HACCP

corrective action as '

'Procedures to be followed when a deviationoccurs

1.1.9.2 Sanitation

'all precautions and measures, which are necessary in the production, processing, storage and distribution, in order to assure an unobjectionable, sound and palatable product which is fit for human consumption'

417.7 Training.

(a) Only an individual who has met the requirements of paragraph (b) of this section, but who need not be an employee of the establishment, shall be permitted to perform the following functions: (1) Development of the HACCP plan, in accordance with § 417.2(b) of this part, which could include adapting a generic model that is appropriate for the specific product; and (2) Reassessment and modification of the HACCP plan, in accordance with § 417.3 of this part. (b) The individual performing the functions listed in paragraph (a) of this section shall have successfully completed a course of instruction in the application of the seven HACCP principles to meat or poultry product processing, including a segment on the development of a HACCP plan for a specific product and on record review.

Bacterial populations killed by heat or chemicals tend to die at constant rates - for example % / Minutes

, 90% every 10 minutes

Principle 3 Establish critical limit(s) for preventive measures associated with each identifiedCCP

,a critical limit or the amount of acceptable deviation has to be established

After these five preliminary tasks have been completed, the seven principles of HACCP are applied

-List all potential hazards associated with each step, -conduct a hazard analysis and consider any measures to control identified hazards (see Principle 1) -Determine CCPs (see Principle 2) -Establish critical limits for each CCP (see Principle 3) -Establish a monitoring system for each CCP (see Principle 4) -Establish corrective actions (see Principle 5) -Establish verification procedures (see Principle 6) -Establish documentation and record keeping (see Principle 7)

Six conditions are required for bacterial growth.

-They need a nutrient, a mildly acid environment (pH = 4.6-7.0), -a temperature between 5 and 60◦C, -time (approximately 4 hours, -different oxygen requiring environments (aerobic, anaerobic and facultative microorganisms), -enough moisture (water activity >85 for disease-causing bacteria to grow.-

Microbialcellshaveagrowthcycle of five phases

-lag phase (adaptation period), -logarithmic growth phases (bacteria multiplication), -stationary growth phase (slowdown of growth), -accelerated death phase (rapid death of microbial cells) and -reduced death phase

The following are examples of control measures for physical hazards:

1. Specifications for raw materials and ingredients and vendor certification that unacceptable physical hazards or levels are not present. 2. Use of magnets, metal detectors, sifter screens, destoners, clarifiers and air tumblers. 3. Ensuring that GMPs are followed and that no physical contamination occurs to the food through the building facilities, work surfaces or equipment

1.1.7.2 Describe product

1. What is the common name of the product? 2. How is the product to be used? 3. What type of packaging encloses the product? 4. shelf life of the product, at what temperature? 5. Where will the product be sold? *Who is the intended consumer and what is the intended use? (*Regulatory requirement) 6. What labeling instructions are needed? 7. Is special distribution control needed? (USDA, 1999).

The basic characteristics of the ideal chemical agent are:

1. capacity to kill all microbes 2. soluble in water 3. stable on standing 4. not lose activity over time 5. non-toxic to humans and animals 6. low persistence/OM binding

Some common points where control can be applied in a process include

1. chilling to temperatures that minimise microbial growth 2. testing ingredients for chemical residues 3. cooking to specific temperatures for exact times in order to destroy microbial pathogens 4. product formulation control, such as the addition of cultures or adjustment of pH or water activity 5. testing product for metal contaminants 6. processing procedures such as filling and sealing cans 7. slaughter procedures such as evisceration or antimicrobial interventions

most important steps in food production to monitor are:

1. cooking 2. cooling 3. reheating 4. hot holding

Viral hazards

1. cooking processes (heating, cooking, steaming, frying, baking) which may destroy viruses

three basic requirements for developing monitoring procedures for the HACCP plan are:

1. defining the monitoring procedure 2. determining the frequency for monitoring 3. determining who will do the monitoring

Parasite hazards

1. dietary control 2. inactivation (heating, drying, freezing) 3. visual examination for parasites

Basic verification procedures include the following:

1. initiation of appropriate verification inspection schedules 2. review of HACCP plan for completeness 3. confirmation of the accuracy of flow diagram 4. review of CCP records 5. review of records for deviations and corrective actions 6. review of critical limits to verify if they are adequate to control significant hazards 7. validation of the HACCP plan,including on-site review 8. review of the modifications made to the HACCP plan 9. a random sample collection and analysis 10. visual inspection of food production operations to determine that CCPs are under control 11. a review of departures from critical limits and how they were corrected

forms are representative of those needed for monitoring the HACCP system in most food plants:

1. raw material evaluation sheet 2. supplier's guarantee 3. cooker log 4. pack room inspection report 5. cooking process validation letter 6. cooking equipment validation letter 7. equipment calibration log 8. corrective action report 9. employee training report

The HACCP will incorporate documents such as the following:

1. the HACCP plan 2. hazard analysis 3. CCP determinations 4. CCP monitoring sheets 5. corrective actions 6. audit records 7. HACCP team meeting minutes 8. calibration records

Bacterial hazards Control measures taken to prevent biological hazards are:

1. time/temperature control (refrigeration, storage time) 2. heating and cooking processes to eliminate or reduce micro-organisms 3. cooling and freezing 4. fermentation and/or pH control 5. addition of salt or other preservatives which may inhibit micro-organism growth 6. drying which may use heat to kill or remove micro-organisms 7. source control (examination of raw materials and ingredients from suppliers).

The purpose of corrective actions is:

1. to adjust the process, such as cooking temperatures or cooling rates to maintain control or prevent a deviation 2. to correct the cause of the deviation 3. to re-establish control over the process and CCP 4. to determine the safety and proper disposition of the food being produced while a defect was occurring 5. to maintain records of corrective actions The corrective action will consist of the decision regarding disposal of non-complying material, correcting the cause of deviation, demonstrating that CCP is once again in control, and, finally, maintaining records of the corrective action

Some of the measures you can use to prevent chemical hazards are:

1. use only approved chemicals 2. have detailed product specifications for chemicals entering the plant 3. maintain letters of guarantee from suppliers 4. inspect trucks used to ship final product 5. proper labeling and storage of chemicals 6. proper training of employees who handle chemicals

Staff should have an understanding of:

1. what hazards are and their importance in food safety 2. CCPs and their role in the assurance of product safety 3. critical limits which should be met 4. corrective actions and responsibilities 5. record-keeping requirements 6. the objective of verification procedures

1.1.7.4 Construct flow diagram

A correct flow diagram that identifies all the steps involved in the process should be drawn. consideration should be given to steps preceding and following the specified operation.

The Canadian Food Inspection Agency (CFIA) defines three classes of physical hazards depending on their likelihood and the severity of the consequences:

Category I (high likelihood) Category II (moderate likelihood) Category III (low risk

7 Principles

Conduct Hazard Analysis Determine CCP Establish Critical Limits Establish Monitoring Procedures Establish Corrective Actions Establish Verification Procedures Establish Record keeping & Documentation procedures

procedures:to fix or correct the cause of the deviation to ensure that the CCP is brought under control, there is appropriate disposition of any food produced during a deviation, records are made of the corrective actions taken. Out-of-control situations should be used to identify opportunities for improvement of the process to prevent future occurrences99*

Corrective Actions

Filtration can act as a consistent and effective barrier for

Cryptosporidium oocysts by direct filtration when chlorine is used as the sole disinfectant

Principle 4

Establish CCP monitoring requirements and procedures for using monitoring results to adjust processes and maintain control

____has by regulation required SEAFOOD and JUICE processors to implement the HACCP approach to preventive controls.

FDA

___________________ ____________is completed by listing all significant hazards associated to each step, and all control measures that can eliminate or control these hazards to an acceptable level

Hazard analysis

is the most common method of killing spoilage and pathogenic bacteria in foods

Heat

FSM

Identifies evaluates and controls hazards which are significant for food safety

Principle2

Identify the critical control points(CCPs) in the process.

is a favoured disinfecting or sterilising agent because it is non-corrosive, economical, has excellent penetration powers, leaves no residue and is active against the majority of microorganisms

Moist heat

Meat Processing Labeling Reqs

Name of product Ingredient Statement ID of MFG Weight Inspection Legend Nutrition Label Safe Handling Instructions Marketing claims must be justified

common problems reported when reviewing HACCP plans:

Only some of the principles are applied (mainly failure to apply Principles 4 and 5). the principles have not been applied appropriately(not identifying hazards properly). The HACCP plan is a 'paper exercise' and is not implemented in practice. The HACCP plan is over-complicated. Critical limits that are not adequate and not supported by scientific studies. Corrective actions do not address the product involved in a deviation. Lack of coordination among responsible authorities, public and private sectors. Lack of understanding and staff training. Lack of commitment by management. Regulations and procedures that are not efficient. Insufficient education and motivation of consumers and food handlers on food protection task

Pre-requisite programs:

Pest Managment GMP SSOP

PCHF

Preventive Controls Human Food

HACCP Principle 1

Principle 1 Conduct a hazard analysis.

HACCP Plan Verification Major 3 points

Review of monitoring Record Checking the Checker Verification of Instrument Accuracy

Food Safety Management

Safe to eat and free from contaminates

1.1.9.1 Training of personnel

Specific training activities should include working instructions and procedures that outline the tasks of employees monitoring each CCP. Management should provide adequate time for thorough education and training. Personnel should be given the materials and equipment necessary to perform these tasks

(NACMCF)

The National Advisory Committee on Microbiological Criteria for Foods

______________________ has also mandated HACCP for meat and poultry processors

The U.S. Department of Agriculture (USDA)

mycotoxins

___________ come from molds Can cause symptoms such as acute nausea, headaches, and chronic liver cancer.

Foodborne infections are caused when

a person eats food containing pathogens, which then grow in the intestines and cause illness. typically, symptoms do not appear for 1-3 days

hazard analysis.

a) ID any hazardous bio, chem or phys property in materials. b)assessment of likely occurrence c) potential for causing food to be unsafe d)review origins of possible hazards e) severity of health consequences

zoonotic

able to move through the animal-human barrier; transmissible from animals to humans

Principle 7 Establish documentation concerning

all procedures and records appropriate to these principles and their application.

Verification is the

application of methods, procedures, tests and other evaluations, in addition to monitoring to determine compliance with the HACCP plan

food safety hazard

as 'Any biological, chemical or physical property that may cause a food to be unsafe for human consumption'

the critical limit for frozen raw poultry storage and shipping would require the product be held

below 5◦C, 41F which does not constitute frozen but prevents bacterial growth

Gram-positive bacteria are more susceptible to

chemical disinfectants

mycobacteria or bacterial endospores are more resistant.

chemical disinfectants

1.1.7.6 On-site verification of flow diagram

confirm the processing operation against the flow diagram during all stages and hours of operation

Examples of biological hazards are

disease causing bacteria, viruses, parasites, moulds, yeasts and naturally occurring toxins

The first step in training is usually motivation

explainingthateverybodycouldbeavitallinkinachain of events leading either to food poisoning or to product safety.

A deviation is a

failure to meet a critical limit

HACCP was based on the engineering concept of

failure, mode and effect analysis (FMEA), which looks at what could potentially go wrong at each stage in an operation and puts effective control mechanisms into place

1.1.7.5 On-site confirmation of flow diagram

includes exceptional items such as breakdowns, rework and cleaning. shift pattern involve relevant personnel

1.1.7.2 Describe product

information about the ingredients, processing methods, retail, packaging and storage conditions should aim at identifying any possible hazards occurring to the product and that which the product may cause

1.1.7.3 Identify intended use

information on whether the product has to be prepared prior to consumption, e.g. by heating or whether it can be consumed directly. With regard to a possible acceptable risk level for a food safety hazard it has to be stated for which group of the population the food is intended The intended consumers may be the general public or a particular segment of the population (e.g. infants, immunocompromised individuals, the elderly etc.)

Food Safety

is a scientific discipline describing handling, preparation, and storage of food in ways that prevent foodborne illness. This includes a number of routines that should be followed to avoid potentially severe health hazards

Lactic acid, acetic acid and citric acid also are

lethal to many microorganisms

Source of Pathogens

low quality of raw materials poor personal hygiene environment (air, water and equipment) inadequate cooking improper storage/holding temperature improper reheating cross-contamination-impropersegregationofrawand cooked foods past use - by time

the validation of a CCP means .

making sure the control measure will achieve its objective in terms of acceptable level of food safety

Principle 5 Establish corrective actions to be taken when

monitoring indicates that a particular CCP is not under control.

1. Assemble the HACCP team,

must include is an individual who has been trained in HACCP

The responsibilities of the HACCP team are:

organising and documenting HACCP study reviewing deviation from critical limits internal auditing of HACCP plans communicating, educating and training employees in the operation of HACCP system understanding the stages of the process the team will be monitoring

1.1.9 Prerequisite programmes e

personal hygiene, GMP, supplier quality assurance and maintenance schedules

aflatoxins

poisons produced by some fungi; cause liver cancer a naturally occurring food contaminant produced by some strains of aspergillus molds; found on peanuts and peanut products

rweakacids(e.g.benzoicacid, sorbic acid, sulphur dioxide etc.) are used as

preservatives

followed by alkaline and acid washing (to remove.

proteins, carbohydrates, lipids and minerals, respectively)This dirt usually contains micro-organisms and nutrients that allow the microbes to grow

Validation should answer whether the CCP can consistently

reduce the hazard to an acceptable level.

The first step of sanitisation is the pre-wash, with the objective of

removing gross dirt,

Critical limits are set for product

safety and not product quality.

CCP

steps at which control can be applied and a food safety hazard can be prevented, eliminated or reduced to acceptable levels

issues to consider when deciding the frequency of non-continuous monitoring checks; should be performed sufficiently often to accurately reflect

that the process is under control

Principle 6 Establish procedures for verification to confirm that .

the HACCP system is working effectively

The first step of sanitisation is

the pre-wash, with the objective of removing gross dirt,

Critical limits for CCPs are expressed as numbers or specific parameters on visual observation, such as

time/temperature, humidity, water activity, pH, salt concentration and chlorine level