program. ... Foreign Material Control. ... Storage. ... Returned Product/Recall . ... Preventive Maintenance PRPs. ... Chemical Controls. ... Environmental Monitoring Programs. ... Employee Training

9. PRINCIPLE 1 - WHAT DOES HACCP INVOLVE ? Facilities: The establishment should be located, constructed and maintained according to sanitary design principles. There should be linear product flow and traffic control to minimize cross-contamination from raw to cooked materials . Supplier Control: Each facility should assure that its suppliers have in place effective GMP and food safety programs. These may be the subject of continuing supplier guarantee and supplier HACCP system verification . Specifications: There should be written specifications for all ingredients, products, and packaging materials . Production Equipment: All equipment should be constructed and installed according to sanitary design principles. Preventive maintenance and calibration schedules should be established and documented . Cleaning and Sanitation: All procedures for cleaning and sanitation of the equipment and the facility should be written and followed. A master sanitation schedule should be in place . Personal Hygiene: All employees and other persons who enter the manufacturing plant should follow the requirements for personal hygiene.

10. PRINCIPLE 1 - WHAT DOES HACCP INVOLVE ? Training : All employees should receive documented training in personal hygiene, GMP, cleaning and sanitation procedures, personal safety, and their role in the HACCP program . Chemical Control: Documented procedures must be in place to assure the segregation and proper use of non-food chemicals in the plant. These include cleaning chemicals, fumigants, and pesticides or baits used in or around the plant . Receiving, Storage and Shipping: All raw materials and products should be stored under sanitary conditions and the proper environmental conditions such as temperature and humidity to assure their safety and wholesomeness Traceability and Recall: All raw materials and products should be lot-coded and a recall system in place so that rapid and complete traces and recalls can be done when a product retrieval is necessary . Pest Control: Effective pest control programs should be in place.

11. OBTAIN MANAGEMENT COMMITMENT The key elements of management commitment might include: Allocation of sufficient staff resources to complete the HACCP study and implement the HACCP system. Recruitment of any specialist staff needed to support the HACCP team. Raising awareness of the HACCP process with all staff and provide sufficient training to those directly involved in the study. Involvement of members of the management team as necessary. A commitment to provide timely management decisions as required by the HACCP team to facilitate the development and implementation of the HACCP. Purchase of additional equipment as required to ensure the effective operation of the HACCP system. WHAT DOES HACCP INVOLVE ?

12. SCOPE OF THE PLAN The typical study will begin with the intake of ingredients and will end with the dispatch of the final product . However, in order to achieve food safety, you may need to consider activities not just within your own establishment but also those carried out by others such as distributors, retailers and customers. Of course you cannot be sure how your food is handled once it has left your control, but you should consider whether the study needs to include details of the likely way that others will handle your products and take these into account by, for example, providing instructions on the product label and/or packaging for storage and use. WHAT DOES HACCP INVOLVE ?

13. Assemble the TEAM What would you consider when assembling the TEAM? WHAT DOES HACCP INVOLVE ?

14. ASSEMBLE THE HACCP TEAM Multidisciplinary - Staff level, Management, Subject matter experts A technical Leader or HACCP coordinator is usually selected from the company’s quality , research and development, or compliance group. One person may fulfill more than one role within the HACCP Team. PRINCIPLE 1 - WHAT DOES HACCP INVOLVE ?

15. Knowledge of HACCP TEAM Applied aspects of food microbiology Science and technology of the process Technology of the equipment used on the processing line HACCP principles and techniques PRINCIPLE 1 WHAT DOES HACCP INVOLVE ?

16. Considerations of HACCP TEAM Commitment from management. Defined scope of the HACCP plan Specific process Specific product A defined part of the food chain Specific tasks or activities should have set timelines at which each activity should be accomplished . PRINCIPLE 1 - WHAT DOES HACCP INVOLVE ?

17. The team coordinator /Leader is charged with distributing the work and responsibilities among team members When selecting the team, the coordinator should focus on: • Those who will be involved in hazard identification • Those who will be involved in determination of critical control points • Those who will monitor critical control points • Those who will verify operations at critical control points • Those who will examine samples and perform verification procedures PRINCIPLE 1 - WHAT DOES HACCP INVOLVE ?

18. The team coordinator /Leader is charged with distributing the work and responsibilities among team members and reviewing the status of the HACCP implementation Tasks include Ensure that the composition of the team meets the needs of the study Suggest changes to the team if necessary Coordinate the team's work Ensure that the agreed established plan is followed Share the work and responsibilities Ensure that a systematic approach is used Ensure that the scope of the study is met Chair meetings so that team members can freely express their ideas Represent the team before management Provide management with an estimate of the time, money and labour required for the study WHAT DOES HACCP INVOLVE ?

19. The team coordinator /Leader is responsible for review of the status of the implementation of the HACCP program and as such will hold meetings with the rest of the team Number of meetings depends on complexity and magnitude of operations Team meeting should be frequent enough to maintain momentum but not too often such that productivity in progress is disrupted WHAT DOES HACCP INVOLVE ?

20. DESCRIBE THE PRODUCT General description of the food and the processing methods used to produce it . Its intended mode of distribution and its intended use. Also the characteristics of the product at each stage of processing . Considerations in defining the product will be determined by the scope of the HACCP system. WHAT DOES HACCP INVOLVE ?

21. Description of the product is normally achieved by considering two types of factors : Intrinsic factors: those found within the product itself such as its structure and composition. Extrinsic factors : those which are external to the food such as temperature control, packaging and method of processing. It is helpful to think about your food in this way because any changes in recipes or ingredients are likely to affect the intrinsic factors, whereas changes in equipment or in the distribution chain are likely to affect the extrinsic factors. If full information about both factors is made available to the HACCP team they may choose to control an identified hazard by a change in the recipe, a change in the method of distribution or both.  WHAT DOES HACCP INVOLVE ?

22. List all the ingredients and the name of the supplier for each one This list will be of assistance later in the study to ensure that all ingredients are properly documented for each product and is of particular relevance to the control and provision of correct information to the consumer of the presence of food allergens.   WHAT DOES HACCP INVOLVE ?

23. State the physical properties of the product The physical properties of the food will influence whether dangerous bacteria will be able to grow in the food and/or produce dangerous toxins. The main factors to consider here are: Physical state – Is the food a liquid, solid, foam, emulsion etc Water activity (a w ) – this is the water that is available to microorganisms in the food. Whilst some foods may appear moist, the presence of sugar or salt in the liquid component of the food may prevent microorganisms from accessing the water thus restricting their growth. This is why the use of sugar, for example in jam making, or salt in the case of smoked salmon can be very effective at controlling the outgrowth of both spoilage and dangerous bacteria. Drying foods has an effect on both the moisture content and the a w . Pure water has an aw of 1.0 and the addition of salt or sugar will reduce this value closer to 0. Most bacteria require an aw value > 0.92 to successfully grow in food but some moulds may be able to grow below this. The aw value is most easily determined in liquid and homogenous foods where the sugar/salt content is likely to be evenly distributed throughout the food. Difficulties in determining a representative aw value may arise in composite foods which contain different varieties of ingredient distributed in an uneven way through the food, for example a meat stew. This will be a matter for your HACCP team to consider.   WHAT DOES HACCP INVOLVE ?

24. State the physical properties of the product pH – This is the measure of the acidity of a food and many bacteria are unable to grow in acidic conditions. For example,  Salmonella  species will typically grow well at neutral pH (7.0) but are unable to grow in acid conditions of 4.0 or below. As for aw, care should be taken to ensure that any pH measurements taken are representative of the food. For example, in a ready meal the pH of the curry sauce may be 5.5, which would inhibit the growth of some bacteria, but within clumps of vegetables it might be 7.0 which might permit the outgrowth of dangerous bacteria. Salt content – Whilst this affects the aw of the food, salt can also have an inhibitory effect on some bacteria in its own right.   WHAT DOES HACCP INVOLVE ?

25. Describe how the product is processed and/or other preservation methods used Many traditional preservation techniques, if performed correctly, will produce safe food by the development of dry or acid conditions in the food. The most common types of process include: Heat treatment – Microorganisms can be affected by heat in different ways. Some, such as  Salmonella  and  Campylobacter , will be easily killed by normal cooking temperatures (70°C for 2 minutes) whereas others, such as  Clostridium botulinum  and  Bacillus cereus , will survive such temperatures by forming spores Hot smoking – Typically used for fish and meat products at temperatures of approximately 70°C – 80°C and often used in combination with brining Brining – Can involve the immersion of food into salt water or the direct application of salt crystals to the outside of the food Drying – used for a range of products including milk, egg, herbs, fish and meat products Fermentation – the production of alcohol and/or acids in foods, used in the production of meats such as salami as well as in bakery and brewing products   WHAT DOES HACCP INVOLVE ?

26. Describe how the product is packed and the packaging materials Some methods of packaging will affect the nature and likelihood of food hazards associated with a food. For example, hot filling product into glass jars or the use of vacuum packing will create anaerobic conditions (reduced oxygen levels) which will favor the growth of certain bacteria such as  Clostridium botulinum . If you are using such materials, then your HACCP team will need to identify suitable controls to prevent the outgrowth and toxin formation by these dangerous bacteria . The packaging may also emit gasses or absorb them from the food, again changing the conditions for growth by microorganisms. Packaging could also protect microorganisms from damage by sunlight.  The use of glass containers may introduce an additional physical hazard, especially if they are reusable, whereas the use of aseptic filling lines may reduce the likelihood of contamination from the environment. WHAT DOES HACCP INVOLVE ?

27. How is the product going to be stored and distributed ? The main options for storage and distribution are: ambient chilled Frozen What is the shelf life for the product What are the storage and handling conditions for the purchaser WHAT DOES HACCP INVOLVE ?

28. DESCRIBE THE INTENDED USE OF THE PRODUCT There are two key factors which are relevant here: 1. The nature of the intended customer . That is , the normal expected use of the food. The intended consumers may be the general public or a particular segment of the population (e.g., infants, immunocompromised individuals, the elderly, etc ) 2. The extent of any further processing of the food prior to consumption WHAT DOES HACCP INVOLVE ?

29. The nature of the intended customer Consider whether the product is intended for supply to other food businesses or direct to the final consumer. Consider whether target consumers fall into one of the following vulnerable groups. Ask yourself “Do the consumers of my product have a particular food safety requirement?”  It is your responsibility to understand your target group and increase your knowledge and awareness of hazards (physical, chemical, biological and allergens) that are of a particular concern to the vulnerable group/s. WHAT DOES HACCP INVOLVE ?

30. The extent of any further processing of the food prior to consumption. Different microbiological criteria will apply depending on whether the food product is supplied raw, processed or ready to eat to the final consumer. The HACCP team will need to clearly define which of these categories applies to the food and what, if any, instructions will need to be provided to the customer to assure the safe consumption of the food. For example, if the product is supplied to the customer as a ready to eat food, this should be clearly stated on the labelling. Most importantly, however, the HACCP team will need to ensure that any decisions made during the hazard analysis element of the HACCP study takes into account the fact that the food will receive no further processing prior to consumption . Critical control points identified by the HACCP team in the production of such foods will need to “prevent or eliminate” hazards arising from the presence of pathogens such as  Salmonella  and  E.coli  o157. WHAT DOES HACCP INVOLVE ?

31. Develop a flow diagram of the process . This should be as simple as possible to be understood be all persons and detail enough so that critical or important areas of the process are not excluded. Block diagrams with abbreviated labels and a diagram key are most popular . WHAT DOES HACCP INVOLVE ?

32. The HACCP team or the person leading the development of the HACCP study should construct a flow diagram.  Whatever format you choose, all steps in the process outlined in the scope of the study should be included. You may wish to use a schematic layout of the factory to help you. Knowledge of what actually occurs in your processes is essential. WHAT DOES HACCP INVOLVE ?

33. List each step in the process or module. You should consider what happens all the way from receiving the raw materials, through to at least the point of dispatch or up to the point of final consumption of the product Think about: Preparation Packing Storage Distribution You could also consider the following: Raw material addition (including water) Services (air, water, steam) Any temporary product storage or hold periods (particularly during peak production times) Recycle or rework loops Process delays WHAT DOES HACCP INVOLVE ?

34. The inclusion of relevant technical data will depend on the complexity of the operation. This data is useful at the Critical Control Points that you will identify later.   Technical data could include: Time for process or process element (e.g. fry for 2 minutes at 190°C or cool to <5°C in 4 hours) Temperature at different parts of the process (e.g. fry at 190°C for 2 minutes or cool to <5°C in four hours) Line speed Floor plan, equipment and services layout Segregation of low/high risk operations Personnel routes Flow conditions for liquids and solids (psi=pounds per square inch or temperature in °C) Waste flows Movement routes for raw materials/ingredients WHAT DOES HACCP INVOLVE ?

35. The Linear plan This would be suitable for a basic food production process where only a limited number of products are produced. For example, a manufacturer of orange juice may choose this approach because the manufacturing process involves a relatively small number of process steps. However, if the manufacturer decides to extend its product range to include apple, grapefruit and pineapple juices then a modular approach may be more suitable. WHAT DOES HACCP INVOLVE ?

36. WHAT DOES HACCP INVOLVE ?

37. Modular plan This is the more common approach where the food production process is more complex and typically involves several steps which are shared with other products. The HACCP principles can be applied to specific activities or “modules” which are then added together to make a complete HACCP plan. For example, a juice manufacturer may identify the following modules which are common to several products: Module 1: Fruit reception Module 5: Juice extraction The hazards and controls will be the same for these operations, irrespective of the type of juice produced and so once the HACCP has been completed for each, they can be used wherever relevant for different products.  WHAT DOES HACCP INVOLVE ?

38. WHAT DOES HACCP INVOLVE ?

39. WHAT DOES HACCP INVOLVE ?

40. Develop a Flowchart Develop a flowchart for KFC chicken from arrival at the restaurant to customer walking out the door with their KFC box

41. PRINCIPLE 1 HAZARD ANALYSIS HAZARD ANALYSIS The purpose of a hazard analysis The types of hazards Identification of hazards Evaluation of hazards

42. PRINCIPLE 1 HAZARD ANALYSIS HAZARD TYPES These can be Biological Chemical Physical Reasonably likely to cause illness or injury in the absence of its control

43. Identification Evaluation PRINCIPLE 1 HAZARD ANALYSIS A biological, chemical, or physical agent that is reasonably likely to cause illness or injury in the absence of its control . HAZARD ANALYSIS

44. The purpose of the hazard analysis is to develop a list of hazards which are of such significance that they are reasonably likely to cause injury or illness if not effectively controlled . Re: PRP, ORP PRINCIPLE 1 - HAZARD ANALYSIS A biological, chemical, or physical agent that is reasonably likely to cause illness or injury in the absence of its control .

45. The hazard identification is effectively a brainstorming exercise performed by the HACCP team , identifying the hazards that may most reasonably likely to occur at each step in the process . Process Flow Diagram Hazard Identification PRINCIPLE 1 HAZARD ANALYSIS

46. The process of hazard identification should consider the following items: The preliminary information collected while developing the product description. Experience. For example, the establishment probably has considerable information on the likelihood of hazards being present in finished products based on results of product testing or information from consumer complaints. External information including, when possible, epidemiological and other historical data. Information from the food chain on food safety hazards that may be of relevance for the safety of the end products, intermediate products, and the food at consumption. Hazard Identification PRINCIPLE 1 HAZARD ANALYSIS

47. Determine acceptable levels for each hazard : Regulatory requirements Customer requirements Intended use by the customer Other relevant data Hazard Identification PRINCIPLE 1 HAZARD ANALYSIS

48. Each potential hazard should be evaluated based on two factors: Severity of the potential illness or injury Likelihood of occurrence Hazard Evaluation PRINCIPLE 1 HAZARD ANALYSIS

49. Evaluation of the severity of a food safety hazard requires consideration of various factors, including: The magnitude and duration of the illness or injury, ( Listeria monocytogenes ) The possible impact of secondary problems (chronic sequelae) The susceptibility of intended customers to foodborne illness (e.g. children versus adults) Hazard Evaluation PRINCIPLE 1 HAZARD ANALYSIS SEVERITY

50. Assessment of this factor can be complex and requires consideration of several factors, including the following Experience of HACCP TEAM members Data from past illness outbreaks Scientific journals/Peer reviewed scientific journals on food borne hazards Historical information gathered by the establishment Hazard Evaluation PRINCIPLE 1 HAZARD ANALYSIS Likelihood of Occurrence

51. The HACCP team also should consider various other factors which can influence the likelihood of occurrence of food safety hazards. These factors include: Effectiveness of prerequisite programs Frequency of association of the potential hazard with the food or ingredient Method of preparation Conditions during transportation Expected storage conditions Likely preparation steps before consumption Hazard Evaluation PRINCIPLE 1 HAZARD ANALYSIS Likelihood of Occurrence

52. PRINCIPLE 2- CRITICAL CONTROL POINTS PRINCIPLE 3 – CRITICAL LIMITS