These regulations were developed in response to outbreaks of Clostridium botulinum poisoning in commercially canned food and have effectively prevented such occurrences since their implementation. Recent outbreaks in commercially canned food have occurred in the products of companies that did not precisely follow the regulations. Toward the end of the s, a number of publications were instrumental in making HACCP the predominant food safety system. This publication, also known as the green book, recommended that the food processing industry and governmental agencies use HACCP, describing it as the most effective means to ensure the safety of the U.
The expert committee stated that HACCP would have to be made a regulatory requirement to ensure widespread use.
Other suppliers soon followed suit. The book described the application of HACCP to the entire food chain from the farm through food preparation in the restaurant and home. Hazard analysis was based on a combination of risk and the severity of the hazard. Build your profile and create a personalized experience today! Sign up is easy! Review the concepts of risk assessment and risk management to identify similarities with the seven HACCP principles listed above.
The expanding acceptance of HACCP suggests that it may someday extend across the entire food industry production, processing, and preparation and around the world for example, see Codex and ISO.
Implementation of a HACCP system will increase the protection of consumers from illness-causing microbes and other hazards in juices. HACCP is intended to reduce the risk of unsafe food products, but it also can lead to improved product quality. Preliminary Steps 1. Describe the food and its method of production and distribution 3. Develop and verify process flow diagram s 4.
Multidisciplinary membership. Know the manufacturing process and the products Know how to take corrective action. What method will be used for distributing the product? Is the product refrigerated, frozen or shelf-stable? What safety hazard or quality issue are associated with this food product?
Step 3 Intended Use and Consumers What impact will the product have on the general public? Are you targeting a specific segment of the market? Particular consumers? Are you targeting a wholesale or retail market?
What are the ingredients? Do any ingredient pose a food safety risk? Does the food offer specific characteristics, such as, a low fat products Step 4 Develop a Flow Diagram The diagram or flow chart must cover all steps of the manufacturing process. It is not an engineering drawing. Verify the accuracy and completeness of the flow diagram. Step 5 Conduct a Hazard Analysis Are you concerned about microbiological, chemical or physical hazards again, this list is expanding?
Identify steps in the manufacturing process where a hazard can happen. Consider risk probability of the hazard and severity if the hazard occurs.
Remember -- hazard is limited to safety; it does not focus on quality issues even though they may be related. Identify preventative measures that can be applied. GMPs can and should control many hazards. Exceeding the CL means a health hazard exists.
CLs can be derived from regulatory standards e. Examples of CLs: temperatures for some products it may be what is too high and for other products it may be what is too low , time, pH, residues, kind and count of bacteria.
Monitoring intervals must be reliable. Microbiological criteria do, however, play a role in verifying that the overall HACCP system is working. In accordance with the National Academy of Sciences recommendation, the HACCP system must be developed by each food establishment and tailored to its individual product, processing and distribution conditions.
In keeping with the Committee's charge to provide recommendations to its sponsoring agencies regarding microbiological food safety issues, this document focuses on this area. The Committee recognizes that in order to assure food safety, properly designed HACCP systems must also consider chemical and physical hazards in addition to other biological hazards.
A commitment by management will indicate an awareness of the benefits and costs of HACCP and include education and training of employees. Benefits, in addition to enhanced assurance of food safety, are better use of resources and timely response to problems.
The Committee designed this document to guide the food industry and advise its sponsoring agencies in the implementation of HACCP systems. Control: a To manage the conditions of an operation to maintain compliance with established criteria. Control Measure: Any action or activity that can be used to prevent, eliminate or reduce a significant hazard.
Critical Control Point: 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. Hazard: A biological, chemical, or physical agent that is reasonably likely to cause illness or injury in the absence of its control. Hazard Analysis: The process of collecting and evaluating information on hazards associated with the food under consideration to decide which are significant and must be addressed in the HACCP plan. Monitor: To conduct a planned sequence of observations or measurements to assess whether a CCP is under control and to produce an accurate record for future use in verification.
Step: A point, procedure, operation or stage in the food system from primary production to final consumption. Validation: That 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.
Verification: Those activities, other than monitoring, that determine the validity of the HACCP plan and that the system is operating according to the plan. HACCP is a systematic approach to the identification, evaluation, and control of food safety hazards based on the following seven principles:.
HACCP is a management system in which food safety is addressed through the analysis and control of biological, chemical, and physical hazards from raw material production, procurement and handling, to manufacturing, distribution and consumption of the finished product.
A firm commitment to HACCP by top management provides company employees with a sense of the importance of producing safe food. HACCP is designed for use in all segments of the food industry from growing, harvesting, processing, manufacturing, distributing, and merchandising to preparing food for consumption.
Food safety systems based on the HACCP principles have been successfully applied in food processing plants, retail food stores, and food service operations. The seven principles of HACCP have been universally accepted by government agencies, trade associations and the food industry around the world.
The following guidelines will facilitate the development and implementation of effective HACCP plans. While the specific application of HACCP to manufacturing facilities is emphasized here, these guidelines should be applied as appropriate to each segment of the food industry under consideration.
The production of safe food products requires that the HACCP system be built upon a solid foundation of prerequisite programs. Examples of common prerequisite programs are listed in Appendix A. Each segment of the food industry must provide the conditions necessary to protect food while it is under their control. This has traditionally been accomplished through the application of cGMPs. These conditions and practices are now considered to be prerequisite to the development and implementation of effective HACCP plans.
Prerequisite programs provide the basic environmental and operating conditions that are necessary for the production of safe, wholesome food.
Many of the conditions and practices are specified in federal, state and local regulations and guidelines e.
The Codex Alimentarius General Principles of Food Hygiene describe the basic conditions and practices expected for foods intended for international trade. In addition to the requirements specified in regulations, industry often adopts policies and procedures that are specific to their operations.
Many of these are proprietary. While prerequisite programs may impact upon the safety of a food, they also are concerned with ensuring that foods are wholesome and suitable for consumption Appendix A. HACCP plans are narrower in scope, being limited to ensuring food is safe to consume.
The existence and effectiveness of prerequisite programs should be assessed during the design and implementation of each HACCP plan. All prerequisite programs should be documented and regularly audited.
For example, many establishments have preventive maintenance procedures for processing equipment to avoid unexpected equipment failure and loss of production. This would further ensure that all the food in the oven is cooked to the minimum internal temperature that is necessary for food safety.
The success of a HACCP system depends on educating and training management and employees in the importance of their role in producing safe foods. This should also include information the control of foodborne hazards related to all stages of the food chain. It is important to recognize that employees must first understand what HACCP is and then learn the skills necessary to make it function properly. Specific training activities should include working instructions and procedures that outline the tasks of employees monitoring each CCP.
Management must provide adequate time for thorough education and training. Personnel must be given the materials and equipment necessary to perform these tasks. In many cases the plans will be product and process specific. However, some plans may use a unit operations approach.
The five preliminary tasks are given in Figure 1. The team should be multi disciplinary and include individuals from areas such as engineering, production, sanitation, quality assurance, and food microbiology. The team should also include local personnel who are involved in the operation as they are more familiar with the variability and limitations of the operation.
In addition, this fosters a sense of ownership among those who must implement the plan. However, a plan which is developed totally by outside sources may be erroneous, incomplete, and lacking in support at the local level. Due to the technical nature of the information required for hazard analysis, it is recommended that experts who are knowledgeable in the food process should either participate in or verify the completeness of the hazard analysis and the HACCP plan.
Such individuals should have the knowledge and experience to correctly: a conduct a hazard analysis; b identify potential hazards; c identify hazards which must be controlled; d recommend controls, critical limits, and procedures for monitoring and verification; e recommend appropriate corrective actions when a deviation occurs; f recommend research related to the HACCP plan if important information is not known; and g validate the HACCP plan.
This consists of a general description of the food, ingredients, and processing methods. The method of distribution should be described along with information on whether the food is to be distributed frozen, refrigerated, or at ambient temperature.
Describe the normal expected use of the food. The intended consumers may be the general public or a particular segment of the population e. The purpose of a flow diagram is to provide a clear, simple outline of the steps involved in the process. The scope of the flow diagram must cover all the steps in the process which are directly under the control of the establishment.
In addition, the flow diagram can include steps in the food chain which are before and after the processing that occurs in the establishment. The flow diagram need not be as complex as engineering drawings.
A block type flow diagram is sufficiently descriptive see Appendix B. Also, a simple schematic of the facility is often useful in understanding and evaluating product and process flow. The HACCP team should perform an on-site review of the operation to verify the accuracy and completeness of the flow diagram.
Modifications should be made to the flow diagram as necessary and documented. After addressing the preliminary tasks discussed above, the HACCP team conducts a hazard analysis and identifies appropriate control measures. The purpose of the hazard analysis is to develop a list of hazards which are of such significance that they are reasonably likely to cause injury or illness if not effectively controlled.
Hazards that are not reasonably likely to occur would not require further consideration within a HACCP plan. It is important to consider in the hazard analysis the ingredients and raw materials, each step in the process, product storage and distribution, and final preparation and use by the consumer.
When conducting a hazard analysis, safety concerns must be differentiated from quality concerns. A hazard is defined as a biological, chemical or physical agent that is reasonably likely to cause illness or injury in the absence of its control. Thus, the word hazard as used in this document is limited to safety. If the hazard analysis is not done correctly and the hazards warranting control within the HACCP system are not identified, the plan will not be effective regardless of how well it is followed.
The hazard analysis and identification of associated control measures accomplish three objectives: Those hazards and associated control measures are identified. The analysis may identify needed modifications to a process or product so that product safety is further assured or improved. The analysis provides a basis for determining CCPs in Principle 2.
The process of conducting a hazard analysis involves two stages. The first, hazard identification, can be regarded as a brain storming session. During this stage, the HACCP team reviews the ingredients used in the product, the activities conducted at each step in the process and the equipment used, the final product and its method of storage and distribution, and the intended use and consumers of the product. Based on this review, the team develops a list of potential biological, chemical or physical hazards which may be introduced, increased, or controlled at each step in the production process.
Appendix C lists examples of questions that may be helpful to consider when identifying potential hazards. Hazard identification focuses on developing a list of potential hazards associated with each process step under direct control of the food operation. A knowledge of any adverse health-related events historically associated with the product will be of value in this exercise.
After the list of potential hazards is assembled, stage two, the hazard evaluation, is conducted. During this stage, each potential hazard is evaluated based on the severity of the potential hazard and its likely occurrence.
Severity is the seriousness of the consequences of exposure to the hazard. Considerations of severity e. Consideration of the likely occurrence is usually based upon a combination of experience, epidemiological data, and information in the technical literature.
When conducting the hazard evaluation, it is helpful to consider the likelihood of exposure and severity of the potential consequences if the hazard is not properly controlled.
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