HACCP and hygiene in honey production ©2005 by QSI Argentina, Oct./Nov. 2005Honey - HACCP1 HACCP & Hygiene in honey production Buenos Aires, Concepción

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 1

HACCP and hygiene in honey production

HACCP & Hygiene in HACCP & Hygiene in honey productionhoney production

Buenos Aires, Concepción del Uruguay, Mendoza

October / November 2005



Content of the seminar

1. General requirements of hygiene in honey production

2. HACCP: A brief introduction

3. “Good beekeeping practice”

4. HACCP in honey processing

5. Establishing self-checking mechanisms in honey production according to HACCP principles



1.

General requirements of hygiene

in honey production



Hygiene in honey production is protection

against

dirt and diseases spoiled food complaints financial losses

1.



Hygiene in honey production is necessary because

• legislations (EC Regulations 852/853/854)• consumer protection• product liability• prerequisite program for HACCP under the aspect of food safety (EC-

Regulation 178/02) demand it.

1.



European Community Legislation

• Council Regulations law in every member state

• EC Directivesshall be adopted in member statesno legal force until promulgated by national parliament

• Horizontal legislation refers to all food stuffs e.g. for contaminants, additives, labelling Regulation EEC 2377/90 drugs )Directive 96/23/EC (monitoring)

Vertical legislation refers to specific products e.g. Honey Directive 2001/110/EC



EC Hygiene Regulations

852/2004 general food hygiene

853/2004 specific requirements for food of animal origin

854/2004 specific procedures for the official control of food of animal origin

replacing 16 different Directives



What is new ?

• primary production is included • all food producing companies must be

registered • principle of equivalence for imported food

from third countries• HACCP mandatory as well as documentation

as self control

.



852/04 (9)

Community rules should not apply either to primary production for private domestic use, or to the domestic preparation, storage or handling of food for private domestic consumption. ..........



HACCP for smaller enterprises

852/04 Article 5

The HACCP requirements .........They should provide sufficient flexibility to be applicable in all situations including small businesses. In particular it is necessary to recognize that in certain businesses it is not possible to identify critical control points and that in some cases a good hygienic practice can replace the monitoring of critical control points. ..........



Basic Regulation Food Safety 178/02

e.g.

Consumer protectionTraceabilityRapid Alert System



Prerequisite for HACCP

Cleaning and sanitationsPest controlSupplier approvalEmployee trainingPersonal hygieneWater controlMaintenanceProduct specifications Product storage control



Hygiene only works for teams, if everyone uses the same set of rules.

validity for everyone regular reminder standard information reliable inspection mutual confidence

1.



Cleaning and sanitation applies to

• the working area • the equipment and • the people coming into contact with or close

to the product is

ESSENTIAL!

1.



Washing facilities must be available:

- Working rooms must be equipped with:

- wash-basin (warm and cold water)

- paper towels, liquid soap dispenser

- Toilets:

- with wash-basin

- separate toilet entrance with anteroom

1.



Also necessary:

- Sufficient air ventilation to prevent condensed water and foreign odors

- Adequate temperatures

- Artificial lighting with splinter protection

- Dressing-rooms with wardrobe for clean working clothes (separated from street clothes)

- No pets

- Exclusion of any people suffering from infectious

diseases

1.



Further prerequisites for working rooms and equipment:

Floors:

- must be cleaned regularly

- made of non-toxic materials

- water-proof and hydrophobic

Ceilings:

- prevent condensed water

- no moulds

- no removable fragments (loose paint particles e.g.)

1.



Windows:

-supplied with gauze or fine mesh (exclusion of pests and insects)

Doors:

- with plane, hydrophobic and easy-to-clean surface

Surfaces, tools and appliances, walls:

- made of plane, cleanable and non-toxic materials.

- desinfection possible

Further prerequisites..., contd.

1.



Equipment:

- free of corrosion

- containers made of food-safe, cleanable and smooth material

- can be disinfected easily

Suitable cleaning devices

- must be easy-to-clean

- corrosion-proof

- must be kept clean best using a dishwasher

Further prerequisites..., contd.

1.



2.

HACCP: A brief introduction



Definition of HACCP

Hazard

Analysis

Critical

Control

Point system

2.



• HACCP is a preventive safety system that

ensures the production of harmless foods

• most powerful method to repel and eliminate possible hazards regarding foods

• enables applying science-based controls

• from raw material to finished products

2.



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

• Biological (e.g. bacteria, virus)• Chemical (e.g. drug residues, cleaning

compounds, heavy metals, mycotoxins)• Physical (e.g. wood, metal, stones, glass, hair,

jewelry, plastic)

The hazards

2.



HACCP is not a stand-alone system. It works hand in hand with

• Standard Operating Procedures (SOPs)

• Definite responsibility

• Documentation

2.



Prerequisites to HACCP

• Good Processing Practices (GPP)• Good Hygiene Practices (GHP)• Good Manufacturing Practices (GMP)

• Appropriate QM systems like ISO series

2.



HACCP

SOP

GPP

GMP

GHP

2.



1. Realization of a hazard analysis 2. Identifying and setting Critical Control Points (CCPs)3. Setting Critical Limit(s) and standards4. Monitoring of each relevant CCP in honey production 5. Establishing corrective actions6. Verification of the system7. Documentation procedures

The seven principles of HACCP

2.



3. Good Beekeeping Practice



Application of good beekeeping practice is required for

1. working at the beehives

2. harvesting and transporting honey

3. extracting honey from supers

4. storing honey

5. bottling honey

3.



Contaminants from beekeeping

Environment

- Pesticides- Heavy metals - Bacteria-Genetically modified organism (GMO)- Radioactivity

Beekeeping

- Acridicides for Varroa control- Antibiotics against diseases e.g. AFB, EFB - Pesticides for wax moth control- Repellents at honey harvest- Other contaminants

Contamination

of honey

Plants, Air, Water

3.



CONTAMINANT SOURCE OF CONTAMINATION

CONTROL MEASURE

1. Antibiotics in honey Control of bacterial diseases with antibiotics (AFB, EFB, Nosema)

Alternative control without the use of antibiotics

2. Synthetic acaricides in bees Wax, propolis and honey

Varroa control with synthetic acaricides

Alternative Varroa control without synthetic acaricides

3. Pesticides in honey and beeswax

Control of wax moth with pesticides; Chemical control of the Small Hive Beetle

Wax moth control by alternative measures. Alternative control of the SHB

4. Repellants for honey harvest

Use of synthetic repellents at the honey harvest

Use of smoker with natural material, “mechanic systems”

5. Toxic metals or organic substances

container, drum Use material which do not diffuse contaminants into honey

6. Wood protectants, Painting Pesticides in wood protectants Use of wood protectants containing no pesticides

Contaminants from beekeeping and control measures



Contamination:

Today major factor for quality of honey

Incorrect apicultural practice

including hygiene e.g. as prevention of diseasesinstead of using „medicine“

3.



Selected examples for important sources for hazards corresponding to “good beekeeping practice”

Example Defect

Control Measures:

1 Jars and lids before filling

Contamination dirt, foreign,l odour, remaining water Hazard of quick deterioration of the content! SEM ! as residue of sealing compound lids Azodicarbonamide

Visual and sensory check

Another cleaning or destroying of the damaged jars/lidsreplace with other material

2 Liquefying honey , heat treatment

D: Reduction of the enzyme activity; if HMF > 40 mg Complaints accord. to honey directives C: Temperature, time, quick cooling

Tempera-ture, time measuring

Use as industrial honey

3.



Example Defect

Control Measures:

3 Straining honey foam

In the scum there might be wax particles that possibly contain harmful residues or other contaminants

Visual control

Removal of remaining honey scum by other methods

4 Addition of nuts or dried fruits to cream honey

Contamination of nuts / dried fruits with mould or pests Honey product is deteriorated

Looking for mould, cocoons etc.

Visual control

Dispose of the nuts / dried fruits

3.



Example Defect Control Measures

5 Cleaning pollen (blowing out, sorting by hand)

Organic contamination, foreign substances (dust), impurities, etc.

Insect bodies or parts of them

Visual control

Another cleaning

6 Insufficient drying of Pollen

storage

Deterioration possible (water content) Storage temperature max. 6 °C (freezer: -18 °C)

Continuos tempera-ture control

Adjustment of temperature

3.



Example Defect Control Measures

7 Storage of Royal jelly- cooled- frozen

Quick deterioration possible Storage temperature max. 4°C (freezer: -18 °C)

Continuos tempera-ture control

Adjustment of temperature; thawed pollen mustn’t be freeze again

3.



4.HACCP in honey processing

- Realization of a hazard analysis - Identifying preventive measures - Identifying and setting critical control points (CCP) - Setting critical limits and standards - Monitoring of each relevant CCP in honey production - Establishing corrective actions - Documentation procedures



HACCP Implementation

1. Must have Management Commitment

2. most Food Safety Failures are Management Failures

3. Must follow the 7 principles to develop HACCP at each Production Plant

.



I. Assembling the HACCP team

Multidisciplinarye.g. beekeepers, co-workers of the collecting stations, analysts, representatives of quality control, engineers4-6 peopleTeam must be able to evaluate risks and make food safety judgements

HACCP Plan Development

.



II. Describing the food and its distribution

• Types of raw material e.g. liquid honey, creamed honey, comb honey, bulk honey, wax, pollen, propolis

• Intrinsic control factors (moisture, colour)

• Process control factors (heating, drying)

4.



III. Describing intended use and consumers

e.g. pharmaceutical industry, food industry, cosmetic industryConsumer all groups of the population

4.



IV. Developing a flow diagram

• Including all process steps e.g. uncapping, extracting, straining, filtering, homogenising, stirring, packing, storage

• Including all inputs e.g. raw material, package material, water, air

4.



V. On-site confirmation of the flow diagram

1.all steps of the operation

2.all times of production

3.modify flow diagram as necessary



VI. List all potential hazards associated with each step, conduct a hazard analysis and consider any measures to control identified hazards.

• likely occurrence of the hazards

• expected severity of the hazards

4.



Physical Hazards (P)

• Insect fragments• Soil• Plant material• Packaging• Glass• Equipment

Hazards in honey processing

4.



Chemical Hazards (C)

• Pesticides and herbicides • Bee medicines, antibiotics• Bee repellents • Coating / varnish of drums

4.



Biological Hazards (B)

• Pathogens e.g. Clostridium botulinum

4.



Hazards may occur as a result of:

• an input (object, material)

• the process itself

• direct or indirect contamination from „other sources“

4.



Inputs & associated hazards

Bee Hive material

Wax

Bee hive sites

Drums

Glass jars

4.



Hazards at different process steps

1. Removing the honey combs out off the hives

2. Holding in hot room

3. Uncapping

4. Extracting

5. Liquefying

.



Form for evaluation of hazards and possibilities for control (Agroscope Liebefeld-Posieux,Schweizerisches Zentrum für Bienenforschung, 2004)

4.

1.1 HAZARD: CONTAMINATION

Hive a) Contamination by the environment: (agriculture, industry) by heavy metals, pesticides etc.

medium Identification and contamination source place the hives to a another site

b) Bees are intoxicated by pesticides small Identification and contamination source and its avoidance



Form for evaluation of hazards and possibilities for control (Agroscope Liebefeld-Posieux,Schweizerisches Zentrum für Bienenforschung, 2004)


IMPORTANCE CONTROL MEASURES

Hive a) Lack of order and hygiene, endangering quality of bee products

medium Re-installment of order, cleanness and hygiene

Extraction Plant resp. room

b) Lack of order, cleanness and hygiene, bees present, foreign odour

great Re-installment of order, cleanness and hygiene

c) Centrifuge, tanks are improper, rusty

great Re-installment of order, cleanness and hygiene

d) Instrumentation and instruments are cleaned with waste water e.g. pond, river

great Use drinking water

4.



1.2 HAZARD: ADULTERATION, CONTAMINATION

Feeding of bees

a) Sugar syrup is mixed with honey great Correct choice of time and quantity of sugar feeding

b) Use of improper water when preparing sugar feed leads to transfer of contaminants into the hive.

great Use of drinking water


Bee diseas-es

Treatments of bees contrary to instructions resp. illegal treatment leads to intolerable residues in honey

great Follow instructions of veterinary authorities

4.




Change and storage of combs

Combs are very dark, there are moths and bee excretions, dirt which might cause bee infections and honey contamination. Use of pesticides for wax moth control

great Regular control of brood and honey combs. Optimise storage of combs. Use alternative control for wax moth control.

1.5 HAZARD: CONTAMINATION, ADULTERATION

Honey harvest

a) Water content of honey >20 % small Harvest honey with less than 20% w.cont.

Packing storage and labelling

b) In honey there are contaminats from wax, bees, dirt, extraneous substances and odours

medium Re-installment of order, cleanness and hygiene

c) Improper conditions of honey storage leads to dcrese of honey quality

medium Store honey at optimal conditions (room, recipients)

d) overheating of honey while packing leads to reaching of too much HMF

medium Liquefy honey at the optimum temperature and time

4.



VII. Identifying preventive measures

4.



Step Risk Measure Application of antibiotics and pesticides

Contamination of bee products caused by the application of anitbiotics/presticides

1. Ban of antibiotics 2. Regulation of pesticides

application by plant sanity 3. Monitoring of chemical

compounds 4. Training

Feeding of bees Quality, application and handling of feedstuff

1. Purchase of suited feedstuff

2. Usage of suited equipment 3. Correct application of

feedstuff Desinfection and cleaning of hives

Transfer of diseases Fufillment of hygenic and health norms

Examples for preventive measures

4.



Identifying and setting Critical Control

Points (CCPs)

The seven principles of HACCP, contd.

4.



CCP =

A step where control can be applied and is essential to prevent, eliminate or reduce a food safety hazard to an acceptable level

CP = means any point, step or procedure in a specific food system at which biological, physical and chemical factors can be controlled

.



Critical control-points show where

processes have to be supervised

Creating a decision tree facilitates finding the CCPs

4.



The decision tree Questions

4.



Q1: Do control measure(s) exist?

No

Is control necessary here? Yes

No

Modify step, process orproduct

Not a CCP Stop

Yes

4.



Q2: Is the step specifically designed to eliminate or reducethe likely occurance of a hazard to an acceptable level?

Yes

CRITICAL CONTROL POINT

4.

No



Q3. Could the identified hazard increase to unacceptable levels?

No

Not a CCP Stop

4.

Yes



Q4. Will a subsequent step eliminate identified hazard(s) or reduce likely occurrence to an acceptable level ?

No

CRITICAL CONTROL POINT

Yes

Not a CCP

Stop

4.



3. Setting Critical Limit(s) and standards


4.



Critical limit =

A criterion that separates

accceptability from unacceptability

4.



A critical limit

- must relate to control measure - must be observable / measurable (time, temp., pH etc.) - must be validated

4.



Examples for critical limits:

• For the application of e.g. antibiotics, bee-repellents, wood preservatives

• Limits in honey for e.g. water content (fermentation), HMF, invertase, diastase, antibiotics, pesticides (regulated by law)

• Contamination by cleaning agents

• Adulteration e.g. by sugar cane, maize (C4-sugars)

4.



Limits are a result of:

- Legislations / guidelines - Directives - Specifications within the own company

if limits exceeded: corrective action

4.




4. Monitoring of each relevant CCP in honey production

4.



Monitoring of each CCP means:

• watch and check CCPs to ensure that instructions and corrective procedures are carried out right

• Determing for each CCP:– Who?– When?– What?

4.



5. Establishing corrective actions


4.



Corrective actions depend on the faults, see examples next pages

4.



Corrective actions have to be introduced as soon as critical limits are exceeded so the CCPs will not get out of control

2nd measure:stop process anddispose products

1st measure: influence products or processes

or

4.



CCPs in the Honey Process

I. The hive and the honey removal

II. Transportation of honey in supers

IV. Filtration

III. Uncapping

VI. Preparation to bottle & bottling

VII. Distribution & display

V. Storage

4.



I. The hive and the honey removal

Inputs

• Honey supers

• Uncapping, sump, pump to tanks

Final Output

• Bulk honey

4.



Hazards

• Physical: soil, wire, wood, varnish particles, rust etc.

• Chemical: - medicines: pest., antibiotics, - plant toxins (e.g. pontic honey, tutin) - paints, preservatives• Biological: - Bacterial spores e.g.

Clostridium

MonitoringCheck:• - No contact with soil /

vegetation • - Chemicals applied for

suitability of use- Regular inspections to detect vermin infestations

- Treatment - Instructions for use• Reliable lab. test, reports

I. The hive and the honey removal4.



Control and corrective action

• Dispose off honey • Use as winter feed (if recognized as safe)

I. The hive and the honey removal4.



II. Transportation of honey supers

Hazard:• Physical and chemical

contamination from:

- Transportation

- Animals

- Rain water

Monitoring:• Inspect vehicles

- Clean and free from petrol, oil, soil, plant & animal material

- Cover super with e.g. polythene sheet

4.



Control and Corrective Action:

• Dispose off honey

II. Transportation of honey supers4.



III. Uncapping and extraction

Hazard• Contamination from

- Equipment (not stainless steel parts)

- room

- people

Monitoring• Inspect all equipment• Clean daily resp.

regularly• Provide suitable

clothing

4.




• Complete all checks before processing start• Documentation !!

III. Uncapping and extraction4.



IV. Filtration

Hazard• wax with residues• foreign matter

Monitoring• Check filters before and

after use for damages

4.




• Re-filter with good filter if found damaged after use

IV. Filtration 4.



V. Storage

Hazard• Contamination from

- container

- surroundings

- pests• high HMF due to high

temperatures• Moisture increase on

surface

Monitoring• Check containers for

food storage suitability• Prevent moisture

absorption • Use suitable lids• Maintain temp. below

40°C

4.




• Make sure conditions have been met before bottling• Organoleptic test• measuring HMF, moisture

Use as industrial honey if the above have failed

V. Storage4.



VI. Preparation to Bottle & Bottling

Hazards• HMF increase • Crystallisation (liquid

honey)

• Foreign matter due to contamination from:

- environment

- glass breakage

Monitoring• Monitor temp. under

50°C• Check area and

surroundings• Check no. of

glass/plastic before & after bottling for breakage

4.




• Downgrade honey if temp. exceeded 50°c• Do not bottle if area is not clean • Dispose honey exposed to broken glass• Re-check unfilled glass jars

VI. Preparation to Bottle & Bottling4.



VII. Distribution & Display

Hazards• Moisture absorption

due to: - damaged seals- poor handling- poor packaging

HMFCrystallisation (liquid

honey)

Monitoring• Suitable shipping

containers• Temperature ?

4.




• Remove damaged product

VII. Distribution & Display4.



6. Verification of the system


4.



Establishing verification procedures

• Procedure to ensure that HACCP is performed correctly and that it is effective

– Is the system suited?– Are the procedures specified (e.g.

monitoring) and the corrective actions applied correctly?

4.



Verifications can be:

– Verification of HACCP-inspections and the respective data

– Verification of deviations– Audits– Validation of determined limits and

tolerances, e.g. participation in ring trials

4.




7. Documentation procedures

4.



Documentation

In terms of a traceable and effective self-control, a minimum of documentation is recommended

4.



Documentation, contd.

Recommended documentation regarding: - Necessary cleanings - Disinfection measures - Storage temperatures - Pest combat - etc.

• Signatures are obligatory There is no proof without evidence!

4.



Date:

Cleaning agent:______

Disinfection agent: ______

Dilution:

Work space and adjacent walls in the processing room / etc.

Floors: __________

Walls, doors, windows:

Honey extractor

Other equipment:

Refrigerator:

Responsible / Signature:

Example 1: Documentation of cleaning and disinfection measures

4.



Example 2: Documentation of pest control and combat

Control date:

Pest detected:

Location / rooms:

Amount:

Measures:

Subsequent control:

Result:

Responsible / Signature:

4.



5.

Establishing self-checking mechanisms in honey production

acc. to HACCP principles



Based on the HACCP approach:

Autocontrol system for beekeepers

- Should be as simple as possible

- should contain all the principles that ensure good quality

- Allows successful management of beekeeping units

- is cheap

The system has to ensure that all factors, which influence honey quality are under control and are within the legal limits

This system is applicable for small and medium beekeeping units.

5.



- The EC demands implementation of an Autocontrol-system

- In some European countries manuals for the production of quality honey based on HACCP have been published

- The implementation of autocontrol-systems in honey production is slow yet, since food control authorities regard honey as a microbiologically safe product

Autocontrol system for beekeepers, contd.

5.



For example, in Switzerland forms have been created for the self control system, which help to evaluate hazards and document control measures

5.



europe.eu.intKeyword: eur-lex, number of regulation

Documents

HACCP and hygiene in honey production ©2005 by QSI Argentina, Oct./Nov. 2005Honey - HACCP1 HACCP & Hygiene in honey production Buenos Aires, Concepción