Title: Introduction to HACCP Principles
1Introduction to HACCP Principles
- Lynn Knipe
- Animal Sciences 555.02
- The Ohio State University
2Why HACCP Training?
- CFR417.7(b) states individual(developing
HACCP plans) shall have successfully completed a
course of instruction of the seven HACCP
principles to meat or poultry processing
3Why HACCP Training?
- HACCP mandated for large meat poultry plants
Jan. 98, small plants - Jan. 99, very small
plants- Jan. 00, under MegaReg.
4Why HACCP Training?
- Seafood HACCP - FDA mandated Dec. 18, 1997
- HACCP recommended for establishments inspected
under 2003 FDA Food Code. - Frozen Dairy Processors, ODA Division of Dairy.
5Why HACCP?
- Consumers expecting more from foods.
- New products present new food safety
challenges. - Previous meat poultry inspection needed
updating.
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7HACCP Summary
- Preventive system for assuring safe food
pro- duction, before it is too late. - Applicable to all phases of food production.
- Control of factors affecting
ingredients, process product.
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9HACCP programs are built upon
- Existing regulations guidelines
- SSOPs
- GMPs
- Employee training
-
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11Pre-HACCP Steps
- Assemble HACCP Team.
- Describe Product.
- First page of handout (also p. 38877)
- Develop List of Ingredients nitrites, peanuts,
milk proteins - Develop Flow Chart.
- steps listed in column 1 of Form A (Handout)
12 - FSIS HACCP Processing Categories
- slaughter
- raw product-ground
- raw product-not ground
- thermally processed - sterile
- not heat treated - shelf stable
- heat treated - shelf stable
- fully cooked - not shelf stable
- heat treated/not fully cooked/not shelf stable
13HACCP Principle 1Conduct a Hazard Analysis
- to determine the food safety hazardshistorical
ly have occurredreasonable possibility that it
will occurin absence of controls.. CFR9 Part
417.2(a)(1) - Column 2 of Form A (handout)
14Types of Potential Hazards
- Biological - L. monocytogenes, Salmonella, E.
coli 0157H7, etc. - Chemical - cleaners, restricted ingredients,
allergens, antibiotics - Physical - glass, metal, bone, needles, shot,
ear tags
15Determine Likelihood of Hazard Occurrence
- Risk Assessment.
- Chemical physical hazards.
- experience plant history may justify
- Biological hazards need documentation.
- pathogen test results, SSOP records, other
records, scientific publications. - not written GMPs!
16Preventive Measures to Control a Hazard
- 1. Prevent contamination
- Letters of guarantee
- 2. Cook or sterilize to destroy pathogens.
- 3. Time/temperature control to prevent
multiplication of pathogens.
17Preventive Measures (Continued)
- 4. Ferment to prevent multiplication of
pathogens. - 5. Airflow to prevent environmental
contamination. - 6. Metal detectors.
- 7. Bone removal systems.
18HACCP Principle 2 Identify Critical Control
Points in the Process
19A CCP is
- the last point where control can (or is needed
to) prevent, reduce or eliminate hazards to
acceptable levels. - Last column of Form A.
20CCP Examples
- Raw product temperature
- Cooking
- Chilling of cooked product
- Slaughter - fecal contamination
- Product formula nitrites, allergens
- pH adjustment
- L. monocytogenes control -fully cooked, RTE
- Hot holding
21HACCP Principle 3 Establish Critical Limits
for Preventive (Control) Measures Associated with
Identified CCPs
- critical limits shall ensure thatapplicable
performance targets estab-lished by FSISare met
- CFR9 Part 417.2(c)(3)
22- CLs are criterion that must be met for each
preventive measure. - If exceeded, or not met, product is considered
adulterated. - (Optional) Set targets (operating limits), to
minimize HACCP deviations. - Start with applicable regulations or
guidelines.
23Critical limits must be
- based upon scientifically determined
parameters. - quantifiable
- , ºF, pH, defects, minutes, CFUs/gm?
- specific (not ranges)
- What cannot be measured, cannot be
controlled.
24Critical Limit Examples
- Temperatures and times
- salt
- Water activity, Aw
- pH or acidity
- visual appearance?
- hand washing?
- microbial standards?
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26HACCP Principle 4 Establish CCP Monitoring
Procedures
- Planned sequence of observations or
measurements - to assess whether or not a CCP is under
control - ...and to produce a record to verify process.
27Monitoring Frequency
- Continuous monitoring.
- ideal system
- thermocouple or pH probe w/chart recorder
- Monitoring at established intervals.
- manual check every X hr(s)/shift.
- Frequency How much out of compliance product
are you able to hold?
28Monitoring Responsibility
- Assign responsibility to management or
production worker? - Training needed in monitoring method, purpose
of monitoring, importance of accuracy. - Records/documents initialed by person
monitoring.
29Monitoring Responsibility
- Note unusual circumstances.
- Report deviations immediately.
30Monitoring Options
- Actual product monitoring.
- accuracy
- labor intensity
- cross contamination
- Process monitoring
- monitor ovens, coolers, etc.
- continuous recording charts.
31HACCP Principle 5 Describe Corrective Actions
- to be taken when there is a deviation (out of
compliance or control) from an established
critical limit. - Four parts of 417.3(a) (p. 38870, Federal
Register)
32Corrective Action Plans to Ensure
- ...cause of deviation I.D.ed eliminated.
- CCPunder control...
33Principle 6 Establish Procedures to Verify
that the HACCP System is Working Correctly
(417.4)
- Verification is to a HACCP plan, what
monitoring is to a CCP. - Includes initial validation on-going
verification.
34Initial Validation
- Demonstrate that your HACCP plan is adequate to
prevent, reduce or eliminate hazards. - New establishments or new product categories
90 day trial period to validate. - Generate and review records.
- Scientific documentation.
35On-Going Verification
- Demonstrate that your HACCP plan is working as
you intended. - Ensure that employees are following your
established procedures for record keeping
handling product deviations.
36Verification Must Include
- Review of records generated by the HACCP plan.
- Direct observations of the monitoring and
corrective actions. - Calibration of monitoring instruments/equipment.
37Reassessment
- Verify that all significant hazards have a CCP
- confirm CLs are appropriate
- establish that corrective actions are in place
and effective - Total reassessment 1x/yr.
38HACCP System Reassessment Triggers
- new information concerning product safety
- monitoring results
- product link to outbreak
- system modified -
formulation, processing, distribution
consumer use
39Pre-Shipment Review
- Must be completed before product is shipped.
- Do ASAP after monitoring.
- Requires lot numbers on products.
- Requires signature.
40Lot ID could be based upon
- full sanitation to full sanitation (FSIS)
- day, shift, 1/2 day (Julian)
- slaughter, cutting
- common ingredients
- mixer batch, brine batch
- sublot by stuffer, oven, etc.
41Lot Identification
- First, ID your product lots
- Later, tie lot information of received product
to lot information of products you produce. - Do mock recalls to test system.
42Verification Summary
- Direct observation record review of
monitoring corrective actions - Equipment calibration
- Reassess plan
- Designate position (person) frequency.
43HACCP Principle 7 Establish effective record
keeping procedures
- ...only reference available to trace product
history - and actions taken to prevent a problem
- ...assist in case of a recall.
44HACCP Records
- Monitoring records
- Deviation/corrective action records
- Verification/pre-shipment review records
45HACCP Records
- Retention of records
- 1 year for unfrozen
- 2 years for frozen
- Store off site after 6 mos.
- Regulatory access in 24 hr.