HACCP in practice

The hazard analysis critical control point system (HACCP) has been evolving in the food industry since it was first deliberated by the First National Food Protection Conference. Small- and medium-sized enterprises (SMEs) are companies with fewer than 500 full-time employees. This article addresses the implementation of HACCP in SMEs, highlighting some of the problems. The problems can be arranged in four groups: insufficient technical resources, concentration of functions, time and financial power. It is the conclusion of this article however, that there are no barriers to the application of HACCP in all food production operations.     

HACCP effectiveness between ISO 22000 certified and non-certified dairy companies

The purpose of the study is to determine the differences between the ISO 22000 certified and non-certified dairy companies with regard to the HACCP (Hazard Analysis Critical Control Points) Food Safety System (FSS) effectiveness. The HACCP FSS effectiveness is defined in the present study as the degree of the achievement of the system objectives (identification, assessment and the control of food borne safety hazards). A research study was carried out in 74 Greek dairy companies using a structured questionnaire. The differences between the ISO 22000 certified and non-certified dairy companies (both implementing HACCP principles) with regard to HACCP effectiveness are determined through non parametric tests such as the Chi-square Test and the Mann–Whitney Test. The vast majority of the participating in the present study dairy companies are small and medium-sized enterprises (SMEs). The ISO 22000 certified dairy companies significantly outperform the non-certified with regard to the HACCP FSS effectiveness, in other words to the degree to which the objectives of HACCP are achieved. Thus, managers of dairy SMEs taking advantage of the structured organization and the documented procedures provided by the ISO 22000 standard can increase the level of achieving the objectives of the HACCP FSS, in other words HACCP effectiveness. In doing so, dairy SMEs can set the foundations in order to optimize the conditions under which safe food is provided, minimize the possibility of food non-conformities and scandals, increase market share and consequently withstand the current downturn.     

An evaluation of process specific information resources,aimed at hazard analysis,in Small and Medium Enterprises in food manufacturing

Food borne illness continues to be a major global concern, with approximately 76 million cases in the US and 70,000 in the UK annually. The adoption of a food safety management system based upon Codex HACCP principles became a legal requirement in the UK on January 1st 2006 but some companies are inexperienced and fail to implement it correctly. Barriers to HACCP include time, money and expertise, particularly for SMEs and microbusinesses. Lack of expertise is a particular problem when constructing the hazard analysis component of HACCP. A sector specific information resource, using simple language with no technical terms or jargon, was developed to assist SMEs with hazard analysis. One hundred and twenty three SME food manufacturers were recruited and intervention and control groups were assigned, with the intervention group receiving the resource. Evaluation visits were performed after four months. Each company was assessed against a specific tool that determined knowledge, behavior and attitude to food safety. The resource was well received but there was no significant improvement in knowledge, behavior or attitude when comparing the intervention and control group scores. Significant differences in the behavior of SMEs and microbusinesses were evident with SMEs scoring higher in all sections of the resource than the microbusinesses. SMEs also had a significantly higher total knowledge score than microbusinesses but there were no significant differences in attitudes. It is apparent action must be taken to assist SMEs with hazard analysis and full HACCP implementation, but provision of a single resource without additional support is not enough.     

Survey on typology,PRPs and HACCP plan in dry fermented sausage sector of Northern Italy

One hundred and fifty four dry fermented sausage small and medium-sized enterprises (SMEs) were visited in Northern Italy, to collect information on building and facilities, production technology and marketing organization. Five businesses, out of 154, were then selected with the aim of analysing their prerequisite programmes (PRPs) and the level of hazard analysis and critical control point (HACCP) system implementation. The results of this survey acknowledge the importance of small enterprises in the dry fermented sausage production sector. This study shows that fully compliance with PRPs and HACCP is far from complete, especially in micro-sized businesses, in spite of derogations for small establishments provided by Italian and European rules. In order to help SMEs to comply with food safety objectives, collaboration with Local Health Unit officers always proves positive for the businesses because they can inform and support enterprises, particularly small food premises.     

A review on food safety and food hygiene studies in Ghana

Food safety and hygiene in Ghana was studied using desk top literature review. Food research was highly concentrated in the capital city of the country and most research focus were on commercial food operations specifically street foods and microbiological safety with limited information from institutional catering and other forms of food hazards. The media currently serves as the main source for reporting of food borne diseases. Food establishments and other sources contributing to food borne diseases included restaurants, food joints, food vendors, schools and individual homes. Limited use of prerequisites measures and food safety management systems was identified. Recommendations on regulating the General Hygiene Principles, implementation of HACCP to strengthen the food sector, regular food safety and hygiene workshops and training for food handlers that commensurate with their roles were made. Government support for SMEs and food handler's health screening were made.     

Implementation of Food Safety Management Systems in small food businesses in Cyprus

EU legislation requires that food businesses in all member states must implement a Food Safety Management System based on HACCP principles. Although manufacturers have used this system successfully for many years it has been less common in small and medium sized enterprises (SMEs), especially those in the food service sector. There are considered to be a number of barriers which small businesses find particularly difficult to overcome. This study assesses the impact of various Food Safety Management Systems in 50 small businesses in Cyprus. It compares food hygiene before, during, and after implementation of the food management systems, assesses the attitude of the Food Business Operators and the hygiene knowledge of the staff. Results show that the maximum improvement came when implementing the pre-requisite programmes and a bespoke HACCP plan but that a deterioration in standards could be identified when using more complex systems such as the CYS 244 standard or ISO 22000. Food Business Operator attitude started positively but became more negative as the complexity of the Food Safety Management System increased.     

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.     

Food quality management system: Reviewing assessment strategies and a feasibility study for European food small and medium-sized enterprises

Literature indicates a need for a user-friendly food quality management system (FQMS) customized to the requirements of food small and medium-sized enterprises (SMEs) for improving product and process quality and enhancing customer satisfaction. Application of quality management system within discreet and process industries is evident. However, there are limited studies that focused on the implementation of a quality management system (QMS) among SMEs operating in the food sector. This study explains the results of a feasibility study on FQMS among European Food SMEs. The objective of this study is to diagnose the status of the FQMS, and to find out what motivates and hinders the successful implementation of FQMS in SMEs. The findings show that none of the food SMEs involved in this study implements FQMS in its true form. The size of the company is a significant factor with respect to quality management implementation, as medium-sized companies were more mature in FQMS implementation compared to their small and micro counterparts. The confectionery, chocolate and meat sectors are more advanced than bakery, packaged fruits and vegetables sectors, with respect to the implementation of quality management tools and techniques. The study revealed that the most important benefits of a quality management system were reduction in cost of production and increased productivity. The key barrier to implementation of FQMS was “lack of knowledge and training” among food SMEs.     

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.     

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     

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.     

Implementation of HACCP and prerequisite programs in food businesses in Turkey

The objectives of this study was to determine food safety practices and procedures related to the hazard analysis critical control point (HACCP) programme and prerequisite programme implementation in food businesses. One hundred and nine food businesses in Turkey were assessed for HACCP-prerequisite programmes and food safety practices. Only eight food businesses had implemented the HACCP system in food businesses. Directors and employees often have insufficient knowledge regarding the basics of food hygiene. Results indicated that proper food safety practices and prerequisite food safety programmes for HACCP were often not being followed in many food businesses. Time and temperature errors and inadequate handwashing practices were wide in the most food businesses. Emphasis on implementing prerequisite programmes in preparation for HACCP is needed in food businesses. The problems of implementing HACCP in food businesses have been namely a low level of food hygiene management training, high staff turnover rate, lack of motivation, lack of financial resources, inadequate equipment and physical conditions of the facility and failure of government.     

Critical factors,food quality management and organizational performance

This paper proposes a model for measuring the effectiveness of quality (ISO 9001) and food safety (HACCP) systems, based on their stated objectives, when these systems are jointly implemented in a food company. In addition, it investigates the critical factors for effective implementation (CFEI) of the ISO 9001 and HACCP systems; and examines the degree to which the combined implementation of ISO 9001 and HACCP influences the overall performance of the certified firms. To achieve these objectives, primary field data was collected through an empirical survey that was conducted among 347 food companies in Greece, which were certified to ISO 9001, HACCP and/or ISO 22000 systems. Initially, Exploratory Factor Analysis (EFA) and then Confirmatory Factor Analysis (CFA) were applied. The connections among the non observed model factors were verified through Structural Equation Modeling (SEM) inspection. The findings suggest that “employee attributes”, “organizations' attributes” and “internal business motives” make a significant contribution to the effective implementation of the ISO 9001 and HACCP systems. In addition, the effective implementation of the ISO 9001 and HACCP systems contribute to the business performance of companies in the Greek food industry. The evidence provided in this study helps managers to realize the importance of CFEI and the effective combined implementation of these systems in order to provide the necessary resources and support and develop the necessary policies, practices and procedures.     

HACCP economics in fish processing plants

This paper is aimed to show in a quantitative way the tech-economic advantages of applying a HACCP-based system in fish processing plants with a focus on the quality costs methodology. Quality costs before and after HACCP implementation at three fish processing plants located in Latin America are analyzed. The problems encountered and the resulting benefits are also described. Some of the findings demonstrate that a HACCP-based system implementation reduces failure costs, improves quality, and allows for better knowledge of production planning and control, showing that in the first years of HACCP implementation, when failure costs are over 80% of TQC, each dollar expended in controllable costs returns more than two dollars in failure savings.     

Effects of HACCP on process hygiene in different types of Serbian food establishments

This paper presents results from a research that analyzed effects of implementing HACCP on process hygiene in food establishments in Serbia. Process hygiene indicators were microbial profiles of 73,428 samples from food contact surfaces, hands of food handlers and cooling facilities collected from 1707 food establishments during a period of seven years. The study covered two periods during the observed period, 41 months before and 43 months after the implementation of the new Food Safety Law in Serbia requiring HACCP. Overall results presented in this paper confirm post-HACCP process hygiene improvement expressed as reduction of at least 0.7 log₁₀ CFU/cm² for food contact surfaces to over 1 log₁₀ CFU/cm² for cooling facilities. Our research confirms that after requiring HACCP, the main differences in process hygiene in respect to food contact surfaces were observed between takeaways (as food establishment with poorest hygiene) and other categories of food establishments. Institutional food services were the best scored establishments. Regarding food handlers' hygiene, results show similar level of hygiene improvements in all types of establishments.     

How to make HACCP really work in practice

A HACCP system that really works in practice will depend on the competency of the people who both developed it and who operate it, and the prerequisite programmes, which support it. If it is to be truly successful then there must be an overriding internal belief in the HACCP approach and what it can do for the business once properly implemented. There are fundamental issues concerning the Training and Education which need to be considered, such as the variable quality of education and training available on a global basis, impinge on the ability of HACCP teams to conduct a Hazard Analysis. Compounded with this is the general weak understanding of the HACCP and prerequisite programme relationship and of the implementation and maintenance phases … on how to make it really happen. These elements are considered against four key stages to the application of HACCP principles.     

Factors influencing HACCP implementation in Taiwanese public hospital kitchens

This study investigated the potential factors which may influence implementation of the HACCP system in hospital catering operations in Taiwan. A total of 132 catering managers and operators at 23 hospitals affiliated with the Department of Health (DOH) participated in the study. Three structured questionnaires were used to collect data concerning employee satisfaction, difficulties, and benefits related to HACCP implementation. The results show that differences in gender, age, and job position are factors that may influence HACCP implementation in Taiwanese hospitals. Most of the catering staff in the observed hospitals agreed that HACCP was very beneficial for hospital catering.     

HACCP “train-in-action” program in the Lithuanian dairy industry

Training in the application of the HACCP method has been performed in the Lithuanian dairy industry, in the frame of a technical assistance project financed by the European Commission (PHARE Programme).The guidelines adopted by the Codex Alimentarius Commission for the application of the HACCP method (Hazard Analysis and Critical Control Point (HACCP) System and Guidelines for its application, Annex to CAC/RCP 1-1969, Rev. 3 (1997a), Codex Alimentarius, Supplement to vol. 1B , General Requirement (Food Hygiene).), the specific training package prepared by FAO for this purpose (Rome, 1997) and the EU directives (93/43/EEC–92/46 EEC–94/71 EEC) have been used as reference for the preparation and implementation of training activities.The programme was organised in two main phases with different and complementary training approaches. After a 4-day intensive training session on food hygiene and HACCP held for all recipients at a training centre, the project team visited each of the 10 dairy plants selected by the Lithuanian Government, to provide on-site & on-the-job training to concerned factory and government staff. Each plant was visited at least twice. First, by teams of foreign and local experts during 2–3 days. Second, by local experts only, in order to provide an additional 2–3 days input on HACCP application.The first phase (training session) was a useful preparatory exercise, but the “on-site sessions” showed that in depth understanding of the HACCP method could be better achieved through such approaches. Exercising at plant level, on practical cases, with the process lines within reach, made it possible to overcome several barriers to the transmission of information. This approach in which foreign and local experts interact during training, was also an opportunity for the recipients to understand how to comply more precisely with the national and international standards for food hygiene.     

HACCP-based procedures in Germany and Poland

A study concerning HACCP implementation was conducted in 86 German and 66 Polish food enterprises. The questions asked in this study addressed HACCP implementation according to the 12 steps defined by Codex Alimentarius Commission. Some deficiencies were identified. As the results show, the specification of biological hazards is frequently not sufficient to provide suitable guidance mechanisms, and to monitor the limits, and therefore, they are not in compliance with Codex Alimentarius and Regulation (EC) No 852/2004. Furthermore, a lack of consistence in defining terms (e.g. CP) leads to their diverging application in practice. Overall, the HACCP implementation in Poland was found to comply somewhat better with the Codex Alimentarius principles and Regulation (EC) No 852/2004 than in Germany.     

Barriers for the developing and implementation of HACCP plans: results from a Spanish regional survey

Despite the fact of compulsory HACCP plan in the regulations, their development and implementation is being difficult and slow. This paper present a survey in an area of Madrid to identify the barriers which are obstructing the implementation of HACCP programs in food companies, following the model of eleven potential barriers organised around three levels proposed by Gillings et al. [J. Food Protect. 64(5) (2001) 710]. The results suggested that lack of understanding and negative guideline factors conduce to inadequate hazard analysis, and this is not solved contacting external advisers. There are also problems at attitude level which obstruct the change of behaviour.It is suggested that regulatory agencies should work to publish clear and detailed HACCP guides in Spanish and to promote activities aimed to external consultants and industry managers and directives.