HACCP – The difficulty with Hazard Analysis

HACCP is a key element of modern food safety management practice such that design, implementation, control and management of HACCP systems are crucial to the production of safe food products. Whilst it is widely accepted that food companies should apply HACCP, understanding of the factors impacting successful HACCP application is limited and this knowledge is important to the delivery of systems that will control all relevant food safety hazards. HACCP principle 1, Conduct a Hazard Analysis, forms a central pillar of any HACCP plan since hazards need to be identified, analysed and understood before effective control measures can be specified. However limited guidance is available to HACCP teams on exactly how to approach the application of this principle. This paper discusses an investigation into the application of HACCP principle 1 by HACCP teams operating within manufacturing sites of a multinational food company. Using a combination of HACCP knowledge testing and HACCP plan assessment, the study identified weaknesses in knowledge of significant hazard identification and errors in the hazard analysis process, including errors in application of structured risk evaluation methods. Findings suggest that this is an area of difficulty for HACCP teams and that further detailed guidance in the application of this HACCP principle is urgently needed.     

Trapping the food safety performance of a small or medium-sized food company using a risk-based model. The HYGRAM system

The requirements of implementing Hazard Analysis and Critical Control Points (HACCP) principles in food production are increasing. A practical risk quantification model, HYGRAM, was developed for small and medium-sized enterprises to meet this challenge. The model makes the user familiar with the HACCP principles by software-assisted guidance through the procedure, connecting special microbiological hazards, good hygiene practice, and other prerequisite programs to HACCP. HYGRAM is a tool to analyze and quantify risks of different processes, and to compare them. It is developed to relieve enterprises with limited resources in confirming the food safety of their production.     

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.     

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.     

HACCP methodology implementation of meat pâté hazard analysis in pork butchery

This paper sets out a bacterial hazard analysis methodology, based on the ISO 22000 standard, which could be adopted by small food manufacturers. The paper provides a practical example: meat pâté prepared by pork butchers. The results of the hazard analysis showed that many bacterial hazards, particularly Listeria monocytogenes, Salmonella and Staphylococcus aureus could be effectively controlled by good hygiene practices. For three microbial hazards – Bacillus cereus, Clostridium botulinum and Clostridium perfringens – specific control measures must be implemented. Hazard analysis provided the necessary basis for a rational choice of these specific control measures.     

HACCP system – hazard analysis and assessment,based on ISO 22000:2005 methodology

Food Safety is a fundamental public health concern, and achieving a safe supply poses major challenges for organisations involved in the food chain. A vide number of food borne hazards, both familiar and new, pose risks to health and obstructions to international trade in foods. These hazards must be properly analysed, assessed and managed to meet growing and increasingly complex sets of global food chain. Proper implementation of food hygiene principles across the food chain in conjunction with Hazard Analysis and Critical Control Point System will ensure food safety. To achieve this, a procedure for hazard analysis and assessment based on ISO 22000:2005 methodology has been developed. The hazard assessment, selection and assessment of control measures, Operational prerequisite programme Plan and HACCP Plan have been summarized in comprehensive tables.     

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.     

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.     

Hazard analysis in hygienic engineering

Hygienic engineering is an essential part of any microbiological quality assurance system, designed to produce foods which will not cause foodborne diseases. Hazard analysis will automatically lead to the determination of critical control points where growth of, survival of or contamination with microorganisms can occur. Hygienic engineering should lead to the elimination of these points, or, if this cannot be achieved, engineering should create conditions which will allow these points to be kept under control. For hazard analysis, some basic knowledge about the behaviour of microorganisms is needed in order to understand some general rules that apply in most situations where product safety has to be built in. More expertise may be needed to estimate the severity and the likelihood of occurrence of specific hazards in a given production line. Teamwork between engineers, hygienists, food technologists and microbiologists is essential to assure safety. Hazard analysis should be carried out systematically for all new factory projects, line extensions, changes in lines, new products etc., in order to be effective. Some examples are given to illustrate the HACCP concept and how to carry out hazard analysis.     

Microbiological safety evaluations and recommendations on fresh produce

In 1995, the National Advisory Committee on Microbiological Criteria for Foods (Committee) was asked to investigate and characterize the association between cases for foodborne illness and fresh produce. The Committee was asked to provide recommendations that could be employed to reduce the risk of foodborne outbreaks associated with these commodities. In furtherance of this assignment, the Committee reviewed current epidemiologic data, the microbial ecology of the outbreak-associated organisms, and considered the current industry practices used for growing, harvesting, packing and distribution. An evaluation of these data provided a basis for hazard identification and the development of related control measures.

The Committee has developed seven specific recommendations: Good Agricultural Practices (GAP) and Good Manufacturing Practices (GMP) should be developed that will provide guidance on those agricultural and processing steps that can reduce pathogen levels on fresh produce. While Hazard Analysis Critical Control Point Programs (HACCP) would be likely to provide the greatest assurance of the safety of these products, there are presently insufficient data upon which to develop such progams. Proactive and practical education programs are needed at all steps in the process, i.e., from the field to the consumer's plate. Additional data are needed to conduct effective risk assessments of the microbial hazards associated with fresh produce. Better product identification and tracing systems are needed for outbreak investigations. Research must be conducted to fill some of the current knowledge gaps in order that improved intervention strategies can be employed. Steps should be taken to ‘streamline’ approval processes for new technologies that will reduce/eliminate microbial hazards.     

A working procedure for identifying emerging food safety issues at an early stage: Implications for European and international risk management practices

There is a need for early identification of emerging food safety issues in order to prevent them from developing into health risks. In this paper, various existing methods and procedures which can be used for early identification of safety issues are reviewed, including the monitoring of the occurrence of specific hazards within the food supply, or the incidences of food-borne diseases, as well as the combination of these data with other data or with expert opinions. Some methods, including hazard analysis critical control points (HACCP), operate pro-actively by pre-defining indicators for hazards and follow-up measures. Vulnerability assessment focuses on potential weak spots within the food supply, whilst futures research employs foresight to enhance preparedness for future hazards and risks. A Delphi survey on food safety risk analysis conducted among professionals revealed concerns with various aspects of current procedures for dealing with emerging issues, and these are discussed. The Delphi respondents also attached great value to the involvement of stakeholders and the inclusion of a broader range of data into risk analysis. Indeed, holistic systems employing indicators from outside the food production chain are now being developed. In conclusion, a four-step procedure for the early identification of emerging issues is proposed.     

The effect of applying GMP and HACCP to traditional food processing at a semi-commercial kenkey production plant in Ghana

To manage the hazards, aflatoxins and enteric pathogens, associated with the production of an indigenous African fermented maize product, kenkey, HACCP was implemented at a semi-commercial kenkey production plant in Accra. As a prerequisite programme, the facility was upgraded and GMP implemented before HACCP. The effectiveness of GMP and HACCP was assessed by monitoring the environment and kenkey production, as well as the auditing and verification of HACCP. Air sampling and swapping of equipment surfaces revealed a microbiota which was consistent with the fermented product. Monitoring showed that the raw materials, products, processing parameters, etc, conformed to the critical limits within which the safety of the food product would be ensured. This was confirmed by the results of laboratory analysis of raw materials, intermediary and final products. Escherichia coli, Staphylococcus aureus, Enterococcus, Salmonella, Bacillus cereus, and Vibro cholera were not detected in any of the finished products and the level of total aflatoxins in the kenkey samples were between 17.2 and 14.5 μg/kg. Levels of aflatoxins in kenkey samples reported at the plant before implementation of GMP and HACCP were between 64.1 and 196 μg/kg. Application of GMP and HACCP was therefore found to be effective as a quality management system for assuring the safety of kenkey in the traditional processing of maize into kenkey.     

Water reuse in a shrimp processing line: Safety considerations using a HACCP approach

The large consumption of water involved in food manufacturing is prompting food processors to optimise the use. Treating and reusing or recycling water within the food plant results in substantial reduction of water use and wastewater production and discharge. If implemented, water reuse should be integrated into existing HACCP programs, and HACCP plans specifically addressed to the actual reuse should be elaborated. This paper evaluates the microbiological safety issues associated with water recycling during the production of shrimps (Pandalus borealis) in brine, and it indicates how the hazards may be effectively controlled using a HACCP approach. Following these procedures, process water recovered from peeling during shrimp processing and treated by means of reverse osmosis could be recycled within the same food unit operation.     

HACCP-based food quality control and rapid detection methods for microorganisms

Foodborne disease is one of the most widespread problems of the contemporary world. Numerous microbiological hazards and risks are associated with different areas of the food industry. The Hazard Analysis Critical Control Point (HACCP) concept is a systematic approach to ensuring food safety. The implementation of an HACCP system is closely connected with microbiological quality control. Rapid microbiological methods are being extensively developed. The methods are based on several different principles of direct or indirect detection of microbes. In the HACCP system, these methods can be used when the system is developed, implemented and maintained. Successful combination of the HACCP programme and rapid microbiological methods may help the industry to find new ways of obtaining reliable results more efficiently and of ensuring food safety.     

Integrating statistical process control to monitor and improve carcasses quality in a poultry slaughterhouse implementing a HACCP system

In meat slaughterhouses, the enumeration of certain microorganisms as microbiological quality indicators is very important for verifying effectiveness of the Good Hygiene Practices (GHP) and Hazard Analysis Critical Control Points (HACCP) systems. Microbiological testing of final products as part of the HACCP verifying process may provide information that a process is in control. The aim of this work was to exploit the data from a poultry slaughterhouse implementing HACCP and demonstrate an alternative approach to the conventional statistical analysis using the principles of the Six Sigma quality. The data collected on Total Viable, Total Coliforms and Staphylococcus aureus counts were used to construct control charts (X bar–R control chart) and perform process capability analysis. Based on X bar–R control charts, the process was in a statistical control state but this before its automation was not capable since process capability and process performance indices were below 1.00, indicating the production of poultry carcasses with poor microbiological quality. After process automation, the indices were much higher than 2.00, indicating that the process was capable of producing poultry carcasses within the specification limits.     

Application of hazard analysis – Critical control point (HACCP) principles to primary production: What is feasible and desirable?

We show that the HACCP system is not fully applicable at the primary production level, and that food safety is obtained through the careful implementation of good hygiene practice (GHP) at the farm. Guides to GHP intended at primary productions cover one activity, such as cattle rearing or corn production. Yet most farms have more than one activity. Hazards from one activity can be transferred to another activity, and in general this is not considered in one-activity guides. There is a need therefore for farmers to be able to detect and control such transfers. We suggest a horizontal complement to the Guides to GHP that would consider only the application of the Step 6 and Principle 1 of the HACCP system amended as follows: “List all potential hazards transferred from one activity to another activity within the farm, conduct a hazard analysis, and consider any measures to control identified hazards”. An outline in two parts is proposed. The first part would help at checking if all generic GHP are in place; the second part would help at disclosing interactions between farm specific activities. Detected hazard transfers could then be controlled with measures that are already described in existing guides. The horizontal complement would benefit from being drafted at the European Community level.     

Principles for the establishment of microbiological food safety objectives and related control measures

The ICMSF has recommended several steps for the management of microbiological hazards in foods in international trade, applying existing Codex documents in a logical sequence. The steps include: the conduct of a risk assessment and an assessment of risk mnanagement options, the establishment of a food safety objective (FSO), and confirmation that the FSO is achievable by application of GHP and HACCP. A FSO is a statement of the frequency or maximum concentration of a microbiological hazard in a food considered acceptable for consumer protection. FSOs can be used by risk managers to communicate to industries this acceptable level of a hazard, in order to establish effective control measures. The effectiveness of control measures is assured through adhering to performance criteria and process criteria set by the industry to meet the FSO. This system of food safety management will facilitate acceptance of seemingly different, but in reality equivalent, food production and food control practices.     

European alerting and monitoring data as inputs for the risk assessment of microbiological and chemical hazards in spices and herbs

Food chains are susceptible to contaminations from food-borne hazards, including pathogens and chemical contaminants. An assessment of the potential product-hazard combinations can be supported by using multiple data sources. The objective of this study was to identify the main trends of food safety hazards in the European spice and herb chain, and then, evaluate how the data sources can be used during each step of a microbiological and a toxicological risk assessment. Thereafter, the possibilities and limitations of the selected data sources for the risk assessment of certain hazards in spices and herbs are examined. European governmental alerting and monitoring data and legislation were examined and evaluated for particular product-hazard combinations. Pathogenic microorganisms, particularly Salmonella spp. and pathogenic Bacillus spp., were identified as a potential concern in black pepper and dried herbs, while mycotoxins like aflatoxin (B₁) and ochratoxin A were a probable concern in chilies (including chili powder and cayenne), paprika, and nutmeg. Evaluating multiple, accessible, data sources can support several steps during the risk assessment process as seen for the hazard identification step. Therefore, identifying the potential spice and herb food safety hazards in the chain and other specific data can support risk assessors in compiling a comprehensive risk assessment.     

A generic model for evaluating consumer food safety behaviour

This paper presents a detailed approach that can be used to evaluate the food safety behaviour of consumers. The preparation of a chicken and mushroom meal is used as a model. Hazard analyses were conducted and an audit hazard check-list compiled. A standard measure of hygienic food handling behaviour, a food operation risk (FOR) score, was devised, tested and refined. Additionally, a food safety risk (FSR) score, indicating the degree of likely risk to the consumer was developed. Early results indicate that these techniques are suitable for investigating the food safety behaviour of a larger sample of consumers with a range of home-produced food products. It will be useful to those involved in hygiene auditing and intervention and could benefit small scale caterers attempting to develop HACCP plans for their 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.