Professional Documents
Culture Documents
Origins of HACCP
Pioneered in the 1960s
First used when foods were developed for the space program
Adopted by many food processors and the U.S. government
HACCP
HACCP is not a zero-risk system.
It is designed to minimize the risk of
food safety hazards.
Recommendation:
The HACCP approach be adopted by all regulatory
agencies and that it be mandatory for food processors.
1985 National Academy of Sciences
HACCP Inspections
Traditional Inspection Methods for Food-Safety Control
versus
The HACCP Approach
HACCP inspections complement traditional
inspection methods
HACCP:
Emphasizes process control
Concentrates on the points in the process
that are critical to the safety of the product
Stresses communication between the
regulator and industry
Hazards
A biological, chemical or physical agent that is reasonably
likely to cause illness or injury in the absence of its control
In HACCP, hazards refer to conditions or
contaminants in foods that can cause illness or injury. It
does not refer to undesirable conditions or
contaminants such as:
Insects
Hair
Filth
Spoilage
Economic fraud and
Violations of regulatory food standards not directly related to
safety
Bacterial Hazards
Food infection and food intoxication
Sporeforming and nonsporeforming bacteria
Sporeforming Bacteria (Pathogens)
Clostridium botulinum
Proteolytic
Nonproteolytic
Clostridium perfringens
Bacillus cereus
Nonsporeforming Bacteria
Viral Hazards
Very small particles that cannot be seen with a light
microscope
Do not need food, water or air to survive
Do not cause spoilage
Infect living cells and are species specific
Reproduce inside the host cell
Survive in human intestines, water or food for
months
Transmission usually by fecal-oral route and related
to poor personnel hygiene
Parasites in Foods
Parasites are organisms that need a host to survive
Thousands of kinds exist worldwide, but only about
100 types are known to infect people through food
contamination
Two types of concern from food or water:
Parasitic worms [e.g., roundworms (nematodes),
tapeworms (cestodes), flukes (trematodes)]
Protozoa
Anisakis simplex
Ascaris lumbricoides
Pseudoterranova dicepiens
Trichinella spiralis
Tapeworms (cestodes)
Diphyllobothrium latum
Taenia solium, T. saginata
Flukes (trematodes)
Cryptosporidium parvum
Entamoeba histolytica
Giardia lamblia
Chemical Hazards
Naturally Occurring
Intentionally added
Unintentionally added
Types of Naturally Occurring Chemical Hazards
Mycotoxins (e.g., aflatoxin)
Scombrotoxin
Ciguatoxin
Shellfish toxins
Paralytic shellfish poisoning (PSP)
Diarrhetic shellfish poisoning (DSP)
Neurotoxic shellfish poisoning (NSP)
Amnesic shellfish poisoning (ASP)/Domoic Acid
Control of
Chemical Hazards
Approved and legal chemicals (cleaners, sanitizers,
hormones, pesticides)
Use a safe level
Letters of guarantee and vendor certification
Proper procedures and rinsing (cleaners and sanitizers)
Storage of feed (aflatoxin)
Storage and labeling for ingredients and raw materials
Physical Hazards
Physical hazard: a hard foreign object that
can cause illness or injury
Inherent to the food or ingredient
Contaminant during processing
Examples of
Physical Hazards
In the food or ingredients
Bone fragments (ground beef)
Feathers from animal carcass (turkey)
Contamination during processing
Stones, rocks, dirt in vegetables
Metal from processing equipment (ground beef)
Jewelry, fingernails (food handler)
Control of
Physical Hazards
Separate and remove physical objects
Filter or sieve (meat grinder)
Water bath (vegetables)
Metal detector (all foods)
Good employee practices (jewelry)
Good sanitation and quality control programs
HACCP System
personnel
building and facilities
equipment and utensils
production and process controls
GMPs: Personnel
Handwashing stations
Storage of ingredients (refrigerated and on pallets)
Separation of raw ingredients from processed foods
Pest management program
Examples
Of
GMPs
Standard Operating
Procedures
Standard Operating Procedures (SOPs) are established or
prescribed methods to be followed routinely for the performance of
designated operations or in designated situations.
Standard Operating
Procedures
SOPs relate to specific tasks and should address the following:
the purpose and frequency of doing a task
who will do the task
a description of the procedure to be performed that includes
all the steps involved
the corrective actions to be taken if the task is performed
incorrectly
Safety of water
Condition and cleanliness of food-contact surfaces
Prevention of cross-contamination
Maintenance of hand-washing, hand-sanitizing and toilet
facilities
Protection from adulterants
Labeling, storage and use of toxic compounds
Employee health conditions
Exclusion of pests
Standard Operating
Procedures
Examples
Of
SOPs
Sanitation SOPs
Sanitation Standard Operating Procedures (SSOPs) are
prescribed methods specifically for cleaning and sanitizing.
Sanitation SOPs
Examples
Of
Sanitation
SOPs
Cleaning
Cleaning is the chemical or physical process of removing dirt or
soil from surfaces.
Cleaning removes 90-99% of the bacteria, but thousands of
bacteria may still be present.
Sanitizing
Sanitizing is the process that results in
reduction/destruction of microbes.
Different sanitizers will be used for different
food products. Chlorine, iodophors, and
quaternary ammonia compounds are the
most common sanitizers used.
Sanitation Programs
Prerequisite
Programs
and
Preliminary
Steps
Preliminary Steps
HACCP Principles
1.
2.
3.
4.
5.
6.
7.
Hazard Analysis
Principle 1
Conduct a hazard analysis
Likelihood of occurrence
Severity
Hazard Analysis
Hazard identification
Hazard evaluation
Hazard Identification
List potential hazards at each operational step
in the process from receipt of raw materials
through release of the finished product
All potentially significant hazards must be
considered
Hazards List
Biological Hazards
Pathogenic microorganisms (e.g., bacteria, viruses)
Parasites
Chemical Hazards
Natural toxins
Chemicals
Pesticides
Drug residues
Unapproved food and color additives
Decomposition (safety only, e.g., histamine)
Physical Hazards
Metal, glass, etc.
Hazard Analysis
A hazard must be controlled if it is:
Reasonably likely to occur, and
Likely to result in an unacceptable risk to consumers
Hazard-Analysis Worksheet
Column 1. Processing step
Column 2. Results of hazard identification
Column 3. Results of hazard evaluation
Column 4. Justification for accepting or
rejecting the potential hazard
Control Measures
Actions and activities that can be used to
prevent or eliminate a food safety hazard or
reduce it to an acceptable level
Removal
Principle 2
Determine the
Critical Control Points
Plant layout
Formulation
Process flow
Equipment
Ingredient selection
Sanitation and support programs
Yes
Q1
Q2
Q3
Q4
CCP
Yes
No
No
Yes
Yes
Yes
Yes
No
No
Yes
No
No
Yes
Yes
Yes
Yes
No
No
Yes
No
Yes
Yes
No
Yes
Thawing
Bacterial pathogens
Q1
Q2
Q3
Q4
CCP
Bacterial pathogens
Yes
No
Yes
Yes
No
Yes
Yes
Yes
Yes
Yes
Cooker
Pathogen survival
Weigh/Pack/Label
Sulfiting agent
Yes
Principle 3
Critical Limit
A maximum and/or minimum value to which
a biological, chemical or physical parameter
must be controlled at a CCP to prevent,
eliminate or reduce to an acceptable level
the occurrence of a food-safety hazard
CCP
Critical Limit
bacterial
pathogens
(biological)
pasteurizer
161oF for 15
seconds
for elimination of
pathogens from
milk
CCP
Critical Limit
bacterial
pathogens
(biological)
drying
oven
drying schedule:
oven temperature: 200oF
drying time: 120 min.
air flow rate: 2 ft3/min.
product thickness: 0.5
inches
CCP
Critical Limit
bacterial
acidification
Batch schedule:
pathogens product weight: 100 lbs.
(biological) soak time: 8 hours
acetic acid concentration: 3.5% volume: 50
gallons
(to achieve maximum pH of 4.6
to control
Clostridium
botulinum in pickled foods)
Sources of Information on
Critical Limits
General Source
Examples
scientific publications
journal articles, food science texts,
microbiology texts
regulatory guidelines
state and local guidelines, tolerances
and action levels; USDA guidelines, tolerances and action
levels; FDA
guidelines, tolerances and action
levels
Examples
experts
university
experimental studies
CCP
fryer
Critical Limits
minimum fryer oil temperature of 350oF
maximum patty thickness of 1/4 inch
minimum cook time in the oil of 1 minute
Operating Limits
Criteria that are more stringent than critical limits
and that are used by an operator to reduce the risk of
a deviation
Operating limits may be selected for various reasons:
For quality reasons
To avoid exceeding a critical limit
To account for normal variability
Process Adjustment
An action taken by the firm to bring the process back
within operating limits
Degrees F
200
Cooker Temperature
195
Operating Limit
190
185
180
Corrective Action
Required
Critical Limit
Lot 1
Lot 2
Lot 3
175
Time
Lot 4
Lot 5
Establishment of Critical
Limits
Critical Control Point Critical Limits
CCP Cooker
Cook at 212oF for 3
minutes
CCP - Weigh/Pack/Label All product containing
sulfiting agent must
declare presence
4.
5.
6.
7
.
Monitoring
What How Frequency Who
8.
9.
10.
Corrective Verification Records
Action(s)
Principle 4
Establish CCP monitoring
procedures
Monitorin
conduct a planned sequence of observations or
g To
measurements to assess whether a CCP is under
control and to produce an accurate record for
future use in verification
Purpose of Monitoring
To track the operation of the process and enable the
identification of trends toward a critical limit that may
trigger process adjustments
To identify when there is loss of control (a deviation
occurs at a CCP), and
To provide written documentation of the process
control system
4.
5.
6.
7
.
Monitoring
What How Frequency Who
8.
Corrective
Action(s)
9.
10.
Verification Records
Monitoring
What: Usually a measurement or observation to
assess if the CCP is operating within the critical limit
How: Usually physical or chemical measurements
(for quantitative critical limits) or observations (for
qualitative critical limits). Needs to be real-time and
accurate.
When (frequency): Can be continuous or
intermittent
Who: Someone trained to perform the specific
monitoring activity
Monitoring Frequency
Continuous
Noncontinuous
Continuous Monitoring
Continuous monitoring is preferred
Continuous monitoring procedures:
Temperature recording chart
Metal detector
Dud detector
Noncontinuous Monitoring
Noncontinuous monitoring must be used when
continuous monitoring is not possible
Frequency of noncontinuous monitoring
How much does the process normally vary?
How close are normal values to the critical limit?
How much product is the processor prepared to
risk if the critical limit is exceeded?
Noncontinuous Monitoring
Examples of noncontinuous monitoring:
Temperature checks of batter on a
breading line at specified intervals
Routine, daily checks for properly iced fish
Periodic sensory examination for
decomposition in histamine-forming
seafood
Principle 5
Establish corrective actions
Corrective Action
Procedures to be followed when a deviation occurs
Corrective Action
Components
Product Disposition
Step 1: Determine if the product presents a safety
hazard based on expert evaluation or on physical,
chemical or microbiological testing
Step 2: If no hazard exists based on the evaluations
in Step 1, the product may be released
Step 3: If a potential hazard exists (based on the
evaluations in Step 1), determine if the product can
be reworked/reprocessed, or diverted for a safe use
Step 4: If potentially hazardous product cannot be
handled as described in Step 3, the product must
be destroyed. This is usually the most expensive
option and is usually regarded as the last resort
4.
5.
6.
7
.
Monitoring
What How Frequency Who
8.
9.
10.
Corrective Verification Records
Action(s)
Principle 6
Establish verification procedures
Verification
Those activities, other than monitoring,
that determine the validity of the HACCP
plan and that verify the system is
operating according to the plan
Elements of Verification
Validation
CCP verification activities
Calibration of monitoring devices
Calibration record review
Targeted sampling and testing
CCP record review
HACCP system verification
Observations and reviews
Microbiological end-product testing
Regulatory agencies
Validation
The element of verification focused on
collecting and evaluating scientific and
technical information to determine if the
HACCP plan, when properly implemented,
will effectively control the hazards
Validation Frequency
Initially
When factors warrant, e.g.,
4.
5.
6.
7
.
Monitoring
What How Frequency Who
8.
9.
10.
Corrective Verification Records
Action(s)
Principle 7
Establish record-keeping and
documentation procedures
4.
5.
6.
7
.
Monitoring
What How Frequency Who
8.
9.
10.
Corrective Verification Records
Action(s)