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1、Food Safety Systems Management,Hazard Analysis Critical Control Point,A systematic approach to the identification,evaluation,and control of significant food safety hazards.Risk Assessment and Management tool not unlike a FMEA(Failure Modes Effects Analysis).,Foundation of HACCP-Prerequisite Programs
2、,Prerequisite Programs,Universal programs/procedures for controlling operational conditions of the plantCreate an environment suitable for the production of safe products.Must be adequate and effective.Must be monitored(requires documentation and records)Internal Audit.Repeated failure of a prerequi
3、site program may indicate that decisions made in a Hazard Analysis are not supported.,Raw Materials Control,Raw Materials Control,Supplier licensing and registration must meet state and federal requirements(e.g.FDA Registration for Bioterrorism Act of 2002)Material Guarantee and Supplier Certificate
4、 of InsuranceSupplier Food Safety Audit(second or third party)Raw Material Specifications-includes capability assessment on critical parametersCertificate of Analysis on critical to quality parametersSupplier HACCP Risk AssessmentHandling/Shipping Requirements,Raw Materials Control,Documented inspec
5、tion of sealed vehicle(temperature,sanitation)in which materials are received.Materials inspected upon receipt.Visual inspection,grading,COA receipt,etc.as your program has defined.Suitably stored to protect quality and integrity of goods.(allergen segregation,temperature,protected,chemicals stored
6、separately and secured,etc).,Sanitation,Sanitation,Effective cleaning procedures for equipment and facility.Documented SSOP(Sanitation Standard Operating Procedures)Defined frequencyChemicals approved for use in food facilities.Records concentrations,times,temperatures.Sanitation monitoring visual i
7、nspections,chemical or microbiological testing.Corrective actions for deficiencies.,Employee Training,Employee Training,Records of training required.Hygienic PracticesDisease ControlCleanliness outer garments,hand-washing,unsecured jewelry and other objects,use of gloves,hair and beard nets,eating,d
8、rinking,tobacco use,nail polish,etc.Manufacturing ControlsTraffic flow to prevent cross contaminationIngredient/product handling to protect productControl measures(pH,cook time/temp,moisture,etc)Scheduling sequential runs to prevent cross contamination(as for allergens)Food Defense,Facility Design a
9、nd Control,Facility Design and Control,Grounds Eliminate pest harborage areas Properly grade roads,yards,parking lots BuildingProvide sufficient space for placement of equipment and storage of materialsPrevent cross contamination,Facility Design and Control,Floors,walls and ceilings cleaned and in g
10、ood repair.Prevent condensateAdequate lightingAdequate ventilationWater Quality(potable,steam,ice,reclaimed water,cooling water,backflow prevention)Employee welfare/sanitary facilitiesWaste controlEnvironmental monitoring,Equipment Design and Maintenance,Equipment Design and Maintenance,Designed and
11、 of materials and workmanship as to be adequately cleanable meets standards(e.g.3A Sanitary Standards).Installed with adequate space to allow for proper cleaning and maintenance and to prevent cross contamination.Properly maintained(records).,Pest Control,Pest Control,Prevention is key(design,mainte
12、nance and sanitation)Rodent control Insect control Bird/Bat Control,Traceability and Product Recovery,Traceability and Product Recovery,Documented program with written procedures to meet federal requirements.Program should include Product Identification/Lot codingFinished product distribution record
13、s retained beyond shelf life of productResponsible individuals and their rolesIdentification of Key Contacts Internal,supplier customerMock Recovery ProgramOne step forward,one step back,Prerequisite programs are in place,Lets talk HACCP,Steps to HACCP Implementation,Assemble the HACCP TeamDescribe
14、the food and its distributionDescribe the intended use and consumers of the foodDevelop a flow diagram which describes the processVerify the Flow Diagram,Multidisciplinary HACCP Team,Quality AssuranceSanitationEngineeringMicrobiologyProductionOutside experts(if necessary),Describe the Food/Distribut
15、ion:Cheddar Cheese,Formal Product name:Cheddar Cheese Food Safety Characteristics:pH(4.9 to 5.4)Packaging type:42#Block,Vacuum sealed in ploy bag and stored in corrugated boxLength of shelf life/storage temperature:3-12 months when stored below 45FWhere it will be sold:Food ManufacturerIntended Cons
16、umers:Consumers of all agesLabeling instructions:Keep RefrigeratedIntended use:Ready to eat product.May be used as ingredient.May be further processed into chunks or shredded.,Develop a Flow Diagram,Verify the Flow Diagram,HACCP Team should perform an on-site review of the operation to verify the ac
17、curacy and completeness of the flow diagram.Take the diagram out to the production floor and walk through the steps.Review periodically,modify and update as necessary(annual review or when change to process occurs).,1-Conduct a Hazard Analysis,Identify hazards at each processing step and for each in
18、gredient and material used.Biological such as pathogenChemical such as toxinPhysical-such as glassEvaluate hazards to determine severity and likelihood to occurThe hazard evaluation provides a basis for determining control measures such as CCPs,2-Determine Critical Control Points,A critical control
19、point(CCP)is defined as a step at which control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level.Information from the hazard analysis should enable the HACCP team to identify which steps in the process are CCPs.,3 Establish Critical Lim
20、its,A critical limit must be scientifically based and is 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 the food safety hazard to an acceptable level.Examples:Temperature,time,Water Activity,pH,safe toler
21、ance level for drug residues,4 Establish Monitoring Procedures,Monitoring is a planned sequence of observations or measurements used to assess whether a CCP is under control.Monitoring should produce an accurate record for use in verification.Where there is loss of control(a CCP limit is exceeded)th
22、ere must be documented corrective action.,Monitoring,Continuous is desirable(recording chart)but where not possible,frequency for monitoring must be established.Responsibility for monitoring must be assigned-Position title/work station,5-Establish Corrective Actions,Corrective actions are procedures
23、 to be followed when a deviation occurs.Corrective actions must be specific.Halt production of productIsolate the affected productReturn the process to controlDetermine the disposition of the productRecords must be kept for a reasonable period after the shelf life of the product,6 _ Establish Verifi
24、cation Procedures,Establish procedures to verify that the system is working properly.Might include calibration and testing of monitoring equipment,demonstration of system performance,documented record review,7-Records,Identify records that are being used to monitor control pointsRecords of trainingR
25、ecords at process step(recording charts,temperature records,etc)Deviation logsVerification and Validation RecordsRecords to show changes to the HACCP Plan,Consider our example,Identify hazard at each step and for each material,1 Conduct Hazards Analysis,Identify the hazards for each step of the proc
26、ess:Raw milk/receivingIdentify the type of hazard:chemical,biological or physicalChemical-lactam(antibiotic)residue,pesticideBiological Vegetative Pathogens,viruses,spoilage organismsPhysical Metal,Determine severity of each hazard and likelihood of occurrence,Severity:Enteric pathogens such as E.co
27、li 0157H7 and Salmonella cause severe health effects including death among children and elderly.Likelihood to occur:Likely that they will occur in raw milk supplyUsing this information,determine if this potential hazard is to be addressed in the HACCP Plan,Hazards Analysis(severity),Is the hazard id
28、entified at this step severe and of sufficient likelihood of occurrence to warrant its control?If Yes,go to next question.If no,identify the prerequisite program or procedure step,which reduces the likelihood or severity of the hazard to ensure that control at this step is not necessary.,Hazards Ana
29、lysis(control),Does a control measure exist at this step to prevent,reduce or eliminate the likely occurrence of the hazard to an acceptable level?If yes,this step is a CCP.If no,identify where control exists.(Pasteurization Step This step is a CCP).,Hazards Analysis(justify),Justification-Research
30、or Reference Document that gives credence to your assumptions.Pasteurized Milk Ordinance,2003 Revision,WDATCP 80.48,2-Determine Critical Control Points,3-Establish Critical Limits,Critical LimitsHTST Limits for raw milk pasteurization are defined in the PMO minimum 161F/15 seconds,4-Establish Monito
31、ring Procedures,Continuous chart monitoring of temperature and flow rate.Performed by Pasteurizer Operator in the Pasteurizer Room.,5-Establish Corrective Actions,When minimum time or temperature requirement is not met,product automatically diverts to back to the balance tank prior to the HTST Paste
32、urizer.Forward flow is prevented.Product diversion must be indicated on Pasteurizer Recording chart.These instances should be carefully reviewed by Licensed Pasteurizer Operator.,6 _ Establish Verification Procedures,Daily:Proper performance of HTST is demonstrated after sanitation and before produc
33、t(Cut In/Cut Out)and recorded on the continuous chart.Charts verified Licensed Pasteurizer Operator.Six months:Representative from WDA Tests Pasteurizer/time(maximum allowable flow for specified distance)and temperature.All controls are sealed.Records are retained by facility and state.Daily:Seal ch
34、eck verify that all seals are intact.Record reviewed by Licensed Pasteurizer Operator.,7 Establish Records,Pasteurizer ChartsSeal Check RecordWDA Pasteurizer Time/Seal Record.Other Equipment Calibration and testing records.,Identify CCP on Flowchart,HACCP Description Chart,References,International Dairy Foods Association HACCP Plant Manual,2007 EditionPasteurized Milk Ordinance,2003 RevisionWDATCP Chapters 60 and 80USDA-FSIS HACCP Website,Questions?,
