Hazard analysis & critical control point by dr vikram gupta

HHazard azard AAnalysis & nalysis &

CCritical ritical CControl ontrol

PPointoint

Dr. Vikram GuptaAssistant Professor,

Department of Community Medicine,Dayanand Medical College & Hospital,

[email protected]

HACCP ?

H = Hazard

A = Analysis

C = Critical

C = Control

P = Point

HACCPHACCP: : A systematic A systematic approach to the approach to the identification, identification, evaluation, and evaluation, and control of food control of food safety hazards.safety hazards.

DefinitionsDefinitions

DefinitionsDefinitions

HHazard azard AAnalysisnalysis: :

The process of The process of collecting and collecting and evaluating information evaluating information on hazards associated on hazards associated with the food under with the food under consideration to consideration to decide which are decide which are significant and must significant and must be addressed in the be addressed in the HACCP plan.HACCP plan.

CCritical ritical CControl ontrol PPoint:oint: A step at which A step at which control can be control can be applied and is applied and is essential to prevent essential to prevent or eliminate a food or eliminate a food safety hazard or safety hazard or reduce it to an reduce it to an acceptable level.acceptable level.

DefinitionsDefinitions

HACCP It is a systematic preventive approach

to food safety and pharmaceutical safety that addresses physical, chemical, and biological hazards as a means of prevention rather than finished product inspection.

HACCP is used in the food industry to identify potential food safety hazards, so that key actions, known as Critical Control Points (CCPs) can be taken to reduce or eliminate the risk of the hazards being realized.

HISTORY

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19591959

Method Development

1.Sampling for Pathogenic microorganisms.

2. The Zero Defect Concept

3. Modes of Failure

3 3 PrinciplesPrinciples

1. Identification and assessment of hazards associated from growing to consumption

2. Determination of the critical control points to control any identified hazards

3.Establishmend of systems to monitor the critical control points

19711971

19721972 Outbreak of botulismOutbreak of botulism!!!!!!

Canned Potato Soup Botulism

FDA promoted regulation of canned foods

FDA inspectors were trained for HACCP

19881988: : 4th volume “HACCP in Food

Safety and Quality”

19891989: HACCP Principles for Food Production

1991:1991:Guidelines for the Application

of the HACCP System

19921992 : “Hazard Analysis and Critical Control Point System”-- NACMCF

Feb,1995Feb,1995

“There is wide agreement that ensuring food safety requires taking steps throughout the continuum of production, slaughter, processing, distribution, and sale of livestock and poultry carcasses and meat and poultry products to prevent hazards and reduce the risk of food-borne illness.

HACCP

Its introduction signaled a shift in emphasis from end product testing to preventive control at all stages of food production.

NEED For HACCP The establishment of the W TO paved the way

for several multilateral agreements on trade which include agreements on the Application of Sanitary and Phytosanitary (SPS) measures and on Technical Barriers to Trade (TBT).

These agreements encouraged countries to adopt international standards.

Within the context of the TBT agreement, the Codex Alimentarius Commission (165 member countries) has been recognized as an international standardizing body.

It has recommended a Hazard Analysis Critical Control Point (HACCP) based approach as a means to enhance food safety

HACCP PLAN

Assemble the HACCP Team

Preliminary Steps:Preliminary Steps:Developing a HACCP Plan

Assemble the HACCP Team

PreliminaryPreliminary

Steps:Steps:

Developing a HACCP Plan

Describe the Food

Assemble the HACCP Team

PreliminaryPreliminary

Steps:Steps:

Developing a HACCP Plan

Describe the Food

Describe the Food and its Distribution

Assemble the HACCP Team

PreliminaryPreliminary

Steps:Steps:

Developing a HACCP Plan

Describe the Food

Describe the Food and its Distribution

Describe the Intended Use andConsumers of the Food

Assemble the HACCP Team

PreliminaryPreliminary

Steps:Steps:

Developing a HACCP Plan

Describe the Food

Describe the Food and its Distribution

Describe the Intended Use andConsumers of the Food

Develop a Flow Diagram WhichDescribes the Process

Verify the Flow Diagram

Developing a HACCP Plan

PreliminaryPreliminary

Steps:Steps:

7 HACCP Principles

7 7 HACCPHACCP PrinciplesPrinciples

1.Conduct a hazard analysisIdentify hazards

1.Conduct a hazard analysisIdentify hazards 2.Determine the critical control points(CCP) in the food preparation.

1.Conduct a hazard analysisIdentify hazards2.Determine the critical control points(CCP) in the food preparation.3.Establish critical limits for preventive measures.

1.Conduct a hazard analysisIdentify hazards 2.Determine the critical control points(CCP) in the food preparation.3.Establish critical limits for preventive measures.

4.Establish procedures to

monitor CCP’s

5.Establish corrective action to be taken when monitoring shows that a critical limit has been exceeded.

5.Establish corrective action to be taken when monitoring shows that a critical limit has been exceeded.

6.Written HACCP Plan

5.Establish corrective action to be taken when monitoring shows that a critical limit has been exceeded.

6.Written HACCP Plan

7.Establish procedures to verify that the HACCP plan is working.

5.Establish corrective action to be taken when monitoring shows that a critical limit has been exceeded.

6.Written HACCP Plan

7.Establish procedures to verify that the HACCP plan is working.

1.Conduct a hazard analysisIdentify hazards

2.Determine the critical control points(CCP) in the food preparation.

3.Establish critical limits for preventive measures.

4.Establish procedures to monitor CCP’s

Validation

Who validates the HACCP plan? HACCP team Individual qualified by training or

experienceWhat does validation involve?

A scientific and technical review of the rationale behind each part of the HACCP plan from hazard analysis through each CCP verification strategy

Validation Frequency Initially When factors warrant, e.g.,

Changes in raw materials Changes in product or process Adverse review findings Recurring deviations New information on hazards or control

measures On-line observations New distribution or consumer handling

practices

Examples of Validation Activities: Cooked hamburgers

Collect data to establish that critical limits for maximum patty thickness, maximum belt speed, and minimum oven temperature will ensure that the internal temperature of every patty reaches the minimum requirement

Verification of CCPs

Calibration Calibration record review Targeted sampling and testing CCP record review

Examples of Calibration Activities A MIG thermometer used to monitor

temperature at a cook CCP may be checked for accuracy by comparing it against a certified thermometer in a hot-water bath

The continuous temperature chart recorder on a pasteurizer may be compared during each batch against a certified accurate thermometer

A pH meter is calibrated against pH buffer standards of 7.0 and 4.0 when it is used to test products with a final pH of 3.8 to 4.2

HACCP System Verification Frequency

AnnuallyOccurrence of a system failure or significant change in product or process

HACCP Plan Form: Verification

1.CCP

2.Hazard

3.CriticalLimits

What How Frequency Who

Monitoring

4. 5. 6. 9.Verification

8.Correctiv

eAction(s)

10.Record

s

7.

The HACCP Approach

The idea is to develop a plan that anticipates and identifies places in the production process –known as critical control points (CCP’s) where contaminants might be introduced or other food safety concerns can be identified

When critical limits are exceeded, corrective action must be taken and documented

An independent third party should be used to verify or validate the effectiveness of a HACCP plan

Why Implement a Food SafetyProgram using HACCP Principles?

To ensure that the food served to children is as safe as possible

HACCP is a food safety system that helps identify foods and procedures that are most likely to cause foodborne illness

Consequences of a foodborneoutbreak…

Medical/legal claims Lost wages Cleaning and sanitizing costs Food loss-costs associated Bad publicity Embarrassment-loss of reputation Child Nutrition Program closes = hungry

children

Causes of foodborne illness:

NO COOK PROCESS

Food passes through the temperature danger zone only once before it is served….. (Cooking or Cooling)

Food passes through the danger zone more than one time…..

Application of HACCP methodology to pharmaceuticals

The present guidelines are aimed at assisting industry to develop and implement effective HACCP plans covering activities such as research and development, sourcing of materials, manufacturing, packaging, testing and distribution.

In the manufacture of pharmaceuticals, these may include the manufacture of certain antibiotics, hormones, cytotoxic substances or other highly active pharmaceuticals, together with operations such as fluidbed drying, granulation is an example of hazard unit operations. The use of inflammable solvents (solutions) and certain laboratory operations may also constitute hazards.

HACCP Study- weaning foods Hazard analysis and critical control points of weaning

foods Mini Sheth, Jigisha Patel, Shikha Sharma and 

Subadra Seshadri in Indian J of Paediatrics. Hazards and critical control points were identified

during the preparation, feeding and storage of weaning foods fed to the children (6–24 months) belonging to low income group (LIG) families using survey methods, spot and indepth observations and microbial analysis.

High microbial counts were obtained for the weaning food samples procured from the families that were rated as poor for both personal hygiene and environmental sanitation

Food samples that were held at ambient temperature (25–35°C) showed high counts of coliforms, yeast and Staphylococcus aureus and Bacillus cereus.

Spice mixtures and mop samples also revealed high counts for all these organisms.

The hazards and critical control points identified were high initial contamination of raw foods, poor environmental sanitation and personal hygiene, feeding of overmight moist foods stored at ambient temperature and insufficient steaming of these foods.

HACCP Training in India

3 -5 day training Course fee is around Rs 10,000 Mumbai, Thiruvananthapuram

ICMR STUDY

The major reported microbial hazards from mushrooms are Clostridium, Salmonella, Bacillus and Coliforms.

The food handlers who grade the fresh mushrooms were carrying Coliforms and were introducing the Coliforms into fresh mushrooms.

Critical Control Point for fresh mushrooms had been identified as the food handler’s personal hygiene and they were informed about the importance of personal hygiene.

In khoa it was the airtight packaging that was responsible for microbial proliferation while the food handlers were responsible in introducing Coliforms in mushroom and paneer.

Simple and economical solutions like muslin cloth packing for khoa and thorough hand washing by food handlers before touching the paneer or mushrooms had totally eliminated the problem of microbial contamination.

HACCP application (USA)

Fish and fishery products  Fresh-cut produces  Juice and nectary products  Food outlets  Meat and poultry products  School food and services 

Food Regulation in India and HACCP In India, quality control with regard to food products is

being enforced through various regulatory mechanisms like the

Prevention of Food Adulteration Act (PFA), Agriculture Grading and Marketing (AGMARK), Fruit Products Order (FPO), etc. The Bureau of Indian Standards (BIS) has recently

launched a HACCP certification programme for the food industry.

The Mother Dairy of Delhi and the Punjab Cooperative Milk Federation have received HACCP certificates.

The Agriculture and Processed Food Export Development Agency (APEDA) has helped mango processing units in Andhra Pradesh in HACCP.

HCCP Application to Animal Production“ The voluntary application of HACCP principles can be useful in establishing the CCPs within the farm management and live animal transportation arenas where pathogenic organisms can enter the food chain” ----USDA/FSIS

THANX…………….