Hazard Analysis and Critical Control Points

1. Hazard Analysis and Critical Control Points History, Overview, and Prerequisites Food Microbiology

2. First Part � Conducting a Hazard Analysis Second Part � Identifying Managing and Implementing Critical Control PointsFirst Part � Conducting a Hazard Analysis Second Part � Identifying Managing and Implementing Critical Control Points

3. Definitions-- �Science based, common sense prevention approach to food contamination� �Common sense application of technical and scientific principles to the food production process from field to table� �A preventive system for assuring the safe production of food products� �A systematic approach to be used in food production as a means to assure food safety� Many Book Definitions DO NOT know all of these�.Many Book Definitions DO NOT know all of these�.

4. SO WHAT IS HACCP????? Common Terms Science Common Sense Prevention Food Safety KNOW THIS---- Use science and common sense to prevent food safety hazards. Management Tool and Thought Process Common Terms Science Common Sense Prevention Food Safety KNOW THIS---- Use science and common sense to prevent food safety hazards. Management Tool and Thought Process

5. 1959 - Pillsbury NASA Natick Laboratories of US Armed Forces U.S. Air Force Space Lab Project Group Why????? Safe Food for Astronauts Prevent Illness that might cause Aborted Mission Wanted Close to 100% Assurance that Food was not Contaminated QC Techniques Could not Assure close to 100% Safe Must Test all Food Nothing left to Eat New System Developed Process Control Recordkeeping Safe Food for Astronauts Prevent Illness that might cause Aborted Mission Wanted Close to 100% Assurance that Food was not Contaminated QC Techniques Could not Assure close to 100% Safe Must Test all Food Nothing left to Eat New System Developed Process Control Recordkeeping

6. 1985- National Academy of Sciences Recommended that HACCP be adopted by all regulatory agencies and mandatory for food processors NACMCF (National Advisory Committee on Microbiological Criteria for Foods) Standardized HACCP Principles

7. NACMCF - 7 Principles of HACCP: Conduct a Hazard Analysis Identify Critical Control Points (CCP) Establish Critical Limits for CCP Establish Monitoring Procedures Establish Corrective Actions Establish Verification Procedures Establish Recordkeeping Procedures

8. HACCP is NOT a regulation!!!!!!!! It is a food safety tool!!! Regulatory � Seafood Meat and Poultry Juice Soon � Egg Dairy? All Industry can follow and SHOULDHACCP is NOT a regulation!!!!!!!! It is a food safety tool!!! Regulatory � Seafood Meat and Poultry Juice Soon � Egg Dairy? All Industry can follow and SHOULD

9. HANDOUT � Flow Diagram MUST BE DEVELOPED PRIOR TO DEVELOPING A HACCP PLAN Clear, Simple Description of Steps of Process Guide for HACCP Team Future Verification All Steps under control of Establishment Verify Review and Modify Periodically Clear, Simple Description of Steps of Process Guide for HACCP Team Future Verification All Steps under control of Establishment Verify Review and Modify Periodically

10. EXAMPLE GROUND BEEF PRODUCTION

11. Step 1 - Receiving

12. Step 2 - Storage

13. Course Grind

14. Course Grind

15. Fine grind

16. Packaging

17. Distribution

18. Principle 1 - Conduct a Hazard Analysis TWO STEPS Hazard Identification Hazard Evaluation/Controls List steps in process where Significant Hazards likely to Occur and Describe Control Measures Hazards must by a Risk Significant enough so that Control is Essential for Safe Food Identify Control Measures Hazard Identification �Brainstorm� List all Potential Hazards Hazard Evaluation Base on Severity and Likelihood of Occurrence Consider Short Term and Long Term Exposure List steps in process where Significant Hazards likely to Occur and Describe Control Measures Hazards must by a Risk Significant enough so that Control is Essential for Safe Food Identify Control Measures Hazard Identification �Brainstorm� List all Potential Hazards Hazard Evaluation Base on Severity and Likelihood of Occurrence Consider Short Term and Long Term Exposure

19. Biological Bacteria, Viruses, Yeast and Molds, Prions � Micro Macro � Rodents, Flies Chemical Sanitizers, Antibiotics, Hormone Physical Metal or Glass Pieces, etc�. Biological Bacteria, Viruses, Yeast and Molds, Prions � Micro Macro � Rodents, Flies Chemical Sanitizers, Antibiotics, Hormone Physical Metal or Glass Pieces, etc�.

20. Physical � Heat/Pasteurization and Sterilization Steam Vac, Steam Past. Chemical Additives Carcass washes Biological LABPhysical � Heat/Pasteurization and Sterilization Steam Vac, Steam Past. Chemical Additives Carcass washes Biological LAB

21. An estimate of likely occurrence of hazard Based on - Experience, epidemiological data, and other information from the scientific literature. Severity is the seriousness of the risk.

22. A tool to Determine Risk

24. Hazard Analysis

25. Principle 2 - Identify CCP CRITICAL control points Point, step or procedure at which Control can be Applied and a Food Safety Hazard can be Prevented, Eliminated or Reduced to Acceptable Levels �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�-NACMCF Loss of Control Results in an Unsafe Product Several Steps in Process where Hazards are Controlled Only a Few Points are CRITICAL Steps That are Critical in One Process may not be Critical in Another Based on Hazard Analysis Point, step or procedure at which Control can be Applied and a Food Safety Hazard can be Prevented, Eliminated or Reduced to Acceptable Levels �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�-NACMCF Loss of Control Results in an Unsafe Product Several Steps in Process where Hazards are Controlled Only a Few Points are CRITICAL Steps That are Critical in One Process may not be Critical in Another Based on Hazard Analysis

27. Determining CCPs

28. Principle 3 - Establish Critical Limits Base on Scientific Literature and/or Regulatory Standards Parameters to Define if a CCP is in or out of control ��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.� � NACMCF Temperature Time Time/Temperature Combinations pH Aw Nitrite Content Salt Content Parameters to Define if a CCP is in or out of control ��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.� � NACMCF Temperature Time Time/Temperature Combinations pH Aw Nitrite Content Salt Content

29. For Each CCP Determine if there is a regulatory limit Determine if there is scientific evidence If no regulatory limit or scientific evidence then consult with University/Industry Experts Conduct Validation Study if Necessary

30. Principle 4- Monitor CCP Assess whether CCP is under control and Record Visual Observations Physical Measurement Track System Operation Trends Toward Loss of Control Action Taken before Limit Exceeded Determines when There is Loss of Control and Corrective Action Needed Provides Written Documentation for use in Verification of HACCP Plan Visual Observations Physical Measurement Track System Operation Trends Toward Loss of Control Action Taken before Limit Exceeded Determines when There is Loss of Control and Corrective Action Needed Provides Written Documentation for use in Verification of HACCP Plan

31. For Each CCP Determine the Best Monitoring Procedure Determine the Frequency of Monitoring and Documentation Determine Decision Criteria Acceptable or Unacceptable

32. Principle 5 - Establish Corrective Action What are you going to do when there is a deviation from critical limit? Reprocess Hold Destroy Product Must Be taken because a CL has been exceeded and a potential hazard may result �procedures followed when a deviation occurs� NACFM Specific CA must be established for each CCP What are you going to do when there is a deviation from critical limit? Reprocess Hold Destroy Product Must Be taken because a CL has been exceeded and a potential hazard may result �procedures followed when a deviation occurs� NACFM Specific CA must be established for each CCP

33. Stop the Line and Correct Problem Hold and Evaluate Product in Question Continue Production after Process Brought back into Control Identify Long-Term Solutions

34. Determine and Correct the Cause on Noncompliance Determine the Disposition of Non-Compliant Product Record the Corrective actions Taken Who is Responsible for Initiating the Corrective Action Who is Responsible for �oversight

36. Principle 6 - Verification Critical Limits at CCP Satisfactory HACCP plan Functioning Validations Generate Scientific Data to Support Plan Regulatory Responsibility and Actions to Ensure HACCP Functioning Those Activities other than Monitoring that Determine the Validity of and Compliance with the HACCP Plan Those Activities other than Monitoring that Determine the Validity of and Compliance with the HACCP Plan

37. Determine if HACCP Plan is Working Are Hazards Reduced by Plan? Initial Verification Periodic Verification Determine if Operations are in Compliance with HACCP Plan Has HACCP been Implemented Properly? On-Going Activities Calibrations Record Reviews Annual Review of Plan Microbial testingCalibrations Record Reviews Annual Review of Plan Microbial testing

38. Principle 7 - Recordkeeping HACCP Team Product Description Flow Diagrams Hazards, CCP and Preventive Measures Critical Limits Monitoring System Corrective Actions Recordkeeping Procedures Verification Procedures The HACCP Plan Records obtained during operation of plan  Supportive Documentation Daily CCP Records Calibration records Receiving log for ingredients, packaging Employee Training Records Validation of HACCP Plan Daily Review for Completeness Review for deviations and irregularities Follow-up on product disposition Designated, responsible individual Initial and date Keep them organized The HACCP Plan Records obtained during operation of plan Supportive Documentation Daily CCP Records Calibration records Receiving log for ingredients, packaging Employee Training Records Validation of HACCP Plan Daily Review for Completeness Review for deviations and irregularities Follow-up on product disposition Designated, responsible individual Initial and date Keep them organized