Implementation of hazard analysis critical control point in the meat and poultry industry

Abstract

Meat and poultry industries today are facing new challenges, with more complex ingredients, processes, and packaging. Consequently, controls are becoming more important as more complex processes are developed. Widespread adoption of Hazard Analysis Critical Control Point (HACCP) by the meat and poultry industry should enhance consumer confidence in its products and reduce the currently existing barriers in international trade. The purpose of this review is to present several comprehensive flow diagrams of meat and poultry products and apply HACCP principles in order to ensure food safety.     

Validation of acid washes as critical control points in hazard analysis and critical control point systems

A 2% lactic acid wash used in a large meat-processing facility was validated as an effective critical control point (CCP) in a hazard analysis and critical control point (HACCP) plan. We examined the microbial profiles of beef carcasses before the acid wash, beef carcasses immediately after the acid wash, beef carcasses 24 h after the acid wash, beef subprimal cuts from the acid-washed carcasses, and on ground beef made from acid-washed carcasses. Total mesophilic, psychrotrophic, coliforms, generic Escherichia coli, lactic acid bacteria, pseudomonads, and acid-tolerant microorganisms were enumerated on all samples. The presence of Salmonella spp. was also determined. Acid washing significantly reduced all counts except for pseudomonads that were present at very low numbers before acid washing. All other counts continued to stay significantly lower (P < 0.05) than those on pre-acid-washed carcasses throughout all processing steps. Total bacteria, coliforms, and generic E. coli enumerated on ground beef samples were more than 1 log cycle lower than those reported in the U.S. Department of Agriculture Baseline data. This study suggests that acid washes may be effective CCPs in HACCP plans and can significantly reduce the total number of microorganisms present on the carcass and during further processing.     

Application of hazard analysis critical control points (HACCP) to organic chemical contaminants in food

Hazard Analysis Critical Control Points (HACCP) is a systematic approach to the identification, assessment, and control of hazards that was developed as an effective alternative to conventional end-point analysis to control food safety. It has been described as the most effective means of controlling foodborne diseases, and its application to the control of microbiological hazards has been accepted internationally. By contrast, relatively little has been reported relating to the potential use of HACCP, or HACCP-like procedures, to control chemical contaminants of food. This article presents an overview of the implementation of HACCP and discusses its application to the control of organic chemical contaminants in the food chain. Although this is likely to result in many of the advantages previously identified for microbiological HACCP, that is, more effective, efficient, and economical hazard management, a number of areas are identified that require further research and development. These include: (1) a need to refine the methods of chemical contaminant identification and risk assessment employed, (2) develop more cost-effective monitoring and control methods for routine chemical contaminant surveillance of food, and (3) improve the effectiveness of process optimization for the control of chemical contaminants in food.     

Salmonella in slaughter pigs: the effect of logistic slaughter procedures of pigs on the prevalence of Salmonella in pork

A substantial part of the finishing pigs in the Netherlands is infected with Salmonella. Infection of pigs with Salmonella can occur already on the farm. Pigs can also get infected or contaminated during transport, lairage or slaughter. The aim of this study was to evaluate the effect of separating pigs from Salmonella-infected farms from pigs from Salmonella-free farms during transport, lairage and slaughter on the prevalence of Salmonella on pork after slaughter. Two experiments were carried out. In the first experiment, farms were selected to participate, based on serology of the pigs (Dutch Salmonella ELISA). The pigs were slaughtered at the beginning of the day: firstly, sero-negative herds, secondly, sero-positive herds and thirdly, again sero-negative herds. The latter were slaughtered to investigate the effect of a contaminated slaughterline due to a previously slaughtered positive herd. In the second experiment, farms were selected to participate, based on both serology and bacteriology of the pigs on the farm. Two hundred pigs from Salmonella-free farms were slaughtered after 200 pigs from Salmonella-infected farms. Results showed that the prevalence of Salmonella in pork samples of sero-negative herds was lower than in samples of sero-positive herds. Results also showed that Salmonella contamination of carcasses after slaughter was partially caused by Salmonella-infected herds that were slaughtered before, and partially by residential flora of the slaughterhouse. It is concluded that separate slaughter of sero-negative pig herds can be useful to decrease the prevalence of Salmonella-contaminated pork after slaughter. To avoid cross-contamination by residential flora from trucks, lairage and slaughterline, cleaning and disinfection have to be improved.     

Salmonella in slaughter pigs: prevalence, serotypes and critical control points during slaughter in two slaughterhouses

The purpose of this study was to show the distribution of Salmonella in slaughtered pigs and the environment of the slaughterhouse. 1114 samples of slaughtered pigs (six different samples for Salmonella isolation and one serum sample for ELISA on antibodies per pig) and 477 samples of the slaughterhouse environment were collected in two slaughterhouses on two sampling days per slaughterhouse. Salmonella was isolated from one or more samples of 47% of the pigs. The highest prevalence of Salmonella was observed in rectal content samples (25.6%), whereas the lowest prevalence of Salmonella was observed on the carcasses (1.4%). The prevalence of Salmonella in other samples was: 19.6% in tonsils, 9.3% on livers, 9.3% on tongues, and 9.3% in mesenterial lymphnodes. The prevalence of Salmonella in environmental samples was high in the drain water samples in both slaughterhouses (61%) and on the carcass splitter in one slaughterhouse (33%). Salmonella typhimurium was the most frequently isolated serotype in pig samples and environmental samples in both slaughterhouses: 43% of the Salmonella isolates from pigs and 33% of the Salmonella isolates from the environment was S. typhimurium.

The results of this study show that Salmonella prevalences in pigs differ a lot, depending on which part of the pig is sampled. Not all different samples of the pig will become available for human consumption, but collecting more than one sample per pig showed that Salmonella can be found in almost the whole pig. The result of surface samples of carcass and liver gives information about hygiene during the slaughter process; the result of tonsils, lymphnodes and rectal contents, combined with the serological result, gives information about infection of the pig before the slaughter process (on the farm, during transport or in lairage).

It can be concluded that results of Salmonella isolation of slaughter pigs should always be carefully interpreted, depending on the type of sample that has been collected.     

Development of hazard analysis by critical control points (HACCP) procedures to control organic chemical hazards in the agricultural production of raw food commodities

Hazard Analysis by Critical Control Points (HACCP) is a systematic approach to the identification, assessment, and control of hazards in the food chain. Effective HACCP requires the consideration of all chemical microbiological, and physical hazards. However, current procedures focus primarily on microbiological and physical hazards, while chemical aspects of HACCP have received relatively little attention. In this article we discuss the application of HACCP to organic chemical contaminants and the problems that are likely to be encountered in agriculture. We also present generic templates for the development of organic chemical contaminant HACCP procedures for selected raw food commodities, that is, cereal crops,raw meats, and milk.     

Application of hazard analysis critical control points system for the control of aflatoxins in the Brazilian groundnut‐based food industry

This study was conducted to identify and assess the critical control points (CCPs) in groundnut‐based food production in southern Brazil in order to reduce or eliminate aflatoxin contamination. This methodology has been suggested by the Food and Agriculture Organization (FAO) of the United Nations. Reception of prime matter, groundnut storage, roasting and thermal treatment were the main CCPs identified. Critical factors were the determination of aflatoxin, moisture content and water activity (A_w) during groundnut reception and storage, control of temperature, roasting time and thermal treatment in the groundnut‐based food manufacturing. The critical limit for moisture was 8.2% and 0.6 was established for A_w. In Brazil, the limit for aflatoxins B₁, B₂, G₁ and G₂ has been established at 20 ppb. Temperatures of 180 °C/1 h and 80 °C/40 min were established for roasting and thermal treatment stages of groundnut‐based food, respectively.     

Aerobic plate counts as a measure of hazard analysis critical control point effectiveness in a pork processing plant

A hazard analysis critical control point (HACCP) system was designed to identify specific hazards so that preventive and control measures to ensure the safety of a food could be implemented. Microbiological data generated through sampling were used to characterize the hygienic performance and to validate and verify the various HACCP plans. Aerobic plate counts (APCs) often are chosen as an indicator of the effectiveness of HACCP plans, because data for all aerobic bacteria are more easily collected than are data for pathogens of concern or other indicator organisms. However, it is not clear whether APCs are useful in verifying that a HACCP plan is working satisfactorily. In this study, APC data were collected from one pork-cutting plant in Korea both before and after the company initiated its HACCP plan. These APC data were used to compare microbiological differences and to determine the effect of any changes before and after implementing the HACCP plan. For this pork plant, after the HACCP plan was implemented the proportion of samples exceeding the 3 log CFU/cm2 limit dropped from 73.39 to 4.29% for the overall process. These results indicate that this plant improved its hygienic performance considerably and that the HACCP plan was an effective and valuable tool for achieving this improvement. The APC data were sufficient for validation and verification of the HACCP system that was successfully implemented to improve hygienic performance.     

A comprehensive review of the implementation of hazard analysis critical control point (HACCP) to the production of flour and flour-based products

The production of flour and semolina and their ensuing products, such as bread, cake, spaghetti, noodles, and corn flakes, is of major importance, because these products constitute some of the main ingredients of the human diet. The Hazard Analysis Critical Control Point (HACCP) system aims at ensuring the safety of these products. HACCP has been implemented within the frame of this study on various products of both Asian and European origin; the hazards, critical control limits (CCLs), observation practices, and corrective actions have been summarized in comprehensive tables. Furthermore, the various production steps, packaging included, were thoroughly analyzed, and reference was made to both the traditional and new methodologies in an attempt to pinpoint the occurring differences (advantages and disadvantages) per process.     

鲜湿米粉生产中HACCP关键控制点分析

将HACCP应用于鲜湿米粉的生产过程,是确保鲜湿米粉安全性的有效措施。文章通过对鲜湿米粉制品生产工艺流程进行危害分析,确定原辅料及包装材料接收、浸泡、金属检测、杀菌4个关键控制点,提出鲜湿米粉制品关键控制点的关键限值。     

HACCP在产业化快餐食品生产中的应用研究

针对目前快餐食品的安全性在世界范围内的受到的广泛关注,将危害分析与关键控制点系统(HACCP)应用于产业化快餐食品的生产过程中,分析其潜在危害,确定其生产中的关键控制点、临界值监控程序及纠偏措施,保证快餐食品的安全性,保护人民的身体健康.     

Hazard analysis critical control points implementation in traditional foods: a case study of Tarhana processing

This paper examines the factors, which influence the safety characteristics of Tarhana (Tarhana is a fermented, dried dough product commonly reconstituted and served as a hot soup). Since Tarhana is becoming an important part of the modern diet in many communities. The objectives of this study were to determine food safety practices and procedures related to the hazard analysis critical control point programme. The significant hazards found in hazard analysis were used for determination of risk assessment by five-class hazard score matrix. The study revealed that the Critical Control Points (CCPs) for Tarhana production were cooking, fermentation, drying and sieving. At the same time, critical factors and limits for CCPs were determined. Preventative and corrective actions were proposed.     

西式方火腿加工中危害分析及关键控制点的研究

介绍了西式方火腿加工全过程中HACCP质量控制体系的建立,研究并讨论了其加工过程中HACCP体系的核心部分-危害分析及关键控制点(CCP),同时也对HACCP体系在食品质量控制方面发挥更有效的作用进行了展望,为我国火腿制品的质量安全控制奠定基础.     

Traditional versus hazard analysis and critical control point-based inspection: results from a poultry slaughter project

Federal meat and poultry inspection has changed little since the Federal Meat Inspection Act was passed in 1906, followed by the Poultry Products Inspection Act of 1957 and related amendments. These acts mandate sensory or organoleptic (sight, smell, and touch) inspection of all carcasses. For several decades, the U.S. Department of Agriculture's Food Safety and Inspection Service (FSIS) has been urged by various organizations to move to a scientific, risk-based inspection system. In partial response to these calls, the FSIS has developed new slaughter inspection models that are currently being tested with volunteer plants in the hazard analysis and critical control point (HACCP)-based inspection models project. To evaluate whether plants operating under the new inspection models perform at least as well as they did under the current or traditional system, microbial and organoleptic data are being collected before and after the implementation of the new inspection models. In this article, we describe the baseline and models data collection procedures and present the results of the baseline and models data collection for eight plants that slaughter young chickens. The results from the first eight volunteer plants suggest that inspection under the new models is equivalent and in some ways superior to that of traditional inspection. This pilot project suggests that new slaughter inspection systems, which rely on HACCP principles with FSIS oversight and verification services, can maintain or even improve food safety and other consumer protection conditions relative to traditional hands-on inspection methods.     

猪肉冷链加工与物流微生物危害分析与控制

基于微生物危害分析,测试冷却分割猪肉冷链加工与物流过程的微生物数量和温度分布,明确关键污染环节和物流过程温度波动,建立关键控制点及其控制措施,制定冷却猪肉冷链加工与物流HACCP计划,提出重点改善卫生管理和温度监控措施,使产品微生物数量控制在可接受水平,确保加工流通过程产品质量安全。     

危害分析与关键点控制（HACCP）程序在固态法食醋生产中的应用

本文对危害分析与关键点控制（HACCP）系统进行简单介绍,并对其在固态法食醋生产中的应用加以阐述,分析了危害物质的成因,确定关键点,确立了关键控制点的临介范围以及该系统的各管理要素,其目的是提高产品质量,并保持产品质量的稳定性。     

Application of hazard analysis and critical control point methodology and risk-based grading to consumer food safety surveys

Traditionally, consumer food safety survey responses have been classified as either "right" or "wrong" and food handling practices that are associated with high risk of infection have been treated in the same way as practices with lower risks. In this study, a risk-based method for consumer food safety surveys has been developed, and HACCP (hazard analysis and critical control point) methodology was used for selecting relevant questions. We conducted a nationally representative Web-based survey (n = 2,008), and to fit the self-reported answers we adjusted a risk-based grading system originally developed for observational studies. The results of the survey were analyzed both with the traditional "right" and "wrong" classification and with the risk-based grading system. The results using the two methods were very different. Only 5 of the 10 most frequent food handling violations were among the 10 practices associated with the highest risk. These 10 practices dealt with different aspects of heat treatment (lacking or insufficient), whereas the majority of the most frequent violations involved storing food at room temperature for too long. Use of the risk-based grading system for survey responses gave a more realistic picture of risks associated with domestic food handling practices. The method highlighted important violations and minor errors, which are performed by most people and are not associated with significant risk. Surveys built on a HACCP-based approach with risk-based grading will contribute to a better understanding of domestic food handling practices and will be of great value for targeted information and educational activities.     

HACCP体系在肉牛屠宰及冷却肉加工中的应用

以肉牛屠宰及冷却肉加工为研究对象,根据危害分析与关键控制点系统（hazard analysis and critical control points,HACCP）原理,对牛肉屠宰加工过程中各个环节可能存在的危害进行分析,确立关键控制点、关键限值、监控方法及纠偏措施,构建规范的HACCP质量管理体系,从而有效消除、预防...     

Use of hazard analysis critical control point and alternative treatments in the production of apple cider.

The purpose of this study was to evaluate the practices of Maryland cider producers and determine whether implementing hazard analysis critical control point (HACCP) would reduce the microbial contamination of cider. Cider producers (n = 11) were surveyed to determine existing manufacturing practices and sanitation. A training program was then conducted to inform operators of safety issues, including contamination with Escherichia coli O157:H7, and teach HACCP concepts and principles, sanitation procedures, and good manufacturing practice (GMP). Although all operators used a control strategy from one of the model HACCP plans provided, only one developed a written HACCP plan. None developed specific GMP, sanitation standard operating procedures, or sanitation monitoring records. Six operators changed or added production controls, including the exclusion of windfall apples, sanitizing apples chemically and by hot dip, and cider treatment with UV light or pasteurization. Facility inspections indicated improved sanitation and hazard control but identified ongoing problems. Microbiological evaluation of bottled cider before and after training, in-line apples, pomace, cider, and inoculated apples was conducted. E. coli O157:H7, Salmonella, or Staphylococcus aureus were not found in samples of in-line apple, pomace, and cider, or bottled cider. Generic E. coli was not isolated on in-coming apples but was found in 4 of 32 (13%) in-line samples and 3 of 17 (18%) bottled fresh cider samples, suggesting that E. coli was introduced during in-plant processing. To produce pathogen-free cider, operators must strictly conform to GMP and sanitation procedures in addition to HACCP controls. Controls aimed at preventing or eliminating pathogens on source apples are critical but alone may not be sufficient for product safety.