Prerequisite Requirements of HACCP B.K.Kolita Kamal Jinadasa, Research officer, Post harvest technology division, NARA, Colombo-15, Sri Lanka
HACCP is one part of larger QUALITY MANAGEMENT/ASSURANCE SYSTEM
Prerequisite programs
Quality management system • Product/ Food Safety
• Not described in the original US National Advisory Committee on Microbiological criteria for Foods (NACMCF) or Codex HACCP guidelines.
– HACCP system
• Product Quality – Quality control system. • i.e. meeting buyer specifications, including legal requirements
• Concept originated in 1993 Agriculture and Agri-Food Canada’s (AAFC) Food Safety Enhancement Program (ESEF).
• Environmental/Operating condition – Prerequisite requirements for HACCP
Prerequisite Programs AAFC/FSEP Definition: • Universal steps or procedures • that control the operational conditions within a food processing establishment • allowing for environmental conditions that are favorable to the production of safe food. • Basically GMP and hygiene/ sanitation control Æ basic requirements for all food industry
HACCP IS NOT A STANDSTAND-ALONE SYSTEM
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HACCP PREREQUISITE PROGRAMS FOUNDATION OF AN EFFECTIVE HACCP SYSTEM
• simpler yet more effective HACCP plans – easier to maintain and manage • Control potential hazards to becoming significant hazards • reduce no. of CCPs - kept to true critical points
Prerequisite Programs
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• Not part of the formal HACCP plan.
• Premises and facilities, equipment, sanitation and hygiene.
• Managed separately rather than include their performance and control as part of the HACCP plan.
• Others- personnel training, supplier control, product traceability and recall, consumer complaints, specification.
• Simpler yet more effective – – HACCP plans- easier to maintain and manage.
• Control potential hazards from becoming significant hazards. • Reduce no. of CCPs– Kept to true critical points.
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Prerequisite program
HACCP Plan
Deals indirectly with food safety issues – environmental/operating conditions
Deals directly with food safety issues
More general and may be applicable throughout the plant crossing multiple product lines
Product and line specific
Deviations from prerequisite requirement will not result in a food safety hazard or concern – non-critical
Deviations from a HACCP Plan critical limit will result in a food safety hazard and action against the product
In other word: • Ensuring that food is safe and wholesome • But may not be enough to control business-specific food safety hazard
Prerequisite programs should be:
Equipments Personnel training
Premises
Prerequisite program should cover:
Sanitation
Recall Receiving/ storage/ transport
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• Cross product line.
• Basically applications of GMP & hygiene/sanitation Control.
Prerequisite Programs
Prerequisite Programs
• Documented with written SOPs. • Monitored with proper record to ensure effectiveness • Reviewed and revised – periodically to ensure relevance
Premises
Premises
• Plant location, construction and layout. • To protect food from unsanitary conditions and cross contamination. • Location – Adequate plot size. – Easy access. – Pollution risk form surrounding
• Construction & layout – – – – – –
Separation of operations. Product flow patterns. Adequate working space. Lighting. Ventilation Building materials.
• Smoke, dust, odors, airborne microbes
Facilities Premises = Structural Operating Environment Poorly designed, constructed and maintained food premises will increase the chance of food becoming contaminated Cover: • Proper plant layout (hygienic design) • Building material, wall and water covering • Water quality • Sanitary facilities
• Adequate supply of energy/power. • Adequate supply of potable cold water, hot water and steam must be available for cleaning & sanitation when necessary. • A suitable water treatment system where appropriate (chlorination plant, waste water treatment)
Facilities • Adequate sewage & waste disposal. • Adequate facilities for washing and disinfecting equipment. • Adequate staff amenities (hand washing facilities, toilets, staff rooms). • Adequate sanitary plumbing (no cross concentration between portable & non portable water lines)
Equipment & Utensils DesignPrevent contamination of product. prevent accumulation of food residues during production. For accessibility and cleanability. Durability. Easy maintain. Performance.
Equipments & Utensils ConstructionFood-safe materials Non toxic. Non absorbent Resistant to the product, cleaning and disinfecting agents. Stainless steel and plastic.
MaintenanceSchedule for servicing, replacement and calibration.
Sanitation & Hygiene 9Proper cleaning and sanitation will: 9Decrease the likelihood of food becoming contaminated; and 9Discourage pests from the premises, vehicle and/or vessels.
Personnel training Staff must be trained to do their jobs competently e.g. processing skills, HACCP monitoring. Includes training in those prerequisite requirements for which they are responsible such as personal hygiene, hygienic handling practices, cleaning and sanitation. Training
Written training program and schedules. Re-training. Training records of personnel. Competency testing.
Cleaning and Sanitation Cleaning: Removing waste, dirt and grease from equipment, premise, vehicles and vessels Sanitation: Reducing the number of microorganisms to a level that keep a food safe. Food contact surfaces, equipment and utensils should be sanitized. Remember: A dirty surface can not be sanitized!
Cleaning and Sanitation
Cleaning and Sanitation
• Develop a written program or Sanitation Standard Operating Procedures (SSOP)
• Cleaning and sanitation procedure and schedule should be written and followed.
• FDA seafood HACCP Rule mandates 8 sanitation area that must be monitored and documented
• A master sanitation schedule should be developed and rigorously applied to assure good housekeeping and minimize product exposure to contaminants.
Cleaning and Sanitation • Written guidance should be developed for personnel hygiene standards for plant workers- include proper attire, hair, hand washing and personnel health expectations. • An environment sampling program may be used to confirm the effectiveness of the cleaning and sanitation program.
Sanitation standard operating procedure (SSOP) • Describe a particular set of objectives associated with sanitary handling of food and the cleanliness of the plant environment and the activities conducted to meat them. • FDA seafood HACCP rule mandates 8 areas of sanitation that must be monitored and documented.
FDA 8 Keys sanitation areas 1. Safety of water- that comes into contact with food or food contact surface, or is used in the manufacture of ice. 2. Condition & cleanliness of food-contact surfaces, include utensils, gloves and outer garments. 3. Prevention of cross-contamination from unsanitary object to food, food packaging materials and other food contact surfaces, including utensils, gloves and outer garments, and from raw to cooked product.
FDA 8 Keys Sanitation areas 6.
Proper labeling, storage and use of toxic compound.
7.Control of employee health conditions that could result in the microbiological contamination of food, food packaging material and food contact surface. 8.
Exclusion of pests from the food plant
FDA 8 Keys Sanitation areas 4. 5.
Maintenance of hand-washing, handsanitizing and toilet facilities Protection food, food packaging materials and food contact surface from adulteration with lubricant, fuel, pesticides, cleaning compounds, sanitizing agents, condensate and other chemical, physical and biological contaminants.
Pest control • Pests such as rodents, birds, insects, animals e.g. cats and dogs. • Carriers of human disease agents.
Pest control program • Based on 3 principles;
Receiving/ storage/ transport
– Exclusion or preventing access• Windows screens, self-closing doors
– Restriction by avoiding to create an environment conducive to pests-
All raw materials and products should be stored under sanitary conditions and proper environmental conditions (temperature and humidity) to assure their safety and wholesomeness
• Elimination of harborage and attractant areas (rapid removal of waste).
– Destruction and eradication• Usually done by specialist company.
Other program
Recall Program ¾ An action plan which gives the company ability to recover or retrieve product it has left the control of the company. ¾ Recall team, coordinator. ¾ Written recall/recover procedures. ¾ Minimize bad publicity, consumer complaints, criminal law suit and damage to the company reputation ¾ Involves product identification and traceability (raw materials, ingredients and finished products, distribution records)
• • • • •
Food transport vehicle. Fishing vessels. Supplier approval. Food packaging. Product identification and labeling.
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