CAPSIG NSW Presentation · HACCP Codex has 12 steps..and the 7 Principles of HACCP •6. List potential hazards, conduct a hazard analysis and consider measures to control any hazards

Correct Food Systems

CCP

CAPSIG NSW Presentation

“HACCP in “Food Manufacturing”

- 4th MAY, 2011

Presented by: Gary Kennedy


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HACCP

HACCP

• Hazard Analysis Critical Control Points

• A preventive system of food safety and

food quality management

• Originally used on the food industry for

the space program


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Codex HACCP

HACCP was standardized by the Codex

Alimentarius Commission in 1993 in

Geneva.

Australian food standard 3.2.1 uses

some (but not all) of this Codex

system.


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HACCP

Codex has 12 steps

5 Preliminary steps:

• 1. Assemble the HACCP team

• 2. Describe the product

• 3. Identify intended use

• 4. Construct flow diagram

• 5. Confirmation of flow diagram


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HACCPCodex has 12 steps

..and the 7 Principles of HACCP• 6. List potential hazards, conduct a hazard

analysis and consider measures to control any hazards

• 7. Determine critical control points [cont.]

• 8. Establish critical limits for critical control points

• 9. Establish a monitoring system for each critical control point

• 10. Establish corrective actions

• 11. Establish verification procedures

• 12. Establish documentation & record keeping


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Legislation

Why the introduction of HACCP based

programs into law?

A steady rise in the number of food

poisoning cases in Australia – Now about

6 million per year

Some very public outbreaks


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Legislation

The Food Standards Code has four sections

1. General requirements

Mainly labelling

2. Specific Product Category Requirements

3. Food Safety Requirements

3.1.1 has the general requirements

3.2.1 covers food safety plans [including HACCP]

3.2.2 covers food hygiene and work practices

3.2.3 covers food premises and equipment

4. Primary Industry Category Requirement


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LegislationBy the 1980‟s HACCP had started to be made

mandatory in some industries

The revised Food Standards Code contained

mandatory HACCP based programs for all

food businesses, but this was not

implemented in any state or territory,

primarily due to the cost of implementation.

A series of outbreaks in smallgoods, peanut

butter and Vietnamese foods in 1995 saw

Victoria introduce mandatory HACCP based

systems.


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Legislation

Some states are now introducing

HACCP to high risk areas such as

hospitals, child care and the like

[standard 3.3.1]

Standard 3.3.2 is proposed for caterers


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Legislation

Food Safety Standard 3.2.1 applies to

all businesses:

From receipt from the farm to the point of

sale to the consumer

Covering small and large business,

including not-for-profit

Including food manufacturing, food service,

food distribution, food storage and food

retailing.


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Legislation

It may never occur that HACCP and

formal auditing by the government is

made mandatory for all businesses.

But is still the standard in a court of law.

– Tables Restaurant case, Pymble, NSW


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Private StandardsAdditionally, all major food businesses require

their suppliers to pass a 3rd party HACCP

audit, including:

• All major supermarket chains

• All major restaurant chains

• Armed forces and hospitals tenders

• Petrol station chains

• Food manufacturers

• Major hotel chains and airline caterers

• AQIS – for high risk exporters.


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HACCP – Principle 1

The hazard analysis is a vital aspect of

the HACCP Plan, and therefore also

for food safety and food quality.

It is done in three parts:

1. Hazard identification

2. Assessment of significance of

hazards

3. Put in place control measures


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HACCP – Principle 1At every step of the flow chart, every hazard

must be identified.

A hazard is defined in the Codex Guidelines as “A biological, chemical or physical agent in, or condition of, food with the potential to cause an adverse health effect.”

These hazards fall into the following groups:Physical

Chemical

Biological

[Allergen]

[Quality]


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These hazards may

• already be existing in the product when

it arrives at a step {such as the

presence of pathogens in a raw

material} or

• may occur at that step {such as metal

filings being introduced during a

mincing step}


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HACCP – Principle 1Physical Hazards

Foreign objects naturally presentHair, bone chips, bones, twigs, leaves

Foreign objects occurring in agricultureDirt, manure, grubs, insects, grass, leaves, twigs

Foreign objects added during processingGlass, wood, plastic, jewellery, paper, hair, metal

shavings

Natural constituents of the food itselfA lump in a puree can choke a patient in a hospital

on a liquid diet


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Chemical Hazards

• Chemical hazards naturally present

Poisons occur naturally in rhubarb, potatoes

Fish and shellfish toxins; algal blooms

Mould toxins in nuts, grains etc.

• Chemical hazards added via water

Run off from other fields, flocculants,

algaecides


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HACCP – Principle 1Chemical Hazards

• Chemical hazards added via agriculture

Soil: Heavy metals, chemicals from previous crops

Plants: Fertilizers, chemicals present in manures,

ground breakers, pesticides, weedicides,

herbicides, plus all of the above from water

Animals: Veterinary, dips, drenches, antibiotics,

hormones, plus all of the above from water and

from plants


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Chemical Hazards

• Chemical hazards added during

processing

– Processing aids, food additives, food

ingredients

– Cleaning chemicals

– Pest control chemicals and

– Maintenance chemicals


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HACCP – Principle 1Allergens

•Cereals containing gluten and their products

•Crustacea and their products

•Egg and egg products,

•Fish and fish products

•Milk and milk products

•Nuts and their products, excluding coconut

•Sesame seeds and their products

•Peanuts and soybeans and their products

•Added sulphites in concentrations of >10 ppm

•[Royal jelly, bee pollen and propolis]


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Biological Hazards include:

Viruses (e.g. Hepatitis , Norwalk Virus,

enterovirus)

Bacteria (e.g. Salmonella species, E. coli,

Listeria monocytogenes, Clostridium

botulinum, Campylobacter jejuni, Bacillus

cereus)

Fungi (Yeasts and Mould)

Parasites (Algae, protozoa, flukes, worms,

tapeworms, etc


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HACCP – Principle 1Biological Hazards

These can occur

• in water,

• in the environment,

• on raw materials,

• on processing equipment,

• from staff contamination,

• from cross contamination, and

• just about everywhere else


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HACCP – Principle 1Common food poisoning pathogens:

• Listeria monocytogenes

• Escherichia coli

• Salmonella species

• Campylobacter jejuni

• Staphylococcus aureus

• Bacillus cereus

• Clostridium perfringens

• Hepatitis species


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Quality Hazards

Colour,

flavour,

texture,

weight,

appearance,

size,

shape, etc


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Assessment of significance is possibly

the most important aspect of the initial

food safety audit.

If a business has not undertaken their

assessment of significance correctly,

the process is likely not under effective

control.


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HACCP – Principle 1Part 2: Assessment of significance of

hazards

Significance is a combination of the severity and the likelihood of the hazard occurring.

Severity – How bad is it, assuming to gets all the way to the consumer?

Likelihood – If we did nothing, what‟s the chance this would happen?

Significance – Is a combination of both of these.


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Hazard Analysis Matrix

LIKELIHOOD

SEVERITY A B C D E

1 1 2 4 7 11

2 3 5 8 12 16

3 6 9 13 17 20

4 10 14 18 21 23

5 15 19 22 24 25


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FOOD SAFETY HAZARD SEVERITY

1. Fatality occurrence

2. Serious Illness

3. Product Recall

4. Customer Complaint

5. Not significant


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QUALITY SEVERITY

1. Immediate& final cessation business

2. Food recall (e.g. due to severe

deterioration or discolouration)

3.Rejection of a delivery by the customer

4.Warning advice of non-significance

5.Not of commercial significance


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FOOD SAFETY HAZARD LIKELIHOOD

A. Common repeating

B. Known to occur or „it has happened‟

(own info)

Could occur or „I‟ve heard of it

happening‟

D. Not expected to occur

E. Practically impossible


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QUALITY LIKELIHOOD

A. Common repeating

B. Known to occur or „it has happened‟

(own info)

C. Could occur or „I‟ve heard of it

happening‟

D. Not expected to occur

E. Practically impossible


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Hazard Analysis Matrix

LIKELIHOOD

SEVERITY A B C D E

1 1 2 4 7 11

2 3 5 8 12 16

3 6 9 13 17 20

4 10 14 18 21 23

5 15 19 22 24 25


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Control Measures

For each hazard, a control measure

should be put in place.

For each SIGNIFICANT HAZARD, a

control measure MUST be put in place.


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Control MeasuresEvery significant hazards must have at least

one control measure that eliminates or

reduced the hazard to an acceptable level.

In reality, hazards have multiple control

measures in most cases.

Control measures can be part of the process,

or part of one of the support programs.

Control measures can occur anywhere in the

process

Example: Chicken receival and presence of

Salmonella


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Control MeasuresIn the example of controlling the growth of spoilage

bacteria in meat at the step of storage in a coolroom, control measures in place would include:– Measure the temperature of the coolroom

– Measure the temperature of the meat

– Buy meat from approved suppliers so that there are less spoilage organisms on the meat in the first place

– Clean the coolroom to reduce the number of potential contaminating areas within the coolroom

– Take microbial samples of the meat

– Train staff in correct storage of meat so that it is stacked to allow efficient air circulation around the meat

– Maintain the coolroom

– Ensure the gauge on the coolroom is calibrated


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Control MeasuresIn this example, some of the control

measures are more practical than others, and some do not occur at the point of storage.

If the step of storage of raw meat was previously assessed in the hazard analysis as significance, then at least one of the above measures must be a significant control measure and must be done routinely to ensure the hazard is under control.

HACCP would also require that this significant control measure can routinely recorded, by whether manual or mechanical means.


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Conclusion

Documents

CAPSIG NSW Presentation · HACCP Codex has 12 steps..and the 7 Principles of HACCP •6. List potential hazards, conduct a hazard analysis and consider measures to control any hazards