Module 5- HACCP

MODULE 5: HAZARD ANALYSIS CRITICAL CONTROL POINT (HACCP)

Overview

  • HACCP is a management system designed to prevent problems in food production to ensure the safety of food products.

  • It operates on seven (7) principles applicable to all phases of food production.

  • The aim is to assure that food products are safe for consumption and provide proof of safety.

  • The system covers all potential food safety hazards.

Development and Historical Context

Origins of HACCP

  • HACCP was developed by Pillsbury Company, the US Army Natick Laboratory, and NASA to meet food safety requirements for space foods used in manned space flights.

  • Key safety issues:

    • Control of food particles (crumbs and water) in zero gravity.

    • Minimization of pathogens and biological toxins.

Public Presentation

  • The HACCP concept was first presented at the 1971 National Conference on Food Protection.

  • Initial principles included:

    • Identification and assessment of hazards from growing to processing.

    • Determination of critical control points (CCPs).

    • Establishment of monitoring systems for CCPs.

  • Important term: Critical Control Point (CCP) - A point in manufacturing where loss of control results in unacceptable food safety risks.

Significant Reports and Committees

NAS Report (1985)

  • The National Academy of Sciences (NAS) report endorsed HACCP as an effective means of ensuring food safety based on a study commissioned by government agencies.

NACMCF Formation

  • The National Advisory Committee on Microbiological Criteria for Foods (NACMCF) was formed based on recommendations from the NAS Report.

  • They adopted a document describing HACCP’s seven principles in 1989, with revisions in 1992 and 1997.

Codex Alimentarius Committee

  • The CODEX is a UN committee helping develop food standards.

  • In collaboration with NACMCF, it updated HACCP principles, with the latest guidance adopted in 2003.

Global Food Safety Initiative (GFSI)

Overview

  • GFSI is a private organization that establishes auditing platforms meeting universal food safety criteria.

  • GFSI certification indicates a structured and effective food safety program, enhancing trust in food processors.

GFSI-Benchmarked Standards

  • Standards recognized by GFSI include:

    • Primus GFS

    • Global Aquaculture Alliance Seafood

    • FSSC 22000

    • BRC Global Standard

    • SQF

HACCP Implementation Steps

Assemble a HACCP Team

  • Diverse team involvement is crucial, including top management and external expertise if necessary.

  • Appoint a HACCP Coordinator to lead the program.

  • Team representatives from QA, production, engineering, maintenance, and regulatory affairs contribute knowledge.

Describe the Product and Distribution

  • Gathering detailed information about the product's nature, distribution, shelf life, and special considerations is essential.

    • Consider specific uses, potential for mishandling, and preparation requirements.

Develop a Process Flow Diagram

  • Create a diagram showcasing all steps in the product preparation process, identifying hazards at each stage.

    • Verify the diagram aligns accurately with actual plant practices.

HACCP Principles

  • Principle 1: Conduct Hazard Analysis

    • Hazard: biological, chemical, or physical agents with potential health effects.

    • Analysis involves identifying and evaluating hazards to determine which must be controlled in the HACCP plan.

    • Stages of analysis include Hazard Identification and Hazard Evaluation (likelihood and severity).

  • Principle 2: Determine Critical Control Points (CCPs)

    • CCP: step where control loss results in unacceptable food safety risk.

    • Decision trees help distinguish between CCPs and other control points.

    • Examples of CCPs include chilling, cooking, product formulation, and specific processing procedures.

  • Principle 3: Establish Critical Limits

    • Critical Limit: max/min values that must be controlled at CCPs to prevent hazards.

    • Sources for limits: scientific literature, regulations, processing authorities.

    • Establish proper critical limits and document them for reference.

  • Principle 4: Establish Monitoring Procedures

    • Monitoring: planned observations to determine if CCPs are under control.

    • Practices include both continuous and non-continuous monitoring methods.

    • Importance of maintaining documentation for correctness and assurance of control.

  • Principle 5: Establish Corrective Actions

    • Address deviations from critical limits with predefined corrective procedures for each CCP.

    • Recordkeeping is crucial for transparency in handling deviations.

  • Principle 6: Establish Verification Procedures

    • Verification: activities determining the effectiveness and validity of the HACCP plan.

    • Internal and external sources can conduct verification, including reviewing records and auditing.

  • Principle 7: Establish Record Keeping Procedures

    • Records serve as documentation for compliance and traceability in the HACCP system.

    • Types of records include hazard analysis summaries, HACCP plans, operational records, and verification records.

Case Example for Pasteurized Apple Juice

Assembly of HACCP Team

  • Team leader: Food Safety Manager and team members from various departments.

Product Description

  • Product: Pasteurized apple juice in 500ml PET bottles.

  • Target consumers include the general public, including vulnerable populations.

Process Flow Diagram and Potential Hazards

  • Detailed process flow includes receiving apples, washing, crushing, pasteurization, bottling, and distribution with identification of potential hazards for each step.

  • Control measures are outlined for each step to ensure safety, such as temperature monitoring, equipment sanitation, and proper inspections.