HAZARD

A review
 Definition

 Hazard is defined as or a biological, chemical or

physical agent in, or condition of , food with potential
to cause adverse health
 Or
 A biological, chemical or physical agent that is
reasonably to cause illness or injury in the absence
of control
 Categories of Hazards: Biological Hazards,
Chemical hazards and Physical hazards.
Assemble HACCP Team
CATEGORIES OF HAZARDS

 Biological Hazards
 Chemical Hazards.
 Physical Hazards
 Origin of Hazards:
 From naturally occurring substances (afflatoxin, allergans)
 From Deterioration or Decomposition of foods
 Contamination of foods with hazards at various stages of their
production., harvesting , storing at processing, Distribution;
preparation and utilisation.
Biological Hazards and Chemical
hazards
Bacteria(gram negative pathogenic bacteria (eg : C. Botulinum, C. Perifringes, Bacillus cereus. Non
spore forming :Salmonella, Shigella Staph.aureus, V. Cholerae, V. Parahemolyticus etc )
Parasites : (eg Trichinella spralis)
Viruses (eg: Hepatits. Norwalk virus Rotavirus)
Fungus or mould (eg:Aspaergillus flavus)
Chemical Hazards:
Chemical hazards are grouped in to three categories
1 Unintentional or incidental chemical contaminants (eg Sanitizers)
2 Naturally occurring chemicals(eg: Aflatoxin,allergans,mushroom toxins,PSP,DSP. ASP and
Ciguatoxin)
3 Intentionally added chemicals (eg Sodiumnitrite, Sodium polyphosphate,antibiotics, pesticides,
growth hormones food additives)
Naturally occurring chemicals

 Allergens (eg:egg, milk,nuts , sea foods etc)

 Mold Toxins(eg:Aflatoxin)
 Toxic compounds(eg: Mushroom, algae)
 Intenionally added chemicals
 a Direct additives –Preservatives (eg; sodium benzoate and sulfting agents
 Nutritional Additives, Calcium, Vitamins, colour additives

 b Indirect
 Packing materials
 Processing plant chemicals like lubricants and sanitizers
Physical Hazards

 Glass : Bottles, jars, light fixtures, thermometers, gauge covers

 Plastic :Bottle jars packaging equipment and packaging materials
 Metal :Machinery, wire staples, building materials, employees personal effects
like jewellery, pen,pencil etc,
Definition of terms

Hazard plan: A document prepared in accordance with the principles of HACCP to

ensure control of hazards which are significant for food safety in the segment of
food chain under consideration is termed as Hazard plan
Hazard Analysis : The process of collecting and evaluating information on hazards
and condition leading to these pressure to decide which are significant for food
safety and therefore should be added in the HACCP plan.
Sanitaion : is the removal of soil, food residue , dirt ,grease or other objectionable
matter.
Food Hygiene : All conditions and measures necessary to ensure the safety and
suitability of foods and all stages of food chain is termed as FOOD HYGIENE
Food Chain-Primary production to Consumer
Control -To take all necessary actions to ensure and made compliance with criteria as
labeled in the HACCP plan.
Corrective Action: Any action to be taken with the results monitoring at the CCP
indicate loss of control.
 Definition

Deviation: Failure to meet a critical limit

Verification: The application methods, procedures , tests and other
evaluation, in addition to monitoring to determine compliance
with the HACCP plan activities include
HACCP plan validation, HACCP system audit
Equipment Calibration, Targeted sample collection and testing
Microbiological end product testing
Regulatory inspection/audit
Verification
Validation: Obtaining the evidence that the elements HACCP plan
are effective,
Codex General principles of Food hygiene

 Principles of food hygiene- 8 hygiene principles

 Primary production
 Design and Facilities
 Control of operation
 Maintenance and Sanitation
 Personal Hygiene
 Transportation
 Product information and consumer awareness
 Training of Personnel
Objectives of GHP

 Identify the essential principles of food hygiene applicable

through out the food chain
 Recommend a HACCP-based approach as a means to
enhance food safety
 Indicate how to implement those principles.
Scope and Use of GHP

 Protect consumers adequately from illness or injury

caused by food ; policies need to consider the
vulnerability of different groups with in the population.
 Provide assurance that food is suitable for human
consumption
 Maintain confidence in internationally traded food.
 Provide health education programme which effectively
communicate the principles of food hygiene on
industry and consumers
Food safety objectives Established

 At relevant functions and levels

 They be consistent with policy
 They be smart.
Primary production

 1.1 Environmental Hygiene

 1.2 Hygiene production of Food source
 1.3Handling Storage and transport.
 1.4 Cleaning ,maintenance and personnel hygiene
 2 Establishment, Design& Facilities
 2.1 Location and Establishment
 2.2 Premises and Rooms
 2.2.1 Design and layout
 2.2.2 Internal structures and fittings
 2.2.3 Temporary / mobile premises and vending machines
2.3 Equipment

 2.3.1 Equipment and containers coming in to contact with food

 2.3.2 Food control and monitoring equipment
 2.3.3 Containers for waste and inedible substances.

 2.4 Facilities
 2.4.1 Water supply
 2.4.2 Drainage and waste disposal
 2.4.3 Cleaning
 2.4.4 Personnel hygiene facilities and toilets
 2.4.5 Temperature control
 2.4.6 Air quality and ventilation
 2.4.7 Lighting
 2.4.8 Storage
2.4 Facilities
 2.4.1 Water supply
 2.4.2 Drainage and waste disposal
 2.4.3 Cleaning
 2.4.4 Personnel hygiene facilities and toilets
 2.4.5 Temperaturecontrol
 2.4.6 Air quality and ventilation
 2,4.7 Lighting
 2.48 Storage.
3 Control of operations

 3.1 Control of food hazards

 3.2 Key aspects of hygiene and control systems
 3.2.1 Time and temperature control.
 3.2.2 Specific process steps
 3.2.3 Microbiological and other specifications
 3.2.4 Microbiological cross contamination
 3.2.5 Physical and chemical contamination
 3.2.6 Incoming material requirements
 3.2.7 Incoming material requirements
 3.2.8 water.
3.2.9 Water

 3.2.9.1In contact with food

 3.2.9.2 As an ingredient
 3.2.9.3
 Ice and steam
 3.3 Management and Supervision
 3.4 Documentation and Records
 3.5 Recall procerdures.
4 Establishment , Maintenace & Sanitation

4.1 Maintenance and cleaning

4.1.2 Cleaning procedures and methods
4,2 Cleaning Programmes
4.3 Pest Control Systems
4.3.1 Preventing access
4.3.2 Harborage and infestation
4.3.3 Monitoring and detection
4.3.4 Eradication
4.4 Waste Management

 4.5 Monitoring Effectiveness

 5 Establishments :Personal Hygiene
 5.1 Health status
 5.2 Illness and Injury
 5:3 Personal cleanness
 5:4 Personal behaviour
 5:Visitors
Transportation

 6:1 Requirements
 6:2 Use and Maintenance
 7 Product Information and Consumer awareness
 7:1 Lot identification
 7:2 Product Information
 7:3 Labelling
 7:4 Consumer Education
 8 Training
 8:1 Awareness and Responsibilities
 8:2 Training Programme
Inhibitory chemicals present

 Many naturally occurring antimicrobial compounds in foods have

fungistatic activity , but they are rarely present in amounts sufficient to
prevent growth of moulds
 Environmental conditions: The majority of fungi associated with foods
are mesophilic, psychrotrophicor psychrophilic.
Hazard Assessment

 Severity of hazard
 Risks associated with hazards identified at
various stages of the operation.
 The points, steps or procedures at which
control can be applied and foods safety
hazard can be prevented, eliminated or
reduced to an acceptable level ie. critical
control point.
Severity

 Severity if the magnitude of a hazard or the degree

of consequences that can result when a hazard exit.
Disease causing hazards can be categorised
according to their severity.
 High (life threatening) examples include illness
caused by Clostridium botulinum, Salmonella typhi,
Listeria monocytogenes, E.coli 0157: H 7, Vibrio
cholerae, Paralytic shellfish poisoning .
Severity.

 Moderate (severe or chronic) examples include

illness caused by Brucella spp, Camylobacter spp,
Salmonella spp, Shigella spp, Streptococcos type A,
Hepatitis A virus, mycotoxins.
 Low (moderate or mild)-examples include illness
caused by Bacillus spp.Clostridium perifringens,
Staphylococcus aureus, most parasites, histamine-
like substances and most heavy metals that caused
mild acute illness.
Risk of Hazard

 Risk is a function of the probability of an

adverse effect and magnitude of that effect,
consequential of a hazard in food.
 Degrees of risk can be categorise as High
(H), Moderate (M) and negligible (N)
Determine Critical Control Point

 The codex guidelines define a critical control point

(CCP) as
 “A step at which the step can be applied and is
essential to prevent or eliminate a food safety
hazard or reduce it to an acceptable level”.
 The determination of a CCP in the HACCP system
can be facilitated by the application of a Decision
tree which indicates a logical reasoning approach.
Critical Control point

 Question 1: Do Control measures exist?

 Control measures could include , for example ,
temperature control, visual examination or use of a
metal detector.
 If the response is “yes”, proceed to the question 2 in
the decision tree.
 If the response is “no”, indicate how the identified
hazard will be controlled before and after the
manufacturing process, for example: Salmonella in
raw poultry is controlled by the end user.
Critical Control Point
 Q2 Is the step specifically designed to eliminate or reduce the likely
occurrence of the identified hazard to an acceptable level?
 Eg : The retorting operation in a canning plant
 Pasteurisation, Metal detector to a process line.
 A particular sanitation procedure performed by the operator to clean
contact surface with out which the line would be stopped and the
product would be contaminated to be defined with in the over all
objectives in identifying the CCPs of the HACCP plan.
 Acceptable and unacceptable level need to be defined with in the over
all objectives in identifying the CCPs of the HACCP plan
Critical Control Point

 If the answer is Yes the step automatically

becomes a CCP.
 If the answer is No proceed to the next
question.
Critical Control Point

 Q3: Could contamination with the idetified hazards occur in

excess of acceptable levels or increased to unacceptable level.
 This question refers to both probability seriousness.
 If the answer is “Yes” proceed to the next question in the
decision tree.
 If the contamination is known to represent the a substantial
threat to human health or is not likely to occur, answer “no”
(not a CCP) and proceed to the next identified hazard in the
process
Critical Control Point

 Q4:Will a subsequent step eliminate the identified hazard or

reduce likely occurrence to an acceptable level.?
 This question is designed to identify those hazards that are
known to represent a human health threat or that could
increase to an unacceptable level, and that will be controlled by
a subsequent process operation.
 If no subsequent operation in the process answer “no” and this
becomes a CCP.
 If there is sub the sequent operation that will eliminate the
identified hazard or reduce it to an acceptable level, answer
“yes” this step not a CCP.
Questions
 Qn no: 1 Do not control preventive measure (s) exist at this step?
 Qn no1A: Is control at this step is necessary for safety?
 Qn no 2: Is the step specifically designed to eliminate or reduce the
likely occurrence of a hazard to an acceptable level?
 Qn no 3:Could contamination with identified hazard occur in excess
of acceptable level(s) or could these increase to acceptable levels ?
 Qn no 4:Will subsequent step eliminate identified hazard (s) or
reduce likely occurrence to an acceptable level
Determination of CCp& OPRP

Sl no Process Idenified Q1no 1A Q.2 Q3 Q4 CCP/OPRP

step hazard
1 Reception of Biological N N - - - N
raw milk
2 R milk Biological N N - - - -
storage
3 Pasteurisatio Biological Y - Y - - CCP-01
n
4 Cold storage Biological Y - N Y N OPRP-1)
of pouched
milk
5 Tanker filling Biological Y - N Y N OPRP-02
&despatch
Establish critical limits for each
CCP (step 8/Principle 3)
 Critical limits are defined as criteria that separates acceptability from
unacceptability
 Eg: of Critical limits are temperature/time/physical product dimension,
water activity, moisture level,pH, titrable acidity,salt content, available
chlorine, viscosity, preservatives, or sensory information such as
aroma, and visual appearances. Eg:Production of beef pattice ,ccp is
heating at 155F for 16 seconds., critical limits are Oven temperature,
time, rate of heating and cooling. (belt speed in feet/inch. Patty
thickness, patty composition, oven humidity) second example
Pasturisation of milk at 72oC for 15 seconds, etc,
 These parameters ,if maintained with in boundaries, will confirm the
safety of the product.
Sources of limits information on critical limits

 Scientific publications/research data

 Regulatory requirements and guidelines.
 Experts (thermal process authorties, consultants,
food scientists, microbiologists, equipment
manufactures, sanitarians and academics
 Experimental studies (eg. In house experiments,
contract laboratories studies.
Examples of Criteria limits

Hazard CCP Critical limits

Bacterial pathogens (non- Pasteurisation 72 oC
spoulating)
Metal fragments Metal detector Metal fragments larger than
0.5mm
Bacterial pathogen Drying oven Aw- 0.85for controlling growth
in dried food products
Excessive nirtite Curing room,brining Max. 200ppm sodium nitrite
in finished product
Bacterial pathogens acidification step Max. pH of 4.6 to control
Clostridium botulinum in
acidified food.
Food allergens Labelling Label that is legible and
contains a listing correct
ingredients.
Histamine receiving Max. of 25 ppm histamine
levels in evaluation of tuna
Critical limits Vs Operating limits

process Critical limits operating limits

Acidification pH 4.6 pH 4.3

Drying 0.84 0.80 Aw
Hot fill 80oC 85oC
Slicing 2 cm 2.5 cm

* The point at which action to prevent loss of control of the CCP taken is
called operating limits.
Establish monitoring system for
each critical control point (step 9)

 Codex HACCP system for each its

application defines monitoring as .
 “The act of conducting a planned sequence
of observations or measurements of control
parameters to assess whether a CCP is
under control .
Purpose

 To measure the performance level of the system’s

operation at the CCP ( trend analysis).
 To determine when the performance level of the
system results in a loss of control at the CCP
eg:when there is a deviation from the critical limit.
 To establish record that reflects performance level
of the system’s operation at the CCP to comply with
the HACCP plan.
Designing a monitoring system.

 What will be monitored?

 How critical limits and preventive measures will be monitored?
 Frequency of monitoring.
 Who will monitor?
 What will be monitored : Measurement of time & temperature of a
thermal processing
 Measurement of cold storage temperature
 Measurement of pH, Aw.
 Visual examination of sealed cans.
 Verification of vendor’s certificate of analysis
Who will Control Limits and Preventive measured
be monitored

 Effective monitoring depends up on proper selection

and calibration of measuring equipment eg:
 Thermometers.
 Clocks.
 Scales.
 pH Meters, Water activity meters, Analytical
equipment.
Who will monitor

 Linepersonnel
 Equipment operators
 Supervisors
 Maintenance personnel
 Quality assurance personnel
Establish Corrective action Step- 10 principle 5

 Codex defines Corrective action as “Failure

to meet a Critical limit”
 Root Cause analysis.
 Corrective action procedures are necessary
to determine the cause of the problem, take
action to prevent recurrence and follow up
with monitoring and reassessment to
ensure that the action taken is effective.
 Corrective action programme should include the
following
 Investigation to determine the cause of the deviation
(non conformance)
 Effective measures to prevent recurrence of the
deviation.
 Verification of the effectiveness of corrective action
taken and record the corrective action that have
been taken place.
Step 11: Principle 6, Establish Verification

 The Codex guidelines define verification as:

 The application of methods, procedures, tests and other
evaluations, in addition to monitoring to determine compliance
with HACCP plan.
 Validation 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.
 Verification
activities include:
 HACCP plan validation.
 HACCP system Audit.
 Equipment calibration.
 Targeted sample collection and testing.
 Microbiological and product testing.
 Regulatory inspection and audit
HACCP Plan Validation

 Examples: Review of Hazard Analysis, CCP

determination.
 Justification for critical limit, based for example . On
current food science and regulatory requirements.
 Determination of whether monitoring activities ,
corrective actions. Record keeping procedures are
appropriate and adequate.
HACCP system audit

 Audits are systematic and independent examinations involving

on site observations, interviews and review of records.
 Calibration: Involves checking instruments or equipment
against a standard to ensures accuracy.
 At a frequency sufficient to assure continuous accuracy.
 According to procedures established in the HACCP plan.
 By checking accuracy against a recognised standard.
 Under condition similar or identical to those under which the
instrument or equipment will be used.
Targeted Sampling and Testing

 Targeted Sampling and Testing involves taking

product samples periodically and testing them to
ensure that critical limit are appropriate for product
safety.
 Targeted sampling may be carried to check vendor
compliance when receipt of material is a CCP and
purchase specification are relied on as critical
limits ,eg: sulphite levels less than 100 ppm in
cooked shrimp.
Verification frequency

 Frequency may be decided when:

 Online observation that CCPs may not be operating
with in critical limits.
 Records reviews indicating in consistent monitoring.
 Records reviews indicationg that CCps are
repetitively operated outside critical limits.
 Consumer complaints or products rejections by
customers. New scientific data.
Records of Verification

 Verification activities should be documented in the

HACCP plan which include:
 Method,
 Date,
 Individual responsible,
 Results and Findings and action taken.
 Deviation Procedures and Root cause Analysis
Establish Documentation and Record Keeping Step
12/ Principle 7

 Four types of records as part of the HACCP

programme.
 Support documents
 Records generated by the HACCP system.
 Documentation of methods and procedures used.
Records employee training programme.
Support documents

 Product description and intended use

 Flow diagram
 Hazard analysis
 Identification of CCPs
 Identification of critical limits for each CCPs
 Documented deviation and corrective action plans
 Planned verification activities and procedures.
 Identification of the preventive measures for each
hazard.
Records Generated by the HACCP system

 This include:
 Monitoring records for all CCPS
 Deviation and Corrective action records.
 Verification/validation.
Documentation of methods and procedure used.

 Description of the monitoring system for the critical limit of each

CCP, including: the methods and equipment used for
monitoring, the frequency of monitoring and the person
performing the monitorings..
 Plans for corrective actions for critical limit violations or
situations resulting in potential hazards.
 Description of record keeping procedures, including copies of
all record forms
 Description of verification and validation procedures.
Records of employee training programme

 Employees involved in in monitoring critical limits for

CCPS.
 Those involved in with deviation review.
 Those involved in corrective actions and verification.
 Completion of HACCP records.
References
 HACCP, Principles and Applicatio Guide lines, The National Advisory Committee on Microbiological
criteria for food (NACMCF) J. Food Production Adapted 1997
 HACCP Principles and application guidelines The National Advisory Committee on Microbiological
criteria for food (NACMCF) J. Food Production Vol.61, No 9, 1998.
 International HACCP Alliance.” International HACCP Alliance”PDF 12 th October 2007.
 Quality Assurance in Sea food Processing (2001) Edited by
T.S Gopalakrishna Iyer, M.K Kandoran, Mary Thomas and P.T Mathew. Published by The Director,
Central Institute of Fisheries Technology, Cochin and The Secretary, Society of Fisheries
Technologist’s( India) , Cochin 682029.
 Product Development and Seafood Safety,
Edited by Dr P.T Mathew et al. 2003.
published by The Director Central Institute of Fisheries Technology, Cochin. -682029
 Bryan, F.L 1992 Hazard Analysis and Critical control Point Evaluation, A guide to identifying hazards and
assessing risks associated with food preparation and storage published by WHO p 72 :
Codex1991 Draft Principles and application of HACCP system. Alinorm 93/13 Appendix VI FAO, Rome.
 Food Safety Management, 2014 A Practical guide for the Food Industry.
Edited by Yasmine Motarjemi and Huub Lelieveld
Published by Academic Press Elsevier Inc ,London.