HACCP & Hygiene in Honey Production

HACCP and hygiene in honey production
HACCP & Hygiene in

honey production
Buenos Aires, Concepción del Uruguay, Mendoza

October / November 2005
©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 1

Content of the seminar

1. General requirements of hygiene in honey production
2. HACCP: A brief introduction
3. “Good beekeeping practice”
4. HACCP in honey processing
5. Establishing self-checking mechanisms in honey production
according to HACCP principles

1.
General requirements of hygiene

in honey production

1.
Hygiene in honey production is protection

against
 dirt and diseases

 spoiled food
 complaints
 financial losses

1.
Hygiene in honey production is necessary

because
• legislations (EC Regulations 852/853/854)
• consumer protection
• product liability
• prerequisite program for HACCP
under the aspect of food safety (EC-
Regulation 178/02)
demand it.

European Community Legislation

• Council Regulations law in every member state
• EC Directivesshall be adopted in member states

no legal force until promulgated by national parliament
• Horizontal legislation refers to all food stuffs
e.g. for contaminants, additives, labelling
Regulation EEC 2377/90 drugs )
Directive 96/23/EC (monitoring)
Vertical legislation refers to specific products
e.g. Honey Directive 2001/110/EC

EC Hygiene Regulations
852/2004 general food hygiene

853/2004 specific requirements for food
of animal origin
854/2004 specific procedures for the
official control of food of animal origin
replacing 16 different Directives
What is new ?
• primary production is included
• all food producing companies must be
registered
• principle of equivalence for imported food
from third countries
• HACCP mandatory as well as documentation
as self control

852/04 (9)
Community rules should not apply either to

primary production for private domestic use,
or to the domestic preparation, storage or
handling of food for private domestic
consumption. ..........

HACCP for smaller enterprises
852/04 Article 5
The HACCP requirements .........They should provide

sufficient flexibility to be applicable in all situations
including small businesses. In particular it is necessary to
recognize that in certain businesses it is not possible to
identify critical control points and that in some cases a good
hygienic practice can replace the monitoring of critical
control points. ..........
Basic Regulation Food Safety 178/02
e.g.
Consumer protection
Traceability
Rapid Alert System

Prerequisite for HACCP
Cleaning and sanitations

Pest control
Supplier approval
Employee training
Personal hygiene
Water control
Maintenance
Product specifications
Product storage control
1.
Hygiene only works for teams, if everyone
uses the same set of rules.
 validity for everyone

 regular reminder
 standard information
 reliable inspection
 mutual confidence

1.
Cleaning and sanitation applies to
• the working area

• the equipment and
• the people coming into contact with or close
to the product is
ESSENTIAL!

1.
Washing facilities must be available:
- Working rooms must be equipped with:

- wash-basin (warm and cold water)
- paper towels, liquid soap dispenser
- Toilets:
- with wash-basin
- separate toilet entrance with anteroom

1.
Also necessary:
- Sufficient air ventilation to prevent condensed water

and foreign odors
- Adequate temperatures
- Artificial lighting with splinter protection
- Dressing-rooms with wardrobe for clean working
clothes (separated from street clothes)
- No pets
- Exclusion of any people suffering from infectious
diseases
1.
Further prerequisites for working rooms and

equipment:
Floors:
- must be cleaned regularly
- made of non-toxic materials
- water-proof and hydrophobic
Ceilings:
- prevent condensed water
- no moulds
- no removable fragments (loose paint particles e.g.)
1.
Further prerequisites..., contd.
Windows:
-supplied with gauze or fine mesh (exclusion of pests and
insects)
Doors:
- with plane, hydrophobic and easy-to-clean surface
Surfaces, tools and appliances, walls:

- made of plane, cleanable and non-toxic materials.
- desinfection possible

1.
Further prerequisites..., contd.
Equipment:
- free of corrosion
- containers made of food-safe, cleanable and smooth
material
- can be disinfected easily
Suitable cleaning devices

- must be easy-to-clean
- corrosion-proof
- must be kept clean best using a dishwasher

2.
HACCP: A brief introduction

2.
Definition of HACCP
Hazard
Analysis
Critical
Control
Point system

2.
• HACCP is a preventive safety system that

ensures the production of harmless foods
• most powerful method to repel and eliminate

possible hazards regarding foods
• enables applying science-based controls
• from raw material to finished products

2.
The hazards
A biological, chemical or physical agent that is
reasonably likely to cause illness or injury in the
absence of control.
• Biological (e.g. bacteria, virus)

• Chemical (e.g. drug residues, cleaning
compounds, heavy metals, mycotoxins)
• Physical (e.g. wood, metal, stones, glass, hair,
jewelry, plastic)

2.
HACCP is not a stand-alone system. It works

hand in hand with
• Standard Operating Procedures (SOPs)
• Definite responsibility
• Documentation

2.
Prerequisites to HACCP
• Good Processing Practices (GPP)

• Good Hygiene Practices (GHP)
• Good Manufacturing Practices (GMP)
• Appropriate QM systems like ISO series

2.
HACCP
S G G G
O P H M
P P P P

2.
The seven principles of HACCP

1. Realization of a hazard analysis
2. Identifying and setting Critical Control Points (CCPs)
3. Setting Critical Limit(s) and standards
4. Monitoring of each relevant CCP in honey production
5. Establishing corrective actions
6. Verification of the system
7. Documentation procedures

3.
Good Beekeeping Practice

3.
Application of good beekeeping practice

is required for
1. working at the beehives

2. harvesting and transporting honey
3. extracting honey from supers
4. storing honey
5. bottling honey

3.
Contaminants from beekeeping
Contamination
Environment Beekeeping
of honey
- Pesticides - Acridicides for Varroa control
- Heavy metals - Antibiotics against diseases e.g.
- Bacteria AFB, EFB
-Genetically modified - Pesticides for wax moth control
organism (GMO) - Repellents at honey harvest
- Radioactivity - Other contaminants
Plants, Air, Water

Contaminants from beekeeping and control measures
CONTAMINANT SOURCE OF CONTROL MEASURE

CONTAMINATION
1. Antibiotics in honey Control of bacterial diseases Alternative control without

with antibiotics (AFB, EFB, the use of antibiotics
Nosema)
2. Synthetic acaricides in Varroa control with Alternative Varroa control
bees Wax, propolis and synthetic acaricides without synthetic
honey acaricides
3. Pesticides in honey and Control of wax moth with Wax moth control by
beeswax pesticides; Chemical control of alternative measures.
the Small Hive Beetle Alternative control of the SHB
4. Repellants for honey Use of synthetic repellents Use of smoker with

harvest at the honey harvest natural

material,
“mechanic systems”
5. Toxic metals or organic container, drum Use material which do not
substances diffuse contaminants into
honey
6. Wood protectants, Painting Pesticides in wood protectants Use of wood protectants

containing no pesticides

3.
Contamination:
Today major factor for quality of honey
Incorrect apicultural practice
including hygiene e.g. as prevention of diseases

instead of using „medicine“

3.
Selected examples for important sources for hazards
corresponding to “good beekeeping practice”
Example Defect Control Measures:
1 Jars and lids before Contamination dirt, Visual and Another

filling foreign,l odour, remaining sensory cleaning or
water  Hazard of quick check destroying of
deterioration of the the damaged
content! jars/lids
replace with
SEM ! as residue of other material
sealing compound lids
2 Liquefying honey , Azodicarbonamide
D: Reduction of the Tempera- Use as
heat treatment enzyme activity; if HMF > ture, time industrial honey
40 mg  Complaints measuring
accord. to honey directives
C: Temperature, time,
quick cooling
3.
Example Defect Control Measures:
3 Straining In the scum there might be wax Visual Removal of

honey foam particles that possibly contain control remaining
harmful residues or other honey scum by
contaminants other methods

4 Addition of Contamination of nuts / dried Visual Dispose of the

nuts or dried fruits with mould or pests  control nuts / dried
fruits to cream Honey product is deteriorated fruits
honey
Looking for mould, cocoons etc.

3.
Example Defect Control Measures
5 Cleaning Organic contamination, foreign Visual Another

pollen (blowing substances (dust), impurities, control cleaning
out, sorting by etc.
hand)
Insect bodies or parts of them
6 Insufficient Deterioration possible (water Continuos Adjustment of

drying of content) tempera- temperature
Pollen Storage temperature max. 6 °C ture
(freezer: -18 °C) control
storage

3.
Example Defect Control Measures
7 Storage of Quick deterioration possible Continuos Adjustment of

Royal jelly tempera- temperature;
- cooled Storage temperature max. 4°C ture control thawed pollen
- frozen (freezer: -18 °C) mustn’t be
freeze again

4.
HACCP in honey processing
- Realization of a hazard analysis
- Identifying preventive measures
- Identifying and setting critical control points (CCP)
- Setting critical limits and standards
- Monitoring of each relevant CCP in honey production
- Establishing corrective actions
- Documentation procedures

HACCP Implementation
1. Must have Management Commitment
2. most Food Safety Failures are Management
Failures
3. Must follow the 7 principles to develop
HACCP at each Production Plant

HACCP Plan Development

I. Assembling the HACCP team
Multidisciplinary
e.g. beekeepers, co-workers of the collecting stations, analysts,
representatives of quality control, engineers
4-6 people
Team must be able to evaluate risks and make food safety
judgements

4.
II. Describing the food and its distribution
• Types of raw material e.g. liquid honey, creamed honey,

comb honey, bulk honey, wax, pollen, propolis
• Intrinsic control factors (moisture, colour)
• Process control factors (heating, drying)

4.
III. Describing intended use and consumers
e.g. pharmaceutical industry, food industry,

cosmetic industry
Consumer  all groups of the population

4.
IV. Developing a flow diagram
• Including all process steps e.g. uncapping,

extracting, straining, filtering,
homogenising, stirring, packing, storage
• Including all inputs e.g. raw material,
package material, water, air

V. On-site confirmation of the flow diagram
1.all steps of the operation

2.all times of production
3.modify flow diagram as necessary

4.
VI. List all potential hazards associated with

each step, conduct a hazard analysis
and consider any measures to control
identified hazards.
• likely occurrence of the hazards

• expected severity of the hazards

4.
Hazards in honey processing

Physical Hazards (P)
• Insect fragments
• Soil
• Plant material
• Packaging
• Glass
• Equipment
4.
Chemical Hazards (C)
• Pesticides and herbicides

• Bee medicines, antibiotics
• Bee repellents
• Coating / varnish of drums

4.
Biological Hazards (B)
• Pathogens e.g. Clostridium botulinum

4.
Hazards may occur as a result of:
• an input (object, material)

• the process itself
• direct or indirect contamination from
„other sources“

4.
Inputs & associated hazards

Bee Hive material
Wax
Bee hive sites
Drums
Glass jars

Hazards at different process steps
1. Removing the honey combs out off the

hives
2. Holding in hot room
3. Uncapping
4. Extracting
5. Liquefying
4.
Form for evaluation of hazards and possibilities for control
(Agroscope Liebefeld-Posieux,Schweizerisches Zentrum für Bienenforschung, 2004)
1.1 HAZARD: CONTAMINATION
Hive a) Contamination by the environment: medium Identification and

(agriculture, industry) by heavy metals, contamination source
pesticides etc. place the hives to a
another site
b) Bees are intoxicated by pesticides small Identification and

contamination source
and its avoidance

4.
Form for evaluation of hazards and possibilities for control
(Agroscope Liebefeld-Posieux,Schweizerisches Zentrum für Bienenforschung, 2004)
1.1 HAZARD: IMPORTANCE CONTROL

CONTAMINATION MEASURES
Hive a) Lack of order and medium Re-installment of

hygiene, endangering order, cleanness and
quality of bee products hygiene
Extraction b) Lack of order, cleanness great Re-installment of
Plant resp. and hygiene, bees present, order, cleanness and
room foreign odour hygiene
c) Centrifuge, tanks are great Re-installment of

improper, rusty order, cleanness and
hygiene
d) Instrumentation and great Use drinking water
instruments are cleaned with
waste water e.g. pond, river


4.
1.2 HAZARD: ADULTERATION,
CONTAMINATION
Feeding a) Sugar syrup is mixed with honey great Correct choice of time
of bees and quantity of sugar
feeding
b) Use of improper water when preparing great Use of drinking water

sugar feed leads to transfer of contaminants
into the hive.

Bee Treatments of bees contrary to instructions great Follow instructions of

diseas- resp. illegal treatment leads to intolerable veterinary authorities
es residues in honey

4.
Change Combs are very dark, there are moths and great Regular control of brood and
and honey combs. Optimise
bee excretions, dirt which might cause bee storage of combs. Use
storage
infections and honey contamination. Use of alternative control for wax
of combs
pesticides for wax moth control moth control.
1.5 HAZARD: CONTAMINATION, ADULTERATION

Honey a) Water content of honey >20 % small Harvest honey with

harvest less than 20% w.cont.
Packing b) In honey there are contaminats from medium Re-installment of
storage wax, bees, dirt, extraneous substances and order, cleanness and
and odours hygiene
labelling
c) Improper conditions of honey storage medium Store honey at optimal
leads to dcrese of honey quality conditions (room,
recipients)
d) overheating of honey while packing medium Liquefy honey at the
leads to reaching of too much HMF optimum temperature and
time

4.
VII. Identifying preventive measures

4.
Examples for preventive measures
Step Risk Measure

Application of antibiotics Contamination of bee 1. Ban of antibiotics
and pesticides products caused by the 2. Regulation of pesticides
application of application by plant sanity
anitbiotics/presticides 3. Monitoring of chemical
compounds
4. Training
Feeding of bees Quality, application and 1. Purchase of suited
handling of feedstuff feedstuff
2. Usage of suited equipment
3. Correct application of
feedstuff
Desinfection and cleaning Transfer of diseases Fufillment of hygenic and
of hives health norms

4.
The seven principles of HACCP, contd.
Identifying and setting Critical Control

Points (CCPs)

CCP =
A step where control can be applied and is

essential to prevent, eliminate or reduce a food
safety hazard to an acceptable level
CP =
means any point, step or procedure in a specific
food system at which biological, physical and
chemical factors can be controlled

4.
Critical control-points show where

processes have to be supervised
Creating a decision tree facilitates

finding the CCPs

4.
The decision tree Questions

4.
Q1: Do control measure(s) exist?
Modify step, process or

Yes No product
Is control necessary here?

Yes
No
Not a CCP Stop

4.
Q2: Is the step specifically designed to eliminate or reduce

the likely occurance of a hazard to an acceptable level?
No Yes
CRITICAL CONTROL POINT

4.
Q3. Could the identified hazard increase to unacceptable levels?
No
Not a CCP Stop

Yes

4.
Q4. Will a subsequent step eliminate identified hazard(s) or reduce

likely occurrence to an acceptable level ?
Yes No
Not a CCP
CRITICAL CONTROL POINT
Stop

4.
3. Setting Critical Limit(s) and standards

4.
Critical limit =
A criterion that separates
accceptability from unacceptability

4.
A critical limit
- must relate to control measure
- must be observable / measurable (time,
temp., pH etc.)
- must be validated

4.
Examples for critical limits:
• For the application of e.g. antibiotics, bee-repellents,

wood preservatives
• Limits in honey for e.g. water content (fermentation),
HMF, invertase, diastase, antibiotics, pesticides
(regulated by law)
• Contamination by cleaning agents
• Adulteration e.g. by sugar cane, maize (C4-sugars)

4.
Limits are a result of:
- Legislations / guidelines
- Directives
- Specifications within the own company
if limits exceeded: corrective action

4.
4. Monitoring of each relevant CCP in

honey production

4.
Monitoring of each CCP means:

• watch and check CCPs to ensure that
instructions and corrective procedures are
carried out right
• Determing for each CCP:
– Who?
– When?
– What?

4.
5. Establishing corrective actions

4.
Corrective actions depend on the

faults, see examples next pages

4.
Corrective actions have to be introduced as soon as

critical limits are exceeded so the CCPs
will not get out of control
1st measure:
influence products or processes
or
2nd measure:
stop process and
dispose products
4.
CCPs in the Honey Process
I. The hive and the honey removal
II. Transportation of honey in supers
III. Uncapping
IV. Filtration
V. Storage
VI. Preparation to bottle & bottling
VII. Distribution & display

4.
Inputs
• Honey supers
• Uncapping, sump, pump to tanks
Final Output
• Bulk honey

4.
Hazards Monitoring
Check:
• Physical: soil, wire, wood, • - No contact with soil /
varnish particles, rust etc.
vegetation
• Chemical:
• - Chemicals applied for
- medicines: pest., antibiotics, suitability of use
- plant toxins (e.g. pontic - Regular inspections to detect
honey, tutin) vermin infestations
- paints, preservatives - Treatment
• Biological: - Instructions for use
- Bacterial spores e.g. • Reliable lab. test, reports
Clostridium

4.
Control and corrective action
• Dispose off honey

• Use as winter feed (if recognized as safe)

4.
II. Transportation of honey supers
Hazard: Monitoring:
• Physical and chemical • Inspect vehicles
contamination from: - Clean and free from
- Transportation petrol, oil, soil, plant &
- Animals animal material
- Rain water - Cover super with e.g.
polythene sheet

4.
II. Transportation of honey supers
Control and Corrective Action:
• Dispose off honey

4.
III. Uncapping and extraction
Hazard Monitoring
• Contamination from • Inspect all equipment
- Equipment (not • Clean daily resp.
stainless steel parts) regularly
- room • Provide suitable
- people clothing

4.
III. Uncapping and extraction
• Complete all checks before processing start

• Documentation !!

4.
IV. Filtration
Hazard Monitoring
• wax with residues • Check filters before and
• foreign matter after use for damages

4.
IV. Filtration
• Re-filter with good filter if found damaged after use

4.
V. Storage
Hazard Monitoring
• Contamination from • Check containers for
- container food storage suitability
- surroundings • Prevent moisture
- pests absorption
• high HMF due to high • Use suitable lids
temperatures • Maintain temp. below
• Moisture increase on 40°C
surface

4.
V. Storage
• Make sure conditions have been met before bottling

• Organoleptic test
• measuring HMF, moisture
Use as industrial honey if the above have failed

4.
VI. Preparation to Bottle & Bottling
Hazards Monitoring
• HMF increase • Monitor temp. under
50°C
• Crystallisation (liquid
• Check area and
honey)
surroundings
• Foreign matter due to • Check no. of
glass/plastic before &
contamination from:
after bottling for
- environment breakage
- glass breakage

4.
VI. Preparation to Bottle & Bottling
• Downgrade honey if temp. exceeded 50°c

• Do not bottle if area is not clean
• Dispose honey exposed to broken glass
• Re-check unfilled glass jars

4.
VII. Distribution & Display
Hazards Monitoring
• Moisture absorption • Suitable shipping
due to: containers
- damaged seals • Temperature ?
- poor handling
- poor packaging
HMF
Crystallisation (liquid
honey)

4.
VII. Distribution & Display
• Remove damaged product

4.
6. Verification of the system

4.
Establishing verification procedures
• Procedure to ensure that HACCP is

performed correctly and that it is effective
– Is the system suited?

– Are the procedures specified (e.g.
monitoring) and the corrective actions
applied correctly?

4.
Verifications can be:
– Verification of HACCP-inspections and the

respective data
– Verification of deviations
– Audits
– Validation of determined limits and
tolerances, e.g. participation in ring trials

4.
7. Documentation procedures

4.
Documentation
In terms of a traceable and effective
self-control, a minimum of
documentation is recommended

4.
Documentation, contd.
Recommended documentation regarding:
- Necessary cleanings
- Disinfection measures
- Storage temperatures
- Pest combat
- etc.
• Signatures are obligatory  There is no proof without evidence!


4.
Example 1: Documentation of cleaning and disinfection measures
Date:
Cleaning agent:______
Disinfection agent: ______
Dilution:
Work space and adjacent walls in
the processing room / etc.
Floors: __________
Walls, doors, windows:
Honey extractor
Other equipment:
Refrigerator:
Responsible / Signature:


4.
Example 2: Documentation of pest control and combat
Control date:
Pest detected:
Location / rooms:
Amount:
Measures:
Subsequent
control:
Result:
Responsible /
Signature:

5.
Establishing self-checking
mechanisms in honey production
acc. to HACCP principles

5.
Based on the HACCP approach:

Autocontrol system for beekeepers
- Should be as simple as possible

- should contain all the principles that ensure good quality
- Allows successful management of beekeeping units
- is cheap
The system has to ensure that all factors, which influence
honey quality are under control and are within the legal limits
This system is applicable for small and medium beekeeping

units.
5.
Autocontrol system for beekeepers, contd.
- The EC demands implementation of an Autocontrol-

system
- In some European countries manuals for the
production of quality honey based on HACCP have
been published
- The implementation of autocontrol-systems in honey
production is slow yet, since food control authorities
regard honey as a microbiologically safe product

5.
For example, in Switzerland forms have

been created for the self control system,
which help to evaluate hazards and
document control measures

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Keyword: eur-lex, number of regulation

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HACCP and hygiene in honey production

HACCP & Hygiene in

Buenos Aires, Concepción del Uruguay, Mendoza

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 1

Content of the seminar

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 2

General requirements of hygiene

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 3

Hygiene in honey production is protection

 dirt and diseases

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 4

Hygiene in honey production is necessary

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 5

European Community Legislation

• EC Directivesshall be adopted in member states

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 6

852/2004 general food hygiene

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 8

Community rules should not apply either to

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 9

HACCP for smaller enterprises

The HACCP requirements .........They should provide

Basic Regulation Food Safety 178/02

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 11

Prerequisite for HACCP

Cleaning and sanitations

 validity for everyone

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 13

Cleaning and sanitation applies to

• the working area

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 14

Washing facilities must be available:

- Working rooms must be equipped with:

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 15

- Sufficient air ventilation to prevent condensed water

Further prerequisites for working rooms and

Surfaces, tools and appliances, walls:

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 18

Suitable cleaning devices

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 19

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 20

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 21

• HACCP is a preventive safety system that

• most powerful method to repel and eliminate

• enables applying science-based controls

• from raw material to finished products

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 22

• Biological (e.g. bacteria, virus)

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 23

HACCP is not a stand-alone system. It works

• Standard Operating Procedures (SOPs)

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 24

• Good Processing Practices (GPP)

• Appropriate QM systems like ISO series

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 25

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 26

The seven principles of HACCP

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 27

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 28

Application of good beekeeping practice

1. working at the beehives

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 29

©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 30