Hazard Analysis And Critical Control Point Plan Research Articles

Development of a HACCP-based approach to control risk factors associated with biscuit manufacturing plant, Bangladesh

PurposeThe purpose of this study is to develop a hazard analysis and critical control point (HACCP)-based approach to control risk factors associated with biscuit manufacturing plant.Design/methodology/approachMethodology was developed to achieve and implement the food safety and quality requirements. Procedure for hazard analysis and risk assessment was based on ISO 22000:2005 and codex standard. The HACCP Plan was summarized in comprehensive figures and tables. Biological, chemical and physical hazards that could exist in every step of biscuits production were identified. Moreover, the critical control points were selected and the critical limits, monitoring, corrective measures, records and verifications were established using risk analysis and decision tree.FindingsWith the implementation of HACCP system, it could be possible to reduce the food safety hazard and provide safe food and increase customer satisfaction. The critical control points were identified in sieving, sugar crushing, baking and detecting metal through the use of risk analysis and decision-making tree to control the biological, physical hazards along with monitoring through the control sheets. Critical limits, monitoring methods and frequency, responsibilities and corrective actions of the processes are also presented. This measuring instrument could be used by a food company as assessment tool and a benchmarking tool.Originality/valueApplying the HACCP system in food manufacturing can effectively assure food safety and quality, as well as expand the market and improve the manufacturers’ management level. In doing so, suitable strategies can be selected by a food company to allocate resources, increase HACCP effectiveness and improve its product safety.

Hazard analysis and critical control point plan for hazards in Ugandan amaranth vegetable value chain

Currently, there is a high demand for amaranth due to its ability to withstand harsh climatic conditions, making it an ideal crop in the changing climate. There is also increased awareness and education on its nutritional and overall health benefits, and the availability of improved recipes. However, the presence of hazards can hinder the commercialisation of amaranth, which is in most cases traded informally. Food safety issues along the amaranth value chain should, therefore, be addressed to cope with both production and safety demands. The objective of this study, therefore, was to develop a Hazard Analysis and Critical Control Point (HACCP) plan for hazards in the amaranth value chain in Uganda. The seven principles outlined by Codex Alimentarius were followed to develop the HACCP plan. A tree diagram was further used to identify each potential hazard at each processing stage and Critical Control Points (CCPs) along the chain. For the CCPs identified, reliable control mechanisms and corrective actions were established to fulfil the requirements set by the critical limits to guarantee the safety of the products. Verification and records systems were proposed to determine the effectiveness and traceability of the HACCP plan. For each of the identified CCPs, samples were collected purposively and analysed for chemical and microbial contaminants. From the analysis, fifteen processing stages, starting from the land section to cooking and serving, were identified. Out of these, eight stages were defined as CCPs. These were site selection, land and seedbed preparation, irrigation, market display/humidity control, washing before preparation, chopping, cooking, and holding time and serving. At CCP 1, soils were contaminated with lead and cadmium, mercury and aflatoxins but at considerably low levels. At CCP 2, organic fertilisers were only contaminated with E. coli . At CCP3, E. coli was present in irrigation water. Heavy metals were also present in the irrigation water but were below the critical limits. At CCP4, E. coli was absent in water and display surfaces. E. coli was, however, present on raw amaranth. S. aureus was detected on vendors’ hands. At CCP5, water was not contaminated with E. coli . At CCP6, only personnel hands were infected with S. aureus and Enterobacteriaceae . No contamination was detected in CCP7 and CCP8. Strict control of E. coli in manure and water and S. aureus and Enterobacteriaceae on personnel hands is required to ensure the amaranth value chain attains good food safety output. Keywords: Amaranth, food safety, prerequisite programs, HACCP plan, hazards, Uganda

Hacia una normalización de la representación de flujogramas en el ámbito hospitalario

En este artículo se presenta una propuesta de normalización para la representación de protocolos hospitalarios a través de diagramas de flujo. En el ámbito clínico se desarrollan procesos de gran complejidad que, si no se gestionan adecuadamente, podrían dar lugar a consecuencias fatales para los pacientes o el personal sanitario implicado. Utilizar una notación clara que formalice las tareas que deben realizarse es un aspecto fundamental para mantener los riesgos controlados. En la práctica, el lenguaje de flujogramas más utilizado desde hace años debido a su sencillez y versatilidad es el definido por la norma ISO 5807:1985. No obstante, este lenguaje resulta insuficientemente expresivo para representar todos los aspectos importantes de un protocolo sanitario. Durante los últimos años este tipo de protocolos han aumentado su complejidad con el fin de dar un paso hacia adelante en el control de aspectos críticos que influyen en la seguridad de los medicamentos, pacientes y personal sanitario. En esta línea, una práctica muy común ha sido la implantación de la metodología APPCC (Análisis de Peligros y Puntos Críticos de Control). Durante el modelado de estos protocolos (dado que la notación de flujogramas tradicional no es suficientemente expresiva) cada centro hospitalario ha adoptado una propuesta propia que complementa los elementos incluidos en la norma ISO (International Organization for Standardization). Con esta práctica se obliga a que el personal tenga que familiarizarse con la notación definida ad-hoc para ese centro que, además de no estar estandarizada, cae en ocasiones en definiciones ambiguas y poco formales. En la propuesta de normalización presentada en este artículo se plantean nuevos estereotipos gráficos fácilmente integrables en la notación ISO y diseñados para representar los aspectos críticos de la metodología APPCC. Para la definición de estos nuevos elementos se han priorizado una serie de requisitos que tienen en cuenta tanto los aspectos relativos a las herramientas software ya existentes como la simplicidad para los usuarios finales en la práctica diaria. Al mismo tiempo se tratan de evitar ambigüedades asegurando que los elementos introducidos no interfieren con la notación base contenida en la norma ISO original. En definitiva, esta propuesta de normalización consigue enriquecer el lenguaje ISO5807:1985 con mecanismos de expresión suficientes para representar la información básica relacionada con la seguridad de los protocolos reduciendo las ambigüedades y facilitando una notación estandarizada.

Development of a food safety toolkit for dry common beans (Phaseolus vulgaris L.) in Uganda using a Hazard Analysis and Critical Control Point (HACCP) approach

Common beans ( Phaseolus vulgaris L) may be contaminated with heavy metals and aflatoxins. Cooked beans may also be contaminated with micro-organisms due to poor hygiene and sanitation practices. Hazard Analysis and Critical Control Point (HACCP), which is a globally recognised food safety program, was proposed as a suitable program to minimise/eliminate the risk of contamination. Therefore, the objective of this study was to develop a HACCP plan for dry common beans in Uganda and an accompanying food safety toolkit. The seven principles of HACCP as outlined by Codex Alimentarius were followed to develop a HACCP plan for the dry common beans value chain in Uganda. A decision tree diagram was further used to identify each potential hazard at each processing stage and Critical Control Points (CCPs) along the chain. The identification of the CCPs was further supported by an evaluation of the actual risk and severity of the hazard. For the CCP identified, reliable control mechanism and corrective actions were established to fulfill the requirements set by the critical limits to guarantee the safety of the products. Verification and records systems were proposed to determine the effectiveness and traceability of the HACCP plan. For identified CCPs, a co-creation methodology was used to develop the food safety toolkit. This was carried out in four sessions that included a background of the chain actors’ ambitions to determine the suitability of the toolkit, assessment of CCPs, expert advice on the CCP and an exercise to develop concepts for each CCP. From the analysis, fourteen processing stages starting from land selection to cooking and serving were identified. Out of these, four stages were CCPs. These were land selection and preparation, storage, post-harvest drying, and cooking and serving. Hazards at the CCPs included heavy metals, mycotoxins, and micro-organisms such as S. aureus, E. coli, and Salmonella spp. A combination of good hygiene and sanitation practices and good agricultural practices were recommended as control measures against the hazards. To further equip the value chain actors with mitigation strategies, a food safety toolkit whose usefulness is to give the actors a systematic means to control identified CCPs was developed. In this regard, the toolkit and HACCP plan will complement each other. From the study results, implementation of the toolkit, followed by an assessment of its uptake and impact on livelihoods and food safety risks is recommended. Key words: Common beans, food safety toolkit, prerequisite programs, HACCP plan, hazards, Uganda

Design of a HACCP plan for indigenous chicken slaughter house in Kenya

Indigenous chicken rearing is seen as a poverty alleviation and food security strategy especially in rural households in Africa. Chicken meat is a delicacy in almost every household in Kenya. It is a common food in restaurants and hotels that serve fast foods in urban areas. Demand for and consumption of indigenous chicken meat in Kenya has been on the rise. Many slaughterhouses have been set up in strategic locations close to towns or in towns to allow for quick supply of the dressed chicken carcass to consumers. Poultry meat is a low acid food and has been associated with the presence of foodborne pathogens such as Campylobacter, Escherichia coli, Salmonella enteritidis, and Staphylococcus aureus, especially when processing conditions are not hygienic. Hazard Analysis and Critical Control Point (HACCP) is based on a scientific verifiable process to identify, control, reduce or eliminate any potential hazards to guarantee food safety. The current study was conducted based on the actual production conditions of the slaughter house. It was initiated through a survey that looked into the operations of the slaughter house on the basis of good manufacturing practices, as well as standard operation and sanitation procedures. From the results of the study and the gap audit analysis based on a checklist, the HACCP study was commissioned. The study aimed at developing a HACCP system; based on the seven HACCP principles and a critical scrutiny of several existing models. Four Critical Control Points (CCPs) were identified and a HACCP plan, complete with perquisite programs was presented to deal with the identified hazards and, therefore, present the consumers with high quality and safe products. Design of a model for the application and operationalization of HACCP system was undertaken as an important step in ensuring consumers enjoy safe products from the indigenous chicken meat prepared from the slaughter house. Key words : Indigenous chicken, slaughter house, HACCP, Critical control points (CCPs)

Costs of Food Safety Investments in the Meat and Poultry Slaughter Industries.

To develop regulations efficiently, federal agencies need to know the costs of implementing various regulatory alternatives. As the regulatory agency responsible for the safety of meat and poultry products, the U.S. Dept. of Agriculture's Food Safety and Inspection Service is interested in the costs borne by meat and poultry establishments. This study estimated the costs of developing, validating, and reassessing hazard analysis and critical control points (HACCP), sanitary standard operating procedures (SSOP), and sampling plans; food safety training for new employees; antimicrobial equipment and solutions; sanitizing equipment; third-party audits; and microbial tests. Using results from an in-person expert consultation, web searches, and contacts with vendors, we estimated capital equipment, labor, materials, and other costs associated with these investments. Results are presented by establishment size (small and large) and species (beef, pork, chicken, and turkey), when applicable. For example, the cost of developing food safety plans, such as HACCP, SSOP, and sampling plans, can range from approximately $6000 to $87000, depending on the type of plan and establishment size. Food safety training costs from approximately $120 to $2500 per employee, depending on the course and type of employee. The costs of third-party audits range from approximately $13000 to $24000 per audit, and establishments are often subject to multiple audits per year. Knowing the cost of these investments will allow researchers and regulators to better assess the effects of food safety regulations and evaluate cost-effective alternatives.

Food Safety Practices in the Egg Products Industry

We conducted a national census survey of egg product plants (n = 57) to obtain information on the technological and food safety practices of the egg products industry and to assess changes in these practices from 2004 to 2014. The questionnaire asked about operational and sanitation practices, microbiological testing practices, food safety training for employees, other food safety issues, and plant characteristics. The findings suggest that improvements were made in the industry's use of food safety technologies and practices between 2004 and 2014. The percentage of plants using advanced pasteurization technology and an integrated, computerized processing system increased by almost 30 percentage points. Over 90% of plants voluntarily use a written hazard analysis and critical control point (HACCP) plan to address food safety for at least one production step. Further, 90% of plants have management employees who are trained in a written HACCP plan. Most plants (93%) conduct voluntary microbiological testing. The percentage of plants conducting this testing on egg products before pasteurization has increased by almost 30 percentage points since 2004. The survey findings identify strengths and weaknesses in egg product plants' food safety practices and can be used to guide regulatory policymaking and to conduct required regulatory impact analysis of potential regulations.

Implementation of HACCP Plan for the Production of Egyptian Kishk (A Traditional Fermented Cereal-Milk Mixture)

The aim of this study is implementation of Hazard Analysis and Critical Control Points (HACCP) system during production of Egyptian Kishk on small scale production. Kishk is a traditional dry fermented product consisted from salted sour butter milk (Laban zeer) or yoghurt with cracked and bran free parboiled wheat grains (Burghol); the mixture of cereal and milk allows fermenting at ambient temperature for different periods, then the fermented mixture is formed in ball form and dried. Kishk is consumed in Egypt and in most Arab countries. Since Kishk is prepared by traditional and consumed widely, safety of this product is very important in terms of consumer health. Therefore, HACCP system as food safety tool was adopted during preparation of Kishk. Hazard analysis of raw materials and during different production steps was established. A simple HACCP plan was implemented; critical control points of production were determined; critical limits, corrective actions and monitoring procedures for each critical control points were established; verification procedures were also discussed.

How and Why to Implement HACCP in Food Businesses in Developing Countries? Suggestions to Afghan Government and Private Sector

In Afghanistan food safety is managed by several ministries including Ministry of Public Health, Ministry of Agriculture, Ministry of Commerce and municipalities. There is no food law but multiple ministerial decrees which ensure if GMP is implemented well. There is no legal requirement to get food safety certification. Hazard analysis and critical control point (HACCP) is recognized as a key part of food safety management practice in the global food industry and can be applied at any stage of the food supply chain. This article discusses accepted approaches to the application of HACCP principles for the development, implementation, and maintenance of HACCP plan. It is intended as an introduction to food safety system in Afghanistan, giving propositions to government on how to apply the principles in a stepwise approach, and showing how HACCP benefit public and private sector and also suggesting ways how to adapt this approach in the food businesses.

Contribution to Risk Analysis of a Standard Brewery: Application of a Hygiene Assessment System Survey

Beer is a food product with a high consumption in Gran Canaria and the brewery industry is also present in this island. In order to carry out this study, it was designed a survey to assist in the assessment of risks from the facilities and infrastructures of the brewery, the raw materials used in the beer production and the HACCP (Hazard Analysis and Critical Control Points) plan. An initial assessment of various aspects of the industry has been conducted at the beginning of hygienic-sanitary counselling and a second assessment on the effects could manifest such counselling. It was observed that there was an increase score in most of points tested following the guidance in the interval of time between the both assessments.

English

The quality and safety of aquatic products has always been the first priority in food quality control in China. The Hazard Analysis and Critical Control Points (HACCP) is recognized as an effective system designed to improve food safety. To promote the establishment and implementation of the HACCP system in the aquaculture industry in China, the paper analyzed potential hazards in the cage aquaculture of Siniperca scherzei and defined the critical control point. Meanwhile, the table of HACCP plan was established.   Key words: Hazard analysis and critical control points (HACCP), cage culture, Siniperca scherzei, quality.

The Design of HACCP Plan for Potato Chips Plant in Bangladesh

The purpose of this study is to design Hazard Analysis and Critical Control Point (HACCP) plan for potato chips production based on actual conditions in the plant. A specific model has been developed to boost the safety and quality of potato chips product in this plant. The spread of some diseases by unsafe products due to pathogen reported makes it important to pay attention to the potential contamination in potato chips production. The prerequisite programs (PRPs), operational prerequisite programs (OPRPs), hazards, critical control point, preventive measure, critical limits, monitoring procedure and corrective actions have been designed in this HACCP plan. The production process of the product was also analyzed scrupulously for this HACCP plan.DOI: http://dx.doi.org/10.3329/jesnr.v5i2.14839 J. Environ. Sci. & Natural Resources, 5(2): 329-338 2012

Evaluation of the quality of foods for special diets produced in a school catering facility within a HACCP-based approach: a case study

A study was carried out to verify the appropriateness of the Hazard Analysis and Critical Control Point (HACCP) plan adopted in a school catering facility. To that end, the microbiological quality of foods, the correct implementation of special diets (lactose- and gluten-free) and the nutritional value of foods were assessed. Thirty-six samples of lactose-free and 87 samples of gluten-free special diet food preparations were subjected to microbiological, chemical, and nutritional analyses. The data collected demonstrate the effectiveness of the HACCP plan in reducing the occurrence of microbial and chemical (lactose and gluten) cross-contamination. The data obtained from the nutritional analyses showed that the dietary intake provided by the meals under study was satisfactory.

Evaluation of the HACCP System in a University Canteen: Microbiological Monitoring and Internal Auditing as Verification Tools

Food safety is essential in mass catering. In Europe, Regulation (EC) No. 852/2004 requires food business operators to put in place, implement and maintain permanent procedures based on Hazard Analysis and Critical Control Point (HACCP) principles. Each HACCP plan is specifically implemented for the processing plant and processing methods and requires a systematic collection of data on the incidence, elimination, prevention, and reduction of risks. In this five-year-study, the effectiveness of the HACCP plan of a University canteen was verified through periodic internal auditing and microbiological monitoring of meals, small equipment, cooking tools, working surfaces, as well as hands and white coats of the canteen staff. The data obtained revealed no safety risks for the consumers, since Escherichia coli, Salmonella spp. and Listeria monocytogenes were never detected; however, a quite discontinuous microbiological quality of meals was revealed. The fluctuations in the microbial loads of mesophilic aerobes, coliforms, Staphylococcus aureus, Bacillus cereus, and sulphite-reducing clostridia were mainly ascribed to inadequate handling or processing procedures, thus suggesting the need for an enhancement of staff training activities and for a reorganization of tasks. Due to the wide variety of the fields covered by internal auditing, the full conformance to all the requirements was never achieved, though high scores, determined by assigning one point to each answer which matched with the requirements, were achieved in all the years.

Effectiveness of Prerequisites and the HACCP Plan in the Control of Microbial Contamination in Ice Cream and Cheese Companies

In food safety, implementation of prerequisites and application of Hazard Analysis and Critical Control Points (HACCP) guarantee the control of processes, and microbiological criteria permit validation of their effectiveness. With these aims in mind, this article presents the results obtained by the official control carried out by the Valencian administration in ice cream and cheese companies, located in the Xativa/Ontinyente area (Valencian region, Spain) in the period between 2005 and 2010. The audits of Good Hygienic Practices (GHP) and HACCP show that "Structure & Design" followed by "Hygiene & Cleaning" and "Traceability" were the evaluated items with most nonconformities. Pathogenic microorganisms were not found in any of the final products analyzed. Microorganism indicators of unhygienic conditions were present in 100% of the analyses; however, 87.98% of them had low levels, which did not exceed the microbiological criteria. These results highlight the general good effectiveness of the safety management systems implemented and emphasize that companies and official control must continue working in order to guarantee the consumers' welfare.

Drug usage hazard analysis and critical control points (HACCP)

The Wisconsin Veterinary Medical Association has prepared a six-step process for developing an on-farm HACCP plan for drug usage on a dairy. The six steps are to define the roles and responsibilities of the veterinarian-client-patient relationship (VCPR) team, evaluate the complete list of drugs purchased, develop protocols for use of the drugs, consider standard operating procedures used by the dairy, develop the treatment records plan, and establish an oversight strategy for monitoring drugs used on the dairy by the veterinarian.

Outbreaks of Foodborne Disease Associated with Fruit and Vegetable Juices, 1922–2010

The FDA has recently mandated that all 100% fruit/vegetable juices sold wholesale be produced under a Hazard Analysis and Critical Control Point (HACCP) plan. As part of their HACCP plan, juice processors must identify and meet a target for reduction of the most resistant microorganism of public health significance that is likely to occur in the juice. This 7-page fact sheet aids juice processors in the identification of these “pertinent microorganisms,” and reviews the locations of juice preparations and severity of juice-associated outbreaks. Written by M. D. Danyluk, R. M. Goodrich-Schneider, K. R. Schneider, L. J. Harris, and R. W. Worobo, and published by the UF Department of Food Science and Human Nutrition, January 2012. FSHN12-04/FS188: Outbreaks of Foodborne Disease Associated with Fruit and Vegetable Juices, 1922–2019 (ufl.edu)

HACCP을 적용하여 생산한 김밥의 유통기한 설정

Abstract This study was conducted to estimate the shelf-life of Kimbab manufactured using a Hazard Analysis and Critical Control Point (HACCP). We performed a microbiological verification after applying the HACCP plan to Kimbab. Additionally, the shelf-life of Kimbab at each holding temperature was calculated as a regression equation between the aerobic plate counts and holding time during the storage period. The critical control points of the HACCP plan, that were applied to Kimbab, included: cold-holding of refrigerated foods, checking the endpoint cooking temperature of heated food, and cold-holding of cooked foods. As a result of the microbiological verification of Kimbab, the aerobic plate counts averaged 3.46 log CFU/g. In contrast, the coliforms, E. coli, Staphylococcus aureus, and Salmonella spp. were not detected in any of the samples. The estimated shelf-life of Kimbab was calculated to be 45 hours at 10℃, 29 hours at 15℃, 6 hours at 25℃ and 3 hours at 35℃. In conclusion, manufacturers should apply a prerequisite program and a HACCP system for a safe consumption of ready-to-eat foods and label products with a proper shelf-life. Distributors should control the proper holding time-temperature until sale and consumers should eat immediately after purchasing ready-to-eat foods. Key words : shelf-life, Kimbab, HACCP, prerequisite program, verification1)

Potential biological hazard of importance for HACCP plans in fresh fish processing

The Hazard Analysis and Critical Control Point (HACCP) system is scientifically based and focused on problem prevention in order to assure the produced food products are safe to consume. Prerequisite programs such as GMP (Good Manufacturing Practices), GHP (Good Hygienic Practices) are an essential foundation for the development and implementation of successful HACCP plans. One of the preliminary tasks in the development of HACCP plan is to conduct a hazard analysis. The process of conducting a hazard analysis involves two stages. The first is hazard identification and the second stage is the HACCP team decision which potential hazards must be addressed in the HACCP plan. By definition, the HACCP concept covers all types of potential food safety hazards: biological, chemical and physical, whether they are naturally occurring in the food, contributed by the environment or generated by a mistake in the manufacturing process. In raw fish processing, potential significant biological hazards which are reasonably likely to cause illness of humans are parasites (Trematodae, Nematodae, Cestodae), bacteria (Salmonella, E. coli, Vibrio parahemolyticus, Vibrio vulnificus, Listeria monocytogenes, Clostridium botulinum, Staphyloccocus aureus), viruses (Norwalk virus, Entero virusesi, Hepatitis A, Rotovirus) and bio-toxins. Upon completion of hazard analysis, any measure(s) that are used to control the hazard(s) should be described.

Factors affecting the incidence of pathogenic micro-organisms in fresh-cut produce

of review: This review focuses on the main factors influencing the incidence of pathogenic micro-organisms in fresh-cut pro- duce. Findings: The increase in the per capita consumption of fresh-cut produce is expected to continue during the forthcoming years, there- fore it is necessary to strengthen microbial safety issues related to fresh-cut produce. Different factors affecting the presence of patho- genic micro-organisms in fresh-cut produce during processing have been identified: the raw produce coming from field and process water quality; the hygiene and health of food handlers; the sanitation and cleanliness of facilities; processing equipment and utensils; and the presence of pests in processing plants. Raw produce quality is one of the most important factors that can affect the arrival of pathogenic micro-organisms on fresh-cut fruits and vegetables. Limitations/implications: The high cost associated with implementing Good Agricultural Practices (GAPs), Good Manufacturing Practices (GMPs) and Hazard Analysis and Critical Control Points (HACCP) as food safety programs. Directions for future research: Efforts should be made to develop feasible procedures for small- and medium-sized industries that ensure high microbiological safety and quality standards, through HACCP plans, for each fresh-cut produce. It is also necessary to explore new treatments that improve the safety and quality of fresh-cut produce in order to prevent the incidence, survival and growth of pathogenic micro-organisms, as well as to prolong the microbiological shelf-life.