HACCP IN PRACTICE
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Transcript of HACCP IN PRACTICE
April 2015 Prepared by : Rahul Gupta
HACCP IN PRACTICE
Safety or Non-safety?
April 2015 Prepared by : Rahul Gupta
WHAT IS HACCP
A system which identifies evaluates & controlsHazards which are significant for food safety
April 2015 Prepared by : Rahul Gupta
HAZARD
• A biological, chemical or physical
agent in, or condition of, food
with the potential
to cause an adverse health effect
• Codex Alimentarius, 1997
April 2015 Prepared by : Rahul Gupta
Types of Hazards
• Biological e.g Bacteria• Chemical hazard e.g preservative• Physical e.g glass
April 2015 Prepared by : Rahul Gupta
Contaminant
Any biological or chemical agent,
foreign matter, or substances
not intentionally added to food
which may compromise
food safety or suitability
Codex 1997
April 2015 Prepared by : Rahul Gupta
Acceptable levels
• Not all levels (or sizes) of all agentsare harmful to all individuals under
all conditions
• Agents (contaminants) are acceptableas long as their levels remain
below a certain maximum
April 2015 Prepared by : Rahul Gupta
Increase or decrease in level
If an agent is present in a food at a
• low, acceptable, level, its increase to an unacceptable level should be prevented
• high, unacceptable, level, its reduction to an acceptable level should be assured
April 2005 Prepared by : Nidhi Bhayana
Control
• Having things under control
• To direct, regulate, command
April 2015 Prepared by : Rahul Gupta
Hazard control
Prevention of contamination
Prevention of increase in level
Assurance of adequate reduction
Prevention of recontamination
Prevention of dissemination (spread)
April 2015 Prepared by : Rahul Gupta
Critical limit
• A criterion which separates
acceptability from
unacceptability
Codex Alimentarius, 1997
April 2015 Prepared by : Rahul Gupta
Microbiological process control
Having control over
conditions
which may lead to
unacceptable
growth, survival, spread
contamination
with / of undesirable microorganism
April 2015 Prepared by : Rahul Gupta
Example of processing for safety
Safety assured by adequate • heating time & temperature
Reliance on monitoring to detect deviations
Timely adjustments and corrective actions
Pasteurization
April 2005 Prepared by : Nidhi Bhayana
Critical Control Point
• A step in the food chain where activities are carried out, or conditions prevail which can have an influence on the safety of the product, and where
control can be exercised over
one or more factors to
prevent or eliminate a food safety hazard
or reduce it to an acceptable level
April 2015 Prepared by : Rahul Gupta
Monitoring
Checking, by testing, measuring
or observing, whether a
Critical Control Point (CCP)
is under control
April 2015 Prepared by : Rahul Gupta
Verification
Checking the implementation
and effectiveness
of the HACCP system
April 2015 Prepared by : Rahul Gupta
Factors contributing to foodborne illness
Contamination - Unclean equipment - Raw materials - Insects / rodents - Aerosols / condensation - Infected handlersSurvival - Inadequate cooking / reheating
Growth - Insufficient cooling / hot holding
April 2015 Prepared by : Rahul Gupta
Examples of adverse health effects
• Acute illness :
• Chronic illness :
• Death
chokingvomitingabdominal crampsdiarrhoeanauseafever
chronic infectionsdamage of various organscancer
April 2015 Prepared by : Rahul Gupta
Controlling growth of microbes
• Clean surfaces
• Dry surfaces
• Food kept hot or cold
• Short holding time
NutrientsWaterTemperatureTime
Control measureNeeded for growth
April 2015 Prepared by : Rahul Gupta
Survival depends on
• Temperature
• Time
• Quantity
• Food
April 2015 Prepared by : Rahul Gupta
Food hygiene
All conditions and measures
necessary to ensure
the safety and suitability of food
at all stages of the food chain
April 2015 Prepared by : Rahul Gupta
Food safety
Assurance that food will not cause harm
to the consumer when it is
prepared and / or eaten
according to its intended use.
April 2015 Prepared by : Rahul Gupta
Food safety assurance
it identifies what we need to do to make food safe
it makes sure that what is planned is correctly implemented
HACCP is a method of food safety assurance
April 2015 Prepared by : Rahul Gupta
Safety
Public health Industry
Consumer
April 2015 Prepared by : Rahul Gupta
Quality assurance
All planned and systematic actions
necessary to provide
adequate confidence that a
product or service will satisfy
given requirements for quality
• (ISO/UNCTAD/GATT)
April 2005 Prepared by : Nidhi Bhayana
Total QualityManagement
Food Quality Assurance
Food Hygiene
HACCP
April 2015 Prepared by : Rahul Gupta
Caterpillar present in finished product
April 2015 Prepared by : Rahul Gupta
Rat droppings off packaging enter dry mix
April 2015 Prepared by : Rahul Gupta
Motor over product losing pieces of paint
April 2015 Prepared by : Rahul Gupta
Person working near product line has hair exposed
April 2015 Prepared by : Rahul Gupta
Chipped jar causes glass pieces to be found in the product
April 2015 Prepared by : Rahul Gupta
Motor over exposed line drops oil and grease onto product
April 2015 Prepared by : Rahul Gupta
Some residues of disinfectant are present after cleaning
April 2015 Prepared by : Rahul Gupta
The growth of pathogens in a dead end
April 2015 Prepared by : Rahul Gupta
The product sieve sometimes loses metal pieces
April 2015 Prepared by : Rahul Gupta
The product is cooled with air that had been poorly filtered
April 2015 Prepared by : Rahul Gupta
The need for the
HACCP system
April 2015 Prepared by : Rahul Gupta
Industrial emissionsand effluents
Landfills
Vehicleemission
Agriculturalpractices
Where hazards ariseWhere hazards arisein the food supplyin the food supply
Processing
Storage
CookingLivestock
Crops
Seafood
Distribution
Retail
April 2015 Prepared by : Rahul Gupta
GMP / GHP for safe food production
+On Line testing
+End - product testing
for obtaining assurance of safety
Food safety Food safety assurance systemassurance system
April 2015 Prepared by : Rahul Gupta
Food safety assurance
• Good Manufacturing Practice (GMP)
• and• Good Hygienic Practice (GHP)
necessary but not always sufficient
April 2015 Prepared by : Rahul Gupta
Objectives of application of the HACCP system
More efficient More efficient quality assurance quality assurance
systemsystem
Prevention of foodborne illnessPrevention of foodborne illness
Protection of reputationProtection of reputation
Reduction of costsReduction of costsof food analysesof food analyses
ReductionReduction of of losses due to losses due to product recallproduct recall
April 2015 Prepared by : Rahul Gupta
HACCP in food hygiene
April 2015 Prepared by : Rahul Gupta
Prerequisites to HACCP
Practices and conditions neededprior to and during
the implementation of HACCPand which are essential for food safety,
as described in the CodexGeneral Principles of Food Hygiene
and other Codes of Practice
FAO/WHO consultation June 1998
April 2015 Prepared by : Rahul Gupta
Cleaning andCleaning anddisinfectiondisinfection
April 2015 Prepared by : Rahul Gupta
Cleaning
The removal of
soil, food residue, dirt, grease
or other objectionable matter
Codex 1997
April 2015 Prepared by : Rahul Gupta
Disinfection
The reduction, by means of
chemical agents and/or physical methods,
of the number of microorganisms
in the environment,
to a level that does not compromise
food safety or suitability
April 2015 Prepared by : Rahul Gupta
Importance of cleaningImportance of cleaningbefore disinfectionbefore disinfection
protect microorganisms
provide nutrients for microbes
reduce effectiveness of disinfectants
reduce efficiency of equipment • (e.g. heat exchangers)
Food residues
April 2015 Prepared by : Rahul Gupta
Methods of disinfectionMethods of disinfection
• High temperature hot water steam
• Chemical halogen or oxidizing• (e.g. chlorine, iodine) surfactant or non-oxidizing
April 2015 Prepared by : Rahul Gupta
Pest controlPest control
•Pathogens can be spread by:
• procedures must be in place to keep themout of the food processing
and handling areas
flies and other insects cockroaches rats mice
April 2015 Prepared by : Rahul Gupta
Good Manufacturing / Hygienic Good Manufacturing / Hygienic PracticePractice
April 2015 Prepared by : Rahul Gupta
Good Manufacturing Practices(GMP)
That combination of manufacturingand quality control procedures
aimed at ensuring that products areconsistently manufactured to their
specifications• IFST ( UK )
Consists of Personal hygiene , Good operational practices and Foreign material & glass control
April 2015 Prepared by : Rahul Gupta
Good Hygienic Practices(GHP)
All practices regarding the conditions and measures
necessary to ensurethe safety and suitability of foodat all stages of the food chain
• ( Based on the Codex definition of Food Hygiene )
April 2015 Prepared by : Rahul Gupta
GMP or Significant Hazard?
Should these potential hazards be controlled by GMPs or do they need to be considered in the HACCP Study, and, if so, are they significant hazards?
April 2015 Prepared by : Rahul Gupta
Codex General Principles ofFood Hygiene (1)
Identify the essential principles
of food hygiene applicable
throughout the food chain,
to achieve the goal of ensuring
that food is safe and suitable for
human consumption
April 2015 Prepared by : Rahul Gupta
Areas examined under GHP
1. Primary production2. Establishment: design and facilities3. Control of operation4. Establishment: maintenance and sanitation5. Establishment: personal hygiene6. Transportation7. Product information and consumer awareness8. Training
April 2015 Prepared by : Rahul Gupta
Primary production
Hygienic practices should reduce the likelihood of introducing hazards
that may be difficult or impossible to control at later stages
of the food chainExamples: pesticides, antibiotics, mycotoxins,
microorganisms in foods eaten raw or fresh
April 2015 Prepared by : Rahul Gupta
Establishment : design (1)
Premises, equipment, surfaces and facilities should be located,
designed and constructed to ensure:
mimimum contamination proper maintenance, cleaning,
disinfection protection against pests
April 2015 Prepared by : Rahul Gupta
Establishment: design (2)
Evaluation of the premises takes into account:
LocationEquipmentFacilities : water
• air• lighting• storage
April 2015 Prepared by : Rahul Gupta
Examples of hygienicequipment design
Good
Bad
April 2015 Prepared by : Rahul Gupta
Inaccessibility of equipment
clearancepumpmotor
condensate
CorrectHygiene risk
April 2015 Prepared by : Rahul Gupta
Establishment : practice “Good housekeeping” applies to the
surroundings and the roof of the establishment Pest control starts at the boundaries of the
premises Water management deals with incoming and
used water Windows are closed or screened Internal surfaces are smooth and easy to clean Floors have rounded corners Ceilings and ducts are accessible for cleaning
April 2005 Prepared by : Nidhi Bhayana
Establishment : practice ( cont. )
Dry zones are designed to remain dry Drains can be cleaned Cable trays carry cables, not dirt or dust Insectocuters are effective Only potable water is in contact with food Air handling systems deliver the required
air quality (and not contaminants) Doors are closed when not used
April 2015 Prepared by : Rahul Gupta
Control of operation Control of food hazards through HACCP Hygiene control: Time & temperature Humidity (Cross) contamination Microbiological specifications Incoming materials (incl. packaging materials) Water, air, steam Management, documentation, recall procedures
April 2015 Prepared by : Rahul Gupta
Control : practice
Keep potentially contaminated materials separated from uncontaminated ones
Assure effectiveness of treatments
Assure effectiveness of cleaning Assure reliability of measurements, tests and
recording
Perform hazard analysis when changes occur
Assure updating of HACCP plan
April 2015 Prepared by : Rahul Gupta
Establishment : personal hygiene
Health status Illness and injuries Personal cleanliness Personal behaviour
To prevent food from being contaminated by the people
who come in contact with it, personnel must receive clear instruction
on the following:
April 2015 Prepared by : Rahul Gupta
Product information and consumer awareness
Lot identificationProduct informationLabellingConsumer education
April 2015 Prepared by : Rahul Gupta
Training
Awareness and responsibilitiesTraining programmes Instruction and supervisionRefresher training
April 2015 Prepared by : Rahul Gupta
Trace & Recall
Track & control the movement of Food Products , from receipt of ingredients to end point of finished goods
Supplier Control
Evaluation & Approval of Suppliers , for Raw Materials , ingredients and services in order to minimize food product contamination
April 2015 Prepared by : Rahul Gupta
Customer complaints for Food Safety
Procedures for handling food safety complaint and forms for tracking the complaint from receipt through resolution
April 2015 Prepared by : Rahul Gupta
HACCP system
and its application
April 2015 Prepared by : Rahul Gupta
Codex HACCP principles
1. Conduct a hazard analysis2. Determine the CCPs3. Establish critical limit(s)4. Establish a monitoring system5. Establish corrective actions6. Establish verification procedures7. Establish documentation
April 2015 Prepared by : Rahul Gupta
How to do HACCP (1)
HACCP study
HACCP plan
Training the personnel
Implementation of the plan
Verifying and improving
April 2015 Prepared by : Rahul Gupta
How to do HACCP (2)
Commitment of management
Resources expertise, equipment, etc.
April 2015 Prepared by : Rahul Gupta
(1) Assemble HACCP team Obtain top management commitment
Appoint a leader and a secretary
Multidisciplinary team
Assure participation of experts in QA, microbiology, chemistry, food technology
Assure co-operation of other experts
Define scope of the study
Set priorities
April 2015 Prepared by : Rahul Gupta
(2) Describe product
Formulation and composition Raw materials & ingredients Parameters influencing safety
Processing Packaging Distribution
April 2015 Prepared by : Rahul Gupta
(3) Identify intended use
Food service establishmentsCaterersHospitalsGeneral populationSpecific groups of the populationPreparation practicesExportation
April 2015 Prepared by : Rahul Gupta
(4) Construct flow diagram
• Cover all steps which might have an influence on the safety of the product
Include important data such as time & temperature
Indicate hygiene level of areas and barriers
April 2015 Prepared by : Rahul Gupta
(5) On - site confirmation of flow diagram
Check correctness of information
Check whether important information was not overlooked
Check during all periods of operation and cleaning, but also during idle hours
Discuss practices with operators
April 2015 Prepared by : Rahul Gupta
(6) List all hazardsassociated with each step,conduct a Hazard Analysis,
consider any measuresto control identified hazards
April 2015 Prepared by : Rahul Gupta
Hazard Analysis
•List all hazards•Conduct the Hazard Analysis to identify for the HACCP Plan•To develop a suitable criteria to conduct the analysis – likely occurrence of hazard
April 2015 Prepared by : Rahul Gupta
When to perform a Hazard Analysis
during product development during industrialization of new product when new hazards emerge when new raw materials are used when formulation or use is changed when equipment is changed with new (layout of) production area
etc.
April 2015 Prepared by : Rahul Gupta
(7) Determine CCPs
• Critical Control Points (CCPs)• can be related to :
Raw materials, Locations, Processes, Procedures, Practices, Product formulations etc.
April 2015 Prepared by : Rahul Gupta
(8) Establish critical limitsfor each CCP
• Critical limits can be :
• Values of : pH, aw, temperature, time
• Maximum residue limits• Maximum levels (of contaminants)• Limits in microbiological criteria• Level of cleanliness• Levels of chlorine, overpressure etc.
April 2015 Prepared by : Rahul Gupta
(9) Establish a monitoring systemfor each CCP
the method or equipment to be used
the moment and / or frequency of checking
the interpretation of the results and the actions to be taken
April 2015 Prepared by : Rahul Gupta
Continuous monitoring
Critical Limit
time
N
Target level
Upper control level
Lower controllevel
April 2015 Prepared by : Rahul Gupta
“Loss of control”
time
N
deviation
corrective action
Critical Limit
Upper control level
April 2015 Prepared by : Rahul Gupta
Corrective actions
Actions to be taken when
the results of monitoring at the CCP
indicate a loss of control
April 2015 Prepared by : Rahul Gupta
Corrective actions
should readjust deviations before the situation is out of control
should prevent hazardous products reaching the consumer
should prevent recurrence of the event
April 2015 Prepared by : Rahul Gupta
(10) Establish corrective actions
Corrective actions should ensure
that only safe products
reach the consumer
April 2015 Prepared by : Rahul Gupta
(11) Establish verification procedures
• Verification procedures
are intended to check
the effectiveness
of the HACCP system
April 2015 Prepared by : Rahul Gupta
Verification
The application of
methods, procedures, tests
and other evaluations
in addition to monitoring,
to determine compliance with
the HACCP plan
April 2015 Prepared by : Rahul Gupta
(12) Establish record keepingand documentation
Minutes of HACCP study meetings, decisions made and their reasons
Records of monitoring Records of verification Records of deviations and corrective actions Records of modifications to the HACCP plan
April 2015 Prepared by : Rahul Gupta
Hazard Analysisand
Critical Control Point determination
April 2015 Prepared by : Rahul Gupta
Hazard AnalysisAssessment of risk
Risk = Likelihood * Consequences Frequent Very high Likely High Occasional Medium Unlikely Minor Improbable
April 2015 Prepared by : Rahul Gupta
Hazard Analysis-Assessment of risk
Process Step No. Process
Hazard Type
(B/P/C) Source Likelihood Consequence RiskLevel of Control
Control Measure
April 2015 Prepared by : Rahul Gupta
Hazard determination-Decision Tree
Do preventive control measures exist? Modify steps in the process or productNO
Is the step specifically designed to eliminate or reduce the likely occurrence of a hazard to an acceptable level ?
YES
YES
NO
Will a subsequent step eliminate identified hazards or reduce likely occurrence to acceptable levels?
Is control at this step necessary for safety ?
Questions to be answered for each potential hazard for each step
NO Not a CCPStop
YES
CCP
Could contamination with identified hazard occur in excess of acceptable levels or could these increase to unacceptable levels?
YES
YES
Not a CCP
Stop
NO
CCP
Stop
Not a CCP
NO
April 2015 Prepared by : Rahul Gupta
Questions for each CCPQuestions for each CCP and Hazard and Hazard (1)(1)
• When is deviation from normality unacceptable?
( i.e. establishment of Critical Limits )
April 2015 Prepared by : Rahul Gupta
Questions for each CCPQuestions for each CCP and hazard and hazard (2)(2)
• How can this be identified?How frequently should it be checked?
How should results be recorded?
( i.e. establishment of monitoring procedures )
April 2015 Prepared by : Rahul Gupta
• What is the appropriate reactionto deviations?
• ( i.e. description of corrective actions )
Questions for each CCP and hazard (3)
April 2015 Prepared by : Rahul Gupta
Documents & Records
April 2015 Prepared by : Rahul Gupta
WORKSHEETS May be considered as "formal records"
• USE and CONTENT of WORKSHEETS is mandatory• Complete records must be available of the information
and decision making process used by the HACCP team.• ACCESS to the WORKSHEETS is restricted
The Worksheets
April 2015 Prepared by : Rahul Gupta
Worksheets
• WS1: Management Review Sheet
• WS2: Product Descriptions
• WS3: Raw , Auxiliary , Packaging Material Sheets Flow Chart & Hazard Analysis Sheet
• WS4: Flow Chart & Hazard Analysis Sheet
• WS5: HACCP plan
• WS6:Verification Plan/Report
• WS7:Validation Plan/Report
• WS8:Internal Audit Report
• All CP & CCP Monitoring Reports
April 2015 Prepared by : Rahul Gupta
Worksheets• WS9: Meeting Activities – HACCP Team/Validation Team• WS10:Lay-outs – Personnel movt , product & material movt etc.The HACCP Manual should contain all requirements of the Dutch
Standard
April 2015 Prepared by : Rahul Gupta
Likelihood of Potential Hazards?
In this exercise, you will try to assess the likelihood that potential hazards will be present in the process of making beverage
EXERCISE A
April 2015 Prepared by : Rahul Gupta
Implementation of HACCP
April 2005 Prepared by : Nidhi Bhayana
Implement
• To carry into effect
April 2015 Prepared by : Rahul Gupta
Approve
• To give one' s consent to ,
sanction ,
confirm
April 2015 Prepared by : Rahul Gupta
HACCPHACCP
Continuous ImprovementContinuous Improvement
DefineDefine
HACCPPlan
ApproveApproveQMS,
Procedures
ImplementImplement
Safe products,Records
ReviewReview
Improvements
Study•List pot. hazards•Hazard Analysis•List significant haz. •CCP (& CPs)•Monitoring•Critical Limits•Corrective actions•Validation•List verification act.
Approval: (NOT VALIDATION)•Monitoring (Prerequisites)•Contr. meas. •Modifications •Corr. actions•VerificationVerif. mation
Implementation•Training•Awareness•Information•Prerequisites•Control Measures•Monitoring•Corrective actions•Recording
Verification•Confirm compliance (HACCP & Prerequis.)•Review the study•Review results•Review records•Review changes•Review of validation data•Gather Int. & Ext. Inf.
ChangeChange
April 2015 Prepared by : Rahul Gupta
Validation & verification
April 2015 Prepared by : Rahul Gupta
Validation
Obtaining evidence
that the elements
of the HACCP plan
are effectiveCodex 1996
The Answer to the Question – Are we doing the right things ?
April 2015 Prepared by : Rahul Gupta
Verification
The application of
methods, procedures, tests,
and other evaluations,
in addition to monitoring,
to determine compliance with
the HACCP plan
Codex 1997
The answer to the question – Are we doing things right ?
April 2015 Prepared by : Rahul Gupta
Verification
•This is primarily the responsibilityof the industry, however some verification
activities can be undertakenduring regulatory assessments
FAO/WHO consultation June 1998
Conformity
•Activities are carried out
according to the established procedures
e.g. the HACCP plan and prerequisites
FAO/WHO consultation June 1998
Compliance
The HACCP plan and prerequisites,
and their implementation,
meet regulatory requirements
FAO/WHO consultation June 1998
Verification data sheet
• What
• Product• test for• coliforms
• Monitoring• trends
Why
Past. &Recont.Control
Improve-ments
Who
Lab.
QA Man.
When
End ofeachbatch
End ofmonth
How
Lab.Instruct-ions
Graphs
HACCP Plan
CCP No. Process StepCritical Limit Action Limit Target Limit
What When How Where Who
Preventive Action Responsibility Correction
Corrective Action Responsibility Verification Responsibility Validation Responsibility
Monitoring
Questions to be asked in verification before approval
Is there evidence that :
1. hazards have been correctly identified ?
2. control measures eliminate or reduce significant hazards to acceptable levels ?
3. corrective actions restore control ?
4. deviating products will not reach the consumer ?
Audit
• A systematic and functionally independent
examination to determine whether
activities and related resultscomply with planned objectives
• Codex 1997
AuditShould ideally be carried out by a
multidisciplinary team of experts
Should validate and review all decisions taken during HACCP study and during HACCP plan implementation
Should, if necessary, recommend improvements in order to satisfy internal or external needs
BY: RAHUL GUPTA
Thank You