Hazard Analysis Critical Control Point A Food Safety Approach Food Safety Training Courses on International Standards & Regulations PAK/AIDCO/2002/0382/13

Hazard Analysis Critical Control Point

A Food Safety Approach

Food Safety Training Courses on International Standards & Regulations PAK/AIDCO/2002/0382/13 A project funded by European Union URS/FS/006 Implemented By

Food hygiene

All conditions and measures necessary to ensure the safety and suitability of food at all stages of the food chain


Food Safety

Assurance that food will not cause harm to the consumer when it is prepared and/or eaten according to its intended use.

Source: Codex Alimentarius (WHO)


Food Safety - Aim

Protecting People

Keeping the Employees and Customers

Preventing Food Safety Errors


Food safety background

First food law written in 2500 B.C.

Pakistan food laws are dated back 1876. First HACCP system was developed between NASA

and Pillsbury in 1971. Got shape of seven principles and adopted as a

regulatory requirement in late 80’s in USA.

Become a regulatory requirements in EU since 1998.


Foodborne illness - Consequences

Contaminated food contributes to 1.5 billion cases of diarrhea in children each year;

Resulting in more than three million premature deaths

WHO - Food Safety Program “ Food Safety – An Essential Public Health Issue for the New Millennium”, 1999, (WHO/SDE/PHE/FOS/99.4), [hereafter “Food Safety An Essential Public Health Issue for the New Millennium], at p. 7


Foodborne illness – Economic cost In US, government estimated cost US$ 5.6 billion

to 9.4 billion.

In EU, estimate is € 3 billion annually. In Australia, estimated cost was calculated as

AU$ 2.6 billion annually. In 1991, Peru lost more than $ 700 million in

export of fish and fish products


Food safety concerns

In developing countries;

Inappropriate use of agricultural chemicals Use of untreated or partially treated waste

water

Use of sewage or animal manure on crops


Food safety concerns

Absence of food inspection, including meat inspection

Lack of infrastructure, such as adequate refrigeration

Poor hygiene, including a lack of clean water supplies


Food safety challenges

Changes in animal husbandry

Changes in agronomic process

Increase in international trade

Changes in food and agriculture technology


Food safety challenges

Increase in susceptible population

Increase in travel

Changes in lifestyle and consumer demands

Bioterrorism


Food chain


Control mechanisms

Regulations

Codes of practice

Inspection regimes

Risk reduction methodologies – HACCP

ISO 9001 Based management systems


HACCP

A proven system.

Proactive approach.

Known way to comply with legislative requirement.

Improved product quality.

Less product recalls and wastage during processing.

More customer reliance on product.


Pre-requisite programs

Steps or Procedures that control the in plant

environmental conditions

Provide foundation for safe food production


Pre-requisite programs

Personnel

Infrastructure

Sanitation and House Keeping

Production and Process Control


Personnel

Supervision

Disease control

Medical examination


Personnel

Illness and injuries

Cleanliness

Education and training


Infrastructure

Physical facilities

Design construction and installation

Maintenance and operation

Pest management

Water supply


Sanitation and housekeeping

Cleaning

– Factors influencing cleaning

– Cleaning agents

Sanitizing

– Heat sanitizing

– Chemical sanitizing

CIP


Production and process control

Elimination or minimizing hazards during RM handling, storage, work in process and production.

Prevention from contamination and spoilage of food product during manufacturing operations.

Prevention of cross contamination and product spoilage during storage and transportation.


Product characteristics

Product name

Composition

Biological, chemical and physical characteristics

Intended shelf life and storage conditions

Packaging

Labeling

Method of distribution


Process flow diagrams

Sequence and interaction of all steps in operation Any outsourced processes and subcontracted

work Ingress points of raw materials, ingredients &

intermediate products

Reworking and recycling steps Egress points for end products, intermediate

products, by-products and waste

Accuracy of flow diagrams


HACCP – Preliminary steps

Assemble HACCP team

Describe product

Identify intended use

Construct flow diagram

On site confirmation of flow diagram


Preparing for ground; movie 01

Preparing the ground; movie 02

HACCP principles

Conduct a Hazard Analysis

Identify Critical Control Points

Establish Critical Limits

Establish CCP Monitoring

Establish Corrective Actions

Establish Verification Procedures

Establish Record Keeping


HACCP principle one

HACCP principle two

HACCP principle three

HACCP principle four

HACCP principle five

HACCP principle six

HACCP principle seven

Hazard analysis

Hazard identification– List of all hazards that are reasonably expected to occur

Hazard assessment– Evaluate Hazard Probabilities – Evaluate Hazard Severities– Risk Characterization


Risk Assessment


Decision tree

Do control preventive measure(s) exist?

Yes No

Is control at this step necessary for safety? Yes

No

Modify step, process, or product

Not a CCP

Go to Next step


Decision tree

Is the step specifically designed to eliminate or reduce the likely occurrence of a hazard to an acceptable level?

No Yes

Go to next step CCP


Decision tree

Could contamination with identified hazard(s)Occur in excess of acceptable level(s) or could

These increase to unacceptable level ?

YesNo Not a CCP

Go to next step


Decision tree

Will a subsequent step eliminate identified Hazard(s) or reduce likely occurrence

To an acceptable level?

Yes No CCP

Not a CCP


Establishing the HACCP plan

Food safety hazards to be controlled at the CCP

Control measures

Critical limits

Monitoring procedures

Corrective actions

Responsibilities and authorities

Records of monitoring


Validation and verification

Validation– Obtaining evidence that the elements of the HACCP plan are

effective

Verification– The application of methods, procedures, tests, and other

evaluations, in addition to monitoring to determine compliance with the HACCP plan


Safety by design

Validation is part of safety by design; activities include– Hazard anticipation– Product formulation– Challenge tests– Storage tests– Line layout– Process parameters– Cleaning and disinfection systems


Verification

Checking system conformity:– the seven principles have been correctly applied– the resulting HACCP plan is correctly and consistently

implemented

Effectiveness confirmation: – the system delivers what is expected


Verification

Activities include:– Review of HACCP system and records– Review of consumer complaints– End-product testing– Review of validation data


System conformity

Things are done verification Things are done right monitoring The right things are done

validation/verification The right results are obtained validation


Documents

Hazard Analysis Critical Control Point A Food Safety Approach Food Safety Training Courses on International Standards & Regulations PAK/AIDCO/2002/0382/13