Food Safety Systems ManagementGS TS BS Lê Hoàng Ninh

Food Safety Systems Management Food Safety Systems Management GS TS BS Lê Hoàng Ninh Hazard Analysis Critical Control Point  Cách tiếp cận hệ thống để xác định, đánh giá và kiểm soát các mối nguy có[.]

Food Safety Systems

Management

GS TS BS Lê Hoàng Ninh

Hazard Analysis Critical

Control Point

 Cách tiếp cận hệ thống để xác định, đánh giá

và kiểm soát các mối nguy có ý nghĩa làm

mất an toàn thực phẩm

 Risk Assessment and Management tool not

unlike a FMEA (Failure Modes Effects

Analysis)

NỀN TẢNG HACCP

-Prerequisite Programs

HACCP

Raw Materials Control

Sanitation

Facility Design And Control

Equipment Design And Maintenance

Pest Control

Traceability

And Recall Employee Training

 Phải tương thích và có hiệu quả

 Phải được giám sát, theo dõi (requires

documentation and records) – Internal Audit.

 Các sai sót cứ lập lại rõ ràng không ủng hộ cho

HACCP.

Raw Materials Control

Kiểm soát chất liệu thô

(Raw Materials Control)

 Supplier licensing and registration must meet state and federal requirements (e.g FDA Registration for Bioterrorism Act of 2002)

 Material Guarantee and Supplier Certificate of

Insurance

 Supplier Food Safety Audit (second or third party)

 Raw Material Specifications - includes capability

assessment on critical parameters

 Certificate of Analysis – on critical to quality

parameters

 Supplier HACCP Risk Assessment

 Handling / Shipping Requirements

Kiểm soát chất liệu thô

(Raw Materials Control

 Phải có hồ sơ thanh / kiểm tra các công cụ phương tiện tiếp nhận các nguyên liệu thô

nầy (temperature, sanitation)

 Vật liệu được kiểm tra phải có chứng nhận Materials inspected upon receipt Visual

inspection, grading, as your program has defined

 Tồn trử phù hợp để đảm bảo chất lượng

(allergen segregation, temperature, protected, chemicals stored separately and secured, etc).

Sanitation

 Effective cleaning procedures for equipment and

facility.

 Documented – SSOP (Sanitation Standard Operating Procedures)

 Defined frequency

 Chemicals approved for use in food facilities.

 Records – concentrations, times, temperatures.

 Sanitation monitoring – visual inspections, chemical or microbiological testing.

 Corrective actions for deficiencies.

Employee Training

 Records of training required.

 Hygienic Practices

 Disease Control

 Cleanliness – outer garments, hand-washing, unsecured jewelry and other objects, use of gloves, hair and beard nets, eating, drinking, tobacco use, nail polish, etc.

 Manufacturing Controls

 Traffic flow to prevent cross contamination

 Ingredient / product handling to protect product

 Control measures (pH, cook time / temp, moisture, etc)

 Scheduling sequential runs to prevent cross contamination (as for allergens)

 Food Defense

Thiết kế và kiểm soát cơ sở (Facility Design and Control)

Thiết kế và kiểm sóat cơ sở

Facility Design and Control

 Mặt đất

 Eliminate pest harborage areas

 Properly grade roads, yards, parking lots

Thiết kế và kiểm soát cơ sở

Facility Design and Control

 Sàn , tường, trần nhà Floors, walls and ceilings

cleaned and in good repair

 Prevent condensate

 Ánh sáng đủ Adequate lighting

 Thông khí phù hợp Adequate ventilation

 Chất lượng nước Water Quality (potable, steam, ice, reclaimed water, cooling water, backflow prevention)

 Nghỉ dưỡng nhân viên / nhà vệ sinh

 Kiểm soát chất thải

 Giám sát theo dõi môi trường

Equipment

Design and Maintenance

Equipment

Design and Maintenance

 Designed and of materials and workmanship

as to be adequately cleanable – meets

standards (e.g 3A Sanitary Standards)

 Installed with adequate space to allow for

proper cleaning and maintenance and to

prevent cross contamination

 Properly maintained (records)

Pest Control

 Prevention is key (design, maintenance and sanitation)

 Rodent control

 Insect control

 Bird / Bat Control

Traceability

and Product Recovery

Traceability

and Product Recovery

 Documented program with written procedures to

meet federal requirements

 Program should include

 Product Identification / Lot coding

 Finished product distribution records retained beyond shelf life of product

 Responsible individuals and their roles

 Identification of Key Contacts – Internal, supplier customer

 Mock Recovery Program

 One step forward, one step back

Prerequisite programs

are in place

Let’s talk HACCP

Steps to

HACCP Implementation

 Assemble the HACCP Team

 Describe the food and its distribution

 Describe the intended use and consumers of the food

 Develop a flow diagram which describes the process

 Verify the Flow Diagram

Multidisciplinary HACCP Team

Describe the Food /

Distribution: Cheddar Cheese

 Formal Product name: Cheddar Cheese

 Food Safety Characteristics: pH (4.9 to 5.4)

 Packaging type: 42# Block, Vacuum sealed in ploy bag and stored in corrugated box

 Length of shelf life/storage temperature: 3-12

months when stored below 45°F

 Where it will be sold: Food Manufacturer

 Intended Consumers: Consumers of all ages

 Labeling instructions: Keep Refrigerated

 Intended use: Ready to eat product May be used

as ingredient May be further processed into

chunks or shredded.

Develop a Flow Diagram

Verify the Flow Diagram

 HACCP Team should perform an on-site

review of the operation to verify the accuracy and completeness of the flow diagram

 Take the diagram out to the production floor and walk through the steps

 Review periodically, modify and update as

necessary (annual review or when change to process occurs)

1 - Conduct a Hazard Analysis

 Identify hazards at each processing step and

for each ingredient and material used.

 Biological – such as pathogen

 Chemical – such as toxin

 Physical - such as glass

 Evaluate hazards to determine severity and

likelihood to occur

 The hazard evaluation provides a basis for

determining control measures such as CCP’s

2 - Determine Critical Control

3 – Establish Critical Limits

 A critical limit must be scientifically based and is a maximum and / or minimum value

to which a biological, chemical or physical parameter must be controlled at a CCP to prevent, eliminate or reduce the food

safety hazard to an acceptable level.

 Examples: Temperature, time, Water

Activity, pH, safe tolerance level for drug residues

4 – Establish Monitoring

Procedures

 Monitoring is a planned sequence of

observations or measurements used to

assess whether a CCP is under control

 Monitoring should produce an accurate

record for use in verification

 Where there is loss of control (a CCP limit is exceeded) there must be documented

corrective action

 Continuous is desirable (recording chart) but where not possible, frequency for monitoring must be established

 Responsibility for monitoring must be

assigned - Position title / work station

5 - Establish Corrective

Actions

 Corrective actions are procedures to be followed when a deviation occurs.

 Corrective actions must be specific.

 Halt production of product

 Isolate the affected product

 Return the process to control

 Determine the disposition of the product

 Records must be kept for a reasonable

period after the shelf life of the product

6 _ Establish Verification

Procedures

 Establish procedures to verify that the system is working properly.

 Might include calibration and testing of

monitoring equipment, demonstration of system performance, documented record review

 Verification and Validation Records

 Records to show changes to the HACCP Plan

Consider our example

Identify hazard at each step and for each material

Raw Milk Receiving

Raw Milk,

Water

1 – Conduct Hazards Analysis

 Identify the hazards for each step of the process: Raw milk / receiving

 Identify the type of hazard: chemical,

Determine severity of each hazard

and likelihood of occurrence

 Severity: Enteric pathogens such as E coli

0157H7 and Salmonella cause severe health effects including death among children and elderly

 Likelihood to occur: Likely that they will

occur in raw milk supply

 Using this information, determine if this

potential hazard is to be addressed in the

HACCP Plan

Hazards Analysis (severity)

 Is the hazard identified at this step severe

and of sufficient likelihood of occurrence to warrant it’s control? If Yes, go to next

question

 If no, identify the prerequisite program or

procedure step, which reduces the likelihood

or severity of the hazard to ensure that

control at this step is not necessary

Hazards Analysis (control)

 Does a control measure exist at this step to prevent, reduce or eliminate the likely

occurrence of the hazard to an acceptable level?

 If yes, this step is a CCP

 If no, identify where control exists

(Pasteurization Step – This step is a CCP)

Hazards Analysis (justify)

 Justification - Research or Reference

Document that gives credence to your

assumptions Pasteurized Milk Ordinance,

2003 Revision, WDATCP 80.48

2 - Determine Critical Control Points

3 - Establish Critical Limits

 Critical Limits

 HTST Limits for raw milk pasteurization are defined in the PMO – minimum 161˚F / 15 seconds

5 - Establish Corrective Actions

 When minimum time or temperature requirement

is not met, product automatically diverts to back

to the balance tank prior to the HTST

Pasteurizer Forward flow is prevented

 Product diversion must be indicated on

Pasteurizer Recording chart These instances

should be carefully reviewed by Licensed

Pasteurizer Operator

6 _ Establish Verification

Procedures

after sanitation and before product (Cut In / Cut Out) and recorded on the continuous chart Charts verified

Licensed Pasteurizer Operator.

Pasteurizer / time (maximum allowable flow for specified distance) and temperature All controls are sealed

Records are retained by facility and state.

reviewed by Licensed Pasteurizer Operator.

7 – Establish Records

 Pasteurizer Charts

 Seal Check Record

 WDA Pasteurizer Time / Seal Record

 Other Equipment Calibration and testing records

Identify CCP on Flowchart

HACCP Description Chart

 International Dairy Foods Association –

HACCP Plant Manual, 2007 Edition

 Pasteurized Milk Ordinance, 2003 Revision

 WDATCP Chapters 60 and 80

 USDA-FSIS HACCP Website