Dr' Zaharah Wahid

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FOOD SAFETY MANAGEMENT SYSTEM THE HACCP WAY

• Presented by
• Dr. Zaharah Wahid
• SENIOR CONSULTANT, SIRIM Berhad
• Seminar
• 18-22 April 2005 Shah Alam
• Kuala Lumpur

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PRESENTATION OUTLINE

• Issues and challeges
• What is HACCP?
• Benefits
• Global impact of HACCP
• Hazards
• Implementation

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Food Safety Issues
Why these?
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WORLD FOOD CRISIS AND CONSEQUENCES

1986-2000 Mad Cow Disease ? started in UK but
spread to other European countries ? 1.2 billion
Euro (RM 4.16 billion) allocated to fight the
disease but estimated cost of crisis 3 billion
Euro ( 10.45 billion) ? 60 drop in European beef
export and 10 drop in local consumption ? Resigna
tion of the Germans minister ?Global ban

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WORLD FOOD CRISIS AND ITS CONSEQUENCES

1996, Japan-E.coli 0157H7 ?9,579 people
affected ?11 death 1999, Japan-Staphylococcal
Toxin ?Resignation of Snow Brand Co.
President 1999, Belgium-Dioxin ?Global ban
involving EU countries ?Due to free downfall of
the Belgium government

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WORLD FOOD CRISIS AND ITS CONSEQUENCES

• 2001, UK-Foot Mouth Disease
• ?Estimated cost 1.5 to 3 billion pound to fight
  the disease
• ?More than 1 million animals culled or earmarked
• ?Estimated lost of meat and livestock export
  until 2004, 1.2 billion pound
• ?Postponement of the general election
• ?Lost to tourism
• currently losing 200 million pound /week
• estimated lost until Sept 2001, 5 billion

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WORLD FOOD CRISIS AND ITS CONSEQUENCES

3-MCPD, crisis in 2001 ?Non-genotoxic
carcinogen ?product recall by UK Antibiotic
residue in shrimps- Thailand, Vietnam Indonesia,
India and Bangladesh ?Effect on Malaysias export
and import Antibiotic residue in
chicken-Thailand, Vietnam, Indonesia and
China Antibiotic residue in honey from China

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What is HACCP

• Hazard
• Analysis
• Critical
• Control
• Points

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What is HACCP

• A powerful food safety management technique
• Structured, proactive system
• Looks for what could go wrong regarding safety
• safety through hazard identification and control

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How does it work?

• Define the process
• Identify hazards which may occur
• Observe those foods throughout your preparation,
  holding serving process to identify points
  critical to product safety
• Manage these points
• Verify

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HISTORY OF HACCP

• 1960 Pillsbury Co, US Army and NASA developed
  foods for the space program using HACCP system
• 1974 introduction to FDA USDA starts HACCP
  voluntary HACCP program in US adoption in low
  acid canned foods regulation

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HISTORY OF HACCP

• Continue...
• 1970/early 1980 HACCP accepted by food companies
• 1985 National Academy of Science (NAS)
  recommended adoption by regulatory agencies
• 1987 national Advisory Committee on Microbiology
  Criteria for Foods (NACMCF)

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HISTORY of HACCP
1998
Imported Seafood to, US
Food Safety, UK
1995
FSIS, FAO/WHO, Hygiene Directive EC
1993
NACMCF
1987
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REFERENCES DOCUMENTS FOR HACCP

PUBLISHED CODEX GUIDELINES 1. Hazard Analysis
and Critical Control Point System Guidelines
for its applications 2. Recommended
International Code of Practice - General
Principles of Food Hygiene (CAC/RCP-1-1969 Rev.
3 (1997)

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REFERENCES DOCUMENTS FOR HACCP

PUBLISHED MALAYSIAN DOCUMENTS 1. MS 14801999
Food Safety According to Hazard Analysis And
Critical Control Point (HACCP) System 2. MS
1514 2001 General Principles of Food
Hygiene

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REFERENCES DOCUMENTS FOR HACCP

OTHER DOCUMENTS HACCP system and
Prerequisite programs should conform to other
relevant CODE OF PRACTICE e.g Code of
practice for frozen, cooked, peeled prawns.

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What is wrong with traditional food quality
systems?

The HACCP system overcomes many of the
limitations of traditional approaches to food
safety control ? Rely solely on inspection
product analysis ? not cost effective ? time
consuming ? identification of problems without
understanding the roots of the problems
? limitation of snap shot inspection

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BENEFITS

? The HACCP system can be easily integrated into
quality management system such as ISO 9001
2000 ? Has the potential to identify all
conceivable, reasonably to be expected hazards,
even where failures have not previously been
experienced and useful for operations ? Capable
to accommodate any changes in terms technology
and processing procedures.

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BENEFITS
? help to target or manage resources to the most
critical area in food processing. ? improve
relationship between processors and inspectors
and processors and suppliers. ? As a vehicle to
improve competition eliminate technical
barriers to trade

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BENEFITS

• Will increase the customer confidence level and
  decrease detentions and confiscation
• Reduce the need for multiple assessment
• Useful for third party assessment certification
• Generate greater consumer confidence about food
  safety and food regulatory

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BENEFITS

• Improve the market image of your company
• Can serve as benchmark for assessing any
  suppliers management system
• Greater chances of succeeding as an exporter to
  countries
• e. g. UK, Canada, Australia, US, EU etc.

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GLOBAL IMPACT OF HACCP
UNITED KINGDOM The Food safety Act, 1990 and the
Food Hygiene Inspection Codes of Practice both
include HACCP

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GLOBAL IMPACT OF HACCP
CANADA Has developed a Food Safety Enhancement
Program (FSEP) to encourage the establishment of
HACCP-based procedures in all registered
establishment in the agricultural and food
processing sectors.

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GLOBAL IMPACT OF HACCP
AUSTRALIA The Australian Quarantine and
Inspection Service (AQIS) has developed a new
inspection system known as the Food Hazard
Control System (FHCS)

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GLOBAL IMPACT OF HACCP
UNITED STATES The Food Adviser to the Center for
Food Safety and Applied Nutrition has recommended
that the US Food and Drug Administration (FDA)
encourage and eventually impose the application
of HACCP on the entire food industry

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GLOBAL IMPACT OF HACCP
Continue... FDA revised its Food Code in 1993 to
make compatible to HACCP concepts.

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GLOBAL IMPACT OF HACCP

UNITED STATES FDAs HACCP regulation on fish and
fishery products produced and marketed in the US
came into effect in Dec. 1997.Under the rules,
FDA verifies HACCP plans prepared by producers.
Importers are required to obtain HACCP plans from
producers (exporters) in exporting countries and
submit them to FDA for verification

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GLOBAL IMPACT OF HACCP
UNITED STATES The juice industry will be subject
to HACCP regulation according to a staggered
schedule starting January 2002 The USDA has
required the use of HACCP for meat and poultry
processing plants since January 1999

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GLOBAL IMPACT OF HACCP

EUROPE In the European Union, Council Directive
No. 93/43/EEC has urged the food business
operators to develop HACCP-based system for
ensuring food safety. European Commission
Decision, directive No. 94/356/EC requires food
establishment to establish a system of own
checks for the production and sale of fishery
products

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GLOBAL IMPACT OF HACCP
EUROPE The European Union has decided that HACCP
Plans prepared by producers and exporters are to
be verified by an authority it nominates. For
example, in India, EU has nominated the Export
Inspection Council, a statutory body under the
Ministry of Commerce, to verify exporters HACCP
plans.

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Types of Hazards

A property which may cause a product to be
unsafe for consumption
What is HAZARD ?
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Where hazards arise
in the food supply

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Types of Hazards
Three type of hazards ? Biological ? Chemical
? Physical
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BIOLOGICAL HAZARDS
Microorganisms ? Bacteria ? Virus ? Parasite

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BIOLOGICAL HAZARDS
Factor contributing to the occurrence ? improper
storage/holding temperature ? in-adequate cooking
process ? improper hygiene practices by food
handlers ? cross contamination ? incorrect
reheating process
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BIOLOGICAL HAZARDS
3 ways of controlling microbiological hazards ?
Eliminate, prevent or reduce the hazards ?
Avoid contamination ? Avoid bacteria growth and
toxin production
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BIOLOGICAL HAZARDS
Eliminate, prevent or reduce the hazards ? proper
cooking and heating process ? freezing- to
destroy parasite in fish and meat Avoid food
contamination ? proper personnel hygiene ? proper
handling and storage ? proper cleaning and
sanitation
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BIOLOGICAL HAZARDS
Avoid microbial growth ? use preservatives ?
proper storage and preparation ? use chilling or
freezing method ? reduce pH and water activity ?
hold at the right temperature - out of the
danger zone (gt 63 ºC)
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CHEMICAL HAZARDS
Chemical substances in foods ? Naturally occur ?
Added 1. Naturally Occur ? Natural
toxins ?mycotoxin ? mushroom
toxin ?scombrotoxin ? shellfish
toxin ?ciguatoxin
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CHEMICAL HAZARDS

• 2. Added chemical
• ? Incidental/added chemical
• agricultural chemicals e.g. pesticides
• ? Permitted additives
• preservative, coating agent, anti-caking
• ? Indirect additive
• lubricants, detergents, sanitizers, paint

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CHEMICAL HAZARDS

• Control of chemical hazards
• ? Before receiving raw/packaging
• specification
• guarantee letter
• vendor certification program
• ? During receiving
• validate the material received

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CHEMICAL HAZARDS

• Control of chemical hazards
• ? During processing
• use permitted chemicals
• follow instruction
• proper labeling and record
• ? During storage
• practicing a proper storage system to avoid
  contamination

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CHEMICAL HAZARDS

• Control of chemical hazards
• ? Before delivery
• check the cleanliness of the transportation
• ? Application of cleaning agent
• use the chemical as per regulation, correct
  dosage and application method.

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PHYSICAL HAZARDS
Physical substances in foods ? metal fragments ?
hair ? glasses ? insect ? chips ?
dropping from rodent ? wood ? stone
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PHYSICAL HAZARDS
Sources of physical hazards ? contaminated raw
material ? unsatisfactory design, equipment and
maintenance facilities. ? wrong procedure
during production. ? incorrect work practices
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PHYSICAL HAZARDS
Control of physical hazards ? GMP ? Appropriate
specification ? Supplier guarantee letter ?
Vendor certification ? Identify type and source
of physical hazards ? Determine CCP ? Install
metal detector
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How do we go about
implementing one?
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APPLICATION OF HACCP
Pre-Requisite Program Pre-requisite programs are
defined as universal steps or procedures that
control the operational conditions within a food
establishment allowing for environmental
conditions that are favorable to the production
of safe food.
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APPLICATION OF HACCP

• Pre-requisite programs are the foundation of the
  HACCP plans
• Must be adequate and effective
• If not adequately controlled, then additional
  critical control points may have to be
  identified, monitored and maintained under HACCP
  Plans.

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• There are six pre-requisite programs include
• Premises
• Outside property
• Building
• Sanitary facilities
• Water/Steam/Ice Quality Program

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• Transportation and storage
• Food carriers
• Temperature control
• Storage of incoming materials, Non-
  food chemicals and finished product
• Personnel
• Training
• Hygiene and Health requirements

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• Sanitation and Pest Control
• Sanitation program
• Pest Control Program
• Recalls
• Recall procedures
• Distribution records

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THE SEVEN PRINCIPLES OF HACCP
Principle 1 Conduct a hazard analysis and
establish control measures Principle 2 Determine
critical control points (CCP) Principle
3 Establish critical limits
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THE SEVEN PRINCIPLES OF HACCP
Principle 4 Establish a system to monitor control
of the CCP Principle 5 Establish the corrective
action to be taken when monitoring indicates that
a particular CCP is not under control
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THE SEVEN PRINCIPLES OF HACCP
Principle 6 Establish procedures for verification
to confirm that the HACCP system is working
effectively Principle 7 Establish documentation
concerning all procedures and records appropriate
to these principles and their application.
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SEQUENCE FOR IMPLEMENTATION

Recommended approach for the development of a
HACCP System 1. Management Commitment 2.
Assemble HACCP Team 3. Describe Product 4.
Identify Intended use 5. Construct process flow
diagram 6. On-site verification of flow diagram
7. List all potential hazards associated with
each step (Principle 1)
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8. Determine CCPs (Principle 2) 9. Establish
Critical Limit for each CCP (Principle 3) 10.
Establish a Monitoring System for each CCP
(Principle 4) 11. Establish Corrective Action for
deviations that may occur (Principle 5) 12.
Establish Verification procedures (Principle
6) 13. Establish Document Control Procedure
(Principle 7)
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HACCP
Essential Requirement for a Successful HACCP
System 1. Strong Management Commitment 2. GHP
GMP, Sanitation Cleaning 3. Training
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Are You
Ready
?
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WHAT NEXT?

• SIRIM offers a range of courses on food safety
  management systems
• HACCP implementation
• Training Consultation
• Enquiry
• Standards Quality Industry Services Dept
  03-55446224/34

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CONCLUSION

• Opportunities for international trade are
  enhanced where food is produced in a strictly
  hygienic environment .
• Country that follow strictly hygienic practices
  gains reputation as a produce of safe food.

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END

• Thank you
• for
• attending!