Prerequisite Requirements Prerequisite Requirements of HACCPof HACCP

B.K.Kolita Kamal Jinadasa,Research officer,

Post harvest technology division,NARA, Colombo-15,

Sri Lanka

HACCP IS NOT A HACCP IS NOT A STANDSTAND--ALONE SYSTEMALONE SYSTEM

HACCP HACCP

is one part of larger is one part of larger

QUALITY QUALITY MANAGEMENT/ASSURANCE MANAGEMENT/ASSURANCE

SYSTEMSYSTEM

Quality management system

• Product/ Food Safety– HACCP system

• Product Quality – Quality control system.

• i.e. meeting buyer specifications, including legal requirements

• Environmental/Operating condition– Prerequisite requirements for HACCP

Prerequisite programsPrerequisite programs

• Not described in the original US National Advisory Committee on Microbiological criteria for Foods (NACMCF) or Codex HACCP guidelines.

• Concept originated in 1993 Agriculture and Agri-Food Canada’s (AAFC) Food Safety Enhancement Program (ESEF).

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Prerequisite ProgramsAAFC/FSEP Definition: AAFC/FSEP Definition:

• Universal steps or procedures • that control the operational conditions within a

food processing establishment • allowing for environmental conditions that are

favorable to the production of safe food. • Basically GMP and hygiene/ sanitation control

basic requirements for all food industry

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HACCP

PREREQUISITE PROGRAMSPREREQUISITE PROGRAMS

FOUNDATION OF AN EFFECTIVE HACCP SYSTEM

• simpler yet more effective HACCP plans – easier to maintain and manage

• Control potential hazards to becoming significant hazards

• reduce no. of CCPs - kept to true critical points

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Prerequisite Programs• Basically applications of GMP & hygiene/sanitation

Control.

• Premises and facilities, equipment, sanitation and hygiene.

• Others- personnel training, supplier control, product traceability and recall, consumer complaints, specification.

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Prerequisite Programs• Cross product line.

• Not part of the formal HACCP plan.

• Managed separately rather than include their performance and control as part of the HACCP plan.

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Prerequisite Programs• Simpler yet more effective –

– HACCP plans- easier to maintain and manage.

• Control potential hazards from becoming significant hazards.

• Reduce no. of CCPs-– Kept to true critical points.

Prerequisite program HACCP Plan

Deals indirectly with food safety issues – environmental/operating conditions

Deals directly with food safety issues

More general and may be applicable throughout the plant crossing multiple product lines

Product and line specific

Deviations from prerequisite requirement will not result in a food safety hazard or concern –non-critical

Deviations from a HACCP Plan critical limit will result in a food safety hazard and action against the product

In other word:• Ensuring that food is safe and wholesome• But may not be enough to control business-specific food safety

hazard

Prerequisite program should cover:

Premises

Receiving/ storage/ transport

Recall Sanitation

Personnel training

EquipmentsPrerequisite programs should be:

• Documented with written SOPs.

• Monitored with proper record to ensure effectiveness

• Reviewed and revised – periodically to ensure relevance

Premises• Plant location, construction and layout.

• To protect food from unsanitary conditions and cross contamination.

• Location– Adequate plot size.– Easy access.– Pollution risk form surrounding

• Smoke, dust, odors, airborne microbes

Premises

• Construction & layout– Separation of operations.– Product flow patterns.– Adequate working space.– Lighting.– Ventilation– Building materials.

Cover:• Proper plant layout (hygienic design)• Building material, wall and water covering• Water quality• Sanitary facilities

Premises = Structural Operating Environment

Poorly designed, constructed and maintained food premises will

increase the chance of food becoming contaminated

Facilities

• Adequate supply of energy/power.• Adequate supply of potable cold water, hot

water and steam must be available for cleaning & sanitation when necessary.

• A suitable water treatment system where appropriate (chlorination plant, waste water treatment)

Facilities

• Adequate sewage & waste disposal.• Adequate facilities for washing and

disinfecting equipment.• Adequate staff amenities (hand washing

facilities, toilets, staff rooms).• Adequate sanitary plumbing (no cross

concentration between portable & non portable water lines)

Design-

Prevent contamination of product.prevent accumulation of food residues during

production.For accessibility and cleanability.Durability.Easy maintain.Performance.

Equipment & Utensils

Equipments & UtensilsConstruction-

Food-safe materialsNon toxic.Non absorbentResistant to the product, cleaning and disinfecting agents.Stainless steel and plastic.

Maintenance-Schedule for servicing, replacement and calibration.

Staff must be trained to do their jobs competently e.g. processing skills, HACCP monitoring.

Includes training in those prerequisite requirements for which they are responsible such as personal hygiene, hygienic handling practices, cleaning and sanitation.

Training-Written training program and schedules.Re-training.Training records of personnel.Competency testing.

Personnel training

Sanitation & Hygiene

Proper cleaning and sanitation will:

Decrease the likelihood of food becoming contaminated; and

Discourage pests from the premises, vehicle and/or vessels.

Cleaning and Sanitation

Cleaning:Removing waste, dirt and grease from equipment, premise, vehicles and vessels

Sanitation:Reducing the number of microorganisms to a level that keep a food safe. Food contact surfaces, equipment and utensils should be sanitized.

Remember: A dirty surface can not be sanitized!

Cleaning and SanitationCleaning and Sanitation• Develop a written program or Sanitation

Standard Operating Procedures (SSOP)

• FDA seafood HACCP Rule mandates 8 sanitation area that must be monitored and documented

Cleaning and SanitationCleaning and Sanitation• Cleaning and sanitation procedure and

schedule should be written and followed.

• A master sanitation schedule should be developed and rigorously applied to assure good housekeeping and minimize product exposure to contaminants.

Cleaning and SanitationCleaning and Sanitation

• Written guidance should be developed for personnel hygiene standards for plant workers- include proper attire, hair, hand washing and personnel health expectations.

• An environment sampling program may be used to confirm the effectiveness of the cleaning and sanitation program.

Sanitation standard operating procedure (SSOP)

• Describe a particular set of objectives associated with sanitary handling of food and the cleanliness of the plant environment and the activities conducted to meat them.

• FDA seafood HACCP rule mandates 8 areas of sanitation that must be monitored and documented.

FDA 8 Keys sanitation areas1. Safety of water- that comes into contact

with food or food contact surface, or is used in the manufacture of ice.

2. Condition & cleanliness of food-contact surfaces, include utensils, gloves and outer garments.

3. Prevention of cross-contamination from unsanitary object to food, food packaging materials and other food contact surfaces, including utensils, gloves and outer garments, and from raw to cooked product.

FDA 8 Keys Sanitation areas4. Maintenance of hand-washing, hand-

sanitizing and toilet facilities5. Protection food, food packaging

materials and food contact surface from adulteration with lubricant, fuel, pesticides, cleaning compounds, sanitizing agents, condensate and other chemical, physical and biological contaminants.

FDA 8 Keys Sanitation areas6. Proper labeling, storage and use of

toxic compound.

7.Control of employee health conditions that could result in the microbiological contamination of food, food packaging material and food contact surface.

8. Exclusion of pests from the food plant

Pest controlPest control

• Pests such as rodents, birds, insects, animals e.g. cats and dogs.

• Carriers of human disease agents.

Pest control programPest control program• Based on 3 principles;

– Exclusion or preventing access-• Windows screens, self-closing doors

– Restriction by avoiding to create an environment conducive to pests-• Elimination of harborage and attractant areas

(rapid removal of waste).– Destruction and eradication-

• Usually done by specialist company.

All raw materials and products should be stored under sanitary conditions and proper environmental conditions (temperature and humidity) to assure their safety and wholesomeness

Receiving/ storage/ transport

An action plan which gives the company ability to recover or retrieve product it has left the control of the company.

Recall team, coordinator.

Written recall/recover procedures.

Minimize bad publicity, consumer complaints, criminal law suit and damage to the company reputation

Involves product identification and traceability (raw materials, ingredients and finished products, distribution records)

Recall ProgramOther program

• Food transport vehicle.• Fishing vessels.• Supplier approval.• Food packaging.• Product identification and labeling.

THANK YOU!!!