The HACCP-system

1. The HACCP-system Hazard Analysis Critical Control Point System A Summary

2. „A holistic approach to food safety management programs, incorporating best practice facility and equipment design, as well as structured management systems“ What is HACCP? HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace

3. Developed as a microbiological safety system Pioneered by Pillsbury Company, NASA and US Army Laboratories Based on Failure Mode and Effect Analysis (FMEA) Where did HACCP come from?

4. Product safety cannot be tested in • Proven system to manage food safety • Foodborne diseases are a public health problem • Increase in susceptible population (elderly, immune-compromised, malnourished) • Changing lifestyles (eating-out, processed food, tourism) • Emerging pathogens • Increase in complexity of supply chain • Improved laboratory testing schemes Why use HACCP?

5. Conduct a hazard analysis Determine the Critical Control Points (CCPs) Establish Critical Limits Establish a system to monitor control of the CCP Establish the corrective actions to be taken when monitoring indicates that a particular CCP is not under control Establish procedures for verification to confirm that HACCP is working correctly Establish documentation concerning all procedures and records appropriate to these principles and their application 7 Principles of HACCP According to: Codex Alimentarius Commission and NACMCF

6. Applicability of HACCP within Supply Chain Wholesalers Primary Producers Sea Food Foodservice Caterers Primary Producers Land Crops Human Processing Animal Feeds Consumers Primary Producers Meat, Dairy, Poultry, Eggs Retailers Adapted from: HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace

7. HACCP is not governed by international legislation Each country has own food safety regulation which may include HACCP European Union, 1st of January 2006: Regulation (EC) No. 852/2004 on the Hygiene of Foodstuffs, Article 5 Governmental Regulation of HACCP

8. Codex 2009b: Primary international reference standard for HACCP ISO 22000 (2005): Certification standard for HACCP (based on Codex 2009b) International Standardisation

9. HACCP Success Structure Adapted from: HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace

10. Planning & Preparation HACCP studies & HACCP plan development Implementation of HACCP plan Maintenance of HACCP system Key Stages in HACCP Development

11. Linear HACCP plans • Applicable to each product or process individually • For simple operations with few product types • Modular HACCP plans • Flexible approach • Applicable to basic operations or modules • Generic HACCP plans • Based on framework approach • For simple operations HACCP System Structure

12. HACCP & Continuous Improvement Monitoring and Corrective/Preventive Actions Verification Implementation Improvement HACCP Plan Development Planning and Realisation of Safe Products Hazard Analysis Establishing PRPs Adapted from: HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace

13. „Universal steps or procedures that control the operational conditions within a food establishment allowing for environmental conditions that are favourable for the production of safe food“ (CFIA, 1998) „Procedures including good manufacturing practices that address operational conditions providing the foundation for the HACCP system“ (NACMCF, 1997) „Practices and conditions needed prior to and during the implementation of HACCP and which are essential for food safety“ (WHO, 1998) PRPs – Prerequisite Programmes

14. A biological, chemical or physical agent in, or condition of, food with the potential to cause an adverse health effect (Codex, 2009b) • Significant hazard • „Hazards that are of such a nature that their elimination or reduction to an acceptable level is essential to the production of safe foods“ (ILSI, 1999) • Control measures • „Any actin or activity that can be used to prevent or eliminate a food safety hazard or reduce it to acceptable level“ (Codex 2009b) Hazards – Significance & Control Hazard... Any factor present in the product that causes illness or harm to the customer. The basis for every HACCP system

15. Macro-biological • Insects • Micro-biological • Direct: invasion of humans • Indirect: via toxins Biological Hazards

16. Pathogenic Gram-negative bacteria • Salmonella enterica • Escherichia coli • Campylobacter jejuni • Vibrio parahaemolyticus • Vibrio vulnificus • Shigella spp. • Yersinia enterocolitica • Cronobacter sakazakii • Habitat: animal intestines • Control: heat processing, segregation of raw and cooked foodstuffs, good hygienic practices Biological Hazards - Bacteria

17. Pathogenic Gram-positive bacteria • Clostridium botulinum • Clostridium perfringens • Bacillus cereus • Staphylococcus aureus • Listeria monocytogenes Biological Hazards - Bacteria

18. Hepatitis A and Norovirus Source: Shellfish Very small and thus difficult to detect But easily to be inactivated by heat Biological Hazards - Viruses

19. Pathogenic flatworms, tapeworms, flukes • Taenia saginata • Trichinella spiralis • Clonorchis sinensis • Source: infected flesh (pork, beef, fish, game) • Prevention: good animal husbandry, veterinary inspection, heating, freezing, drying • Encysted larvae: • Toxoplamsa gondii • Giardia intestinalis • Cyclospora cayetanensis • Cryptosporidium parvum Biological Hazards – Parasites & Protozoa

20. Transmissible agents Misfolded cellular proteins Initiation of abnormal folding of normal protein in brain Formation of plaques Destruction of brain cells BSE (Bovine Spongiform Encephalopathy) Scrapie (Sheep disease) Creutzfeldt-Jakob Disease (Human) Biological Hazards - Prions

21. Listeria monocytogenes • Escherichia coli O157:H7 • Cronobacter spp. • Prions • Expected: Continued emergence of new foodborne microbial pathogens • Drivers: • Changes in land use or agricultural practices • Changes in human demographics and society • Poor population health • Hospitals & medical procedures • Pathogen evolution (antibiotics) • Contamination of food sources or water supplies • International travel • Failure of public health programmes • Climate change Emerging Pathogens

22. Intrinsic factors • pH and acidity • Organic acids • Preservatives • Water activity • Ingredients • Process Technologies • Thermal processes • Fermentation • Drying • Freezing • Irradiation Control of biological Hazards

23. Not well understood – lack of toxicological expertise Contamination can happen at any stage Chronic (carcinogenic) or acute (allergenic reaction) effects for customer Chemical Hazards

24. Secondary metabolites of certain fungi • Long-term carcinogenic effect or short-term acute toxic effects • Affected food: cereals, nuts, dried fruit, coffee, cocoa, spices, beans, fruit, etc. • Very stable • Aflatoxins • Aspergillus flavus • Patulin • Penicillium spp. • Deoxynivalenol • Fusarium spp. • Fumonisins • Fusarium spp. Chemical Hazards - Mycotoxins

25. Most common potential contaminant Use of non-toxic and food-grade chemicals PRP: Design & management of cleaning procedures Chemical Hazards – Cleaning Chemicals

26. Insecticides Herbicides Fungicides Wood preservatives Masonry biocides Bird & animal repellents Food storage protectors Rodenticides Anti-fouling paints Industrial/domestic hygiene products Consider cross-contamination at any stage Chemical Hazards - Pesticides

27. Immune mediated • Non-immune mediated (majority) • Allergens: • Peanuts, tree nuts, eggs, milk products, shellfish, fish, soya, wheat (Big 8 allergens) • Lactose intolerance: 70% of population are lactase deficient • HACCP must consider cross-contamination • PRP: general control of allergens Allergens & Food Intolerances

28. Toxic/heavy metals Nitrites, nitrates, N-nitroso compounds Polychlorinated Biphenyls Dioxins and Furans Polycyclic aromatic hydrocarbons Plasticizers & packaging migration Veterinary residues Melamine & cyanuric acid Chemical additives Chemical Hazards

29. Can enter at any stage Glass Metal Stones Wood Plastic Pests Intrinsic material (bones in meat/fish, nut shells) Physical Hazards

30. Hazard Significance Adapted from: HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace

31. Hazard Significance Significant Hazard High Severity Medium Low Medium Low High Likelihood of Occurrence Adapted from: HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace

32. PRPs – HACCP Support Network Adapted from: HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace

33. PRPs – the Foundation of HACCP Focus on: raw materials, product and processes Focus on: Production environment, facility, programs and people Adapted from: HACCP A Practical Approach, 3rd Edition, Sara Mortimore and Carol Wallace

34. “A document prepared in accordance with the principles of HACCP to ensure control of hazards that are significant for food safety in the segment of the food chain under consideration”(Codex, 2009b) A formal document Pulls together key information from HACCP study Details of all that is critical to food safety Developed by HACCP team The HACCP Plan

35. Logic Sequence for HACCP Application

36. HACCP - A Practical Approach, 3rd Edition Sara Mortimore and Carol Wallace, Springer 2013 (ISBN: 978-1-4614-5027-6) References - Book http://www.springer.com/food+science/book/978-1-4614-5027-6

37. Codex Alimentarius • http://www.codexalimentarius.org/ • National Advisory Committee on Microbiological Criteria for Foods (NACMCF) • http://www.fsis.usda.gov/about/NACMCF/index.asp • World Health Organisation (WHO) • http://www.who.int/topics/food_safety/en/ • EU legislation • http://europa.eu/legislation_summaries/food_safety/veterinary_checks_and_food_hygiene/f84001_en.htm References – Websites