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PrerequisitePrerequisite RequirementsRequirements ofof HACCPHACCP B.K.Kolita Kamal Jinadasa, Research officer, Post
PrerequisitePrerequisite RequirementsRequirements
ofof HACCPHACCP
B.K.Kolita Kamal Jinadasa,
Research officer,
Post harvest technology division,
NARA, Colombo-15,
Sri Lanka
Quality management system • Product/ Food Safety – HACCP system • Product Quality – Quality
Quality management system
• Product/ Food Safety
– HACCP system
• Product Quality
– Quality control system.
• i.e. meeting buyer specifications, including legal
requirements
• Environmental/Operating condition
– Prerequisite requirements for HACCP
5 Prerequisite Programs AAFC/FSEPAAFC/FSEP Definition:Definition: • Universal steps or procedures • that control
5
Prerequisite Programs
AAFC/FSEPAAFC/FSEP Definition: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
basic requirements for all food industry
HACCPHACCP ISIS NOTNOT AA STANDSTAND--ALONEALONE SYSTEMSYSTEM HACCPHACCP isis oneone partpart ofof largerlarger
HACCPHACCP ISIS NOTNOT AA
STANDSTAND--ALONEALONE SYSTEMSYSTEM
HACCPHACCP
isis oneone partpart ofof largerlarger
QUALITYQUALITY
MANAGEMENT/ASSURANCEMANAGEMENT/ASSURANCE
SYSTEMSYSTEM
PrerequisitePrerequisite programsprograms • Not described in the original US National Advisory Committee on
PrerequisitePrerequisite programsprograms
• Not described in the original US National
Advisory Committee on Microbiological
criteria for Foods (NACMCF) or Codex
HACCP guidelines.
• Concept originated in 1993 Agriculture and
Agri-Food Canada’s (AAFC) Food Safety
Enhancement Program (ESEF).
6 HACCP PREREQUISITEPREREQUISITE PROGRAMSPROGRAMS FOUNDATION OF AN EFFECTIVE HACCP SYSTEM • simpler yet more
6
HACCP
PREREQUISITEPREREQUISITE PROGRAMSPROGRAMS
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
7 Prerequisite Programs • Basically applications of GMP & hygiene/sanitation Control. • Premises and
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Prerequisite Programs
• Basically applications of GMP & hygiene/sanitation
Control.
• Premises and facilities, equipment, sanitation and
hygiene.
• Others- personnel training, supplier control,
product traceability and recall, consumer
complaints, specification.
9 Prerequisite Programs • Simpler yet more effective – – HACCP plans- easier to maintain
9
Prerequisite Programs
• 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.
Equipments Personnel Premises training Prerequisite program should cover: Sanitation Recall Receiving/ storage/
Equipments
Personnel
Premises
training
Prerequisite program
should cover:
Sanitation
Recall
Receiving/
storage/
transport
8 Prerequisite Programs • Cross product line. • Not part of the formal HACCP plan.
8
Prerequisite Programs
• Cross product line.
• Not part of the formal HACCP plan.
• Managed separately rather than include
their performance and control as part of
the HACCP plan.
Prerequisite program HACCP Plan Deals indirectly with food safety issues – environmental/operating conditions Deals
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: • Documented with written SOPs. • Monitored with proper record to
Prerequisite programs should be:
• Documented with written SOPs.
• Monitored with proper record to ensure
effectiveness
• Reviewed and revised
– periodically to ensure relevance
Premises • Plant location, construction and layout. • To protect food from unsanitary conditions and
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
• Smoke, dust, odors, airborne microbes
Premises = Structural Operating Environment Poorly designed, constructed and maintained food premises will increase
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
Facilities • Adequate sewage & waste disposal. • Adequate facilities for washing and disinfecting equipment.
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)
Premises • Construction & layout – Separation of operations. – Product flow patterns. – Adequate
Premises
• Construction & layout
– Separation of operations.
– Product flow patterns.
– Adequate working space.
– Lighting.
– Ventilation
– Building materials.
Facilities • Adequate supply of energy/power. • Adequate supply of potable cold water, hot water
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)
Equipment & Utensils Design- Prevent contamination of product. prevent accumulation of food residues during
Equipment & Utensils
Design-
Prevent contamination of product.
prevent accumulation of food residues during
production.
For accessibility and cleanability.
Durability.
Easy maintain.
Performance.
Equipments & Utensils Construction- Food-safe materials Non toxic. Non absorbent Resistant to the product,
Equipments & Utensils
Construction-
Food-safe materials
Non toxic.
Non absorbent
Resistant to the product, cleaning and
disinfecting agents.
Stainless steel and plastic.
Maintenance-
Schedule for servicing, replacement and
calibration.
Sanitation & Hygiene Proper cleaning and sanitation will: Decrease the likelihood of food becoming contaminated;
Sanitation & Hygiene
Proper cleaning and sanitation will:
Decrease the likelihood of food becoming
contaminated; and
Discourage pests from the premises, vehicle
and/or vessels.
CleaningCleaning andand SanitationSanitation • Develop a written program or Sanitation Standard Operating Procedures
CleaningCleaning andand SanitationSanitation
• Develop a written program or Sanitation
Standard Operating Procedures (SSOP)
• FDA seafood HACCP Rule mandates 8
sanitation area that must be monitored
and documented
Personnel training Staff must be trained to do their jobs competently e.g. processing skills, HACCP
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
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!
CleaningCleaning andand SanitationSanitation • Cleaning and sanitation procedure and schedule should be written and
CleaningCleaning andand SanitationSanitation
• Cleaning and sanitation procedure and
schedule should be written and followed.
• A master sanitation schedule should be
developed and rigorously applied to assure
good housekeeping and minimize product
exposure to contaminants.
CleaningCleaning andand SanitationSanitation • Written guidance should be developed for personnel hygiene standards
CleaningCleaning andand SanitationSanitation
• 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.
FDA 8 Keys sanitation areas 1. Safety of water- that comes into contact with food
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
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
Sanitation standard operating procedure (SSOP) • Describe a particular set of objectives associated with sanitary
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 4. Maintenance of hand-washing, hand- sanitizing and toilet facilities 5.
FDA 8 Keys Sanitation areas
4. Maintenance of hand-washing, hand-
sanitizing and toilet facilities
5. 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.
PestPest controlcontrol • Pests such as rodents, birds, insects, animals e.g. cats and dogs. •
PestPest controlcontrol
• Pests such as rodents, birds, insects,
animals e.g. cats and dogs.
• Carriers of human disease agents.
PestPest controlcontrol programprogram • Based on 3 principles; – Exclusion or preventing access- • Windows
PestPest controlcontrol programprogram
• Based on 3 principles;
– Exclusion or preventing access-
• Windows screens, self-closing doors
– Restriction by avoiding to create an
environment conducive to pests-
• Elimination of harborage and attractant areas
(rapid removal of waste).
– Destruction and eradication-
• Usually done by specialist company.
Recall Program An action plan which gives the company ability to recover or retrieve product
Recall Program
An action plan which gives the company ability to recover or
retrieve product it has left the control of the company.
Recall team, coordinator.
Written recall/recover procedures.
Minimize bad publicity, consumer complaints, criminal law
suit and damage to the company reputation
Involves product identification and traceability (raw
materials, ingredients and finished products, distribution
records)
ingredients and finished products, distribution records) Receiving/ storage/ transport All raw materials and
Receiving/ storage/ transport All raw materials and products should be stored under sanitary conditions and
Receiving/ storage/ transport
All raw materials and products should be stored
under sanitary conditions and proper
environmental conditions (temperature and
humidity) to assure their safety and
wholesomeness
Other program • Food transport vehicle. • Fishing vessels. • Supplier approval. • Food packaging.
Other program
• Food transport vehicle.
• Fishing vessels.
• Supplier approval.
• Food packaging.
• Product identification and labeling.
vehicle. • Fishing vessels. • Supplier approval. • Food packaging. • Product identification and labeling.
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