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Think about the role of process control as the canary in the mine shaft: the
canarys untimely death indicates a dangerous situation in the mine shaft, much
like HACCP alerts a plant manager of a potential hazard. And just as ventilating
the mine shaft and monitoring the process ensures that dangerous conditions
cannot arise, conducting statistical process control in a food processing plant will
prevent dangerous conditions from happening in the first place.
Hazard Analysis Critical Control Point is a food safety management system
designed to ensure the safe production and packaging of food. The HACCP
process (Table 1) has both strengths and limitations. It provides a systematic and
effective method to analyze a process, and identifies potential biological, chemical
and physical hazards that can occur in food. In addition, HACCP requires the
development of strategies to prevent the inclusion or reduction of these hazards
to an acceptable level in the food.
Table 1: Preliminary Tasks in the Development of the HACCP Plan and HACCP
Principles
TASKS PRINCIPLES
1. Assemble the HACCP team
1. Conduct a hazard analysis
2. Describe the food and its distribution 2. Determine the critical control points
(CCPs)
3. Describe the intended use and consumers of the food
3. Establish critical limits
4. Develop a flow diagram that describes the process
4. Establish monitoring procedures
5. Verify the flow diagram
5. Establish corrective actions
6. Establish verification procedures
7. Establish record-keeping and documentation procedures
The most effective way to avoid product hazard is to control the process properly
rather than relying on final product inspection. For example, a good HACCP
program cannot depend on microbiological tests as the means to prevent a
hazard because they are too slow to provide the real-time information needed to
maintain process control properly.
The problem, however, is that most HACCP monitoring systems take an attribute
approach to analyzing data. Even if variable data are collected to monitor a
critical control point, the data are typically categorized as either good (not
exceeding the critical limit) or bad (exceeding the critical limit). This approach
can limit the effective use of variable data by failing to detect process changes
over time, where the process control may be deteriorating before a problem
manifests itself.
One way to think about the role of process control is to consider the example of
the canary in the mine shaft. The canarys untimely death indicates a dangerous
situation in the mine shaft, much like HACCP alerts a plant manager of a potential
hazard. Just as ventilating the mine shaft and monitoring the process ensures that
dangerous conditions cannot arise, conducting statistical process control (SPC) in
a food processing plant will prevent dangerous conditions from happening in the
first place.
Statistical thinking
Food processors can strengthen HACCP programs by incorporating concepts of
statistical thinking. Statistical thinking, a term first used by the American Society
for Qualitys Statistics Division in 1960, is based on the following assumptions:
All work occurs in a system of interconnected processes;
Variation exists in all processes;
Understanding and reducing variation are the keys to success.
Recognizing the first assumption, conceptualizing all work in terms of
interconnected processes, ensures a thorough and detailed understanding of the
processing system. Next, understanding that every process displays variation as
an accepted fact of life prompts analysis of variation. Quality professionals need
to know the extent and predictability of process variation.
Variation can be divided into two types, common causes and special causes. If a
process is controlled and influenced so that the process output measurements are
predictable and vary within statistically defined upper and lower control chart
limits, then the process is said to be stable and in statistical control. Thus, only
common causes of variation are affecting the process. However, if the process
variability is uncontrolled, and the process output measurements do not fall within
the upper and lower control chart limits, the process is classified as unstable or
out of statistical control. The process is affected by special causes of variation.
The National Advisory Committee on the Microbiological Criteria for Foods adopted
this revised series of HACCP principles and application guidelines last year. The
basic premises for these principles have not changed; however, the principles are
now more concise and the definitions have been revised. In addition, the new
document emphasizes the importance of prerequisite programs, education and
training, and implementing and maintaining HACCP plans. There are also new
guidelines to help professionals select appropriate critical control points.
The final aspect of statistical thinking is the realization that variation is the enemy.
Variation must be reduced or eliminated if a company wants to increase
productivity and decrease waste significantly. Quality improvement theory states
that the first step of quality improvement is to remove the special causes of
variation by determining and eliminating the root cause of the problem. If only
common causes of variation are affecting the process, then the process is
operating at the most efficient point for the currently defined system.
Control charts
Control charts provide the primary tool to determine the extent and type of
process variation. They are used to analyze two major groups of data: variable
data, or measurement data, and attribute data, or count data. Table 2 describes
different types of control charts and their uses. The most effective control chart
that can be used to evaluate individual variable data that monitors control points
is the individual moving range (x-mR) control chart. This chart allows the
evaluation of individual data points rather than averages.
Table 2: Types of Control Charts
TYPE OF DATA
TYPE OF CHART USE OF CHART
Variable
Individual moving range (x-mR)
Each subsample is a data point
Average - range (x-bar R)
The subsample consists of less than ten data points
Average - standard deviation (x-bar s)
The subsample consists of ten or more data points
Attribute
p chart
Nonconforming units
np chart
Portion of nonconforming units
c chart
Nonconformities
u chart
Portion of nonconformities
Individual moving range (x-mR)
Any type of attribute data
Note: Some quality professionals suggest that most variable data can be analyzed
using either the individual moving range control chart or the x-bar R control chart,
and all attribute data can be analyzed using the individual moving range control
chart.
An alternative method to analyze HACCP data is to use a two-step evaluation
process. During the first step, data taken from the critical control point would be
compared to the critical limits to determine whether a potential for a food safety
hazard exists. Next, the data would be analyzed using an individual moving range
control chart (see case study). The control chart allows for a graphical
interpretation of the type and extent of variation that affects the process. If a
process is capable of meeting critical limits, then it is or could be possible to make
adjustments in the process prior to producing unsafe food. In addition, the
analysis can provide the means to identify potential opportunities for
improvements and increase the capability of the HACCP program, thus reducing
the risk of making unsafe food.
Any HACCP program should be directed to food safety issues. The process is not
2). The level was still below the critical level. Fortunately, because the process
was very capable, the problems were identified and a corrective action team
comprising plant operations, quality assurance, maintenance and procurement
personnel was formed to identify and remove the problems root cause. As part of
the solution, procurement personnel worked closely with the producers to
maintain and improve the conditions of the birds coming into the plant. In
addition, new chlorinated spray cabinets were added to the processing line after
the pickers. Also, the first and final wash cabinets were improved to include a new
chlorinating system and higher water pressures. Checks were implemented to
control and verify chlorine levels and water pressures. Additionally inspectors
were added to the line after the final wash and before the birds entered the chill
system.
Conclusion
Butterball has successfully linked the monitoring of control points to statistical
process control, and the quality improvement processes. This linkage has
permitted the
development of a highly capable manufacturing process. As a result, if a change
or other factor affects the system, a quality improvement team can identify the
root cause of the problem and take corrective and preventive action. This strategy
has additional benefits to the company: It increases employee involvement,
awareness, attention to detail and motivation, while improving quality and
productivity.
Note: The above is a classic study initially published in Food Quality Magazine,
May 1998, with another version published as Clemson University Cooperative
Extension Service EB 152, September 1998. The line of thinking developed in this
study has had a significant impact on the development of modern Food Safety
Management Systems. One of the authors, John Surak, has long been a strong
proponent of the role process management in food safety management systems.
This is reflected in his contributions to the ISO 22000 standard.
Hazard Analysis and Critical Control Points (HACCP) can be simply viewed as a
prevention based food safety system that identifies and monitors specific food
safety hazards that can adversely affect the safety of food products.
HACCP is
internationally recognized as the best method to ensure food safety and can be
applied at all stages of food production, from harvest through to consumption.
HACCP is a two part process. The first part is to identify potential food safety
hazards (this is also known as
Today the benefits of HACCP are widely recognized by food manufacturers and
food retailers.
large food companies, and also by many medium and small sized food
businesses. Looking forward, HACCP implementation will increase in all food
industry sectors with HACCP systems being commonly used in every type and size
of food business.
- Time
- Temperature
How much time at a particular temperature is required to kill the specific
number of micro-organisms to ensure food safety. Time and temperature
are inversely proportional, as the temperature rises, the time of
processing decreases and can easily be calculated as TDT (thermal death
time) for a particular pathogen.
The processing methods are designed as:
- Cooking/frying/roasting
- Heating/boiling/thawing
- Pasteurization
- Sterilization
- UHT (Ultra high temperature)
There are various other techniques of heat treatment, but our major
concern is with food safety. The question here is, have we ensured the
safety of food with heat treatments?
To be able to account food to be safe for human consumption, we need
some more considerations apart from heat, they are:
- Fouling of equipments
- Rusting of equipments
For Food safety, heat treatment by steam or dry air, these above factors
always comes in existence. Fouling refers to the accumulation of
unwanted material on solid surfaces also known as scaling, scale
formation and sludge formation. Rusting is a common term used for
corrosion, occurs when equipments gets contact with water and oxygen.
Because of these factors the effectiveness of heat treatment lower down
and chances of food deterioration occurs.
In food industries, to prevent these problems, equipments made with
steel are used and to ensure the effectiveness, efficiency, food
safety one must to apply manual cleaning or CIP/SIP (Cleaning in place /
Sterilization in place) for equipments.
In the next blog, Ill discuss the food safety by Microbial means
Food safety: Microbial
Upcoming articles:
- Food safety: Chemical
- Food safety: Microbial
- Food safety: Irradiation
W E D N E S D A Y, M A Y 1 9 , 2 0 1 0
methods
of
food
preservation
are
used
for
ensuring food
During HPP, pressure is uniformly applied around and throughout the food product
Foods with a high acid content are particularly good candidates for
HPP technology
M O N D A Y, A P R I L 1 9 , 2 0 1 0
- Safe Food
- Natural
- Convenient
- Healthy
Foreign materials in foods are a real concern, not only in terms of the consumer
complaints that arise, but as an important factor in the effective implementation
of the company's food safety guidelines, particularly the Hazard Analysis
Critical Control (HACCP) system.
Risk Categories:
- Low risk
- Medium risk
- High risk
safety/HACCP systems.
In the next blog, I'll discuss new food safety technology developed such as
HPP High Pressure Processing
Upcoming articles:
time savings
Whilst there are many benefits to using computer based HACCP development
software, it must be appreciated that computer software can only be a tool to aid
the development of aHACCP
With all of the above in mind, NSF-CMi has developed a Microsoft Excel based
Practical
Practical HACCP Toolkit has been developed to meet the HACCP needs of small to
medium sized food businesses in the Asia Pacific region and to comply with the
HACCP principles set out by the internationally recognized Codex Alimentarius
Commission. Our Practical HACCP Toolkit provides a step by step approach to
developing an effective HACCP system by:
HACCP
plan
generating process flow diagrams
helping the user create HACCP plans for different food products
allowing product specific food safety hazards to be inputted
allowing process specific control measures and monitoring procedures to be
included
automatically producing critical control points verifications sheets
creating checklists for prerequisite programmes
HACCP
HACCP as it is commonly
known) is a worthy subject to spend some time discussing. My plan during the
coming few weeks is to write a series of
HACCP
system to help ensure the safety of the food that you produce.
Government regulatory agencies across Asia are now providing more resources
for the education, control and enforcement of food safety standards than ever
before, with HACCP being viewed as an integral part of the process. India is one
country in particular that is focused on improving food safety standards. Through
the establishment of the Food Safety & Standards Authority of India (FSSAI) and
the introduction of new food safety laws and educational programmes,
improvements in food safety awareness and standards are already resulting in
safer food supply chains.
You will see from my upcoming blogs that HACCP is not difficult to understand
and
HACCP system does require planning, production process expertise and continued
business commitment. As a general rule, the simpler and more focused a HACCP
plan is the more likely that it will be implemented correctly and food safety
hazards will be controlled.
Hazard Analysis and Critical Control Points (HACCP) can be simply viewed as a
prevention based food safety system that identifies and monitors specific food
safety hazards that can adversely affect the safety of food products.
HACCP is
internationally recognized as the best method to ensure food safety and can be
applied at all stages of food production, from harvest through to consumption.
HACCP is a two part process. The first part is to identify potential food safety
hazards (this is also known as
Today the benefits of HACCP are widely recognized by food manufacturers and
food retailers.
large food companies, and also by many medium and small sized food
businesses. Looking forward, HACCP implementation will increase in all food
industry sectors with HACCP systems being commonly used in every type and size
of food business.
HACCP training
blogs and is a
The common
HACCP
plan. These preliminary steps will help ensure that a HACCP system is effective
and safe food is produced.
system.
The HACCP Team needs to be formed with people who have operational
experience, product specific knowledge and a good understanding of the
production process. The HACCP Team should include the following types of
employees: Quality Control (QC), technical staff, production managers /
supervisors, laboratory personnel, engineering staff and sanitation staff.
Product Descriptions must describe relevant food safety information, such as:
Available water
pH
End product characteristics e.g. shape, size, colour, texture, odour etc.
Method of preservation
Packaging
Storage conditions
Shelf life
Special labelling information
Customer preparation
Method of distribution.
Intended use information also needs to identify whether the end user will be the
general public or a specific consumer group, particularly vulnerable groups of the
population such as infants, the elderly, pregnant women, ill people, immunocompromised persons or cancer patients.
steps in the process must be set out, including any rework or recycling of
materials.
The flow diagram will provide the basis for carrying out a systematic hazard
analysis.
When verifying the accuracy of the flow diagram consideration needs to be given
to different shifts and hours of operation, different batch sizes, optional
ingredients and non-routine steps such as maintenance of equipment.
M O N D A Y, D E C E M B E R 7 , 2 0 0 9
Food safety hazards are found throughout the food supply chain and can
be described as:
biological, physical or chemical agents in food that are reasonably likely to cause
illness or injury in the absence of their control.
1.
Food infections and food intoxications can cause severe vomiting, diarrhoea,
nausea, abdominal pain and fever to one or lots of people, they can even result in
death in some serious cases.
presenting the greatest risk of harm and the highest frequency of occurrence.
2.
Metal, glass, wood, insects, stones, soil, dirt, jewellery, hair, fingernails, plasters,
personal items, bone, nuts / bolts, wire, plastic, paper and cardboard.
3.
Chemical Hazards
Can include:
CLEANING CHEMICAL RESIDUES: Chemicals used for cleaning and sanitizing food
contact surfaces
FOOD ALLERGENS: Eggs, fish, milk, peanuts, sesame seeds, soy, sulphites, tree
nuts and wheat
HACCP
systems. All significant food safety hazards at each stage of production must
be identified in a HACCP plan. Once you know where food safety hazards
occur, it is possible to implement control measures to prevent, reduce or
eliminate food safety hazards to an acceptable level.
continuation of our earlier post The Five Preliminary Steps to Developing a HACCP
Plan)
The Codex Alimentarius Commission sets out seven principles for the basis
of
after the Five Preliminary Steps to Developing a HACCP Plan have been
completed.
HACCP plan.
Firstly, the HACCP Team must think about the product and process to identify all
hazards (biological, physical and chemical) that may be reasonably expected to
occur at each step in the production process.
When identifying hazards it is necessary to consider:
HACCP
Original HACCP study (e.g. HACCP Team, product description, hazard analysis,
CCP determination, identification and selection of critical limits etc.)
CCP monitoring activities
Critical limit deviations and the associated corrective actions taken
Verification procedures
Internal and external audits
HACCP system reviews and modifications.
commitment to food safety at all levels within a company. It is essential that all
personnel directly or indirectly involved in food production are given adequate
training to ensure that they are aware of their roles and responsibilities in
maintaining food safety.
To facilitate effective
summary of the training provided, the dates of the training, results of any
evaluation assessments and the signature of the person receiving the training.
When considering the training needs within your company, it must be appreciated
that the type of training required will vary between different groups of employees.
It is essential that the employee training provided is at a level appropriate to the
work tasks that will be carried out. For example:
The HACCP Team, particularly the HACCP Team Leader should have a good
understanding of:
HACCP
system. Giving employees knowledge and skills will significantly reduce the
risks associated with food production and help to ensure the consistent
production of safe food.
Semester - III
Food Chemistry
Foods and Nutrition
Principles of Food Processing and Preservation
Food Storage and Transport Engineering
Fruits and Vegetables Processing Technology
IT Application in Food Industry
Village Adoption
Semester - IV
Biochemistry
Food Microbiology and Safety
Food Engineering I
Technology of Milk and Milk Products Processing
Food Industrial Economics
Agripractices and Environmental Sciences
Semester - V
Instrumental Methods of Food Analysis
Food Engineering - II
Food Packaging Technology
Food Biotechnology
Cereals, Pulses and Oilseeds Technology
Semester - VI
Food Additives and Ingredients
Instrumentation and Process Control
Meat, Fish and Poultry Product Technology
Food Laws, Standards and Regulation
Food Production Trends and Programmes
Business Plan Development
Semester - VII
Food Plant Design and Process Modelling
Food Product Development and Sensory Evaluation