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LEARNING OUTCOMES:
On completion of this module, the learner will be able to: 1. Explain the function of HACCP in the canning industry 2. Discuss the 12 steps involved in implementing a HACCP plan 3. Explain what is meant by the terms HACCP Hazard Analysis Critical Control Points Monitoring Verification Validation 4. Describe the operation and structure of a flow chart for canning 5. Describe the use of a Hazard Analysis Table 6. Describe the use of a HACCP Audit Table 7. The importance of control measures
INTRODUCTION
HACCP is a tool used as part of a Total Quality Management system to reduce the risk of consumers becoming injured by the consumption of food products. The system was introduced by NASA to reduce the likelihood of astronauts becoming ill due to food poisoning while in space. The concept introduced the term Zero Defects. The system was mainly introduced to deal with microbiological issues but its application has broadened to include all other possible hazards as well as quality issues. The importance of HACCP has increased as a result of legislation by Food Standards Australia and New Zealand (ANZFA) as part of the revised Food Standards Code. Chapter 3 - Food Safety Standards ( Australia only ) [ pdf 83 kb ] PART 3.1 Standard 3.1.1 Preliminary Interpretation and Application
PART 3.2 Food Safety Requirements Standard 3.2.1 Food Safety Programs Standard 3.2.2 Food Safety Practices and General Requirements Standard 3.2.3 Food Premises and Equipment
3 While 3.2.1 is currently only mandatory in Victoria the other states are considering various options in terms of its adoption. However, irrespective of this many food companies, manufactures, retailers, and food outlets have quality systems in place that requires the mandatory use of a Food Safety Program in order to operate with that company or organisation.
DEFINITIONS
Control (verb): To take all necessary actions to ensure and maintain compliance with criteria established in the HACCP plan. Control (noun): To state wherein correct procedures are being followed and criteria are being met. Control measure: Any action and activity that can be used to prevent or eliminate a food safety hazard or reduce it to an acceptable level. Corrective action: Any action to betaken when the results of monitoring at the CCP indicate a loss of control. Critical Control Point (CCP): 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. Critical limit: A criterion, which separates acceptability from unacceptability. Deviation: Failure to meet a critical limit. Flow diagram: A systematic representation of the sequence of steps or operations used in the production or manufacture of a particular food item. HACCP: A system, which identifies, evaluates, and controls hazards, which are significant for food safety. HACCP plan: A document prepared in accordance with the principles of HACCP to ensure control of hazards which are significant for food safety in the segment of the food chain under consideration. Hazard: A biological, chemical or physical agent in, or condition of, food with the potential to cause an adverse health effect. Hazard analysis: The process of collecting and evaluating information on hazards and conditions loading to their presence to decide which are significant for food safety and therefore should be addressed in the HACCP plan. Monitor: The act of conducting a planned sequence of observations or measurements of control parameters to assess whether a CCP is under control. Step: A point, procedure, operation or stage in the food chain including raw materials, from primary production to final consumption.
4 Validation: Obtaining evidence that the elements of the HACCP plan are effective. Verification: The application of methods, procedures, tests and other evaluations, in addition to monitoring to determine compliance with the HACCP plan.
HACCP is no guarantee of product safety an its effectiveness depends on: Skill/knowledge of HACCP team Hazard identification Effectiveness of control measures Level of implementation Commitment by management Awareness of employees
6 The key elements for the successful application of a HACCP Plan are: commonsense knowledge of product process understanding of HACCP
This is done by taking the draft flow chart and walking around the plant and checking that what has been recorded is what is actually happening. Observation and interviews of staff are the essential aspects of this process.
1. Identifying potential hazards A hazard is any biological, chemical or physical agent in, or condition of, food with the potential to cause an adverse health effect. (codex) Potential hazards are anything that will result in product spec. not being achieved. Hazards may relate to the 5 Ps products raw materials, ingredients, packaging, water finished product plant/equipment metal premises dust, rodents procedures methods, processes people hygiene, training Hazards are categorised by how they affect product integrity. food safety product quality environmental legal OH&S The scope defines which ones apply. Food safety hazards may be: 1. Biological hazards : Bacteria e.g. salmonella sp. clostridium sp. fungal e.g. aspergillus spp. viral eg hepatitus parasitic eg liverfluke, giardia 2. Chemical hazards\ naturally occuring mycotoxins shellfish toxins oxalic acid solanine added chemicals pesticides food additives and preservatives fertilizers cleaning chemicals heavy metals
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3. Physical hazards glass dirt wood metal, plastic jewelry human particles eg hair, fingernails, false teeth 4. Quality hazards Quality hazards are those hazards that prevent the product from meeting specified customer requirements. Customer size shape colour weight Legislation which may affect ingredient or additive composition and level
2. Determining the cause of hazards It is important to distinguish between the hazard and its cause.eg. microbial growth is a hazard and high product temperature may be the cause. Control measures and critical limits usually address the cause. The cause of a hazard may be related to : defective raw material defective equipment incorrect storage conditions inappropriate handling practices incorrect packaging materials unsuitable environmental conditions 3. Assessing the significance of the hazard. This is a subjective assessment based on the knowledge and experience of the HACCP team. To determine the significance consider: Severity what are the consequences if the hazard occurs Likelihood of the hazard occurring
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or by the Work Risk Assessment Classification (WRAC) system for risk management. Results of the hazard analysis are recorded in the Hazard Analysis Table/report using the checklist. 4. Control measures The purpose of a control measure is to : prevent a hazard from occurring eliminate the hazard when it occurs reduce the hazard to an acceptable level
Where a significant hazard has been identified, a control measure must be developed and implemented. The control measure may occur at an earlier or later step eg metal detectors at end pasteurisation after receival
There may be more than one control measure eg source from approved supplier and store ,5c.
Control measures include : For product : heating (cooking, pasteurisation, retorting, baking, frying) cooling (freezing, refrigeration) acidification chemicals ( preservatives) gases (map and cap )
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Control measures need to be documented in the HACCP plan or the support programs such as : cleaning calibration pest control hygiene
CRITICAL
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. ( codex ) a point where a food safety hazard of high significance can occur ( 1-10 ) for each significant hazard there must be at least one ccp
A CP (control point) is : a point where a food safety hazard of moderate significance can occur
control of the hazard is needed but not critical A CQP (critical quality point) is: a point where a quality hazard of high significance can occur control of the hazard is essential
A QP (quality point) is a point where a quality hazard of moderate significance can occur control of the hazard is needed but not critical
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Documents and records need to be controlled to : keep in good condition readily accessible legal requirements
A record system should state: where documents and records are stored. who is responsible date and length of storage
SUPPORT PROGRAMS
Support programs are necessary to ensure the effectiveness of a HACCP plan. Support programs can be linked to Food Safety Standards calibration cleaning GHP pest control training approved supplier document control preventative maintenance 3.2.2.21 3.2.2.18-19 3.2.2.2.13-17 3.2.2.23 3.2.2.3 3.2.2.5 3.2.2.3(c)&4(e) 3.2.2.20
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APPROVED SUPPLIER
These are suppliers approved on their ability to supply safe material. Company should have records of approved suppliers. companies inspection data audit reports corrective action
Approved suppliers are monitored by: certificates of analysis audits receival inspection testing ( chemical, micro, physical)
DOCUMENT CONTROL
The actual procedure for control of documents can be a support program.
PREVENTATIVE MAINTENANCE
Engineering staff part of HACCP team Sub-contractors need to be controlled and need to have a schedule of activities eg lubrication (food grade grease) bearing changes oil changes blade sharpening ( count tools in/out)
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AUDITING
Auditing provides confidence that the food safety program: meets the requirements of the standard (ANZFA, SQF, Woolworths) has been effectively implemented appropriate effective
Types of audit include internal ( first party )( us on us ) external ( second party )( us on them ) extrinsic ( third party )( them on us )
REFERENCES
Anon (1997) A Guide to the implementation and auditing of HACCP. SCARM Report : no 60. Standing Committee on Agriculture and Resource Management. CSIRO Publishing Vic. http://courses.che.umn.edu/01fscn1102-1s/topics.html http://www.fao.org/docrep/W6419E/w6419e03.htm#principles%20of%20the%20hacc p%20system http://www.fao.org/docrep/W8088E/w8088e05.htm http://www.foodstandards.gov.au/foodstandardscode/