Would your food businesses be able to do the same? A food business in Norway got to experience a real life crisis this week after one of their trucks carrying 27 tons of goats cheese caught fire in a tunnel. It took around five 5 days to put the fire out with the tunnel now to be closed for several weeks whilst repairs are made. I would hate to think of the lost production time this food business had to endure whilst this crisis was going on. Amanda, Thanks for all yuor efforts!
They are a real asset. Your email address will not be published. Related Posts. Leave a Comment Cancel Reply Your email address will not be published. Each CCP will have one or more control measures to assure that the identified hazards are prevented, eliminated or reduced to acceptable levels.
Each control measure has one or more associated critical limits. Critical limits may be based upon factors such as: temperature, time, physical dimensions, humidity, moisture level, water activity a w , pH, titratable acidity, salt concentration, available chlorine, viscosity, preservatives, or sensory information such as aroma and visual appearance.
Critical limits must be scientifically based. For each CCP, there is at least one criterion for food safety that is to be met. An example of a criterion is a specific lethality of a cooking process such as a 5D reduction in Salmonella. The critical limits and criteria for food safety may be derived from sources such as regulatory standards and guidelines, literature surveys, experimental results, and experts.
An example is the cooking of beef patties Appendix B. The process should be designed to ensure the production of a safe product. The hazard analysis for cooked meat patties identified enteric pathogens e.
Furthermore, cooking is the step in the process at which control can be applied to reduce the enteric pathogens to an acceptable level. To ensure that an acceptable level is consistently achieved, accurate information is needed on the probable number of the pathogens in the raw patties, their heat resistance, the factors that influence the heating of the patties, and the area of the patty which heats the slowest. Collectively, this information forms the scientific basis for the critical limits that are established.
Some of the factors that may affect the thermal destruction of enteric pathogens are listed in the following table. To ensure that this time and temperature are attained, the HACCP team for one facility determined that it would be necessary to establish critical limits for the oven temperature and humidity, belt speed time in oven , patty thickness and composition e. In this second facility the internal temperature and hold time of the patties are monitored at a frequency to ensure that the critical limits are constantly met as they exit the oven.
The example given below applies to the first facility. Patty composition: e. Monitoring is a planned sequence of observations or measurements to assess whether a CCP is under control and to produce an accurate record for future use in verification. Monitoring serves three main purposes. First, monitoring is essential to food safety management in that it facilitates tracking of the operation.
If monitoring indicates that there is a trend towards loss of control, then action can be taken to bring the process back into control before a deviation from a critical limit occurs. Second, monitoring is used to determine when there is loss of control and a deviation occurs at a CCP, i. When a deviation occurs, an appropriate corrective action must be taken. Third, it provides written documentation for use in verification. An unsafe food may result if a process is not properly controlled and a deviation occurs.
Because of the potentially serious consequences of a critical limit deviation, monitoring procedures must be effective.
Ideally, monitoring should be continuous, which is possible with many types of physical and chemical methods. For example, the temperature and time for the scheduled thermal process of low-acid canned foods is recorded continuously on temperature recording charts. If the temperature falls below the scheduled temperature or the time is insufficient, as recorded on the chart, the product from the retort is retained and the disposition determined as in Principle 5.
Likewise, pH measurement may be performed continually in fluids or by testing each batch before processing. There are many ways to monitor critical limits on a continuous or batch basis and record the data on charts. Continuous monitoring is always preferred when feasible. Monitoring equipment must be carefully calibrated for accuracy. Assignment of the responsibility for monitoring is an important consideration for each CCP.
Specific assignments will depend on the number of CCPs and control measures and the complexity of monitoring. Personnel who monitor CCPs are often associated with production e. Those individuals must be trained in the monitoring technique for which they are responsible, fully understand the purpose and importance of monitoring, be unbiased in monitoring and reporting, and accurately report the results of monitoring. In addition, employees should be trained in procedures to follow when there is a trend towards loss of control so that adjustments can be made in a timely manner to assure that the process remains under control.
The person responsible for monitoring must also immediately report a process or product that does not meet critical limits. All records and documents associated with CCP monitoring should be dated and signed or initialed by the person doing the monitoring.
When it is not possible to monitor a CCP on a continuous basis, it is necessary to establish a monitoring frequency and procedure that will be reliable enough to indicate that the CCP is under control. Statistically designed data collection or sampling systems lend themselves to this purpose.
Most monitoring procedures need to be rapid because they relate to on-line, "real-time" processes and there will not be time for lengthy analytical testing. Examples of monitoring activities include: visual observations and measurement of temperature, time, pH, and moisture level.
Microbiological tests are seldom effective for monitoring due to their time-consuming nature and problems with assuring detection of contaminants. Physical and chemical measurements are often preferred because they are rapid and usually more effective for assuring control of microbiological hazards. For example, the safety of pasteurized milk is based upon measurements of time and temperature of heating rather than testing the heated milk to assure the absence of surviving pathogens.
With certain foods, processes, ingredients, or imports, there may be no alternative to microbiological testing. However, it is important to recognize that a sampling protocol that is adequate to reliably detect low levels of pathogens is seldom possible because of the large number of samples needed.
This sampling limitation could result in a false sense of security by those who use an inadequate sampling protocol. The HACCP system for food safety management is designed to identify health hazards and to establish strategies to prevent, eliminate, or reduce their occurrence.
However, ideal circumstances do not always prevail and deviations from established processes may occur. An important purpose of corrective actions is to prevent foods which may be hazardous from reaching consumers. Where there is a deviation from established critical limits, corrective actions are necessary.
Therefore, corrective actions should include the following elements: a determine and correct the cause of non-compliance; b determine the disposition of non-compliant product and c record the corrective actions that have been taken. As a minimum, the HACCP plan should specify what is done when a deviation occurs, who is responsible for implementing the corrective actions, and that a record will be developed and maintained of the actions taken.
Individuals who have a thorough understanding of the process, product and HACCP plan should be assigned the responsibility for oversight of corrective actions. As appropriate, experts may be consulted to review the information available and to assist in determining disposition of non-compliant product. Verification is defined as those activities, other than monitoring, that determine the validity of the HACCP plan and that the system is operating according to the plan.
The NAS 2 pointed out that the major infusion of science in a HACCP system centers on proper identification of the hazards, critical control points, critical limits, and instituting proper verification procedures. An example of a verification schedule is given in Figure 2.
An effective HACCP system requires little end-product testing, since sufficient validated safeguards are built in early in the process. Therefore, rather than relying on end-product testing, firms should rely on frequent reviews of their HACCP plan, verification that the HACCP plan is being correctly followed, and review of CCP monitoring and corrective action records.
Another important aspect of verification is the initial validation of the HACCP plan to determine that the plan is scientifically and technically sound, that all hazards have been identified and that if the HACCP plan is properly implemented these hazards will be effectively controlled.
Information needed to validate the HACCP plan often include 1 expert advice and scientific studies and 2 in-plant observations, measurements, and evaluations. For example, validation of the cooking process for beef patties should include the scientific justification of the heating times and temperatures needed to obtain an appropriate destruction of pathogenic microorganisms i.
Subsequent validations are performed and documented by a HACCP team or an independent expert as needed. For example, validations are conducted when there is an unexplained system failure; a significant product, process or packaging change occurs; or new hazards are recognized. In addition, a periodic comprehensive verification of the HACCP system should be conducted by an unbiased, independent authority. Such authorities can be internal or external to the food operation.
This should include a technical evaluation of the hazard analysis and each element of the HACCP plan as well as on-site review of all flow diagrams and appropriate records from operation of the plan.
A comprehensive verification is independent of other verification procedures and must be performed to ensure that the HACCP plan is resulting in the control of the hazards. Verification activities are carried out by individuals within a company, third party experts, and regulatory agencies.
It is important that individuals doing verification have appropriate technical expertise to perform this function. Figure 2. May require additional technical expertise as well as laboratory and plant test studies.
A summary of the hazard analysis, including the rationale for determining hazards and control measures. The next step is to establish a plan that describes the individuals responsible for developing, implementing and maintaining the HACCP system.
The team is then responsible for developing the initial plan and coordinating its implementation. An important aspect in developing these teams is to assure that they have appropriate training. The workers who will be responsible for monitoring need to be adequately trained. Upon completion of the HACCP plan, operator procedures, forms and procedures for monitoring and corrective action are developed.
Often it is a good idea to develop a timeline for the activities involved in the initial implementation of the HACCP plan. Implementation of the HACCP system involves the continual application of the monitoring, record-keeping, corrective action procedures and other activities as described in the HACCP plan.
Maintaining an effective HACCP system depends largely on regularly scheduled verification activities. An important aspect of maintaining the HACCP system is to assure that all individuals involved are properly trained so they understand their role and can effectively fulfill their responsibilities.
The principles of risk assessment for illness caused by foodborne biological agents. Adopted April 4, Food Microbiol. Common prerequisite programs may include, but are not limited to:. The product description for various food groups is specified and documented. The description of the safety of the product group encompasses the food chain, ranging from raw materials used to the distribution of the finished products.
Since this has a direct influence on the required product characteristics. These descriptions are drawn up and verified by the Food Safety and Validation Teams. Prospective changes are reported to Food Safety Team as per the Documentation Control Procedure and its supporting documents.
Verified flow diagrams and layouts, with changes marked on them if applicable, are maintained with the FSTL. These periodic verifications are a part of the Internal Audit cum Verification. The identification includes all aspects of the operation within the scope of the ISO system.
Potential hazards have been documented in the Hazard Analysis Worksheet. The source of hazards i. Hazard analysis shall be applied at all points from incoming material inspection to consumer. Methodology followed for arriving a hazard is as follows: - Number all steps in the flow Diagrams. All the risks are included with the help of group discussions by Food Safety Team and other associates from relevant areas.
All steps that are repeated throughout the process have been allocated the same number to save repetition in the risk analysis table. These hazards are all monitored and a record of that activity maintained. Frequent event 5: Critical: Public health : once per day risk.
The assessment is based on, amongst other things, the varied expertise within the team, and has utilized external and internal information as needed. More than one control measure, if required to control a hazard, shall be identified and documented and more than hazard may be controlled by a specific control measure.
The reason for deciding a CCP shall be documented. The effectiveness of the general control measures shall be verified at defined intervals through the Food Safety Audits. While selecting CCPs, care has been exercised that on-line process related parameters which does not require elaborate and time consuming testing but ensures products safety only have been selected. These are actions or activities, often measurable in terms of physical or chemical parameters such as temperature, time, pH, and sensory parameters such as visual appearance.
Their monitoring mechanisms, corrective actions provided, validation and verification have also been documented in the same. In general, these measures achieve control at acceptable levels. Also, normal operational target values have been indicated are the various parameters, as well as the action limit values which indicate when intervention in the operation is required in order to continuously meet the critical limits.
Records associated with the monitoring have been indicated in relevant Column. The actions taken ensure that the CCP has been brought under control.
An audit checklist based on Codex Standard prepared to conform to food hygiene, personnel hygiene and good manufacturing practices for the applicable food sector. Note-Like the products and the process, the PRP is subjected to the hazard analysis in order to identify potential hazards and to decide in which way the hazards risk need to be controlled.
Training has also been provided to personnel at various levels on principles of maintaining cleanliness and hygiene and this is an on-going activity. As an aid in developing specific training, work instruction and procedures have been prepared. The frequency of verification activity which inter-alia include the following should be sufficient to confirm that the FS System is working effectively: - Review of the FS System and its records, - review of non-conformities and product disposition, and - Confirmation that CCPs are kept under control.
This review is done at regular intervals, for each product and is submitted on prescribed format. This report is reviewed by FS Team Leader. This verification is done at regular intervals specified in for each product and records maintained. This review includes verification of following records to ensure that FS System is in place and working satisfactorily: - Monitoring activities have been performed at the locations specified in the HACCP plan.
It is a thorough review of hazard analysis to address specific hazards to determine if they are controlled. A reassessment of the adequacy of the plan is done on any changes that could affect the hazard analysis or alter the plan in any way such as raw materials, source of raw materials, product formulation, processing methods or system, intended use or consumers of the product, product distribution system etc, or at least annually.
The identification and traceability helps in effective stock rotation and ensures product recall, if called for. The organization has established a traceability system that enables the identification of product lots and their relation to raw material, processing and delivery record for identifying incoming material for the immediate suppliers.
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