OAS REGIONAL PROJECT

1. OAS REGIONAL PROJECT QUALITY MANAGEMENT MODULES 3 & 4

2. PRESENTER: Marcia Henry Manager, Project & Quality Management Systems Scientific Research Council

3. Course Objectives • Understanding the Seven Principles of HACCP • Understanding the Guidelines for the Development of a HACCP Plan for each Enterprise • Understanding the Principles and Requirements for Quality Documentation

4. HACCP HAZARD ANALYSIS AND CRITICAL CONTROL POINTS

5. What is HACCP? • HACCP Systems Are Designed to Prevent and Control Food SafetyHazards Associated With Food From the Time a Company Receives Raw Material, Through Production to Distribution to the Consumer

6. What is HACCP? • It Is a Preventive, Systematic System for Ensuring Food Safety • It Is Not a Stand-alone System • HACCP Systems Must Be Built on a Firm Foundation of Compliance With Current Good Manufacturing Practices and Acceptable Sanitation Control Procedures (SCP) for It to Work Effectively

7. HACCP versus Traditional • Traditional Methods Evaluate Processing Practices on the Day or Days of Inspection • HACCP Allows Regulators to Look at What Happens at the Plant Through Time by Examining the Monitoring and Corrective Action Records of the Enterprise

8. HACCP • Emphasizes Process Control • Concentrates on the Points in the Process That Are Critical to the Safety of the Product • Stresses Communication Between the Regulator and Industry

9. HACCP • Applicable to Any Food ChainFrom Primary Production to Final Consumer. The Idea of “Farm to Fork” • Emphasizes Commitment of Top Management and Involvement of People (Staff)

10. Prerequisite Programmes • GMP and Sanitation Procedures Affect the Processing Environment and Should Be Considered Prerequisite Programs to HACCP • Prerequisite Programs Are Procedures Including GMP, that Address Operational Conditions Providing the Foundation for the HACCP System

11. Prerequisite Programmes • When Sanitation Standard Operating Procedures (SSOPs) are well designed and fully and effectively implemented they are valuable in controlling hazards • With SSOPs in place, HACCP can be more effective since they would concentrate on controlling hazards associated with the food or processing and not on the processing plant environment

12. HACCP & HAZARDS • Hazard Refers to Conditions or Contaminants That Can Cause Illness or Injury.

13. FOOD HAZARDS • A hazard is a biological, chemical or physical agent that is reasonably likely to cause illness or injury in the absence of its control

14. 3 TYPES OF FOOD HAZARD • BIOLOGICAL • CHEMICAL • PHYSICAL

15. BIOLOGICAL HAZARDS OR PATHOGENS

16. BIOLOGICAL HAZARDS • BACTERIAL • VIRAL • PARASITIC

17. BACTERIAL HAZARDS • CAN BE INTRODUCED DURING THE PROCESSING OF FOODS FROM: • The People Involved in the Processing • The Environment in Which the Food Is Processed • From Other Ingredients in the Product • From the Processes Themselves

18. BACTERIAL HAZARDS • Bacterial hazards are defined as bacteria that, if they occur in food, may cause illness in humans, either by infection or intoxication • Bacterial hazards can be grouped into spore formers and non-spore formers. • Spores are normally very resistant to chemicals, heat and other treatments

19. What Do Microorganisms Need? • Food • Water • Proper Temperature • Air, No Air, Minimal Air Without adequate amount of these, microorganisms stop growing and multiplying. Some die; others stop functioning until they get the elements theyneed (spore formers)

20. Sporeforming Bacteria • These include the following: • Clostridium botulinum • Clostridium perfringens • Bacillus cereus

21. Non-sporeforming Bacteria • These include the following: • Pathogenic Escherichia coli (e.g. E. coli 0157:H7) • Streptococcus pyrogenes • Salmonella spp • Listeria monocytogenes • Campylobacter spp.

22. Viral Hazards • Viruses exists everywhere • They are very small particles that cannot be seen with a light microscope • Viruses exists in food without growing. They do not cause spoilage • Viruses cause illness by infection

23. Viral Hazards • Viruses only grow once they enter a suitable host • Only some viruses consider humans a suitable host • Viruses can survive in human intestines, contaminated water and frozen foods for months

24. Viruses • Include the following: • Hepatitis A virus – causes fever and abdominal discomfort, followed by jaundice • Norwalk virus – causes nausea, vomiting, diarrhoea and abdominal pain (gastroenteritis). Headache and low-grade fever may also occur • Rotavirus

25. ACTION • Transmission of viruses to foods is usually related to Poor Hygiene Practices. • Food handlers must wash and sanitize their hands properly

26. ACTION • Food spoilage or decomposition that can result in a food-safety problem should be prevented or controlled by a HACCP programme • Microorganisms that will cause food spoilage must be controlled

27. Parasitic Hazards • Parasites are organisms that need a host to survive, living on or within it • Parasitic worms and protozoa are two types of parasites that can infect people through food and water

28. Parasitic Worms • Include the following: • Roundworms (nematodes) e.g. Ascaris lumbricoides that causes intestinal and lung infection • Tapeworms (cestodes) e.g. Diphyllobothrium latum that attaches itself to the intestinal walls and can grow up to 7 feet long. Causes abdominal pain, flatulence and diarrhoea. • Flukes (trematodes)

29. Protozoa • Single-celled animals • Most cannot be seen without a microscope • Examples: Giardia lamblia that causes diarrhoea, abdominal cramps, fatigue, nausea, flatulence (intestinal gas) and weight loss. Illness may last up to two weeks but chronic infections can last months to a year • Entamoeba histolytica that causes dysentry (severe bloody diarrhoea)

30. CHEMICAL HAZARDS

31. Chemical Hazards • Chemicals Are Not Hazardous If Properly Used and Controlled • The Presence of a Chemical May Not Always Represent a Hazard • The Amount of the Chemical May Determine Whether It Is a Hazard or Not. • Regulatory Limits Are Set for Some Chemical Contaminants

32. Chemical Hazards • 3 Categories • Naturally Occurring Chemicals • Intentionally Added Chemicals • Unintentionally or Incidentally Added Chemicals

33. Naturally Occurring Chemicals • These Include Allergens and Are Derived From a Variety of Plants, Animals and Microorganisms • Examples: Mycotoxins e.g. Aflatoxin From Moulds That Can Grow on Corn & nuts; Scombrotoxin; Shellfish Toxins • Certain Varieties of Nuts and Seafood Produce an Allergic Reaction in Sensitive People

34. Intentionally Added Chemicals • These are Chemicals that are added to food at some point during the food’s growth and distribution • Safe when used at established safe levels but can be dangerous when those levels are exceeded

35. Potential Chemical Hazards

36. Intentionally Added Chemicals • Food processors should review the appropriate regulations for approval status and any limitations on the use of food additives

37. Unintentionally or Incidentally Added Chemicals • Agricultural Chemicals (e.g. pesticides, fungicides, herbicides, fertilizers, antibiotics and growth hormones) • Prohibited Chemicals (Reference: Code of Federal Regulations, Chapter 21, Section 189)

38. Unintentionally or Incidentally Added Chemicals • Toxic elements and compounds (e.g. lead, zinc, arsenic, mercury, cyanide) • Secondary direct and indirect e.g. lubricants, cleaning compounds, sanitizers and paints

39. Unintentionally or Incidentally Added Chemicals • Packaging materials that are in direct contact with the ingredient or the product can be a source of incidental chemicals, such as sanitizers or inks • These are of concern if they are in too high an amount

40. PHYSICAL HAZARDS

41. Physical Hazards • Include any harmful extraneous matter not normally found in food. • If eaten may cause choking, injury or other adverse health effects • Most commonly reported consumer complaints because the injury occurs immediately or soon after eating and the source is often easy to be identified

42. Physical Hazards

43. 7 PRINCIPLES OF HACCP

44. PRINCIPLES OF HACCP • Conduct Hazard Analysis • Determine Critical Control Points in the Process • Establish Critical Limits • Monitor Each Critical Control Point • Establish Corrective Actions • Establish Verification Procedures • Establish Record Keeping and Documentation Procedures

45. SOME DEFINITIONS • CONTROL • CONTROL MEASURE • CONTROL POINT • CRITICAL CONTROL POINT • CRITICAL LIMIT • HAZARD

46. PRINCIPLE 1 • Conduct a Hazard Analysis • Must look at the: • Likelihood of occurrence and • Severity (seriousness of a hazard) • For each food safety hazard, identify a preventive measure

47. PRINCIPLE 2 • Identify The Critical Control Points in the Process • This is a point, step or procedure in a food process at which control can be applied and, as a result, a food safety hazard can be prevented, eliminated or reduced to acceptable levels • The Decision Tree Approach can be used to determine CCP

48. PRINCIPLE 3 • Establish Critical Limits for Each Critical Control Point • A Critical Limit Is the Maximum or Minimum Value to Which a Physical, Biological or Chemical Hazard Must Be Controlled at a Critical Control Point to Prevent, Eliminate or Reduce to an Acceptable Level, the Occurrence of the Identified Food Safety Hazard

49. PRINCIPLE 4 • Establish Monitoring Procedure for Each Critical Control Point • These are Activities that are done routinely either by an employee or mechanically, to measure the process at a given CCP, and create a record for future use. These include employee observations or checks and records from instruments • Physical and chemical monitoring procedures are preferred over microbial approaches because they provide rapid feedback.

50. PRINCIPLE 5 • Establish Corrective Actions • These are the activities to be taken when there is deviation from critical limits • This is a very important principle as deviations from critical limits will occur. The enterprise must ensure that deviations do not lead to unsafe foods