The HACCP-system

THE HACCP-SYSTEMHazard Analysis Critical Control Point System

A Summary

What is HACCP?

„A holistic approach to food safety management programs, incorporating best practice facility and equipment

design, as well as structured management systems“

HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace

Where did HACCP come from?

Developed as a microbiological safety system

Pioneered by Pillsbury Company, NASA and US Army Laboratories

Based on Failure Mode and Effect Analysis (FMEA)

Why use HACCP?

Product safety cannot be tested in Proven system to manage food safety Foodborne diseases are a public health problem

Increase in susceptible population (elderly, immune-compromised, malnourished)

Changing lifestyles (eating-out, processed food, tourism)

Emerging pathogens Increase in complexity of supply chain Improved laboratory testing schemes

7 Principles of HACCP1. Conduct a hazard analysis2. Determine the Critical Control Points (CCPs)3. Establish Critical Limits4. Establish a system to monitor control of the CCP5. Establish the corrective actions to be taken

when monitoring indicates that a particular CCP is not under control

6. Establish procedures for verification to confirm that HACCP is working correctly

7. Establish documentation concerning all procedures and records appropriate to these principles and their application

According to: Codex Alimentarius Commission and NACMCF

Applicability of HACCP within Supply Chain

Primary ProducersLand Crops

Animal Feeds

Primary Producers

Sea Food

Primary ProducersMeat, Dairy, Poultry, Eggs

Human Processing

Wholesalers

FoodserviceCaterers

Consumers

Retailers

Adapted from: HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace

Governmental Regulation of HACCP HACCP is not governed by

international legislation Each country has own food safety

regulation which may include HACCP European Union, 1st of January 2006:

Regulation (EC) No. 852/2004 on the Hygiene of Foodstuffs, Article 5

International Standardisation

Codex 2009b: Primary international reference standard for HACCP ISO 22000 (2005): Certification standard for HACCP (based on Codex 2009b)

HACCP Success Structure

Adapted from: HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace

External Pressure

Resource Availability

Education and Training

Management Commitment

Key Stages in HACCP Development

Planning & Preparation HACCP studies & HACCP plan

development Implementation of HACCP plan Maintenance of HACCP system

HACCP System Structure Linear HACCP plans

Applicable to each product or process individually

For simple operations with few product types Modular HACCP plans

Flexible approach Applicable to basic operations or modules

Generic HACCP plans Based on framework approach For simple operations

HACCP & Continuous Improvement

VerificationMonitoring and

Corrective/Preventive Actions

Implementation

Improvement

Planning and Realisation of Safe Products

Hazard Analysis

HACCP Plan Development

Establishing PRPs

Adapted from: HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace

PRPs – Prerequisite Programmes „Universal steps or procedures that control the

operational conditions within a food establishment allowing for environmental conditions that are favourable for the production of safe food“ (CFIA, 1998)

„Procedures including good manufacturing practices that address operational conditions providing the foundation for the HACCP system“ (NACMCF, 1997)

„Practices and conditions needed prior to and during the implementation of HACCP and which are essential for food safety“ (WHO, 1998)

Hazards – Significance & Control

A biological, chemical or physical agent in, or condition of, food with the potential to cause an adverse health effect (Codex, 2009b)

Significant hazard „Hazards that are of such a nature that their

elimination or reduction to an acceptable level is essential to the production of safe foods“ (ILSI, 1999)

Control measures „Any actin or activity that can be used to prevent or

eliminate a food safety hazard or reduce it to acceptable level“ (Codex 2009b)

Hazard... Any factor present in the product that causes illness or harm to the customer. The basis for every HACCP system

Biological Hazards

Macro-biological Insects

Micro-biological Direct: invasion of humans Indirect: via toxins

Biological Hazards - Bacteria Pathogenic Gram-negative bacteria

Salmonella enterica Escherichia coli Campylobacter jejuni Vibrio parahaemolyticus Vibrio vulnificus Shigella spp. Yersinia enterocolitica Cronobacter sakazakii

Habitat: animal intestines Control: heat processing, segregation of raw

and cooked foodstuffs, good hygienic practices

Biological Hazards - Bacteria

Pathogenic Gram-positive bacteria Clostridium botulinum Clostridium perfringens Bacillus cereus Staphylococcus aureus Listeria monocytogenes

Biological Hazards - Viruses

Hepatitis A and Norovirus Source: Shellfish Very small and thus difficult to

detect But easily to be inactivated by

heat

Biological Hazards – Parasites & Protozoa Pathogenic flatworms, tapeworms, flukes

Taenia saginata Trichinella spiralis Clonorchis sinensis

Source: infected flesh (pork, beef, fish, game) Prevention: good animal husbandry,

veterinary inspection, heating, freezing, drying Encysted larvae:

Toxoplamsa gondii Giardia intestinalis Cyclospora cayetanensis Cryptosporidium parvum

Biological Hazards - Prions Transmissible agents Misfolded cellular proteins Initiation of abnormal folding of normal

protein in brain Formation of plaques Destruction of brain cells BSE (Bovine Spongiform Encephalopathy) Scrapie (Sheep disease) Creutzfeldt-Jakob Disease (Human)

Emerging Pathogens Listeria monocytogenes Escherichia coli O157:H7 Cronobacter spp. Prions Expected: Continued emergence of new foodborne microbial

pathogens Drivers:

Changes in land use or agricultural practices Changes in human demographics and society Poor population health Hospitals & medical procedures Pathogen evolution (antibiotics) Contamination of food sources or water supplies International travel Failure of public health programmes Climate change

Control of biological Hazards Intrinsic factors

pH and acidity Organic acids Preservatives Water activity Ingredients

Process Technologies Thermal processes Fermentation Drying Freezing Irradiation

Chemical Hazards

Not well understood – lack of toxicological expertise

Contamination can happen at any stage

Chronic (carcinogenic) or acute (allergenic reaction) effects for customer

Chemical Hazards - Mycotoxins Secondary metabolites of certain fungi Long-term carcinogenic effect or short-term acute

toxic effects Affected food: cereals, nuts, dried fruit, coffee,

cocoa, spices, beans, fruit, etc. Very stable

Aflatoxins Aspergillus flavus

Patulin Penicillium spp.

Deoxynivalenol Fusarium spp.

Fumonisins Fusarium spp.

Chemical Hazards – Cleaning Chemicals

Most common potential contaminant

Use of non-toxic and food-grade chemicals

PRP: Design & management of cleaning procedures

Chemical Hazards - Pesticides Insecticides Herbicides Fungicides Wood preservatives Masonry biocides Bird & animal repellents Food storage protectors Rodenticides Anti-fouling paints Industrial/domestic hygiene products

Consider cross-contamination at any stage

Allergens & Food Intolerances Immune mediated Non-immune mediated (majority) Allergens:

Peanuts, tree nuts, eggs, milk products, shellfish, fish, soya, wheat (Big 8 allergens)

Lactose intolerance: 70% of population are lactase deficient

HACCP must consider cross-contamination PRP: general control of allergens

Chemical Hazards Toxic/heavy metals Nitrites, nitrates, N-nitroso compounds Polychlorinated Biphenyls Dioxins and Furans Polycyclic aromatic hydrocarbons Plasticizers & packaging migration Veterinary residues Melamine & cyanuric acid Chemical additives

Physical Hazards

Can enter at any stage

Glass Metal Stones Wood Plastic Pests Intrinsic material (bones in meat/fish, nut

shells)

Hazard Significance

Risk Evaluation CategoriesLikelihood of Occurrence

High Highly probable. Known history in the sector.

Medium Could occur. Minimal history within the sector –but has happened.

Low Unlikely to occur. No known examples

Hazard Severity

High Life threatening or long-term chronic illness

Medium Injury or intolerance. Not usually life threatening

Low Minor effect. Short duration

Adapted from: HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace

Hazard Significance

Adapted from: HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace

Significant Hazard

Severi

ty

High

Medium

Low

HighMediumLow

Likelihood of Occurrence

PRPs – HACCP Support Network

Adapted from: HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace

HACCP

Good Manufacturin

g Practice Statistical Process Control

Supplier Quality

Assurance

Preventative Maintenance

Education and

TrainingQuality

Management Systems

Incident Managemen

t

Sanitary Design

and Sanitation

Good Laboratory Practice

Good Distributi

on Practice

PRPs – the Foundation of HACCP

HACCP

PRPs

Focus on: raw materials, product and processes

Focus on: Production

environment, facility, programs

and people

Adapted from: HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace

The HACCP Plan

“A document prepared in accordance with the principles of HACCP to ensure control of hazards that are significant for food safety in the segment of the food chain under consideration” (Codex, 2009b)

A formal document Pulls together key information from

HACCP study Details of all that is critical to food safety Developed by HACCP team

Logic Sequence for HACCP Application

Step Action

Step 1 Assemble HACCP team

Step 2 Describe product

Step 3 Identify intended use

Step 4 Construct Flow Diagram

Step 5 On-site confirmation of Flow Diagram

Step 6 List all potential hazards, conduct hazard analysis, and consider control measures

Step 7 Determine critical control points (CCPs)

Step 8 Establish critical limits for each CCP

Step 9 Establish a monitoring system for each CCP

Step 10 Establish corrective actions

Step 11 Establish verification procedures

Step 12 Establish documentation and record keeping

References - Book

HACCP - A Practical Approach, 3rd EditionSara Mortimore and Carol Wallace,

Springer 2013 (ISBN: 978-1-4614-5027-6)

http://www.springer.com/food+science/book/978-1-4614-5027-6

References – Websites

Codex Alimentarius http://www.codexalimentarius.org/

National Advisory Committee on Microbiological Criteria for Foods (NACMCF)

http://www.fsis.usda.gov/about/NACMCF/index.asp World Health Organisation (WHO)

http://www.who.int/topics/food_safety/en/ EU legislation http://europa.eu/legislation_summaries/food_saf

ety/veterinary_checks_and_food_hygiene/f84001_en.htm