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CONTENTS
Part I
HACCP Introduction, History HACCP Key Concepts Why HACCP
Part II
HACCP Pre-Requisites Program
Part III
How to HACCP
Part IV
HACCP & Quality System (ISO)
Part V
HACCP Practicing Bottlenecks
Part VI
HACCP Future
Part I
Module 1 Introduction to HACCP
H A C C P
HAZARDS
HACCP
HACCP
H A C C P
The most effective tool to prevent occurrence of food borne diseases and avoid consumer illness and injuries linked to the consumption of our products
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H A C C P
Systematic approach to the identification and assessment of the hazards and risks associated with a food operation and the defining of the means of their control
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Part I
Module 2 WHY HACCP
WHY HACCP ?
To have safe, reliable
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WHY HACCP ?
Management of product safety Prevention of product safety incidents Limitations of traditional quality control External pressure Other benefits Foundation for the development of effective product management systems
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WHY HACCP ?
Successful implementation of HACCP brings along;
Primary benefits
Product Safety
Secondary benefits:
Quality improvement Cost effectiveness Loss and down time reduction Increase consumer confidence in product safety Design of line/product Hygiene, housekeeping & improve manufacturing conditions Reduce maintenance Reduce inspection time Competitive advantage
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Part I
Module 3 Where it has come from & Where does it work
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Basic Idea behind; To provide risk free safe food for astronauts.
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Traditional Quality Control - Inspection - Random sampling and testing Prevention base food safety assurance program - HACCP
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HISTORY OF HACCP
1960 - Concept originated - U.S space program (NASA) 1971 - Used in by Pillsbury company in space program 1971 - Concept took proper form in National Conference on Food Protection. 1985 - Recommended by National Academy of Science (NAS) USA 1989 - Final approval by National Advisory Committee on Microbiological Criteria for Foods (NACMCF) 1991 - Accepted by Codex Committee. 1995/6 - HACCP was first time used in US Regulations 1997 - UN/Codex Alimentarious HACCP System was developed and adopted by US regulatory authorities. 2000 - Embraced by USA, UK, European Union, Japan, Canada, Australia and New Zealand till now.
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HACCP SCOPE
HACCP is for every one !!
From;
Farm to Fork
HACCP SCOPE
Commercially This system is mainly applicable to;
All food processing facilities/factories: Sea Food/Meat Juice & Beverage Dairy Industries Culinary/ Spices industry Hotels & Restaurants Air line kitchens Confectionery Cereal Rice Industry Food raw materials Hospitals Pharmaceuticals
&
Part I
Module 3 HACCP Key Concepts & Basic philosophy
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CLASSIFICATION OF FOOD
According to Perisability;
1.Non perishable e.g. Flour 2.Semi Perisability e.g Apple 3.Perishable e.g. Raw meat
(aw)
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CLASSIFICATION OF FOOD
According to Acidity;
Low Acid Food Medium Acid Food Acid food High Acid food
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FOOD MICROBIOLOGY
A subject dealing with the study of microbial life
Microbial Growth Factors
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FOOD CONTAMINATION
Presence of any any objectionable thing in food
Nature of contaminants could be; Physical Chemical Microbiological
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FOOD SPOILAGE
Any change in food which makes it unacceptable for human consumption.
It may be caused by variety of reasons; 1. 2. 3. 4. 5. Insect damage Physical Injury Enzyme activity Chemical change Micro-organisms Product shelf depends upon rate of spoilage 1. Food preservation is done to stop spoilage
HACCP KEY CONCEPTS
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FOOD POISONING
Wide variety of illness or clinical condition affecting the gastro-intestinal tract. Causes
Bacteria Virus Fungi Plants Chemical
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Intoxication;
Caused by ingestion of a performed bacterial toxin e.g. Staphylococcus aureus and botulism.
HACCP KEY CONCEPTS
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Food Type
Contaminants
Cause
Effect
Cost
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Part II
Module 4 HACCP Pre -Requisites
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HACCP PRE-REQUISITES
Statistical Process
Control
Manufacturing Practices
Good
Supplier Quality Assurance Preventive maintenance System Environment monitoring Quality Management System
HACCP
Training & education
Recourses (finance & manpower)
Incident Management
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BASIC REQUIREMENTS Management commitment A trained multidisciplinary team Product Knowledge Time Resource
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HEALTH & SAFETY SYSTEMS Hazardous Chemical Control Occupational Health Procedures
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Part III
How to HACCP
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HOW TO HACCP ?
In 4 - STAGES
3
2
1
Planning and preparation
Implementation
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Part III
Module 1 Planning & Preparation
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STAGE - 1
Planning & Preparation
HACCP Concept Awareness for Top Management External Expert Team formation
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HACCP TEAM
Team Leader (HACCP Expert) A Microbiologist An Engineer A Production representative A Quality. Assurance representative Any other person having crucial concern with the project.
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GAP ANALYSIS
(Pre-designing assessment)
Objectives to achieve Current status
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GAP ANALYSIS
Considerable points
Supplier QA GMP GLP QMS Preventive maintenance Recall & incident management SPC Calibration Personnel/Plant Hygiene & House keeping Sanitation
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March
10 12
April
14 16
May
18 20
June
22 24
July
26 28
August
30 32
ID
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20
Tasks
Start of project HACCP Steering group awareness training Team development and training Baseline audit and gap analysis Establish process capability Plan the HACCP study Determine method of implementation Agree actions and time table Process flow diagram Hazard analysis Identify CCPs Complete control charts Validate the HACCP plan Conduct awareness training of operators Set up monitoring system Train monitoring personnel Set up facilities and equipment Implementations action completed Verify implementation action through audit HACCP plan re-validation
02
04
Time of Completion
Project Duration :
32 weeks
01 : 01 : 00
31:08:00
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Part III
Module 2 HACCP Studies & Plan Development
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STAGE - 2
HACCP Studies & Plan Development
Define Terms of Reference
Describe the Product & Intended use Construct Flow Diagram Validate Flow Diagram
Hazard Analysis
CCP Identification
Establish Critical Limits
Identify Monitoring Sys
Establish Corrective Action
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Scope
Which Product Which Process Whole process or any module Start and end points
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Batch preparation
Pasteurization Section
- Accurat e & Caref ul weighing - Pulp/ Concent rat e - Sugar - Flavor - Vit - C - Color - St abilizer - So d i um B enz o at e - Cit ric acid/ M alice acid - Sodium Cit rat e - et c ...
Pump
Balance Tank
Regenerat or-1 Homogenizer-1 Regenerat or-2 St erilizer Holding Tube Regenerat or-2 Homogenizer-2 Regenerat or-1 Cooler
Sealing
Product Pump
Bat ch Preparat ion Tank
Forming
- Hydrogen per oxide - Qualit y - Quant it y
Filtration
P asteurizatio n Temperature
Conveyer
Standardization
TBA 1 9 - M ain heat er Temperat ure
Final Analysis
Aseptic Storage
Storage
Warehousing
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HACCP PRINCIPLES
1. 2. 3. 4. 5. 6. 7. Conduct Analysis Identify Critical Control Points (CCPs) Establish target levels/critical limits Establish monitoring system Establish corrective action system Establish verification System Establish documentation system
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HACCP PRINCIPLES
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HAZARDS
1. 2. A potential to cause harm to the consumer Safety A property that may cause a product to be unsafe for consumption
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HAZARDS TYPES
PHYSICAL CHEMICAL BIOLOGICAL
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PHYSICAL HAZARDS
Dirt Fruit pits Stones Wood Glass Metal Hairs Bones Insects broken parts
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CHEMICAL HAZARDS
1. Agricultural Chemicals Pesticide, Antibiotics, Growth stimulators, Growth hormones and Fertilizers etc.. 2. Industrial Chemicals Cleaners, Sanitisers, Oils, Lubricants & Greases Ammonia and Polychlorinated biphenol etc... 3. Naturally Occurring Chemicals Aflatoxins 4. Environmental contaminants Lead, Arsenic, cadmium, mercury and PCVs 5. Food Chemicals Seasoning, Preservatives, acids, additives, sulfites and processing aids
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MICROBIOLOGICAL HAZARDS
Clostridium botulinum
Clostridium perfringens Salmonella Listeria monocytogenes Staphylococcus aureus Shegella sp. Vibrio parahaemoliticus Bacillus cereus Vibrio cholera Comphaylobactor sp. Brucella sp. Streptococus sp. E. coli
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RISK
The chance (probability) that a given hazard will occur. HIGH RISK
MEDIUM RISK
LOW RISK
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HAZARDS ANALYSIS
Considerable points;
Ingredients Intrinsic factors Procedures used for processing Microbial contents of food Facility design Equipment design and use Packaging Sanitation Employee health, health and education Storage condition Intended use Intended consumer
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PREVENTIVE MEASURES
Physical, Chemical or other factors can be used to prevent or eliminate an identified hazard or reduce it to acceptable level
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Cooking
Survival of Salmonella
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Risk free milk, Perform (adulterant tests) Hygienic Environment. Temperature sensor calibration. (Monthly)
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INFORMATION SOURCES
Team members Scientific literature Technical consultants & research organizations Company specialists Supplier/ Customers Trade associations Experimental data Mathematical models
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HACCP PRINCIPLES
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CCP IDENTIFICATION
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Yes
No
Q2. Are you or the consumer going to process this hazard out of this product?
Yes
Q3. Is there a cross contamination risk to the facility or to other products which will not be controlled?
No
No
Process to next raw materials
Yes
Sensitive raw materials High level of control required ..
CCP
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Yes
Q2. Do preventive measure(s) exist for the identified hazard?
No
Stop*
Yes
Q3. Is the step specifically designed to eliminate or reduce the likely occurrence of the hazard to an acceptable level?
No
No
Yes
Not a CCP
Stop *
No
Q4. Could contamination occur at or increase to an unacceptable level?
Yes
Yes
Not a CCP
No
Q5. Will a subsequent step or action eliminate or reduce the hazard to an accpteptible level?
Not a CCP
Stop *
No
Stop *
CCP
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Principles 3, 4, & 5
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Monitoring
Frequency Responsibility
Corrective Action
Procedure Responsibility
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IDENTIFIED CCPS
HACCP CONTROL CHART
Fruit Juice/Drinks
CCP No. Process steps Hazard Types Preventive Action Critical limits
Procedure
Monitoring
Frequency Responsibility
Corrective Action
Procedure Responsibility
03
05
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Monitoring
Frequency Responsibility
Corrective Action
Procedure Responsibility
Proper weighing
P, B B
Quality evaluation for being food grade Measure and add exact dosage /badge
05
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HACCP PRINCIPLES
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CRTICAL LIMITS
Considerable points;
Chemical Limits Physical limits Procedural limits Microbiological limits Must be measurable by test or observation Criteria which must be met for each preventive measures at CCP Not necessary the same as the existing processing parameters
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Monitoring
Frequency Responsibility
Corrective Action
Procedure Responsibility
Proper weighing
Permissible limits
P, B B
Weekly Cleaning Temperature sensor calib. (Monthly) Quality evaluation for being food grade Measure and add exact dosage /badge Temperature sensor calib. Annually
Food grade No heavy metals No arsenic or lead Exact quantity as per standard Set point Temperature 360 0oC Pressure 0.5 bar
05
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HACCP PRINCIPLES
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MONITORING
Observations or measurements to assess whether preventive measures at critical points are being implemented effectively.
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CCP MONITORING
Considerable points;
1. Continuous 2. Non Continuous
Monitoring
Frequency Responsibility
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CCP MONITORING
HACCP CONTROL CHART
Fruit Juice/Drinks
CCP No. Process steps Hazard Types Preventive Action Critical limits
Procedure
Monitoring
Frequency
Per batch
Corrective Action
Responsibility
Pasteurization operator
Procedure
Responsibility
Proper weighing
Permissible limits
Careful weighing
P, B
Weekly Cleaning
03
Physical inspection for choking and leakage Temperature monitoring from panel & graph
Hourly
UHT operator
Hourly
UHT operator
Quality evaluation for being food grade Measure and add exact dosage /badge
Food grade No heavy metals No arsenic or lead Exact quantity as per standard Set point Temperature 360 0oC Pressure 0.5 bar
Check lab release for quality Record dosage/ check end usage Temperature monitoring from regulator Pressure form gauge
Tetra operator/Foreman
05
Hourly
Tetra operator
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Reviewed by :
Date:
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HACCP PRINCIPLES
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- Adjust the process to bring it back to control - Deal with the materials produced during the deviation period Destroy non complying products Re-work Direct into less sampling products Release following sampling and testing Release?
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CORRECTIVE ACTIONS
HACCP CONTROL CHART
Fruit Juice/Drinks
CCP No. Process steps Hazard Types Preventive Action Critical limits
Procedure
Monitoring
Frequency
Per batch
Corrective Action
Responsibility
Pasteurization operator
Procedure
Dont use the product
Responsibility
Shift Incharge erator
Proper weighing
Permissible limits
Careful weighing
P, B
Weekly Cleaning
No choking or leakage/damage
Physical inspection for choking and leakage Temperature monitoring from panel & graph
Hourly
UHT operator
UHT operator
03
UHT Temperature
Hourly
UHT operator
Quality evaluation for being food grade Measure and add exact dosage /badge
Food grade No heavy metals No arsenic or lead Exact quantity as per standard Set point Temperature 360 0oC Pressure 0.5 bar
Check lab release for quality Record dosage/ check end usage Temperature monitoring from regulator Pressure form gauge
Tetra operator/Foreman
Ask lab for product results/ Safe product should be released Immediate calibration Process gets stop in case of deviation
inbuilt security system
Tetra operator/Foreman
05
Hourly
Tetra operator
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HACCP PRINCIPLES
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WHAT ?
The assessment of the HACCP plan before implementation to provide confirmation that it is accurate and complete
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HOW TO VALIDATE ?
Use personnel with audit skills Assess all elements of the HACCP plan - Process flow diagram - HACCP Control chart Assess the process area - Preventive measures - Process capability
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HACCP PRINCIPLES
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HACCP DOCUMENTATION
Main Records
A summary of Hazards analysis, with rationale of determining hazards and control measures. The HACCP Plan Support documentation such as validation records Records that are generated during the operation of the plan.
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Part III
Module 3 Implementation of HACCP Plan
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STAGE - 3
Implementation Of HACCP Plan
Determine The Method of Implementation
Set Up Implementation Team
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HACCP IMPLEMENTATION
Method Big Bang
Method
Advantages
1. 2. Rapid implementation potential Works well in companies with well established Quality Systems Whole work force involved Ease of work force briefing
1.
Disadvantages
May take longer period overall than anticipated- All HACCP monitoring and control procedure will have to be developed before implementation starts No trial of individual system elements Loss of credibility If employ see that it is poorly managed If CCP fails through poor support network Large immediate training requirement Resource thinly spread e.g. HACCP Team
All at once
3. 4.
2. 3.
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HACCP IMPLEMENTATION
Method - Phased
Method
Advantages
1. Quality management system support can be developed as required and alongside Staged training allows more individual attention System can be trailed and refined as implementation progress More manageable approach HACCP Resource can be focused on each stage
1. 2. 3.
Disadvantages
Longer over all implementation time table Working of small group in isolation difficult to change culture Implementation may loose momentum
Phased
2. 3.
4. 5.
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PERSONNEL CONSIDERATIONS
Fundamentals to HACCP effectiveness
Key Questions
- Enough people - Ability - Time - Supervisor - Training
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TRAINING PERSONNEL
All personnel - An understanding of HACCP - How HACCP applies to process - Why monitoring is vital CCP monitors and their Supervisors - How to monitor - Monitoring frequency required - Record keeping /Deviation reporting - Use of critical limits/Target levels - Adjusting the process to maintain control - Corrective action
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Facility Considerations;
- Production - Additional space requirements - Extra facilities - Training and briefing staff - Space - Environment - Equipment
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Part III
Module 4 Maintaining the HACCP System
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STAGE - 4
Maintaining the HACCP System
Define standards and regular audits
Ongoing Maintenance
Corrective & Preventive Action HACCP Plan Validation Documentation control Update Data analysis
Problem Solving
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HACCP AUDITING
Types of audits
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Process
(List of process steps)
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Action required by (date): Auditors: Accepted by Audi tee: Corrective Action: Verified (Auditor): Date:
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Refresher Training New Personnel - HACCP - CCP monitors - Others Updating training - New emerging hazards - Developments in HACCP Awareness training
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Date: Quarterly audit of HACCP plan annual plan revalidation HACCP plan to be revised for all process ingredients changes Quarterly CCP log sheet review for deviation trend analysis Monthly review of consumer complaints data for trends 6 monthly simulation of trace/recall procedures Ongoing technical update through symposia and technical journals Quarterly analysis of training needs
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HISTORY OF AMENDMENTS
HACCP Plan Ref. Page:
Date Amendment Reason Approval Signature
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HACCP VERIFICATION
1. 2. 3. 4. Initial validation of plan Subsequent validation of plan Verification of CCP monitoring as per plan Review of monitoring, corrective action records to show compliance with plan 5. Comprehensive HACCP system verification.
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HACCP VERIFICATION
1. Establish procedures
2. Responsibility
3. Frequency of Verification
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Part IV
Module 1
FOOD SAFETY & Quality System
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The Danger
If unsafe product is specified .. ..then it will always be produced
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: : :
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CCP
QCP
LQP
Procedure
Frequency
CCP = Critical Control Points QCP = Quality Control Points LCP = Legal Control Points
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Part V
Module 1 System Bottlenecks
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Part VI
Module 1 HACCP FUTURE
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HACCP FUTURE
Outside Pakistan In Pakistan
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