HACCP Concept

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HACCP (Hazard Analysis Critical Control Point) Concept

A preventive strategy that is standardized and formalized to control all

factors affecting the safety and quality of food.

Mainly concerned with manufacturing food that is safe to eat but can be

applied to aesthetic and commercial aspects of quality as well.

The system is based on the assumption that safety and quality hazards exist

at various points from capture/harvest to consumption.

Main elements of the HACCP-System

1. Identification of Potential Hazards

Hazard is anything in the total operation that might contaminate

foodand make it unsafe for the consumers who buy the product, or

that can mislead consumers,making the firm liable to economic

fraud (ASEAN Executing Agency, 1994).


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Steps outlined below identifies the critical control points:

Step 1. Describe the product.

The product must be describe based on raw materials, ingredients,

additives, structure and physical characteristics (solid, liquid, gel, etc.),

processing method and the extent of processing, packaging method and

material, conditions for storage and distribution, shelflife requirement(sell

by date and best before date), instructions for use and the particular

microbiological or chemical criteria.Step 2. State the intended use for the product.

The target consumers and how will they prepare or use the product

mustbe determined. Furthermore, special considerations such as dangers in

use by any vulnerable groupsin the population by particular requirementsprescribed by the importer must be stated.

Step 3. Develop a flow diagram.

All particular steps in the manufacturing process from the time the raw

materials are received until the end-product reaches the market are charted. A

detailed flow chart supported by full technical data is presented.


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Step 4. Confirm the flow diagram and all recorded details.

The flow diagram must be prepared based on accurate and actual

activities in the facility.

Step 5. Identify hazards and establish critical control points (CCP) for every

step involved in making the product.

In each step of production the same question must be asked: Is there

a hazard? If there is a hazard at a particular stage, determine if it can be

controlled. If it can be controlled, it is declared as CCP.

2. Determination of Critical Control Points (CCPs)

CCP- is a point, step or procedure at which control can be applied and a

food safety hazard can be prevented, eliminated or reduced to an

acceptable level (NACMCF, 1992).

3. Establishment of Criteria, Target Levels and Tolerances for each CCP

Critical limits must be set for factors such as temperature, time,

physical dimensions which can influence hazards, moisture and salt

content, pH, and available chlorine content in cleaning water.


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4. Establishment of Monitoring System for each CCP

All data from the monitoring must be recorded on well-designed forms

or charts, and the records checked and evaluated regularly andunannounced by the assigned personnel acting separately of the control

staff (Connell, 1995).

5. Establishment of Corrective Action when CCP is not under Control

A plan is put in place to ensure that corrective action is taken

immediately whenever the monitoring procedures show that there is a

problem at any CCP. Action must be taken before deviation leads to a safety

hazard. Corrective action involves the following activities (Tompkin, 1992):

Using monitoring results to adjust the process in order to maintain

control

Dealing with non-compliance products if control is lost

Fixing or correcting the cause of non-compliance

Keeping records of the corrective actions


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A person must be assigned to be responsible for adjusting the process

and for informing others of what has happened. There are five options for

dealing with non-compliance products:

Release the product (not the wisest option if safety is involved)

Test the product

Divert product to safe use

Reprocess the product

Destroy the product

6. Establishment of Procedures for Verification

Verification and review procedures are set up to ensure that the system

of monitoring is working effectively. Random sampling and analysis can beused to gather additional information in checking whether the HACCP

system is working. Verification can also be undertaken by independent

arties such as government authorities, trade partners, consumer

organizations and others (Huss, 1994).


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7. Documentation and Record Keeping Establishment

A designated person who is responsible for maintaining and keeping

the records must be known to everybody. All documentation and recordsshould be compiled in a manual and accessible at all times for inspection

by regulatory agencies (Devlin, 1996).

Introduction of the HACCP-System

It is proper then to adapt a logical and step-wise order for

introduction of the system (Huss, 1994). The steps involved are:

Commitment

Strong commitment of the top-level management in

introducing the system is very essential.


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Formation of an HACCP-Team and Materials

The most important members of an HACCP-team are the

microbiologists and processing specialists. Other members that may be

included are the chemist, quality assurance manager, engineer, packaging

technologist, sales staff, training and personnel managers.

Initiation of Program

A detailed description and specification of the product must be given tothe team during this time. The specification must contain all technological

matters including preservative criteria, proposed storage temperature,

packaging technology and intended use of the product.

Process Analysis

Analysis of the data must ensure when all the information regarding

product and process has been collected. All hazards must be identified and

CCPs must be established as well. Creation of a decision tree can be very

useful in this process.


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Control Procedures

Equipment and instruments used in control functions must also be

kept uner strict control, and their performance must be inspected

periodically.

Monitoring Procedures

Monitoring and recording of data are key elements of the system. All

alterations to product-formulas or processing lines brought as a result of

the HACCP-study must be on record, as well as corrective actions taken

when something was out of control.

Training of Staff

Training of staff must occur when the HACCP-study is finished and the

programme is set for implementation. Training and refresher courses

must take place periodically and new staff should not be permitted to

start work without undergoing training in HACCP principles and

procedures.


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Application of the HACCP-System in the Fish Processing

Industry

The ultimate use of the HACCP-concept in fish processing is specific

for every process and for every plant. In any case a definite study of process

flow is essential in order to identify the hazards and the CCPs. The application

of the HACCP-system in fish processing technology is discussed below:

Molluscs

Molluscs are a very high-risk food if they are eaten raw or very lightly

cooked since they grow and are harvested in shallow, near-shore estuarine

waters which maybe contaminated with sewage-derived pathogens as

well as those naturally occurring in the overall-environment.


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Hazards and Preventive Measures in Chilled Molluscs

Product Flow Hazard Preventive Measure

Live Molluscs

Contamination with

pathogens, biotoxins,

parasites and chemicals

Monitoring of environment

Chilling Microbial growth Time-temperature control

Transport Microbial growth Time-temperature control

All processing stepsMicrobial growth

Contamination

Time-temperature control

Water quality

Hygiene and sanitation


Distribution Microbial growth Time-temperature control


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Fresh and Frozen Fish

In the manufacture of fresh and frozen products the majority of the

hazards can be controlled in a routine quality assurance programme using very

simple equipment and methods. However, the presence of heat stable toxins canresult in uncontrolled hazards.

Hazards and Preventive Measures in Fresh and Frozen Fish


Live Fish

Contamination with pathogens,

biotoxins, viruses, parasites and

chemicals

Monitoring of

environment

Catch and catchhandling

Microbial growth Time-temperature control


Landing Microbial growthTime-temperature control

Hygienic handling


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Raw material (receipt)Poor quality entering

processing

Secure reliable source

Sensory evaluation

Filleting Presence of parasites Candling

All processing stepsMicrobial growth

Contamination


Water qualityHygiene and sanitation

Packaging Chemical spoilagePackaging

material/vacuum


FreezingChemical/enzymatic

spoilageTime-temperature control

Dried Products

Dried products usually have a very high salt contentwhich makes them stable at ambient temperature. These products may be

eaten with or without cooking. Processing is usually carried out at ambient

temperature, and if reduction of moisture takes too long, growth and toxin

production by microorganisms could occur.


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Hazards and Preventive Measures in Dried Products


Live Fish

Contamination with

pathogens, biotoxins, viruses,



Catch and catch

handlingMicrobial growth Time-temperature control



Hygienic handling

Raw material (receipt) Microbial growth Time-temperature control

Salting Improper salt content

Control of salt concentration

in brine and time for fish in

brine (NaCl concentrationand holding time to be

specified)

Drying Microbial growthControl of drying time and

temperature

StorageMicrobial growth

Chemical spoilage

Packaging material



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Fermented Products

The use of spoiled fish may cause the formation of toxic substances

such as histamine. The improper handling of raw fish before salting, and high

pH conditions created due to very low salt concentrations may allow the

growth of pathogenic bacteria such as Clostridium botulinum (Virulhakul,

1995). Consumption of these products in raw or partially cooked form may

present hazards due to contamination with parasites.

Hazards and Preventive Measures in Fermented Products


Live Fish

Contamination with


viruses, parasites and

chemicals


Catch and catch handling Microbial growth Time-temperature control



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Hygienic handling

Raw material (receipt) Microbial growth Time-temperature control

Washing

Presence of extraneous

materials (sand, dirt, etc.) Proper washing procedure

Salting Microbial growth Control of salt : fish ratio

Fermentation Microbial growthControl of fermentation

conditions

Packaging

Microbial

growth/fermentation

persistence

Control of pasteurization

process and packaging

material

Marinated Products

The presence of biotoxins and parasites in raw material for

production of marinated products becomes a hazard depending on the

fishing area and season.


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Hazards and Preventive Measures in Pickled/Marinated

Products


Live Fish

Contamination with


viruses, parasites and

chemicals

Monitoring of

environment

Catch and catch

handlingMicrobial growth

Time-temperature

control

Chilling Microbial growthTime-temperature

control

Landing Microbial growthTime-temperature

control

Hygienic handling

Raw material (receipt)Poor quality entering

processing


Sensory evaluation


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Salting

Improper salt content in fish

(spoilage and/or survival of

parasites)

Control of salt

concentration in brine and

time of fish in brine (NaCl

concentration and holding

time to be specified)

Pickling/Marinating

Improper NaCl and acetic acid

concentration in fish (taste,

spoilage and/or survival ofparasites)

Control of composition of

marinade and marinating

time.

Holding time to be

specified for pickling.

Packaging in glass jars

in final picklePoor sensory quality

Control of composition of

pickle (concentration of

sugar, acetic acid, spices,

etc.)

Distribution

Microbial growth (bacteria,

yeasts and production of toxin

from C. botulinum type A and B)

Control of temperature


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Smoked Products

Improperly prepared smoked products may be contaminated with

pathogens particularly Clostridium botulinum type E spores.

Hazards and Preventive Measures in Smoked Products


Live Fish

Contamination with



Monitoring ofenvironment

Catch and catch

handlingMicrobial growth

Time-temperature

control

Chilling Microbial growth

Time-temperature

control

Landing Microbial growth

Time-temperature

control

Hygienic handling

Raw material (receipt)

Poor quality entering

processing


Sensory evaluation


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Salting

Improper salt content in fish

(spoilage and/or survival of

parasites)

Control of salt

concentration in brine and

time of fish in brine (NaCl

concentration and holding

time to be specified)

SmokingMicrobial growth

Contamination


Plant hygiene and

sanitation;

Water quality

Packaging Microbial spoilage; oxidation Time-temperature controlPackaging material

Storage and

distribution

Microbial growth (molds,

bacteria particularly toxin from

C. botulinum type E


Minced Products

Minced products are usually heated before consumption. However,

several hazards are present during the preparation of the products.


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Hazards and Preventive Measures in Minced Products


Live FishContamination with pathogens,biotoxins, viruses, parasites and

chemicals

Monitoring of

environment

Catch and catch handling Microbial growth Time-temperature control



Hygienic handling

Raw material and

ingredients (receipt)


processing

Microbial contamination

Ensure reliable source

Sensory evaluation


Mincing fish (and

leaching for surimi)Microbial growth



Grinding minced fish

with ingredientsMicrobial growth


Sanitation of equipments

and utensils


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Forming Microbial growthTime-temperature control


Battering/breading

Microbial growth;

contamination with foreignmaterials



Packaging Microbial contamination



Packaging material

Canned Fish

Canned products are marketed at ambient temperature and

generally stored for months, even years under these conditions. Theseproducts are usually eaten without any heating prior to consumption.


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Hazards and Preventive Measures in Smoked Products


Live FishContamination with




Catch and catch

handlingMicrobial growth Time-temperature control



Hygienic handling

Raw material, fish and

cans (receipt)


processingSecure reliable source

Filling cansPoor filling affects heat

penetration during retorting

Avoid inclusion of air,control weights of solids,

liquids, product density

and headspace

Exhaustion, seaming RecontaminationControl of closures at

regular intervals


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Retorting Survival of pathogens Time-temperature control

Cooling Bacterial contamination

Control of quality of cooling

water, chlorine level > 1-2

ppm

Handling of wet canned

productsRecontamination

Proper handling procedure

to minimize recontamination

and mechanical shock


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HACCP Concept

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