INTRODUCTION TO PRODUCT SAFETY

AND HYGIENE
HACCP – what is it?
 Hazard Analysis: identification of safety hazards and
their control measures
&
 Critical Control Points: A Critical Control Point (CCP)
is a point, step, or procedure in a food manufacturing
process (food chain) at which control can be applied
and, as a result, a product safety hazard can be
prevented, eliminated, or reduced to an acceptable
level

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Hazard
 Product Safety Hazard – chemical, biological or
physical agent/organism in the product or condition of
the product with a potential to cause quality defect or
an adverse health effect.

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THE HACCP SYSTEM
REDUCES DEPENDENCE ON
FINISHED PRODUCT SAMPLING &
TESTING
HAZARD ANALYSIS and CRITICAL
CONTROL POINTS
IT USES A PREVENTIVE
APPROACH TO FOOD SAFETY
 HACCP CONCEPT
DESIGNING AND BUILDING OF SAFETY INTO
PRODUCT

SAFE PRODUCT IS PRODUCT THAT DOES NOT CAUSE

HARM TO THE CONSUMER WHEN IT IS PREPARED
AND / OR CONSUMED/USED ACCORDING TO ITS
INTENDED USE
Origins of HACCP
 NASA SPACE PROGRAMME

 PILLSBURY / GENERAL MILLS

 MICROBIOLOGICAL HAZARDS

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 Origin of HACCP CONT’D
•From the NASA work, Pillsbury developed the
philosophy

If one could understand how a product becomes

unsafe, one can prevent the specific failure that
causes the product to become unsafe in the first place
 Application of HACCP
 GROWING
 HARVESTING
 PROCESSING
 MANUFACTURING
 DISTRIBUTING
 MERCHANDISING
 PREPARING
 CONSUMPTION
 HACCP System Set Up
1. Assemble a HACCP team

2. Obtain product and process information

3. Describe finished product and identify intended use

4. Construct process flow diagram and plant schematic

5. Verify flow diagram and plant schematic on site

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 Seven Principles of HACCP

Harvesting

Holding
Transport
Packaging

Store

Dispatch
Principles of the HACCP System
 PRINCIPLE 1
 Conduct a hazard analysis.
 PRINCIPLE 2
 Determine the Critical Control Points (CCPs).
 PRINCIPLE 3
 Establish critical limit(s).
 PRINCIPLE 4
 Establish a system to monitor control of the CCP

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Principles of the HACCP System
 PRINCIPLE 5
 Establish the corrective action to be taken when
monitoring indicates that a particular CCP is not
under control.
 PRINCIPLE 6
 Establish procedures for verification to confirm that
the HACCP system is working effectively.
 PRINCIPLE 7
 Establish documentation and record keeping

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 Principle #1 Conduct hazard analysis
 Identify all potential hazards per product or product
line per process step.
 Determine the likelihood of occurrence of each hazard
and the severity associated with the occurrence.
 (This is called risk analysis)

Risk is a function of the probability and the severity of the

adverse safety effect that may occur consequential to a hazard
in food
 Risk = Probability x Severity

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 Conduct a hazard analysis
 Establish the significance levels of each risk.
 Example
 R ≥ 6, risk is significant, otherwise not significant.

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 Types of Hazard
• Biological e.g. B. Cereus, E. Coli, Salmonella,
S. Aureus, Clostridium, Yeast, Mould etc.
• Chemical e.g. Afflatoxins, Chemical residues,
grease, heavy metals etc.
• Physical e.g. stone, glass, bone etc.

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SOURCES OF HAZARDS
1. Physical contamination/hazards
A. Inherent
(i) In containers
• Heavy metals
• Dust
• Iron filings from equipment
(ii) Dried products
• Grit
• Insects

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SOURCES OF HAZARDS
B. Introduced
(i) From the environment
 Glass fragments
 Metal pieces i.e. nuts,
 bolts, screws and pins
 Stones
 Paint chippings Rust
 Pieces of wood & plastic

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SOURCES OF HAZARDS
 B. Introduced
(ii) From handlers
• Jewellery
• Buttons
• Hair
• Nail fragments and nail varnish
• Cigarettes etc.

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 Principle # 2 Determine CCPs
 For hazards with a risk of ≥ 6 (i.e. significant hazard)
use the CCP decision tree to determine whether that
process step is a CCP.

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 Principle # 3 Establish Critical
Limits
 A value of physical, chemical or biological nature
which separates acceptability from unacceptability.
 CL indicate absolute tolerance for safety. Critical
limits are not necessarily equal to existing
processing parameters.
 Criteria often used include measurements of
temperature, time, moisture level, pH, Aw,
available chlorine and sensory parameters.

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 CRITICAL LIMIT
 A VALUE OF PHYSICAL, CHEMICAL OR BIOLOGICAL NATURE WHICH
SEPARATES

ACCEPTABILITY FROM UNACCEPTABILITY

 DISPLAY CRITICAL LIMITS NEXT TO CCP’s

HOW TO SET CRITICAL LIMITS

 > PUBLISHED DATA > EXPERIMENTAL DATA

 > EXPERT ADVICE > MATH. MODELLING
 --------------------------------------------------------------------
 INDICATE ABSOLUTE TOLERANCE FOR SAFETY
 CRITICAL LIMITS NOT NECESSARILY EQUAL TO EXISTING PROCESSING
PARAMETERS

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MMC HACCP
 CONTINOUS MONITORING

CRITICAL LIMIT

UCL
TARGET LEVEL
LCL
TIME

NORMAL TEMP
AVE TEMP

CRITICAL LIMIT

UNACCEPTABLE DEVIATION (CRITICAL DEFECT)

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 Principle # 4 CCP Monitoring
COMMONLY MEASURED PARAMETERS
 PHYSICAL CHEMICAL
 VISUAL SENSORY
 (BIOLOGICAL)
MONITORING

 > TEMPERATURE > TIME > PESTICIDE RESIDUES

 > FLOW RATE > pH
 > WATER ACTIVITY > SALT
 > AVAILABLE CHLORINE > WEIGHT
ON - LINE OR OFF - LINE SYSTEMS
PLANNED SEQUENCE OF OBSERVATIONS / MEASUREMENTS

DEMONSTRATES THAT CCP IS UNDER CONTROL

RECORD FOR FUTURE VERIFICATION
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Principle # 5 Corrective Action
 Any action to be taken when the results of
monitoring at the CCP indicate a loss of
control.
 Specific corrective actions must be
developed for each CCP in the HACCP
system in order to deal with deviations when
they occur.
 The actions must ensure that the CCP has
been brought under control.
 Deviation and product disposition procedures must
be documented in the HACCP record keeping

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 Principle # 6 HACCP Verification
 Establish procedures for verification.
 Verification should be carried out by someone other
than the person who is responsible for performing the
monitoring and corrective actions.
 Where certain verification activities cannot be
performed in house, verification should be performed
on behalf of the business by external experts or
qualified third parties.
 Examples of verification activities include:
 Review of the HACCP system and plan and its records;
 Review of deviations and product dispositions;
 Confirmation that CCPs are kept under control.
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 Principle # 7 Documentation and
Record Keeping

 Efficient and accurate record keeping

 Record example:
 CCP monitoring activities;

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The HACCP plan

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 HACCP CONTROL
PREVENTIVE
MONITORING
PROCESS STEP CCP NO. (CONTROL) CRITICAL LIMTS CORRECTIVE
HAZARD
PROCED. FREQU. RESPONSIBILITY
MEASURE ACTION
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 Prerequisite programs
 Personal hygiene
 Cleaning and sanitation
 Pest control
 Waste management
 Prevention of cross contamination
 Product information
 Management of purchased materials

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 Pest Control

Pest Control should be done on a REGULAR basis

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 Pest Control
 Keep them out – seal the food premises.
 Starve them out – keep food premises clean.
 Throw them out – conduct regular pest
inspections or services.
 Don’t give them a home - remove all unnecessary
equipment and items.
Report all pest sightings or evidence of pest activity
to your supervisor.

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No Pest Control

Flies on the Food Cockroaches Rats and Mice

In the Kitchen

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 Waste Management
 Place waste in plastic lined bins.
 Remove all waste from the premises as
required.
 Empty and clean waste bins regularly.
 Ensure all external bins are covered.
 Protect external waste bin area from
pests and birds.

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Rubbish Bins not Emptied Regularly

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 Personal Hygiene
 Personal hygiene facilities and toilets
 Staff canteens and designated eating areas
 Work wear and protective clothing
 Health status
 Illness and injury
 Personal cleanliness
 Personal behaviour

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 Visitors
 Visitors to food manufacturing, processing or handling
areas should, where appropriate, wear protective
clothing and adhere to the other personal hygiene
provisions in this section.

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 Transport
 Products may become contaminated, or may not reach
its destination in a suitable condition for consumption,
unless effective control measures are taken during
transport, even where adequate hygiene control
measures have been taken earlier in the supply chain.
Vehicles, conveyances and containers.
Vehicles, conveyances and containers shall be maintained
in a state of repair and cleanliness.
Where the same are used for non flower products, cleaning
shall be carried out between loads.

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 Training
 Those engaged in production operations should be
trained, and/or instructed in basic hygiene to a level
appropriate to the operations they are to perform.
 Awareness and responsibilities
 Training programs
 Instruction and supervision
 Refresher training

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BENEFITS OF HACCP
• IMPROVED PRODUCT SAFETY
• BETTER USE OF RESOURCES
• TIMELY RESPONSE TO PROBLEMS
• IMPROVE OPERATIONS EFFICIENCY
• IMPROVE PRODUCT QUALITY
• SATISFY CUSTOMER REQUIREMENTS
• SATISFY REGULATORY REQUIREMENTS
• KEEP UP WITH COMPETITORS
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 Provision of safe
product starts with
YOU!
  THANK YOU

• Q&A

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