Incorporating HACCP into national food control systems - Analyzing progress in the United Arab Emirates

Today governments and other parties involved in food control are under constant pressure to find more efficient and effective mechanisms to carry out their mandates for food control. This has led to international recognition of the importance of the HACCP system as a food control tool and guidance on the role of government agencies in the application of such a system has been developed. Based on this international guidance, four main elements identified as key activities have been used in this study to evaluate the progress of HACCP implementation in the UAE. The internal Strengths and Weaknesses, as well as the external Opportunities and Threats that the government is facing towards the implementation of a HACCP-based food control system have been identified. The analysis shows that the government’s dedicated role has been an essential driving force to encourage the implementation of a HACCP-based food control system. Some areas of difficulty, including the dependence on high levels of food imports, are highlighted.     

HACCP-based program for on-farm food safety for pig production in Australia

The standard Codex HACCP approach was modified to allow a hazard analysis and critical control point determination to be conducted at an industry level and then used to determine the appropriate on-farm food safety control measures for pig production in Australia. A detailed risk-based profile with hazard identification, hazard characterisation and levels of microbial contamination for production and primary processing was used as a major technical resource to inform HACCP determinations. The process resulted in the identification of Critical Control Points for control of a specific physical hazard (non-recovered broken needles) and prevention of violations of Maximum Residue Limits with agricultural and veterinary chemicals. In relation to the identified microbiological hazards, it was noted that there are numerous Good Agricultural Practices (GAP) to prevent and/or reduce their risk and these controls would also need to be a feature of any on-farm food safety program. By applying a HACCP-based approach it was determined that the application of a set of Good Agricultural Practices on-farm would be effective in ensuring low risk. It was, therefore, concluded that on-farm food safety programs may not warrant full (i.e. Codex compliant) HACCP plans at the individual enterprise level provided appropriate GAP is in place. The results provide pig producers and the Australian pig industry with the elements of a HACCP-based food safety system that are scientifically justifiable, understandable and realistic to apply. These features are essential elements that underpin successful implementation and compliance by industry.     

The role of government agencies in assessing HACCP

There is worldwide evaluation and reorganization of food inspection and control systems geared towards improving efficiencies, rationalizing human resources and introducing risk analysis-based approaches. The HACCP principles play a pivotal role in these preventive approaches. Their application is a responsibility of the food industry, whereas government control agencies are responsible for monitoring and assessing their proper implementation. This paper reviews some of the issues pertinent to HACCP assessment, namely its purpose, activities involved, frequency of assessment, HACCP approval/certification, qualifications and training of assessors. It is based on the experience of the author in training and assisting industry and government agencies in implementing HACCP-based quality systems, especially in developing countries, where food export has a major impact on the national economies.     

HACCP development and regulatory assessment in the United States of America

Hazard Analysis Critical Control Point (HACCP) is internationally recognized as the best method of assuring product safety by controlling foodborne safety hazards. Currently, within the USA, the FDA has mandated HACCP for fish and fishery products and is proposing mandating HACCP for fruit and vegetable juices. The USDA has mandated Pathogen Reduction/HACCP requirements for meat and poultry processing, and the NMFS Seafood Inspection Program operates a voluntary HACCP program for seafood plants. The requirements for mandatory implementation and proposed regulations represent a significant change in the manner in which foods are regulated for food safety and necessitate a new understanding of the different roles and responsibilities between the food industries and the regulatory agencies within the USA. Each agency will approach the evaluation process differently given their unique legislative authorities and programmatic operations. Nevertheless, each agency agrees that HACCP is the best food control system of choice and is committed to improve food safety requirements.     

Actual situation in the area of implementing quality assurance systems GMP,GHP and HACCP in Polish food production and processing plants

The survey was carried out in 16 provinces of Poland. Its objective was to collect information on the actual situation in the area of implementing Good Manufacture Practice (GMP), Good Hygiene Practice (GHP) and Hazard Analysis and Critical Control Point (HACCP) in food production and processing plants. The survey demonstrated that 91% of the surveyed plants are familiar with GHP rules and 95% with HACCP. 34% of the plants have already implemented the system, 35% are in the process of implementing it, 28% are thinking of its adoption and 3% do not intend to implement the system as long as possible. The advancement of the surveyed plants in GMP, GHP and HACCP implementation can be regarded as satisfactory.     

Role of government in HACCP audit: a Cuban perspective

Since 1992 the Ministry of Fishery Industry (MIP) through its Quality Assurance Directorate (DAC) began HACCP implementation works as a basis of its Quality Management System, meeting in this way requirements of its major importers and tailoring to changes in inspection and quality control activities that were taking part worldwide.According to the Minister's Resolution No. 344/1996, HACCP is mandatory for all activities carried out by all entities of MIP, whose activity is related to the manufacturing of fish products from catching operations to its placing in the market.HACCP assessment in fishery establishment is performed in different ways:

• •Submission of HACCP-based Quality Assurance Program (QAP) to DAC for validation. This draft of QAP is revised and returned with suggestions and remarks for its redrafting and new submission.
• •Supervisions performed by DAC and National Fishery Inspection Office (ONIP) specialists to end products, manufacturing process' stages and facilities to verify the compliance of regulations, procedures, cleaning and sanitizing procedures and quality specifications standards.
• •Verifications by means of microbiological, physical, chemical and sensory testing to end products at the reference laboratory requested by DAC
• •Cost/profit assessment of HACCP implementation in fishery establishments with the utilization of Prevention–Appraisal–Failure Model (PAF), according to a procedure developed at the `FAO's Economical Engineering Workshop applied to Fishery Industry, March 1997'.
• •As on January 1998, regulatory audits to HACCP-based QAPs began to be performed in fishery establishments, verifying compliance of applicable documentation (Quality Assurance Programs; Cleaning and Sanitizing Procedures, Working Operational Procedures, and so forth) using the `General Procedure for HACCP Audit's performance in fishery establishments' with a group of auditors made up by DAC specialists and ONIP officer inspectors.

For the development of these activities in force up to date, we relied on the collaboration and consultancy of FAO/DANIDA GCP/INT/609/DEN Project in national courses, exchange of experience exchange and training with Inspection and Quality Assurance Bodies of other countries and as a multiplying effect of these activities, the consultancy and training carried out by experts from DAC of MIP to inspectors and industry's technical staff.     

Effectiveness and performance of HACCP-based programs

Since the early 1990’s, HACCP-based programs are being implemented as a means of preventing food hazards in fish and seafood products. From an engineering perspective, a system designed to control a manufacturing process is expected to result in final product that consistently meet requirements. Although audits are used to verify program implementation, there is a need for some product monitoring to measure the effectiveness and performance of the control systems. This paper discusses the need to monitor final product in seafood HACCP-based programs to measure effectiveness from a systems approach. Information time series of audits and inspections conducted are shown to be more indicative of program performance than snapshot inspections of the final product.     

Comparison of implementing HACCP systems of exporter Mexican and Chinese meat enterprises

International trade scrutinises food safety practices and procedures, and food businesses have to review their safety procedures more rigorously. HACCP is increasingly relied on to ensure food safety in both meat-producing and meat-processing enterprises. The objective of this study was to compare incentives, costs, difficulties and benefits of Chinese and Mexican meat-exporting enterprises related to food safety management systems implementation. A questionnaire was applied to identify the main factors involved in HACCP implementation. Data were collected among 32 Chinese and 42 Mexican companies, and analysed using the SAS package. The implementation of the HACCP system was filled out in all exporting meat industries. The results indicated that the major incentives were related to improving product quality for both countries, whilst improving control of the process was the first motivation in the Chinese industry and access to new foreign markets was the first motivation in the Mexican one. In addition, both countries' industries reported that staff training was the most important implementing cost, while product testing was the major operating cost. The difficulties found during HACCP implementation and operation activities were associated with availability of personnel for other tasks for China and costs of certification for Mexico. The reported benefits were relevant for the two countries, due to the ability to reduce microbial counts and increased access to foreign and domestic markets. A better understanding of the costs and benefits associated with HACCP systems could be helpful and is necessary in every segment of the food chain in every sector of domestic and international markets in order to assure food quality and safety.     

Bacteriological quality and histamine-forming bacteria associated with fish meats and environments in HACCP and non-HACCP fish processing factories

Twenty fish meats and 21 environmental surface samples obtained from a Hazard Analysis Critical Control Points (HACCP) fish processing factory and two non-HACCP fish processing factories in Pingtung, southern Taiwan were tested to determine the hygienic quality and histamine-forming bacteria. The levels of aerobic plate count (APC), total volatile basic nitrogen and total coliform in fish samples obtained from the HACCP factory were significantly lower than those of fish samples obtained from the two non-HACCP factories. The average content of the eight biogenic amines in HACCP fish samples was less than 1.0 mg/100 g, while that in non-HACCP fish samples was less than 1.5 mg/100 g. In environmental surface samples, the average levels of ATP bioluminescence and APC (swabbing method) of HACCP processing factory were significantly (P < 0.05) lower than those of non-HACCP processing factories. Fifteen histamine-forming bacterial strains isolated from fish meats and environmental samples producing 2.3–561.5 ppm of histamine in trypticase soy broth supplemented with 1.0% l-histidine (TSBH), belonged to Enterobacteriaceae (thirteen strains) and Staphylococcus spp. (two strains).     

HACCP-based approach to the derivation of an on-farm food safety program for the Australian red meat industry

The standard Codex HACCP approach was modified to allow a hazard analysis to be conducted at an industry level which could then be used to derive appropriate on-farm food safety control measures for cattle, sheep and goat production in Australia. Scientific information from a through chain risk profile of the red meat industry was used as a major resource for the hazard analysis. The process resulted in the identification of critical control points for control of bovine spongioform encephalopathy (BSE), prevention of violations of maximum residue limits with agricultural and veterinary chemicals and infection with Cysticercus bovis (Beef Measles). By applying this HACCP-based approach it was determined that the application of a simple set of good agricultural practices (GAP) on-farm would be effective in ensuring low risk. It was, therefore, concluded that on-farm food safety schemes may not warrant full HACCP plans at the individual enterprise level as long as appropriate GAP is in place. The results provide red meat producers with the elements of a HACCP-based food safety scheme that is scientifically justifiable, understandable and realistic to apply which are essential elements that underpin successful implementation and compliance by industry. Subsequently, an on-farm food safety program has been developed to provide an appropriate level of protection for consumers as well as to protect Australia’s trade from food safety-related issues.     

Application of hazard analysis critical control points (HACCP) system to vacuum-packed sauced pork in Chinese food corporations

Our study aims to establish an HACCP system which was implemented for the quality assurance of vacuum-packed sauced pork processing in Chinese food corporations. After identified hazards, the critical control points were defined using a decision tree. In addition, the vacuum-packed sauced pork products, manufactured by three corporations, were detected for chemical and microbial contaminants before and after the implementation of the HACCP system, respectively. According to the national food hygiene standards accepted by PR China, for nitrite, aerobic plate count and coliforms, the percentage of products obtained before vs. after the implementation of HACCP satisfying the standards was 86.2% vs. 100%, 71.3% vs. 96.4% and 71.3% vs. 95.5%, respectively. In conclusion, the contaminants of vacuum-packed sauced pork can be reduced or eliminated if an HACCP system is applied effectively.     

HACCP implementation in the Thai fisheries industry

As the implementation of HACCP is making headways in food safety management systems of fishery industry in Thailand, the role of the department of Fisheries is also changing. In addition to the inspection for compliance to GMPs, other regulatory requirements, the fish inspectors have to assume new responsibilities and these include validation and verification of the HACCP plan and implementation of the HACCP system.     

The role of the Canadian government agency in assessing HACCP

In Canada, two food inspection programs have developed to embody internationally recognized principles of safe food processing. The Food Safety Enhancement Program (FSEP) is for establishments registered under the Meat Inspection Act and the Canada Agricultural Products Act, while the Quality Management Program (QMP) is for federally registered fish processing establishments. Both FSEP and QMP are fully compatible with the international HACCP guidelines adopted by Codex alimentarius. Under both QMP and FSEP initiatives, food manufacturers are responsible for the development, implementation and maintenance of HACCP food safety systems. The CFIA is responsible for verifying or auditing that industry operates acceptable systems.     

Cost–benefit analysis of HACCP implementation in the Mexican meat industry

This paper reports the levels of HACCP implementation, costs of implementation and operation, and benefits of implementation for the Mexican meat industry. One hundred and sixty Federal Inspection Type (TIF) enterprises were surveyed, with a 58% response rate. Only 18% of the TIF enterprises interviewed had totally adopted HACCP, while 20% did not have an interest in adoption. The norm of ISO 9000 appeared to be an intermediate step in HACCP implementation. The results show that investment in new equipment and microbiological tests of products accounted for most of the implementation and operational costs, respectively. The main benefit reported was reduction in microbial counts, while staff training was reported as a significant problem. The study shows that although the level of total HACCP implementation is not high, HACCP has implications for both the domestic and international markets.     

The HACCP system implementation in small businesses of Madrid’s community

The main goal of this paper is addressed to evaluate the HACCP system implementation in small food industries of Madrid’s autonomous community. Important practical barriers about HACCP development have been identified. There were investigated the manufacturing food industries of animal origin during 5 years, between 1999 and 2003. The research analyzed areas concerning business demand, legal requirements and quality management systems, food industry size, human resources, technical support and assessors, prerequisites, time scale and HACCP implementation official assessment. Conclusions have met the beginning of HACCP system implementation by food industries following the application of a strategic plan and public health program, as well as several difficulties in small food industries with regard to HACCP system applying, and the fundamental influence of prerequisites implementation and management commitment on effective HACCP system. To overcome such barriers, it is proposed a strategy, which includes all different stakeholders.     

Costs and investments of implementing and maintaining HACCP in a pasteurized milk plant

Results of an economic study associated with the implementation and maintenance of HACCP in a pasteurized milk plant are presented. The GMP/SSOP pre-requisites were evaluated in the plant. Two HACCP plans were proposed: a first plan was developed under the actual operating conditions, without previous compliance of GMP/SSOP pre-requisites, and a second plan was developed considering compliance of GMP/SSOP. The cost estimation for implementation and maintenance of HACCP, with or without previous adoption of the pre-requisite programs, was performed and a comparative analysis of the estimated values was carried out. The results suggest that a previous compliance of GMP/SSOP pre-requisites is essential for developing an effective HACCP plan with a small number of critical control points, leading to lower costs and investments for implementation and maintenance of HACCP.     

Semi-quantitative study to evaluate the performance of a HACCP-based food safety management system in Japanese milk processing plants

This study aimed to gain an insight in the performance of Hazard Analysis and Critical Control Points (HACCP)-based food safety management systems (FSMS) implemented in Japanese milk processing plants. Since 1995, Japan has a comprehensive approval system for food manufacturing establishments by evaluating the development and implementation of GHP and HACCP by the food manufacturing companies/operators. An FSMS-diagnostic instrument was applied to assess the level of the core control and assurance activities in the FSMS and to judge the risk level of the context wherein the companies operate. The data were collected in 13 dairy companies (mostly located around Tokyo area) and involved in-depth interviews performed (by the National Institute of Public Health) with responsible quality assurance persons of respective companies.The results revealed that the microbial food safety output was higher for companies with national HACCP approval. They have more advanced FSMS in combination with a less risky context. All Japanese companies scored high on technology-dependent activities (i.e. preventive measures and intervention processes), but less in managerial activities as monitoring and typical quality assurance activities as validation and verification of the FSMS. Japan has a detailed vertical legislation, leading to a “hazard-based” and ”legislation-based” FSMS compared to a “science- or risk-based” FSMS common in Europe.     

Pre-requisites: a help or a hindrance to HACCP?

Formal pre-requisite programmes are increasingly and successfully used to support the implementation of HACCP in food processing. However, in many areas there is a lack of understanding of the pre-requisites concept, and even a fear in some sectors that pre-requisites might dilute the strength of HACCP, making it a less effective food safety control mechanism. This paper explores the concept of pre-requisite programmes and discusses whether they are of benefit to the HACCP approach or whether food safety is best managed through the HACCP plan alone, concluding that they are an essential element in the task of developing simple, effective HACCP systems     

Implementation of HACCP to large scale production line of Greek ouzo and brandy: a case study

The advanced technology of high speed operations and the large scale of incoming materials and components used for food and drink production often cause hazards for the product safety. These hazards can hardly be controlled by the use of classical quality control methods. The most secure and cost-effective method for controlling the possible product contamination or cross contamination, due to physical or chemical hazard during the production is the implementation of the Hazard Analysis of Critical Control Points (HACCP system), particularly, if the latter is a part of a total quality system (TQS). The following case study on the application of HACCP to ouzo and brandy production demonstrates how the hazards at the 6 Critical Control Points (CCPs) of the process are easily and effectively controlled through the implementation of HACCP.     

Seafood safety and quality: An analysis of the supply chain in the Sultanate of Oman

The globalization of trade in fish has created many challenges for the developing world specifically with regard to food safety and quality. International organisations have established a good basis for standards in international trade. Whilst these requirements are frequently embraced by the major importers (such as Japan, the EU and the USA), they often impose additional safety requirements and regularly identify batches which fail to meet their strict standards. Creating an effective national seafood control system which meets both the internal national needs as well the requirements for the export market can be challenging. Many countries adopt a dual system where seafood products for the major export markets are subject to tight control whilst the majority of the products (whether for the local market or for more regional trade) are less tightly controlled. With regional liberalization also occurring, deciding on appropriate controls is complex. In the Sultanate of Oman, fisheries production is one of the countries' chief sources of economic revenue after oil production and is a major source of the national food supply. In this paper the structure of the fish supply chain has been analysed and highlighted the different routes operating for the different markets. Although much of the fish are consumed within Oman, there is a major export trade to the local regional markets. Much smaller quantities meet the more stringent standards imposed by the major importing countries and exports to these are limited. The paper has considered the development of the Omani fish control system including the key legislative documents and the administrative structures that have been developed. Establishing modern controls which satisfy the demands of the major importers is possible but places additional costs on businesses. Enhanced controls such as HACCP and other management standards are required but can be difficult to justify when alternative markets do not specify these. These enhanced controls do however provide additional consumer protection and can bring benefits to local consumers. The Omani government is attempting to upgrade the system of controls and has made tremendous progress toward the implementation of HACCP and introducing enhanced management systems into its industrial sector. The existence of strengthened legislative and government support, including subsidies, has encouraged some businesses to implement HACCP. The current control systems have been reviewed and an SWOT analysis approach used to identify key factors for their future development. The study shows that seafood products in the supply chain are often exposed to lengthy handling and distribution process before reaching the consumers, a typical issue faced by many developing countries. As seafood products are often perishable, they safety is compromised if not adequately controlled. The enforcement of current food safety laws in the Sultanate of Oman is shared across various government agencies. Consequently, there is a need to harmonize all regulatory requirements, enhancing the domestic food protection and to continue to work towards a fully risk-based approach in order to compete successfully in the global market.