Integrating HACCP and SPC

8/19/2019 Integrating HACCP and SPC

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Integrating HACCP and SPCPosted: February 25th, 2012 - 11:15am

Source: Food Safety Tech

Think about the role of process control as the canary in the mine shaft: the

canarys untimely death indicates a dan!erous situation in the mine shaft, much

like "#$$P alerts a plant mana!er of a potential ha%ard& #nd 'ust as (entilatin!

the mine shaft and monitorin! the process ensures that dan!erous conditions

cannot arise, conductin! statistical process control in a food processin! plant )ill

pre(ent dan!erous conditions from happenin! in the *rst place&

"a%ard #nalysis $ritical $ontrol Point is a food safety mana!ement system

desi!ned to ensure the safe production and packa!in! of food& The "#$$P

process +Table 1 has both stren!ths and limitations& t pro(ides a systematic and

e.ecti(e method to analy%e a process, and identi*es potential biolo!ical, chemical

and physical ha%ards that can occur in food& n addition, "#$$P re/uires thede(elopment of strate!ies to pre(ent the inclusion or reduction of these ha%ards

to an acceptable le(el in the food&

Table 1: Preliminary Tasks in the e(elopment of the "#$$P Plan and "#$$P

Principles

TASKS PRINCIPLES

1& #ssemble the "#$$P team

1& $onduct a ha%ard analysis

2& escribe the food and its distribution 2& etermine the critical control points+$$Ps

& escribe the intended use and consumers of the food

& stablish critical limits

3& e(elop a 4o) dia!ram that describes the process

3& stablish monitorin! procedures

5& erify the 4o) dia!ram

5& stablish correcti(e actions

6& stablish (eri*cation procedures

7& stablish record-keepin! and documentation procedures

The most e.ecti(e )ay to a(oid product ha%ard is to control the process properly

rather than relyin! on *nal product inspection& For e8ample, a !ood "#$$P

pro!ram cannot depend on microbiolo!ical tests as the means to pre(ent a

ha%ard because they are too slo) to pro(ide the real-time information needed to

maintain process control properly&

The problem, ho)e(er, is that most "#$$P monitorin! systems take an attribute

approach to analy%in! data& (en if (ariable data are collected to monitor a

critical control point, the data are typically cate!ori%ed as either 9!ood +not

e8ceedin! the critical limit or 9bad +e8ceedin! the critical limit& This approach

can limit the e.ecti(e use of (ariable data by failin! to detect process chan!es

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o(er time, )here the process control may be deterioratin! before a problem

manifests itself&

;ne )ay to think about the role of process control is to consider the e8ample of

the canary in the mine shaft& The canarys untimely death indicates a dan!erous

situation in the mine shaft, much like "#$$P alerts a plant mana!er of a potentialha%ard&


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$ontrol charts pro(ide the primary tool to determine the e8tent and type of

process (ariation& They are used to analy%e t)o ma'or !roups of data: (ariable

data, or measurement data, and attribute data, or count data& Table 2 describes

di.erent types of control charts and their uses& The most e.ecti(e control chart

that can be used to e(aluate indi(idual (ariable data that monitors control pointsis the indi(idual mo(in! ran!e +8-mA control chart& This chart allo)s the

e(aluation of indi(idual data points rather than a(era!es&

Table 2: Types of $ontrol $harts

TEP ;F #T#

TEP ;F $"#AT @S ;F $"#AT

ariable

ndi(idual mo(in! ran!e +8-mA

ach subsample is a data point

#(era!e - ran!e +8-bar A

The subsample consists of less than ten data points

#(era!e - standard de(iation +8-bar s

The subsample consists of ten or more data points

#ttribute

p chart

Bonconformin! units

np chart

Portion of nonconformin! units

c chart

Bonconformitiesu chart

Portion of nonconformities

ndi(idual mo(in! ran!e +8-mA

#ny type of attribute data

Bote: Some /uality professionals su!!est that most (ariable data can be analy%ed

usin! either the indi(idual mo(in! ran!e control chart or the 8-bar A control chart,

and all attribute data can be analy%ed usin! the indi(idual mo(in! ran!e control

chart&

#n alternati(e method to analy%e "#$$P data is to use a t)o-step e(aluation

process& urin! the *rst step, data taken from the critical control point )ould be

compared to the critical limits to determine )hether a potential for a food safety

ha%ard e8ists& Be8t, the data )ould be analy%ed usin! an indi(idual mo(in! ran!e

control chart +see case study& The control chart allo)s for a !raphical

interpretation of the type and e8tent of (ariation that a.ects the process& f a

process is capable of meetin! critical limits, then it is or could be possible to make

ad'ustments in the process prior to producin! unsafe food& n addition, the

analysis can pro(ide the means to identify potential opportunities for

impro(ements and increase the capability of the "#$$P pro!ram, thus reducin!

the risk of makin! unsafe food&

#ny "#$$P pro!ram should be directed to food safety issues& The process is not


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desi!ned to identify /uality enhancement areas, e(en thou!h )ell-desi!ned

"#$$P pro!rams can enhance the /uality of products& ike)ise, /uality

impro(ement processes can pro(ide a "#$$P bene*t by reducin! the risk of

ha(in! a food safety ha%ard& For e8ample, a processGproduct impro(ement pro'ect

could center on reducin! the amount of re)ork& This pro'ect may be implementedto increase the producti(ity and decrease the re)ork& Speci*c /uality

enhancement issues should be addressed throu!h a /uality mana!ement system

such as described in the S; >000 standards&

# "#$$P pro!ram must be linked to, rather than combined )ith, other /uality

systems& ach /uality system is desi!ned to accomplish speci*c ob'ecti(es? it is

important to keep those ob'ecti(es separate& First and foremost, food processin!

companies must pro(ide a safe supply of food& Still, a sound approach to increase

the eDcacy of the "#$$P system is to combine the traditional analysis of data

)ith the use of statistical /uality techni/ues&

$ase in point

Hutterball Turkey $ompany, o)ners Iro(e, , has applied this statistical

methodolo!y to continually e8pand and impro(e its ne) Turkey nspection

System& #s part of the control system, the company routinely analy%es data usin!

control charts& ts process control charts and procedures are desi!ned to identify

trends and ad'ust the process to reduce the risks that defecti(e products are

!enerated& ;ne e8ample in(ol(es selectin! carcasses and inspectin! them for

!eneric & coli& This is done to determine )hether the birds contain unacceptable

le(els of & coli or other bacteria&

Samplin! and bacterial testin!$arcasses are aseptically sampled at the end of the chill system, after the drip

line, usin! statistical samplin! procedures& urin! the time these data )ere

collected

the )hole-bird rinse techni/ue )as used& The carcasses )ere collected in a ba!

containin! 600 m of Hutter*elds phosphate diluent& Be8t, they )ere rinsed

inside and out by usin! a rockin! motion of 0 cycles for appro8imately one

minute& The rinse )ater )as collected and plated usin! the #;#$ 17&&03 method&

Aesults )ere reported as colony formin! units per milliliter +$F@Gm& ata )ere

statistically analy%ed and control strate!ies )ere de(eloped& This method of

samplin! has been replaced by a s)ab samplin! procedure, but the concepts

presented remain applicable for process control&

Process analysis

Fi!ures 1 throu!h demonstrate the analysis of this data usin! histo!rams and

indi(idual mo(in! ran!e control charts& urin! the *rst part of the sample year,

statistical analysis re(ealed that the process )as both stable and (ery capable

+Fi!ure 1&

dentifyin! root problems

#t the end of


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2& The le(el )as still belo) the critical le(el& Fortunately, because the process

)as (ery capable, the problems )ere identi*ed and a correcti(e action team

comprisin! plant operations, /uality assurance, maintenance and procurement

personnel )as formed to identify and remo(e the problems root cause& #s part of

the solution, procurement personnel )orked closely )ith the producers tomaintain and impro(e the conditions of the birds comin! into the plant& n

addition, ne) chlorinated spray cabinets )ere added to the processin! line after

the pickers& #lso, the *rst and *nal )ash cabinets )ere impro(ed to include a ne)

chlorinatin! system and hi!her )ater pressures& $hecks )ere implemented to

control and (erify chlorine le(els and )ater pressures& #dditionally inspectors

)ere added to the line after the *nal )ash and before the birds entered the chill

system&

$onclusion

Hutterball has successfully linked the monitorin! of control points to statistical

process control, and the /uality impro(ement processes& This linka!e has

permitted the

de(elopment of a hi!hly capable manufacturin! process& #s a result, if a chan!e

or other factor a.ects the system, a /uality impro(ement team can identify the

root cause of the problem and take correcti(e and pre(enti(e action& This strate!y

has additional bene*ts to the company: t increases employee in(ol(ement,

a)areness, attention to detail and moti(ation, )hile impro(in! /uality and

producti(ity&

Bote: The abo(e is a classic study initially published in Food =uality Ca!a%ine,

Cay 1>>J, )ith another (ersion published as $lemson @ni(ersity $ooperati(e8tension Ser(ice H 152, September 1>>J& The line of thinkin! de(eloped in this

study has had a si!ni*cant impact on the de(elopment of modern Food Safety

Cana!ement Systems& ;ne of the authors,


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HACCP – The Basics and Benefits

(This post is Part 1 of a series of HACCP training blogs and is a

continuation of our earlier post HACCP - A Worthy Subect!

Ha"ard Analysis and Critical Control Points (HACCP! can be si#ply $ie%ed as a

pre$ention based food safety syste# that identifies and #onitors specific food

safety ha"ards that can ad$ersely affect the safety of food products& HACCP is

internationally recogni"ed as the best #ethod to ensure food safety and can be

applied at all stages of food production' fro# har$est through to consu#ption&

The standards for HACCP systems ha$e been the subect of #uch debate

and interpretation' ho%e$er' in recent years the Code Ali#entarius Co##ission)s

#ethodology for HACCP has beco#e the uni$ersally accepted standard& *ost

go$ern#ent organi"ations and food businesses throughout the %orld no% align

their interpretation of HACCP to the principles and guidelines set out by the Code

Ali#entarius Co##ission&

HACCP is a t%o part process& The first part is to identify potential food safety

ha"ards (this is also +no%n as hazard analysis! and the second part is to

design a syste# that pre$ents or eli#inates ha"ards& The proper identification of

potential food safety ha"ards is a critical part of HACCP as the entire HACCP

syste# depends on the effecti$e identification of significant ha"ards& HACCP

syste#s therefore' need to be de$eloped by a #ultidisciplinary tea# of people

%ho understand the food production operations and #ust be specifically designed

for indi$idual food production processes&

As %ell as pro$iding a cost effecti$e syste# for controlling food safety'

i#ple#entingHACCP also has the follo%ing benefits,

.educed ris+ of foodborne illness

/ocuses e#ployees on food safety precautions and i#pro$es their understanding

of food safety ha"ards

.educed product loss and decreased li+elihood of food recalls

Protection of business reputation and reduced liability ris+

*eets large retailer)s prere0uisite supplier standards

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Helps to open the door) to international trade #ar+ets&

Today the benefits of HACCP are %idely recogni"ed by food #anufacturers and

food retailers&

HACCP systems are i#ple#ented across the %orld by #ost

large food co#panies' and also by #any #ediu# and s#all si"ed food

businesses& 2oo+ing for%ard' HACCP i#ple#entation %ill increase in all food

industry sectors %ith HACCP syste#s being co##only used in e$ery type and si"e

of food business&

Food safety: Thermal

The application of heat is both an i#portant #ethod of preser$ing foods

by destroying $egetati$e cells 3 spores and a #eans of de$eloping

teture' fla$or' color and aro#a& 4t has long been recogni"ed that ther#al

technologies #ust ensure the food safety %ithout co#pro#ising food

0uality& But still' there is al%ays a contradiction for food safety on

Ther#al processing' as %e generally ensure the food safety %ith heat

treat#ents and the general perception of consu#er5#anufacturer

recogni"es only %ith loss of nutrients&

4#pro$ing the ther#al processing of foods su##ari"es +ey research both

on i#pro$ing particular techni0ues and #easuring their effecti$eness&

The t%o basic factors are crucial for effecti$eness and efficiency of anyther#al processing techni0ue as,

- Ti#e

- Te#perature

Ho% #uch ti#e at a particular te#perature is re0uired to +ill the specific

nu#ber of #icro-organis#s to ensure food safety& Ti#e and te#perature

are in$ersely proportional' as the te#perature rises' the ti#e of

processing decreases and can easily be calculated as T6T (ther#al death

ti#e! for a particular pathogen&

The processing #ethods are designed as,

- Batch (2T2T- 2o% te#perature long ti#e!

- Continuous (HTST- High te#perature short ti#e!

The food safety is ensured %ith the application of heat by destroying

$egetati$e cells 3 spores' but in case of high acidic foods

( pH78&9!':generally do not re0uire a high te#perature heat treat#ent'because acidic foods resists the gro%th of $egetati$e cells 3 spores&

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Techni0ues of ensuring food safety by heat treat#ents,

- Coo+ing5frying5roasting

- Heating5boiling5tha%ing

- Pasteuri"ation

- Sterili"ation

- ;HT (;ltra high te#perature!

There are $arious other techni0ues of heat treat#ent' but our #aor

concern is %ith food safety& The 0uestion here is' ha$e %e ensured the

safety of food %ith heat treat#ents<

To be able to account food to be safe for hu#an consu#ption' %e need

so#e #ore considerations apart fro# heat' they are,

- Fouling of equipments

- Rusting of equipments

/or Food safety' heat treat#ent by stea# or dry air' these abo$e factors

al%ays co#es in eistence& Fouling refers to the accu#ulation of

un%anted #aterial on solid surfaces also +no%n as scaling' scale

for#ation and sludge for#ation& Rusting is a co##on ter# used for

corrosion' occurs %hen e0uip#ents gets contact %ith %ater and oygen&

Because of these factors the effecti$eness of heat treat#ent lo%er do%n

and chances of food deterioration occurs&

4n food industries' to pre$ent these proble#s' e0uip#ents #ade %ith

steel are used and to ensure the effecti$eness' efficiency' food

safety one #ust to apply #anual cleaning or C4P5S4P (Cleaning in place 5

Sterili"ation in place! for e0uip#ents&

4n the net blog' 4)ll discuss the food safety by *icrobial #eans

Food safety: Microbial

pcoming articles:

- /ood safety, Che#ical

- /ood safety, *icrobial

- /ood safety, 4rradiation


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- - Food safety: Physical/Visible

P=ST?6 B@ >4SHA2 ;PTA AT 1,8F P* 1 C=**?ETS

2AB?2S, BAS4CS =/ /==6 SA/?T@

M O N D A Y , A P R I L 1 9 , 2 0 1 0

/ood Safety - Why should 4 do it<

Food safety: Physical!"isible

Whene$er anyone one of us eats or drin+s so#ething' %e ha$e certain

epectations fro# that food e&g& it should loo+' s#ell and taste as epected& But

%hat happens %hen so#ething unepected occurs' such as finding a foreign

#aterial in the food' food is considered to be spoiled or unsafe& Food

safety concerns a lot for consu#able food ite#s& The epectations are

categori"ed as,

- Safe /ood

- Eatural

- Con$enient

- Healthy

/oreign #aterials in foods are a real concern' not only in ter#s of the consu#er

co#plaints that arise' but as an i#portant factor in the effecti$e i#ple#entation

of the co#panyGs food safety guidelines' particularly the Hazard Analysis

Critical Control #HACCP$ system&

Ris% Categories:

- 2o% ris+

- *ediu# ris+

- High ris+

.a% #aterial5finished goods inspection and specification testing' $endor

certification' standard operating procedures (S=P!' e0uip#ent calibration'

effecti$e pest control in the facility' pre$entati$e e0uip#ent #aintenance and

proper cleaning and sanitation procedures are the re0uire#ents to establish food

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safety5HACCP syste#s&

&road benefits of food safety to a product manufacturers are:

- Separation of #eans of pathogens5conta#ination

- 4ncreased product shelf life

- Ee% product de$elop#ents

Selection of appropriate and efficient processing #ethods %ill pre$ent physical

ha"ards in food and ensure consu#er safety& There are lots of recent ad$ances

de$eloped to pro$ide food safety' natural' safe and healthy food as per

epectations of the consu#ers&

4n the net blog' 4Gll discuss ne% food safety technology de$eloped such as

HPP ' High Pressure Processing

pcoming articles:

- /ood safety, Ther#al- /ood safety, Che#ical

- /ood safety, *icrobial

- /ood safety, 4rradiation

- ="one and /ood safety

Co#puter Soft%are – A HACCP 6e$elop#ent Tool

Co#puters and their soft%are ha$e beco#e the #ost %idely used tools in today)s

%orld to #anage data and are used in all aspects of business& The use of

co#puters to aid food safety #anage#ent has e$ol$ed progressi$ely in the last

fe% years' %ith co#puter based HACCP soft%are e#erging as an effecti$e tool to

help support the de$elop#ent of HACCP systems& Co#puter based HACCP

de$elop#ent soft%are can pro$ide the follo%ing benefits,

ti#e sa$ings

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reduction in the a#ount of paper %or+ and files

ensure that all HACCP syste# de$elop#ent steps are co#pleted and none are

o$erloo+ed

pro$ide technical +no%ledge of food safety ha"ards' control #easures'#onitoring procedures and $erification procedures

help to +eep HACCP data organi"ed and up-to-date&

Whilst there are #any benefits to using co#puter based HACCP de$elop#ent

soft%are' it #ust be appreciated that co#puter soft%are can only be a tool to aid

the de$elop#ent of aHACCP system& /ood product +no%ledge' production

epertise and professional udge#ent are still re0uired to de$elop an effecti$e

HACCP syste#& 4t is also i#portant to understand that co#puter based HACCP

de$elop#ent soft%are needs to be fleible to enable the de$elop#ent of HACCP

syste#s that are specific to food production processes and suitable for indi$idual

food businesses& /urther#ore' co#puter based HACCP de$elop#ent soft%are

needs to be easy to use and allo% HACCP syste#s to be effecti$ely updated %hen

ne% production processes are introduced' %hen production processes change or

%hene$er updating is necessary&

With all of the abo$e in #ind' ES/-C*i has de$eloped a *icrosoft ?cel based

Practical HACCP (ool%it) for food #anufacturers and food retailers& =ur

Practical HACCP Tool+it) has been de$eloped to #eet the HACCP needs of s#all to

#ediu# si"ed food businesses in the Asia Pacific region and to co#ply %ith the

HACCP principles set out by the internationally recogni"ed Code Ali#entarius

Co##ission& =ur Practical HACCP Tool+it) pro$ides a step by step approach to

de$eloping an effecti$e HACCP syste# by,

guiding the user through the fi$e preli#inary steps of de$eloping a HACCP

plan

generating process flo% diagra#s

helping the user create HACCP plans for different food products

allo%ing product specific food safety ha"ards to be inputted

allo%ing process specific control #easures and #onitoring procedures to be

included

auto#atically producing critical control points $erifications sheets creating chec+lists for prere0uisite progra##es


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pro$iding ea#ple HACCP records %hich can be sa$ed and printed&

Co#puter based HACCP de$elop#ent soft%are has the potential to be a po%erful

tool to help food businesses create HACCP syste#s' ho%e$er' it is i#portant tochoose the right soft%are and it #ust be appreciated that production +no%ledge

and business co##it#ent %ill al%ays be needed to de$elop and #aintain an

effecti$e HACCP syste#&

4f you %ould li+e to recei$e #ore infor#ation about de$eloping an effecti$e

HACCP syste# for your food business or you %ould li+e to see ho% our *icrosoft

?cel based Practical HACCP Tool+it) can help you de$elop a HACCP

system' please contact,

HACCP – A Worthy Subect

Thin+ing about the recent increased focus on food safety by o$ern#ent

regulatory agencies and ne%s organi"ations across the %orld' 4 thought that

Ha"ard Analysis and Critical Control Points (or HACCP as it is co##only

+no%n! is a %orthy subect to spend so#e ti#e discussing& *y plan during the

co#ing fe% %ee+s is to %rite a series of HACCP training blogsbased around the follo%ing areas of HACCP,


Prere0uisite Progra##es for HACCP

/ood Safety Ha"ards

The /i$e Preli#inary Steps to 6e$eloping a HACCP Plan

The Se$en Principles of HACCP

HACCP and /ood Safety Training&

Currently' there is no better ti#e to de$elop an effecti$e HACCPsystem to help ensure the safety of the food that you produce&o$ern#ent regulatory agencies across Asia are no% pro$iding #ore resources

for the education' control and enforce#ent of food safety standards than e$er

before' %ith HACCP being $ie%ed as an integral part of the process& 4ndia is one

country in particular that is focused on i#pro$ing food safety standards& Through

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the establish#ent of the /ood Safety 3 Standards Authority of 4ndia (/SSA4! and

the introduction of ne% food safety la%s and educational progra##es'

i#pro$e#ents in food safety a%areness and standards are already resulting in

safer food supply chains&

@ou %ill see fro# #y upco#ing blogs that HACCP is not difficult to understand

and HACCP plans do not need to be co#ple' ho%e$er' an effecti$eHACCP syste# does re0uire planning' production process epertise and continued

business co##it#ent& As a general rule' the si#pler and #ore focused a HACCP

plan is the #ore li+ely that it %ill be i#ple#ented correctly and food safety

ha"ards %ill be controlled&

4 hope you %ill find #y HACCP training blogs beneficial and they%ill help to i#pro$e your understanding of HACCP' encourage you to de$elop a

HACCP syste# for your business and #ost i#portantly result in safer food being

produced&



continuation of our earlier post HACCP - A Worthy Subect!

Ha"ard Analysis and Critical Control Points (HACCP! can be si#ply $ie%ed as a

pre$ention based food safety syste# that identifies and #onitors specific food

safety ha"ards that can ad$ersely affect the safety of food products& HACCP is

internationally recogni"ed as the best #ethod to ensure food safety and can be

applied at all stages of food production' fro# har$est through to consu#ption&

The standards for HACCP systems ha$e been the subect of #uch debate

and interpretation' ho%e$er' in recent years the Code Ali#entarius Co##ission)s

#ethodology for HACCP has beco#e the uni$ersally accepted standard& *ost

go$ern#ent organi"ations and food businesses throughout the %orld no% align

their interpretation of HACCP to the principles and guidelines set out by the Code

Ali#entarius Co##ission&

HACCP is a t%o part process& The first part is to identify potential food safety

ha"ards (this is also +no%n as hazard analysis! and the second part is to

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design a syste# that pre$ents or eli#inates ha"ards& The proper identification of

potential food safety ha"ards is a critical part of HACCP as the entire HACCP

syste# depends on the effecti$e identification of significant ha"ards& HACCP

syste#s therefore' need to be de$eloped by a #ultidisciplinary tea# of people%ho understand the food production operations and #ust be specifically designed

for indi$idual food production processes&

As %ell as pro$iding a cost effecti$e syste# for controlling food safety'

i#ple#entingHACCP also has the follo%ing benefits,

.educed ris+ of foodborne illness

/ocuses e#ployees on food safety precautions and i#pro$es their understanding

of food safety ha"ards

.educed product loss and decreased li+elihood of food recalls

Protection of business reputation and reduced liability ris+

*eets large retailer)s prere0uisite supplier standards

Helps to open the door) to international trade #ar+ets&

Today the benefits of HACCP are %idely recogni"ed by food #anufacturers and

food retailers& HACCP systems are i#ple#ented across the %orld by #ost

large food co#panies' and also by #any #ediu# and s#all si"ed food

businesses& 2oo+ing for%ard' HACCP i#ple#entation %ill increase in all food

industry sectors %ith HACCP syste#s being co##only used in e$ery type and si"e

of food business&

Prere0uisite Progra##es for HACCP

(This post is Part of a series of HACCP training blogs and is acontinuation of our earlier post HACCP – The Basics and Benefits!

Prerequisite programmes (P.Ps! are all the processes and hard%are

that %or+ alongside the HACCP syste#& They pro$ide the basic en$iron#ental and

operating conditions essential for the safe production of food& ;nli+e HACCP %hich

is product and process specific' prere0uisite progra##es are #ore general and

apply to all areas in a food production facility& ?a#ples of prere0uisite

progra##es include' but are not li#ited to' ood *anufacturing Practices

(*Ps!' ood Hygiene Practices (HPs!' Standard =perating Procedures (S=Ps!

http://www.foodsafetyindia.com/2009/12/prerequisite-programmes-for-haccp.htmlhttp://www.foodsafetyindia.com/2009/11/haccp-worthy-subject.htmlhttp://www.foodsafetyindia.com/2009/11/haccp-worthy-subject.htmlhttp://www.foodsafetyindia.com/2009/11/haccp-worthy-subject.htmlhttp://www.foodsafetyindia.com/2009/11/haccp-worthy-subject.htmlhttp://www.foodsafetyindia.com/2009/11/haccp-worthy-subject.htmlhttp://www.foodsafetyindia.com/2009/11/haccp-basics-and-benefits.htmlhttp://www.foodsafetyindia.com/2009/12/prerequisite-programmes-for-haccp.htmlhttp://www.foodsafetyindia.com/2009/12/prerequisite-programmes-for-haccp.htmlhttp://www.foodsafetyindia.com/2009/11/haccp-worthy-subject.htmlhttp://www.foodsafetyindia.com/2009/11/haccp-basics-and-benefits.html


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and Sanitation Standard =perating Procedures (SS=Ps!& The design and

construction of food pre#ises are also part of the prere0uisite progra##es&

HACCP is not a standalone syste#& Prere0uisite progra##es are critical to the

successful application of HACCP as they pro$ide the foundations for de$eloping

effecti$e HACCP systems& Prior to i#ple#enting HACCP and also after a

HACCP plan is i#ple#ented' it is i#perati$e that prere0uisite progra##es are in

place&

The co##on prerequisite programmes for food production relate to,

Construction' layout and facilities of pre#ises

Supplies of %ater' po%er and other utilities

Waste control

?0uip#ent suitability – cleaning and #aintenance

*easures for the pre$ention of cross conta#ination

Supplier control and #anage#ent of purchased #aterials

Cleaning and saniti"ing

Pest control

Personal hygiene

Training

Transportation

Traceability syste#s

.ecall procedures&

Whilst the abo$e list of prere0uisite progra##es is reasonably co#prehensi$e

and #ost of the prere0uisite progra##es %ill be rele$ant to all types of food

businesses& 4t is i#portant to appreciate that the prere0uisite progra##es that

need to be i#ple#ented by a food business depends on the si"e and type of food

production operation and the nature of the products being produced&

When choosing and de$eloping prerequisite programmes it is essential

to consider infor#ation fro# the follo%ing sources,

Statutory and regulatory re0uire#ents 4ndustry standards and codes of practices


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Code Ali#entarius Co##ission principles and codes of practices

4nternational food safety standards e&g& /SSC DDD' B.C' SI/' 4/S and 6utch

HACCP

Custo#er re0uire#ents Historic data such as audit reports and custo#er co#plaints&

All prere0uisite progra#s should be docu#ented' regularly audited' re$ie%ed

periodically and #odified %hen necessary& As a general rule' prere0uisite

progra##es are #anaged separately fro# HACCP plans' ho%e$er'

so#eti#es there #ay be certain parts of prere0uisite progra##es that are

integrated into a HACCP plan&

The /i$e Preli#inary Steps to 6e$eloping a HACCP Plan


continuation of our earlier post /ood Safety Ha"ards!

The internationally recogni"ed Code Ali#entarius Co##ission outlines fi$e

preli#inary steps that need to be co#pleted before de$eloping a HACCP

plan& These preli#inary steps %ill help ensure that a HACCP syste# is effecti$e

and safe food is produced&

Preliminary )tep * ' Assemble HACCP (eam

To ensure that all li+ely ha"ards and critical control points (CCPs! are identified' a

#ultidisciplinary tea# of people #ust be asse#bled to de$elop' i#ple#ent and

#aintain theHACCP system&

The HACCP Tea# needs to be for#ed %ith people %ho ha$e operational

eperience' product specific +no%ledge and a good understanding of the

production process& The HACCP Tea# should include the follo%ing types of

e#ployees, Iuality Control (IC!' technical staff' production #anagers 5

super$isors' laboratory personnel' engineering staff and sanitation staff&

A HACCP Tea# 2eader needs to be designated to o$ersee the de$elop#ent'

i#ple#entation and #aintenance of the HACCP syste#& The HACCP Tea# 2eader

#ust ha$e a good understanding of HACCP and a %or+ing +no%ledge of the

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product and its production process&

Preliminary )tep + ' ,escribe Product

A full description of the product needs to be prepared to pro$ide a profile of the

product and to help deter#ine the food safety ha"ards associated %ith its

production&

Product 6escriptions #ust describe rele$ant food safety infor#ation' such as,

A$ailable %ater

pH

?nd product characteristics e&g& shape' si"e' colour' teture' odour etc&

*ethod of preser$ation

Pac+aging

Storage conditions

Shelf life

Special labelling infor#ation

Custo#er preparation

*ethod of distribution&

Preliminary )tep ' .dentify .ntended se

4t is i#portant to identify the epected use of a product by the end user or

consu#er (e&g& coo+ed before consu#ption or ready to eat %ithout coo+ing!

because the intended use of a product %ill affect ha"ard analysis decisions&

4ntended use infor#ation also needs to identify %hether the end user %ill be the

general public or a specific consu#er group' particularly $ulnerable groups of the

population such as infants' the elderly' pregnant %o#en' ill people' i##uno-

co#pro#ised persons or cancer patients&

Preliminary )tep / ' Construct Flo0 ,iagram

The HACCP Tea# needs to create a flo% diagra# that pro$ides a clear' si#pleoutline of all inputs' steps and outputs in the food production process& The #ain


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steps in the process #ust be set out' including any re%or+ or recycling of

#aterials&

The flo% diagra# %ill pro$ide the basis for carrying out a syste#atic ha"ardanalysis&

Preliminary )tep 1 ' 2n-site Confirmation of Flo0

,iagram

An on-site re$ie% of the flo% diagra# #ust be carried out to chec+ that the flo%

diagra# accurately reflects the production process for the product& The HACCP

Tea# should follo% the production process on-site and chec+ that the flo%

diagra# includes all steps that are carried out&

When $erifying the accuracy of the flo% diagra# consideration needs to be gi$en

to different shifts and hours of operation' different batch si"es' optional

ingredients and non-routine steps such as #aintenance of e0uip#ent&

After the fi$e preli#inary steps to de$eloping a HACCP plan ha$e been

co#pleted' a solid foundation is in place to successfully apply to the se$en

principles of HACCP&

P=ST?6 B@ AE6.?W C=*B?22ACJ AT 1D,D A* D C=**?ETS

2AB?2S, HACCP

M O N D A Y , D E C E M B E R 7 , 2 0 0 9

/ood Safety Ha"ards

(This post is Part K of a series of HACCP training blogs and is a

continuation of our earlier post Prere0uisite Progra##es for HACCP!

Food safety hazards are found throughout the food supply chain and can

be described as,

biological' physical or che#ical agents in food that are reasonably li+ely to causeillness or inury in the absence of their control&)

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There are three #ain types of food safety ha"ards,

1&

&iological Hazards Caused by bacteria' $iruses or parasites that are

present in air' food' %ater' soil' ani#als and hu#ans&

/ood infections and food intoications can cause se$ere $o#iting' diarrhoea'

nausea' abdo#inal pain and fe$er to one or lots of people' they can e$en result in

death in so#e serious cases&

Biological ha"ards recei$e the #ost attention in HACCP systems due to

presenting the greatest ris+ of har# and the highest fre0uency of occurrence&

*icroorganis#s of concern include,

Salmonella species' Escherichia coli, Staphylococcus aureus, Shigella, Clostridium

perfringens, Clostridium botulinum, Listeria

monocytogenes, Campylobacter, Hepatitis A and .oto$irus&

& Physical Hazards /oreign bodies in food are usually due to accidental

conta#ination and 5 or poor handling practices& Physical ha"ards are #ost

recogni"ed by consu#ers as they usually find this food safety ha"ard&

?a#ples of physical ha"ards include,

*etal' glass' %ood' insects' stones' soil' dirt' e%ellery' hair' fingernails' plasters'

personal ite#s' bone' nuts 5 bolts' %ire' plastic' paper and cardboard&

K& Chemical Hazards Can include,

C2?AE4E CH?*4CA2 .?S46;?S, Che#icals used for cleaning and saniti"ing food

contact surfaces

/ACT=.@ C=ETA*4EAETS, Pest control che#icals' lubricants' coatings' paints'

refrigerants and %ater treat#ent che#icals


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A.4C;2T;.A2 .?S46;?S, Pesticides' fertili"ers' fungicides' antibiotics and

gro%th hor#ones

/==6 A22?.?ES, ?ggs' fish' #il+' peanuts' sesa#e seeds' soy' sulphites' treenuts and %heat

EAT;.A22@ =CC;..4E HA.*/;2 CH?*4CA2S, *ycotoins' sco#brotoin

(hista#ine!' #ushroo# toins and shellfish toins

4E6;ST.4A2 H?A>@ *?TA2S, 2ead' "inc' cad#iu#' arsenic and #ercury&

/ood safety ha"ards are best controlled through the use of HACCPsystems& All significant food safety ha"ards at each stage of production #ust

be identified in a HACCP plan& =nce you +no% %here food safety ha"ards

occur' it is possible to i#ple#ent control #easures to pre$ent' reduce or

eli#inate food safety ha"ards to an acceptable le$el&

The Se$en Principles of HACCP

(This post is Part F of a series of HACCP training blogs and is acontinuation of our earlier post The /i$e Preli#inary Steps to 6e$eloping a HACCP

Plan!

The Code Ali#entarius Co##ission sets out se$en principles for the basis

of HACCP systems& The Se$en Principles of HACCP should only be applied

after the /i$e Preli#inary Steps to 6e$eloping a HACCP Plan ha$e been

co#pleted&

Principle * ' Conduct a Hazard Analysis

?ffecti$e ha"ard identification and ha"ard analysis are essential to the

de$elop#ent of a successful HACCP plan&

/irstly' the HACCP Tea# #ust thin+ about the product and process to identify all

ha"ards (biological' physical and che#ical! that #ay be reasonably epected to

occur at each step in the production process&

When identifying ha"ards it is necessary to consider,

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=riginal HACCP study (e&g& HACCP Tea#' product description' ha"ard analysis'

CCP deter#ination' identification and selection of critical li#its etc&!

CCP #onitoring acti$ities

Critical li#it de$iations and the associated correcti$e actions ta+en >erification procedures

4nternal and eternal audits

HACCP syste# re$ie%s and #odifications&

HACCP and /ood Safety Training

(This post is Part 9 of a series of HACCP training blogs and is a continuation of our

earlier post The Se$en Principles of HACCP!

The +ey to successful HACCP systems is training' e#ployee beha$iour and

co##it#ent to food safety at all le$els %ithin a co#pany& 4t is essential that all

personnel directly or indirectly in$ol$ed in food production are gi$en ade0uate

training to ensure that they are a%are of their roles and responsibilities in

#aintaining food safety&

To facilitate effecti$e

food safety training food #anufacturers should

ha$e a %ritten training progra##e that is specific to their production operations&

/ood safety training progra##es should include,

4nduction training on the funda#entals of food safety (gi$en before a person

starts %or+!

Basic food safety training that builds on the +no%ledge pro$ided during

induction training (gi$en during the first couple of #onths of e#ploy#ent!

=n-the-ob training relating specifically to %or+ tas+s and practices

Periodic refresher training to reinforce understanding of %or+ procedures and

ensure that e#ployees re#ain a%are of all %or+ practices

6e$elop#ent training as ob responsibilities increase or change

;pdate training on ne% %or+ing practices or changes to eisting %or+

procedures&

To support the i#ple#entation of a food safety training progra##e it is

necessary to #aintain training records& Training records should include a

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su##ary of the training pro$ided' the dates of the training' results of any

e$aluation assess#ents and the signature of the person recei$ing the training&

When considering the training needs %ithin your co#pany' it #ust be appreciatedthat the type of training re0uired %ill $ary bet%een different groups of e#ployees&

4t is essential that the e#ployee training pro$ided is at a le$el appropriate to the

%or+ tas+s that %ill be carried out& /or ea#ple,

The HACCP (eam' particularly the HACCP Tea# 2eader should ha$e a good

understanding of,

/ood safety ha"ards associated to products and processes

ood *anufacturing Practices (*Ps! for the production facility

The purpose of prere0uisite progra##es

The principles of HACCP' particularly ha"ard analysis' identification of CCPs and

the deter#ination of critical li#its

Concepts of #onitoring' correcti$e actions and $erification

4#portance of record +eeping and docu#entation

Audit principles and the benefits of internal audits

.egulatory re0uire#ents

The i#portance of #anage#ent co##it#ent&

Food production super5isors and managers should ha$e a good

understanding of,

/ood safety ris+s and food hygiene procedures

The specific responsibilities associated %ith super$ising and #anaging food

#anufacturing operations

The principles of effecti$e food safety #anage#ent

The basics of HACCP

The i#portance of i#ple#enting control #easures and CCPs

The i#portance of the critical control points for %hich they are responsible'

including the critical li#its' the procedures for #onitoring' correcti$e actions if

critical li#its are not #et and the records to be +ept&

Food production personnel should at least be +no%ledgeable of,


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Semester - III

Food Chemistry

Foods and Nutrition

Principles of Food Processing and Preservation

Food Storage and Transport Engineering

Fruits and Vegetables Processing Technology

IT Application in Food Industry

Village Adoption

Semester - IV

iochemistry

Food !icrobiology and Safety

Food Engineering " I

Technology of !il# and !il# Products Processing

Food Industrial Economics

Agripractices and Environmental Sciences

Semester - V

Instrumental !ethods of Food Analysis

Food Engineering $ II

Food Pac#aging Technology

Food iotechnology

Cereals% Pulses and &ilseeds Technology

Semester - VI

Food Additives and Ingredients

Instrumentation and Process Control

!eat% Fish and Poultry Product Technology

Food 'a(s% Standards and )egulation

Food Production Trends and Programmes

usiness Plan *evelopment

http://www.niftem.ac.in/NIFTEM/downloads/3.pdfhttp://www.niftem.ac.in/NIFTEM/downloads/4.pdfhttp://www.niftem.ac.in/NIFTEM/downloads/5.pdfhttp://www.niftem.ac.in/NIFTEM/downloads/6.pdfhttp://www.niftem.ac.in/NIFTEM/downloads/3.pdfhttp://www.niftem.ac.in/NIFTEM/downloads/4.pdfhttp://www.niftem.ac.in/NIFTEM/downloads/5.pdfhttp://www.niftem.ac.in/NIFTEM/downloads/6.pdf


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Semester - VII

Food Plant *esign and Process !odelling

Food Product *evelopment and Sensory Evaluation
http://www.niftem.ac.in/NIFTEM/downloads/7.pdfhttp://www.niftem.ac.in/NIFTEM/downloads/7.pdf

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Integrating HACCP and SPC

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