TA2018.

201 Optimization of Processes and Safety

Systems
Dr. Raúl Villarreal Lara

Homework 5. Hazard
research (Part 1)
Alejandro Meza Merla - A00833756
Danae M. Sepúlveda de la Paz - A01177931
Nadia E. Gonzalez Garcia - A01570359
Vannya N. Hernández Saiza - A01754610
Shanelle Janine Pech Tzul - A00834698
Elizabeth Galván Carmona - A01747648
 Hazard
Agent that may cause a illness, damage or other impacts in people health such as Ioss of life ; It
can be biological (bacteria,virus,mold,parasite) physical (metal,glass, plastics) or chemical
(allergens,heavy metals,toxins, chemicals, pesticides)
Hepatitis A
 Description and characteristics
(Mayoclinic,2022)
What is hepaptitis A Symptoms
Is a highly contagious short-term liver -Unusual tiredness and weakness
-Nausea, vomiting and diarrhea
infection caused by the hepatitis A -Abdominal pain or discomfort
virus. (WOH,2022) -Colored stool
-Loss of appetite
-Low-grade fever
Transmission -Dark urine
-Joint pain
Fecal-oral route (food/water) -Yellowing of the skin and the whites of your
waterborne outbreaks eyes (jaundice)
-Intense itching
physical contact with an infectious person

(CDC, n.d)

The incubation period of hepatitis A is usually 14–28 days.

Risk level
Hepatitis A can cause debilitating symptoms and it can last a few
weeks or months, most people get a full recovery and do not have
lasting liver damage.

Fulminate hepatitis is a rare cause that can cause death, it has a

mortality estimates up to 80% and basically the liver stop
working properly. (CDC, n.d)

Individuals who have had hepatitis A before or who have been

vaccinated are immune to hepatitis A infection.

People most at risk include those with pre-existing liver problems

and elderly people. If liver failure does occur, a liver transplant is
usually needed to treat it. (NHS, n.d)
 Food it can be found in (FDA,2021)

Shellfish Fruit or frozen berries

Water Raw vegetables

 Hazard control

Cooking temperature above 185°F/85°C for 1

minute
Washing of fruits and vegetables with
chlorine
 known outbreak/case ?
Date: Illnesses started on October 8 to November 15, 2019
Place: 7 states (Indiana, Michigan, Minnesota, Missouri,
Nebraska, Pennsylvania and Wisconsin)
Consequences:
20 outbreaks
11 hospitalization
0 deaths
Product: Fresh blackberries from Fresh Thyme Farmers
Market or Woodman's Market during September 9-30, 2019.

(CDC, 2023)
 Prevention
Hepatitis A vaccine
Good practice of personal hygiene
Sanitation programs
Employee health policy implementation
Salmonella
typhi
 Description and characteristics

Salmonella typhi is a bacterium that infects the

intestinal tract and the blood. The disease caused by
this bacteria is known as Typhoid fever (CDC, 2019).
Salmonella typhi is mainly a human pathogen and it is
transmitted through contaminated food and water.
Therefore it is common in developing countries
where sewage and water treatment systems are poor,
regular outbreaks are in Africa and South Asia (NHS,
2023).
Symptoms include prolonged high fever, tiredness,
headaches, nausea, abdominal pain, and constipation
or diarrhea (Mayo Clinic, 2023).
Risk level

If Salmonella typhi isn't treated, it may cause internal bleeding in

the digestive system and the perforation or splitting of a section of
the digestive system, which may be fatal.

Children are most at risk of developing typhoid fever since their

immune systems are still developing(NHS, 2023).

Typhoid fever is the most common infection caused by the

bacterium Salmonella typhi. From the 9 million cases of typhoid
fever, 110,000 died(WHO, 2023).

The major risks persist in populations that lack access to safe water
and appropriate sanitation.

 Foods it can be found in

Raw or undercooked
Shellfish
meat

Raw fruits and

Raw or undercooked vegetables
eggs and egg products

(CDC, 2023)
 Hazard control
Clean
Wash hands after handling raw food
Wash utensils after use
Don't wash raw meat or eggs as they ca spread microorganisms
to other surfaces
Pull apart
Keep raw meat and eggs separate from other food
Cook
Cook food at a temperature of 145-160 degrees Fahrenheit
Refrigerate
Keep the refrigerator temperature at 40 degrees Fahrenheit
(MN Department of Health2022)
 known outbreak/case ?
Date: Illnesses started from December 6, 2022, to February
13, 2023(CDC, 2023)
Place: 11 states (California, Illinois,
Iowa, Minnesota, Missouri, Nebraska, New York, Ohio,
Oregon, Tennessee and Virginia)
Consequences:
12 outbreaks
3 hospitalization
0 deaths
Product: Flour contaminated with Salmonella.
 Prevention

Typhoid vaccine
Good practice of personal hygiene
Wash you hands after contact with animals
Keep your food preparation areas clean

(NHS, 2023)
 References

-World Health Organization: WHO. (2022). Hepatitis A. www.who.int. https://www.who.int/news-room/fact-

sheets/detail/hepatitis-a
-Hepatitis A - Symptoms and causes - Mayo Clinic. (2022, August 27). Mayo Clinic.
https://www.mayoclinic.org/diseases-conditions/hepatitis-a/symptoms-causes/syc-20367007
-Hepatitis A FAQs | CDC. (2021, February 17). Centers for Disease Control and Prevention.
https://www.cdc.gov/hepatitis/hav/afaq.htm#A1
-Hepatitis A. (n.d.). NHS Inform. https://www.nhsinform.scot/illnesses-and-conditions/stomach-liver-and-
gastrointestinal-tract/hepatitis-a#:~:text=Outlook%20for%20hepatitis%20A,-
For%20most%20people&text=Life%2Dthreatening%20complications%20such%20as,usually%20needed%20t
o%20treat%20it.
-NutritionU.S. Food And Drug Administration. https://www.fda.gov/food/foodborne-pathogens/hepatitis-
virus-
hav#:~:text=Although%20foodborne%20illnesses%20caused%20by,cited%20as%20potential%20foodborne
%20sources.
 References
-Typhoid Fever (Salmonella Typhi). (2019). Bccdc.ca. http://www.bccdc.ca/health-info/diseases-
conditions/typhoid-fever-salmonella-typhi
-Typhoid fever - Symptoms and causes. (2023). Mayo Clinic; https://www.mayoclinic.org/diseases-
conditions/typhoid-fever/symptoms-causes/syc-20378661
-CDC. (2023, March 24). Salmonella and Food. Centers for Disease Control and Prevention.
https://www.cdc.gov/foodsafety/communication/salmonella-
food.html#:~:text=You%20can%20get%20a%20Salmonella,nuggets%2C%20and%20stuffed%20chicken%20entre
es.
-Outbreak of Hepatitis A Linked to Fresh Blackberries. (2023). https://www.cdc.gov/hepatitis/outbreaks/2019/hav-
berries/index.htm
-CDC. (2022, May 27). La Salmonella y los alimentos. Centers for Disease Control and Prevention.
https://www.cdc.gov/foodsafety/es/communication/salmonella-and-food-sp.html
-NHS Choices. (2023). Overview - Typhoid fever. https://www.nhs.uk/conditions/typhoid-
fever/#:~:text=Typhoid%20fever%20is%20a%20bacterial,that%20cause%20salmonella%20food%20poisoning.
-World. (2023, March 30). Typhoid. Who.int; World Health Organization: WHO. https://www.who.int/news-
room/fact-sheets/detail/typhoid
‌-Preventing Salmonellosis - MN Dept. of Health. (2022). State.mn.us.
https://www.health.state.mn.us/diseases/salmonellosis/prevention.html
-Salmonella Outbreak Linked to Flour. (2023, March 30). Centers for Disease Control and Prevention.
https://www.cdc.gov/salmonella/infantis-03-23/details.html
 TA2018.201 Optimization of Processes and Safety
Systems
Dr. Raúl Villarreal Lara

Homework 5. Hazard
research (Part 2)
Chemical hazard:
allergens
 Description
What is an allergen?
An allergen is any normally harmless
substance that causes an immediate allergic
reaction in a susceptible person.
Food allergens are almost always proteins
Symptoms
Gastrointestinal system: nausea, vomiting,
abdominal cramping and diarrhoea.
Respiratory system: wheezing, asthma and
rhinitis.
Cutaneous: itching, hives, eczema and rash.
Other symptoms: hypertension, increased

(Safefood, n.d).
heart rate, tongue swelling, anaphylactic

shock, oral allergy syndrome and laryngeal
What is an allergy/allergic reaction? oedema.
A food allergy can be defined as an adverse,
(Safefood, n.d)
immune- mediated reaction to food. It
involves the production of a specific kind of
antibody which reacts to a particular food
component and, in doing so, causes an
allergic reaction (Safefood, n.d).

(Center for Food Safety and Applied
Nutrition. (n.d.))
Risk level
There are eight major food allergens: milk, eggs, fish,
Crustacean shellfish, tree nuts, peanuts, wheat, and
soybeans.
Symptoms of food allergies:
-Vomiting and/or diarrhea
-Swelling of the throat and vocal cords
-Flushed skin or rash.
According to the FDA, food allergies can progress to
severe as a life-threatening allergic reaction that
can lead to:
-Constricted airways in the lungs
-Severe lowering of blood pressure and shock
-Suffocation by swelling of the throat and larynx
 ( Neogen, 2017)

Hazard control

Identify potential allergens

Prevent cross-contamination
Proper labeling
Proper documentation
Build a proficient allergen control team
Adhere to allergen policy
 known case

Date: 27th December 2017

Place: Melksham in Wiltshire, UK
Product: A Pret wrap labeled as “Vegan” with a yogurt dressing that
contained dairy.
Consequences: Celia Marsh, a 42-year-old mother went into
anaphylactic shock and died in the centre of Bath, shortly after
eating the wrap.
The chemist who analyzed the wrap believed it contained milk.
(BBC News, 2022)
 Prevention

Adequate allergen labels Have an emergency plan

"lecithin (soy)," Train staff on food allergies
"flour (wheat)" Personal emergency plans
"whey (milk)"

Advisory statements Use separate equipment

"may contain [allergen]" avoid contact with surfaces
"cross-contact" where allergens have been
"produced in a facility that also uses [allergen]" previously manipulated

(“Avoiding Food Allergy Reactions,” 2022)

Physical hazard:
glass
 Description
Foreign materials unintentionally introduced to food products that are hazardous to the
consumer, this can contaminate a food product at any stage of production.
(foodsafetyprogramm,nd)

These materials can often be transparent

and difficult to detect when present in
food. Glass is a major contributor to
injury, It can result in claims and on
occasion litigation. (Safefood360, 2006)

Common sources: : Bottles, jars, light fixtures, utensils and gauge covers.
 Risk level
Hard or sharp objects can cause:
-cuts to the mouth or throat
-damage to the intestines
-damage to teeth or gums
-bleeding
-Surgery in some cases

Factors that cause potential risk to consumers

• Size: Anything in a food product, that is extraneous,
and measures two millimeters or more.
• Type of consumer: Products that target infants, and
elderly have a higher risk level.
• Physical characteristics: hardness, shape and
sharpness of a product can affect risk level.
(foodsafetyprogram, nd)
 Hazard control

Policy and Procedure Maintenance

Inventory of items and breakage conduct maintenance during
procedures so that employees are non-production hours or
informed about the steps to take in adequately cover materials before
the event of an accident doing so.

Inspection Specific processing areas

Inspect raw materials and food Packaging of products that
ingredients for glass shards require glass jars/ bottles can be
done at a separate processing areas

(Safe Food 360°, 2022)

 known case

Date: February 4, 1986

Place: At least in 30 states of the USA
Product: glass pieces were found in jars of Gerber baby food
Consequences: several babies suffered minor cuts in their mouths
and it was reported that after eating food from a Gerber jar a 1-year-
old baby suffered a cut on the tongue.
Out of 137 complaints the FDA, found glass in 21 cases and reported
that a breakage during shipment to the store might have occurred
(Risen, J, 1986).
(Risen, J, 1986 )
 Prevention
Install detection and Good manufacturing practices
elimination system
Keeping production area clean and
Using metal detectors or X- implementing appropriate
ray systems to check food packaging materials
before packaged

Regular inspections in Eliminate potential sources of

production line
Inspections of raw material ,
food ingredients and
equipment to avoid foreign
objects
physical hazards in processing and
storage areas
Prevent contamination by
breakable glass
(Food Safety Program, 2010)
 References
Risen, J. (1986, March 5). 137 Reports of Glass in Gerber Jars : All-American Firm Focus of Chain Reaction of Fear. Los Angeles
Times; Los Angeles Times. https://www.latimes.com/archives/la-xpm-1986-03-05-mn-15326-story.html
(2010). Physical Hazards in Food. Food Safety Program Fact sheet #16.https://www.gov.mb.ca/agriculture/food-safety/at-the-food-
processor/food-safety-program/pubs/fs_16.pdf
‌Milk Allergy: Causes, Symptoms, Diagnosis & Treatment. (2022). Cleveland Clinic.
https://my.clevelandclinic.org/health/diseases/11315-milk-allergy
‌BBC News. (2022, September 15). Pret A Manger: Yoghurt producer weeps at Celia Marsh inquest. BBC News.
https://www.bbc.com/news/uk-england-wiltshire-62919404
Neogen. (2017, May 4). Allergen control plans in the food industry: Best practices. Https://Www.neogen.com.
https://www.neogen.com/neocenter/blog/allergen-control-plans-in-the-food-industry-best-practices/
‌HACCP Allergen Control Program for Your Food Business. (2021). Fooddocs.com. https://www.fooddocs.com/post/haccp-allergen-
control-program
Chemical Hazard. (n.d.). Allegens. Safefood 360°. From https://safefood360.com/wp-content/uploads/2022/03/Allergens.pdf
Avoiding Food Allergy Reactions. (2022). FoodSafety.gov. https://www.foodsafety.gov/blog/avoiding-food-allergy-reactions

Safe Food 360°. (2022). Physical hazard. Glass, 1. https://safefood360.com/wp-content/uploads/2022/03/Glass.pdf

Center for Food Safety and Applied Nutrition. (n.d.). Food allergies. U.S. Food and Drug Administration. Retrieved April 26, 2023,
from https://www.fda.gov/food/food-labeling-nutrition/food-allergies
 TA2018.201 Optimization of Processes and Safety
Systems
Dr. Raúl Villarreal Lara

Homework 5. Hazard
research (Part 3)
 ● Include the food process diagram.

Figure 1. Flow chart of cheddar cheese production(Aguirre-Villegas, H., et al, 2012)

● For your project, name 4 of the most important prerequisite programs.

We’ve considered that 4 of the most important prerequisite programs for our project are the
following;
1. Storage and transportation, storage rooms must follow specific conditions in order
to provide safe and necessary conditions like temperature and humidity for raw
materials and the final product (Zhao, M., 2003).
2. Building design, the building and working areas must be in good conditions and ideal
for the production. Constant maintenance and cleaning of the work space is very
important in order to avoid pest, environmental and cross contamination (Zhao, M.,
2003).
 3. Sanitation, it is important to establish adequate sanitation facilities in order to remove
potential hazards. All equipment, containers and tools in the process must be sanitized
(Zhao, M., 2003).
4. Equipment, the food processing equipment is important as it speeds up the process
and requires less labor, as well as minimizing accidents (Zhao, M., 2003).

● Include a brief theoretical framework on prerequisite programs, including Good

Manufacturing Practices, for the "Implementation of a Safety System"
(Maximum 1/2 page)
By definition, prerequisite programs (PRP) are “systems that provides the basic conditions to
operate in a safe environment for the production of wholesome food. These programs can be
treated as the foundation of every succeeding food safety plan” (Prerequisite of HACCP –
What Are Prerequisite Programs?, n.d.). Unlike Critical Control Point (CCP) and Operational
Prerequisite Program (OPRP), PRP is based on the general principles of food safety, safety
policies and regulatory requirements to prevent hazards, while CCP and OPRP focuses on
hazard analysis and risk assessment. Among the most crucial PRP in food industry are good
manufacturing practices, sanitation standard operating procedures, waste management plans,
pest control programs, and traceability & recall plan. It is important to note that PRP must be
satisfied before more complex plans such as Hazard Analysis Critical Control Point
(HACCP) are implemented to have an effective safety system in the food industry. With this
in mind, the following principles from the Hazard analysis critical control point (HACCP)
plan can be implemented to ensure safety measures (Nutrition, n.d):
- Hazard analysis
- CCP identification
- Establishing critical limits
- Monitoring procedures
- Corrective actions
- Verification procedures
- Record keeping and documentation

● Design of a cleaning and disinfection program (POES) of 1 "unit operation" for

the case of "selected industrialized food" (1/2 - 1 page).
For the cleaning and disinfecting program, we choose the Clean in Place (CIP) system, since
this system minimizes human mistakes, reduces chemical exposure, increases in product
quality and utility savings(CSI, 2022). This process can reduce the water and energy usage
since it's a repeatable cycle control.
This process consists of 5 steps and every CIP has its own specifications or parameters. The
1st step consists of a pre rinse cycle, where it wets the interiors of the lines and tanks,
dissolves sugars and partially melts fats. The 2nd step consists in a caustic wash between
145-185° F(CSI, 2022). The 3rd step is called intermediate rinse, where water flushes out any
residual trace of detergents from the caustic wash. Finally the 4th and 5th steps consists in
final rinse and sanitizing rinse, were they rinse with deionized water or use reverse osmosis to
flush residual cleaning agents so that finally hypochlorite solutions are used as sanitizers in
the final rinse.

The look of the CIP is shown in Figure 2.

Figure 2. Clean in Place system(CSI,2022)

● Design of the supplier control program specification sheet for 1 main raw
material (1 pages).
The supplier control program specification for milk because milk is the main raw
material in our process.
There are some implementation and practices for the manufacturing of the milk
Supplier assessment data sheet
Food safety and risk assessment at Hazard analysis critical control point
manufacturing premises
program
Good manufacturing practices

Records - Cleaning schedules

- Temperature of the process: The
product should be stored under
the correct temperatures,
ventilated and with hygienic
conditions.

Procedures -Cleaning
-Hygiene
-Risk assessment
-Environmental monitoring programme

Instructions Process instruction that has the same

constituent needed it

Quality Manual Process of the factory

Product Specification -Appearance: white, creamy,

homogeneous
-Taste and smell: Free from rancidity
and unacceptable odor or taste.

Packaging -Product packed in a appropriate

packaging that safeguard the hygienic,
nutritional, technological and
organoleptic qualities of the milk
LDPE poly packs

Shelf Life 7 days

Labeling instruction Store in refrigerated condition <4°C

Distribution conditions <5°C

 CCPs Microorganisms
Test for antibiotics
Physical chemical tests

Supplier assessment data sheet

Constituent Percentage

Water 87.7%

Fat 3.4%

Protein 3.3%

Carbohydrates 4.9%

Minerals 0.7%

Ash 0.7%

Table 1. Composition of milk for cheese production

The protein in milk is casein. That is why it is important to have around 3.3% of protein
because when the milk is heated casein forms crumbs that are used in cheese production.
References

[1] Central States Industrial. (2022, June 13). Central States Industrial.
https://www.csidesigns.com/blog/articles/5-steps-in-a-common-food-dairy-beverage-clean-in
-place-cycle

[2] Horacio Andres Aguirre-Villegas, Milani, F., Kraatz, S., & Reinemann, D. J. (2012,
March). Life Cycle Impact Assessment and Allocation Methods Development for Cheese and
Whey Processing. ResearchGate; unknown.
https://www.researchgate.net/publication/269848154_Life_Cycle_Impact_Assessment_and_
Allocation_Methods_Development_for_Cheese_and_Whey_Processing

‌[3] (2021). Ziphaccp.com; Altametrics.

https://ziphaccp.com/food-processing/food-processing-equipment.html

‌[4] Prerequisite of HACCP – What Are Prerequisite Programs? (n.d.).

https://www.fooddocs.com/post/prerequisite-of-haccp#:~:text=What%20is%20a%20prerequi
site%20program,every%20succeeding%20food%20safety%20plan.

[5] Zhao, M. (2003). The design of HACCP plan for a small-scale cheese
plant.https://core.ac.uk/download/pdf/5066452.pdf

[6] Admin, C. F. H. (2023, April 13). Milk for cheesemaking: Finding the best milk to make
cheese. Cultures For Health. Retrieved April 27, 2023, from
https://culturesforhealth.com/blogs/learn/best-milk-for-cheesemaking

[7] NutritionU.S. Food And Drug Administration.

https://www.fda.gov/food/hazard-analysis-critical-control-point-haccp/haccp-principle

s-application-guidelines#:~:text=Seven%20basic%20principles%20are%20employed,

and%20record%2Dkeeping%20and%20documentation

[8] Admin, C. F. H. (2023, April 13). Milk for cheesemaking: Finding the best milk to make

cheese. Cultures For Health. Retrieved April 27, 2023, from

https://culturesforhealth.com/blogs/learn/best-milk-for-cheesemaking