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Haccp System
Haccp System
2. Origins of HACCP
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3. HACCP is
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HACCP is designed for use in all segments of the food industry ---
4. Recommendation:
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By the USDA
By the FDA
Routinely,
on an unannounced basis,
8. Salient features
o
9.
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Attendant uncertainties
The probability of occurrence
RISK
RISK
PERCEPTIONS
o
o
Communicate to
This allows setting priorities on risk and emphasizes operations that offer the greatest
potential for control.
18. CORRECTIVE ACTION
It is a specified prompt action to be taken when the criteria are not met or when the
results of monitoring the CCP indicates a trend towards loss of control.
VERIFICATION
Review of monitoring records to determine whether the HACCP system is in place and
functioning as planned and to ensure that monitoring is carried out effectively and
efficiently.
19. DECISION TREE
A sequence of Questions applied to each process step with a potential hazard to identify
which process steps are critical to food safety.
20. 7-HACCP
Principles
21. 7-HACCP Principles
1. Conduct Hazard AnalysisProcess flow diagram.
Identify hazards and Preventive measure
2. Determine CCPs in process
Establish the points where control is critical to mange the safety of the product.
3. Establish critical limits for preventive measures
associated with each identified CCP
The critical limits describe the difference between safe and unsafe product at the CCPs
These must involve a measureable parameter and may also known as the absolute
tolerance for the CCP
22. 4. Establish a system to monitor control of the CCP.
Specify monitoring requirements for management of the CCP within its critical limit.
It involves specifying monitoring actions along with frequency and responsibility.
5. Establish the corrective action to be taken when monitoring
Act to bring the process back under control.
Act to deal with product manufactured while the process was out of control.
23. 6. Establish procedures for verification to
confirm that the HACCP system is working effectively
7. Establish documentation concerning all
procedures and records appropriate to these principles and their application.
24. Application Stages
of
HACCP
25. Application Stages of HACCP
Determine the terms of reference
Assemble and Train the HACCP team
Meat
Dairy products
Poultry, eggs
7. Classifications of Hazards
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Chemical- are toxin substances that may occur naturally or may be added during
the processing of foods.
Physical-are hard or soft objects in food that can contaminate the food(metal,
jewelry, hair pins)
9. Examples of CCPs:
o
10. Principle 3- Establish the Critical limits m(thresholds) Which must be met at EACH
Critical Contrl Point
Critical Limits-it must be specified and validated if possible for each Critical Control
Point. In some cases more than one critical limit will be elaborated at a particular step
11. CRITERIA MOST FREQUENTLY USED
12. Each CCP has one or more critical limits to monitor to assure that hazards are:
Prevented
Eliminated
Reduce to acceptable level
13.
14. Principle 4-Establish Procedures to Monitor CCPs
Monitoring
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Is a critical part of the HACCP system and provides written documentation that
can be used to verify that the HACCP system is working properly
Is necessary to ensure that the process is under control at each critical control
point
15. Principle 5- Establish the Corrective Action to Be Taken When Monitoring Shows That a
Critical Limit Has Been Exceeded
1st. Determine what went wrong
2nd. Choose and apply the appropriate corrective4 action
16. Principle #6 Record keeping
The HACCP system requires the preparation and maintenance of a written HACCP plan
together with other documentation. This must include all records generated during the
monitoring of each CCP and notations of corrective actions taken. Usually, the simplest
record keeping system possible to ensure effectiveness is the most desirable.
17. Principle #7 Verification
Verification has several steps. The scientific or technical validity of the hazard analysis
Food Safety
(Microbiology, Sanitation and HACCP) - Presentation
Transcript
1. Food Safety (Microbiology, Sanitation and HACCP) Frank T. Jones Extension Poultry
Specialist Cooperative Extension Service University of Arkansas Fayetteville, AR
2. Presentation Outline
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Sanitation Definitions
Microorganisms Overview
Sanitation on Farm
Sanitation in Plants
HACCP Overview
3. What is Sanitation?
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World Health Organization (WHO) All precautions and measures which are
necessary in production, processing, storage and distribution, in order to assure an
unobjectionable, sound and palatable product which is suited for human
consumption.
Fermentation
Enzymes
Decay
7. The Enemies
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8. Bacteria
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Rod
Cocci (spheres)
Spiral
Binary Fission
F ood
A cid (pH)
T ime
T emperature
O xygen
M oisture
FAT TOM
11. The Spore Cycle
o Spores VERY resistant
o
Bacillus
Clostridium
Very adaptable
Molds multicellular
Yeasts bud
13. Basic Virus Structure Genetic Material (DNA or RNA) Protein Coat Tail Fibers Hollow
Protein Tail
14. Viruses
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Tiny
Simple structure
Living?
17. Foodborne Hazards Hazard Est. Cases Deaths Norwalk virus 23,000,000 na
Campylobacter 2,453,926 0.1% Salmonella 1,412,498 0.8% C. perfringens 248,520 .05%
S. aureus 185,060 .02% E. coli O157:H7 73,480 .83% L. monocytogenes 2,518 20% C.
botulinum 58 8.6% (Centers for Disease Control and Prevention, 2001)
18. FOOD BORNE PATHOGENS:
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Salmonella
E. coli 0157:H7
Campylobacter
Listeria monocyctogens
19. SALMONELLA
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Grown on any food under the right conditions: Moisture and Temperature
Consumer education of safe handling practices for food, raw and cooked,
essential for control
Can survive for long periods in SOIL, SEWAGE, DUST, VEGATATION AND
WATER
Vermin Control
Moisture Control
Feed Storage
Biosecurity
Water Sanitation
Provide ventilation
25. Vermin
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Damage facilities
Eat feed
Contaminate facilities
26. Moisture is often THE SINGLE Most Important Factor in Determining Microbial Growth
27. Moisture Control
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Ventilation
Control of Drinkers
28.
29. Feed Storage
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Moisture Migration
UV Destruction
Feed Freshness
Procedures that work for bird pathogens also keep out human pathogens
Basic Steps
General Sanitation
39. Disinfectant Types and Qualities Can be corrosive Low Low Kills effects Wide no spores
Hypochlorite May stain clothing, porous surfaces Low Mod Reduces effects Wide no
spores Iodophors Limited residual, Mod corrosive Low Mod Kills effects Mod. No
spores Oxidizer Gets everything, but can be highly toxic Mod Mod Limits effects Wide
Aldehyde Good residual activity Low Mod Little to none Wide no spores Phenolic Soaps,
detergents and hard water limit effectiveness Low Low Reduces effects Limited no
spores QAC (Quaternary Ammonia Compounds) Non Corrosive, Fire Hazard, conc 7095%, Low Exp Reduces effects Wide no spores Alcohols Comments Human Toxicity
Cost Organic Mattter Effect Activity Type
40. A Broad Look at Disinfectants Clean surfaces Hydrogen Peroxide, Peracetic Acid
Oxidizer Fumigation, clean surfaces Formaldehyde, Glutaraldehyde Aldehyde
Hatcheries, Equipment, Footbaths Lysol, Pine-Sol, Cresi-400, Environ, Tek-Trol Phenolic
Hatcheries, with some soaps Roccal, Germex, Hi-Lethol, San-O-Fec, Warden, Zephiran
QAC (Quaternary Ammonia Compounds) Water, Hands, Equipment, Walls Betadine,
Iofec, Isodyne, Tamed Iodine, Weladol Iodophors Water, Clean surfaces Chlorox,
Chloramine-T, Halazone Hypochlorite Small objects, hands Rubbing Alcohol, Isopropyl,
Ethanol Alcohols Uses Examples Type
41. Water Sanitation
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Clean open waterers often, but dont dump water in the litter
42. Bacterial Counts from Poultry Water Systems From: Watkins. 2003
43. Used with permission from: The Center for Biofilm Engineering at Montana State
University Bozeman http://www.erc.montana.edu/CBEssentials-SW/bf-basics99/bbasics-01.htm
44. Used with permission from: The Center for Biofilm Engineering at Montana State
University Bozeman http://www.erc.montana.edu/CBEssentials-SW/bf-basics99/bbasics-01.htm
45. Biofilm in a Municipal Water Line
46. Water Line Cleaners for Use Once a Week When Birds are Present teaspoon per gallon
of water 1 oz per gallon of water teaspoon per gallon of water teaspoon per gallon of
water Iodine (18.05%) White Household Vinegar Household Bleach Clear Household
Ammonia
47. Cleaning Closed Watering Systems with Birds in the House Meter stock solution at 1 oz /
128 oz (gal) water Prepare a stock solution 2 oz per gallon 128 oz per gallon 6 oz per
gallon 6 oz per gallon Iodine (18.05%) Clear Vinegar Household Bleach Clear Household
Ammonia
48. Basic Steps in Poultry Processing Pre-slaughter Immobilize Feather Removal
Evisceration Chilling Further Processing or Packaging Kill Line Evisceration Line
Separation Wall Air Flow
49. Sanitation in Small Processing
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Separate slaughter and picking from evisceration and cut up -- Job Specialize
50. Loblolly Pine Birch 100 Staphylococcus - 1.0 Clostridium - 0.4 x 3 Treponema
0.2x 11 Wood Should be Avoided in Processing Areas
51. Sanitizers for Food Contact Surfaces Co, Cu, Ti, Mishandling Danger, Concentrate Odor
Broad Act., Degrade, Non Corrosive, Temp. Tolerant Peroxy Acid Low Temp., Corrosive
Broad Act., Stable, W/ Organic Matter, High Temp Carboxylic Acid Cost, pH Stable, W/
Organic Matter, Non Corrosive, Odorless Acid-Anionic Low temps, Hard water, Little
effect on gram negative bacteria Stable, Innocuous, Some Residual QAC Stains, Hard
water, Temps (High & Low), Odor, Cl cheaper Broad Act., Low Tox., Stable, Color,
Good Residual Iodophores Cl gas, Corrosive, Organic material, Degrades, THMs, pH
range Broad Act., Not temp. sensitive, Cheap, No Foam Chlorine, Dioxides
Disadvantages Advantages Category
52. Natural Disinfecting Agents
Heat (>85 F)
HACCP -(HAS-SIP)
H azard
A nalysis and
C ritical
C ontrol
P oints
55. HACCP What is it? How do you know the system works? 7. Establish Verification
Procedures If you dont write it down it doesnt exit. 6. Establish a Record Keeping
System What happens if we exceed a Critical limit? 5. Establish Corrective Actions Who,
what, when , where and how will CCPs be monitored? 4. Establish Monitoring
Procedures What value indicates the process is in control? 3. Establish Critical Limits
Where do things go wrong and how can we reliably control it? 2. Establish Critical
Control Points What are the controllable food safety hazards? 1. Hazard Analysis
Meaning Step
56. HOW DOES HACCP WORK?
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Identify at each step of the production flow chart any hazard to food safety as to:
Chemical
Physical
Bacterial
Support the hazard with a decision making document and scientific data
FSIS has made a commitment to expanding into the pre harvest areas of the food
chain, working in a non regulatory capacity, to promote food safety.
You will have a solid foundation for implementing a food safety plan and SOPS
using the process approach to HACCP principles.
Today we will:
Time and Temperature controls are best methods to prevent the growth of harmful
microorganisms.
The best way to prevent hazards from causing foodborne illness is to have a
comprehensive food safety program.
6.
o
H Hazard
A Analysis
C Critical
C Control
P Points
What is HACCP
7. What is HACCP
o HACCP is a food safety system that helps identify foods and procedures that are
most likely to cause foodborne illness
8. Key Terms
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Hazard Analysis
Control Measures
Process Approach
Medical/legal claims
Lost wages
Bad publicity
Embarrassment-loss of reputation
10. What are some common activities in a Food production that could cause a foodborne
illness?
11. Causes of foodborne illness:
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Cross contamination
12. An Effective Food Safety Program Controls Food Safety Hazards During All Aspects of
Food Service
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Holding
Assembling
Packaging
Transporting
Serving
Receiving
Storing
Preparing
Cooking
Cooling
Reheating
Sanitation
Temperature
Control
14. Sanitation
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16.
17. Potentially Hazardous Foods:
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High Protein
Moist
Neutral pH
Personal Hygiene
Washing Hands
Keep records
20. An Effective Food Safety Program Controls Food Safety Hazards During Each Step of
the Food Preparation ProcessSOPs are needed for all of these:
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Cooking
Holding
Serving
Cooling
Reheating
Date Marking
Receiving
Storing
Preparing
Purpose
Scope
Key Words
Instructions
Monitoring
Corrective Measure
No Cook Process
Food passes through the temperature danger zone only once before it is served..
(Cooking or Cooling)
Receive > Store > Prepare > Cook > Hold > Serve
Receive > Store > Prepare > Cook > Cool > Reheat > Hot Hold > Serve
Control measures are any means taken to prevent, eliminate or reduce hazards
A CCP is a key point where a step can be taken to prevent, eliminate, or reduce a
food safety hazard
The SOPs have critical limits for you to use i.e. when cooking chicken, the
critical limit at 75 for 15 seconds.
Cold holding or limiting time in the danger zone to inhibit bacterial growth and
toxin production (e.g. limiting time would be holding at room temperature for 4
hours and then discarding)
Hot holding or limiting time in the danger zone to prevent the growth of bacteria
Hot and cold holding or limiting time in the danger zone to inhibit bacterial
growth and toxin formation
Employees must know what these corrective actions are and be trained in making
the right decisions.
Records provide a basis for review of the overall food safety program.
SOPs
IF Change happens:
Menus
Equipment
Staff
Schedules
Food Safety Plans need to change to cover the needs of the foodservice.
Ongoing review allows you to verify that the program is addressing the food
safety concerns and, if it is not, checking to see what needs to be modified or
improved.