Lecture s until visa exam Quality In manufacturing a measure of excellence or a state of being free from defects deficiencies and significant variations It is brought ID: 931945
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Slide1
Food Quality AssuranceFE 425
Lecture
s
until
visa
exam
Slide2Quality
In manufacturing, a measure of excellence or a state
of
being
free from defects, deficiencies and significant variations. It
is
brought
about by strict and consistent commitment to
certain
standards
that achieve uniformity of a product in order to
satisfy
specific
customer or user requirements.
Slide3Quality
T
he
totality of features and characteristics of a
product
or
service that bears its ability to satisfy stated or implied needs.
Slide4Common Meanings of Quality
• Quality is fitness for use
• Quality is meeting customers
expectations
• Quality is exceeding the customers
expectations
• Quality is superiority to competitors
Slide5The Difference between Quality Assurance and Quality
Contro
l
• Inspection
and testing are
examples of the quality
control process.
• Quality control identifies the
defects after the product is
produced but is not yetreleased or is still in theproduction phase.
• Quality audit is an example
of quality assurance.
• The goal of the quality
assurance process is to
develop a process so that
defects do not arise when
you are producing the
product
Slide6Food Quality
Quality can be defined as combinations of attributes or characteristics of a product that have significance in determining the degree of acceptability of that product to the consumer.
Slide7Food Quality
It can also be said as measure of purity, strength, physicochemical & oregano-
leptic
characteristic of food products but the classical definition of quality is composite of these characters that differentiate between individual units of the products & have significance in determining the degree of acceptability of that unit by the user
Slide8Definition
Quality
is a measure of the degree of excellence or degree of acceptability by the consumer. It can be defined as “summary of features and characteristics of a product or service that bear on its ability to satisfy stated or implied needs”. In simple words the product should have attributes to “satisfy the wants/ needs of the consumer or conformance with the user’s requirements”. It also covers the safety and value for money. Food quality can be considered as
Slide9Every food product has characteristics and indices measurable by sensory,
physical
,
chemical,
or
microbiological methods. Some characteristics are easily perceived;
others
are unseen. Understanding these quality characteristics and being familiar with the
appropriate
measuring tools are vital to quality control and the quality assurance of food
products.
Slide10a complex characteristic of food that determines its value or acceptability to consumers. Thus it may be defined as “the composite of those characteristics which have significance in determining the degree of acceptability by the buyer. These characteristics should also have the ability to differentiate individual unit of the product.”
Slide11Components
The
important components of food quality are
: food safety, sensory characteristics and nutritional value. Safety of food is a basic requirement of food quality. “Food safety” implies absence or acceptable and safe levels of
contaminants,a
dulterants
, naturally occurring toxins or any other substance that may make food injurious to health on an acute or chronic basis. Besides safety, quality attributes include: nutritional value; organoleptic properties such as appearance,
colour
, texture, taste; and functional properties.
Slide12Components:
The quality attributes are outlined in Table and includes primarily sensory attributes and hidden attributes. The sensory attributes include characteristics such as
colour
and appearance, viscosity and consistency, smell, taste, touch etc. The hidden characteristics are those which cannot be evaluated with human senses and yet are of real importance to human health and welfare. Nutritive value is one of the hidden characteristics, which is now considered by the consumers as a quality attribute. Adulterants and toxicants are the other hidden characteristics. Toxic substances may be of microbial origin, veterinary drugs residues, pesticide residues or heavy metals.
Slide13Food safety:
In
order to understand “food safety” we must first know the terms safe and hazard. “Safe” means that nothing harmful happens when we consume a food. A “hazard” is the capacity of a thing to cause harm. The objective of the food safety is to protect the food supply from microbial, chemical and physical hazards or contamination that may occur during all stages of
production and handling-management of animals at farm,
transportation,
storage
of raw milk, processing, production of value added products, distribution and storage of end products. It aims for keeping food wholesome and free from food borne illness. The important associated definitions and factors are described for better understanding of the food safety.
Slide14Food borne illness:
Food
borne illness or food poisoning is caused by consuming food contaminated
with
pathogenic
bacteria, toxins, viruses or parasites. The contamination may or may not alter a food’s organoleptic properties but cause illness and disease to human beings after consumption and usually arises from improper handling, preparation or storage
of
food.
Slide15Food-borne
diseases are classified as food infections or food intoxications. Food infections involve microorganisms present in the food at the time of consumption which then grow in the host and cause illness and disease
.
Food
intoxications involve toxic substances produced in foods by microorganisms prior to consumption and cause disease upon ingestion
.
The
toxin producing microorganisms need not to grow in the host to produce a disease or even be present in the food. So we must acknowledge that intoxication can occur even if no viable microorganisms are ingested.
Slide16Food hazards:
Food
becomes hazardous by contamination. Contamination is the unintended presence of harmful substances or microorganisms in food.
Food hazards can be defined as a biological, chemical or physical agent in a food, with the potential to cause an adverse health effect
(Table). Physical hazards are foreign particles, like glass/wood or metal pieces, stone, bone fragments, feathers,
fibre
, hair, etc. Chemical hazards include substances such as cleaning solutions and sanitizers, non permitted adulterants, pesticide and heavy metal residues. Biological hazards come mainly from microorganisms
Slide17Quality
,
Ministry
of Health is pursuing a broad and long-term
science
based
strategy to improve the food safety and to better protect the public health. Part of this strategy is a farm-to-table approach to improve the safety of food at each step in the food production, distribution, and marketing chain
Slide18Table
.
Types
of
Food
Hazards
Slide19Safety concerns
: We know that the goal of food safety is to reduce the size of risks to the lowest reasonable level without severe disruption of the food supply. For this we should first identify hazards related to foods or food components and then estimate the size of the risk that the hazard will cause. It is important to note that all foods have some degree of risk and that no food is absolutely “safe.” The important consideration becomes “the size of the risk and how the size of the risk can be reduced” without eliminating the food source.
Slide20The Benefits of Quality Assurance an
d
Quality
Control
•
It gives you a high quality output.
• It increases the efficiency of operations.
• It brings customer satisfaction, which affects your
brand and helps you grow your business.• If your product is of good quality, you will not needmuch rework and there will not be much after-salesupport required. This will help you save a lot of
money.
• A high level of confidence and a motivated team.
Slide21Quality Assurance (QA) systems
The food industry has a number of Quality Assurance (QA) systems available like GMP (Good Manufacturing Practices), HACCP (Hazard Analysis. Critical Control Points), ISO (International
Organisation
for
Standardisation
) standards. These systems and their combinations are recommended for food quality and safety assurance. The
agri
-food production requires a specific approach to achieve the expected quality level. It is important to know to what extent the systems contribute to the total quality of the product and to balance the tools used for achieving the quality and safety objective
Slide22-A
quality management system (QMS) system can be defined as:
a
set of coordinated activities to direct and control an organization in order to continually improve the effectiveness and efficiency of it performance. Food quality is a complex concept that can be assessed only in relation to food safety. To be considered safe for consumption, a food must meet: legislative requirements; technological criteria; hygiene requirements; transport and handling requirements; trading conditions and satisfy its intended use
..
Slide23The relation between quality and safety is intricate and although safety cannot be viewed as a totally independent aspect from quality,
recognising
the complexity of both concepts brought the need of managing them separately
Slide24In fact the reasoning behind separating food safety from quality was the need to place the concept of safety first and above all the other quality aspects
.
The result can be classified in
quality assurance systems (QA)
that includes the prerequisites (GMPs, GHPs, GAPs) and
HACCP;
quality
management systems (QMS) that refers to ISO or TQM; and integrated systems (IS) such as ISO 22000.
Slide25Qulity Assurance
systems
The systems can be classified according to the extent of activities they cover, in
:
- basic safety systems: prerequisites (GAPs, GMPs, GLPs, etc.);
advanced
safety systems such as HACCP;
-
integrated food safety management – ISO 22000;
- basic quality management systems - ISO 9001
;
- advanced quality management systems - ISO 9004. A part of the quality assurance systems and prerequisite programs that are applied by the industry are presented bellow.
Slide26Food Quality Assurance
Assist.Prof
. Dr. Çisem BULUT ALBAYRAK
FE 425
Slide27Food safety concerns: is their breakout a product of problems in the food system?
E. coli
0157:H7
Salmonella
“Mad cow”, Bovine spongiform encephalopathy (BSE)
SARS (Sudden Acute Respiratory Syndrome)
Slide28Escherichia coli
Hemolytic diarrhea caused by strain of
E. coli
O157:H7 in hamburger meat
1993- 500 Jack-in-the-Box patrons
1998- 25 million pounds Hudson Co. hamburger recalled
Animals can have it without causing symptoms, problem when butchering, entering from fecal material
Slide29Microbes in manure that might affect organic produce
Killed at 60°C in compost
No evidence that there is any
E coli
poisoning resulting from organically manured land (Soil Asso 2001)
“No evidence at present to support the assertion with organically grown produce is any more or less safe than conventionally grown” recently tested and confirmed in UK with 3200 samples
Slide30Salmonella
Genus
Salmonella
includes 2400 pathogenic species causes diseases in chickens and turkeys and then consumers via poultry and eggs
50 billion eggs sold/year and 20 million infected with Salmonella
New--pasteurization of eggs 1 hr at 56°C (or 134° F)
Slide31Mad cow disease or Bovine Spongiform Encephalopathy
Caused by prion (proteinaceous infectious particle), discovered in 1982
Causes brain tissue to become “spongy”
1996 connection between BSE and human disease Creutzfeldt Jacob disease
Symptoms nervousness, bizarre behavior, memory loss, wobbly walk, lethargy, hunched posture and death
Slide32Caused by cannibalistic feeding in food chain, ie mammals eating mammals
Like
kuru
disease in New Guinea, scrapie of sheep, wasting disease of elk and deer
Can survive heat, radiation and chemicals
No case of BSE in any animal grown organically from organic stock (Heaton, S. 2001 Soil Association Report)
Slide33E.coli
Slide34Concept of QualityQuality management Systems
ISO 9000 Quality management systems
Documentation
Process management
Audit
Food safety
Food Safety applications
Food safety
prorequirem
ent programs (HACCP)Food safety management SystemsISO 22000-Food safety management system
IFS (International food standard)
BRC (British retail consortium)
Slide35Quality Assurance
Total Quality Management
GMP/GHP,GLP,GAP
Sanitary and Hygienic Practices
Slide36ISO 9000:2000 definition of Quality
It is degree to which a set of inherent characteristics fulfills requirements
«Fitness for use»
Quality is excellence that is better than minimum standard.
Conformance to requirements
To ability of your product or service to satisfy
Slide37What is Quality Assurance
«Planned and systematic activities
implemented within the quality system that can be demonstrated to provide confidence that a product or service will fulfill requirements for quality»
Qu
a
lity
assurance is a
sy
stem for evaluating performance, service, of the quality of the product against system, product or specified requirement for customers.
Slide38Planned activity or systematic approach to provide adequate confidence of product and services
Quality
improvements
Quality
Assurance
Allocate
the
resources
Quality
audit
Mission
Objectives
Slide39Components of Quality Assurance
Operational
level
Tactical
level
Strategic
level
Medium
term
decision
(
training,facilities,operation
of
quality
assurance
)
Long
term
decision
(
quality
policy
)
Day
to
day
operation
Slide40Quality Assurance
QA is a way of preventing mistakes and defects in manufactured products and avoiding problems when delivering solutions or services to customers
ISO 9000 defined «A part of quality management focused on providing confidence that quality requirements will be fulfilled»
Slide41General principles of QA
Fit to purpose
The product should be suitable for the intended purpose
Right first time
Mistakes should be eliminated
Slide42Functions of Quality Assurance
To maintain standards and specification for all raw material and finished product.
To give service to company in all areas related to product quality includes
tro
u
ble
s
h
o
oting, visiting, production, facilities, designing ands training quality control panelTo produce information that is accurate, reliable and adequate for the intended purpose.Evaluating performance, service, of the quality of a product against a system,
standard or specified requirement for customers
Slide43Activities in Quality Assurance
Planning
Data collection
Quality Control
Documentation
Evaluation
Reporting activities
Slide44Objective of Quality Assurance
Managing good manufacturing practices(GMP) including
Managing Good Laboratory Practices(GLP)
Managing a safety
programme
Assuring quality of raw materials
Assuring quality and traceability of finished product
Evaluating plant environment
Developing HACCP plan
Slide45Total Quality Management
TOTAL-Made up of the whole
QUALİTY-Degree of excellence a product or service provides
MANAGEMENT-Act, manner of handling (or)Art.
Slide46What Does Total Quality Mean?
A philosophy that involves ever
y
one in an organization in continual effort to improve quality and achieve customer satisfaction
Slide47What’s the goal of TQM
«Do the right things right the first time,
every time»
Slide48Total Quality Management (or TQM) is a supervision concepts coined by W
Edwards Deming
«Total quality management is an approach that seeks to improve quality and performance which will meet or exceed customer expectations»
Slide49Total Quality Management Program
1.Top management commitment and involvement
2.Customer involvement and designing products for quality
3.Designing and controlling production processes
4.Deveoping supplier partnerships
5. Customer service,
distribution and installation
6.Building teams of empowered employees
7. Benchmarking and continuous improvement.
Slide50TQM in Food Industry
Systems for development of Quality assurance
GMP-Good Manufacturing Practices
HACCP-Hazard analysis and critical control points
ISO-International organization for standards
BRC-(British
Reta
i
l Consortium)
Slide51Deming Wheel for Continuous improvement
Plan
Act
Check
Do
What changes can
be made for improvement
Implenting
plans , taking
small controlled steps
Evaluate results
Take action to
standardize the process
Slide52Deming Wheel for Continuous improvement
Slide53TQM is the integration of all functions and processes within an organization in order to achieve continuous improvement of the
qulity
of goods and
services.The
goal is customer satisfaction
Slide54Objective of TQM
1. Process improvement
2. Defect prevention
3.Measurement system capacity
4.Devepoing improving check list
5.Helping teams make better decisions
6.Developing operational definitions
7.Observing behavior changes over a period of time
Slide55Principles of TQM
8 QMS principles
Customer focus
Involvement of people
Process approach
System approach
Continual improvement
Factual approach to decision making
Mutulally
beneficial supplier relationship
Leadesrhip
Slide56Quality management
Sum of activities performed in an
organisationto
produce and maintain a product with desired quality level against minimum cost.
Quality management functions:
Design
Control
ımprovement
Assurance
Slide57Good Manufacturing Practices
«Good manufacturing practice is that part of quality assurance which ensures that products are consistently produced and controlled to the quality standards appropriate to their intended use and as required by the marketing
authorization or product specification»
Slide58Definition
Good Manufacturing practice guidelines provide guidance for manufacturing,
testing and quality assurance in order to ensure that a food product is safe for human consumption.
Slide59General guidelines for GMP
Plant maintenance
Storage
Work surfaces
Supervision
Walls
Training
Doors
Plant construction and design
Air quality and ventilation
Water
Windows
Lighting
Cleaning and san
i
tation
Personal Hygiene
Ceiling
Staff hygiene
Foods
Slide60Good Agricultural Practices
«GAP are set of practices that address to environments, eco and social sustainability for all farm processes for safety and quality produces»
GAP are a collection of
principle to apply for on farm production and post production processes resulting in safe and heathy food
agricultural products, while taking into account economical,
social and environmental sustainability»
Slide61Objectives of GAP
1.To ensure safety and quality of produce in food chain
2.To capture new market advantage
3. To improve use of natural resources
4.To improve workers health and working conditions
5.To create new market
oppotunites
to farmers and to exporters
6. To export trade of agricultural produce.
Slide62Food Quality Assurance
Lecture-3 (HACCP
sysytem
)
FE 425
Slide63Hazard
A
nalysis
C
ritical
C
ontrol
P
oint
A systematic approach to the identification , evaluation, and control of significant food safety hazards.
Slide64Slide65Slide66Glossary
HACCP has lots
of
technical sounding
t
terminology that
be a little confusing.THE SEVEN PRINCIPLES of HACCP Establish Verification Procedures1. Conduct a Hazard Analysis2. Determine Critical Control Points
3. Establish Critical
Limits
4. Establish Monitoring
Procedures
5. Establish Corrective
Actions
7. Document the system
Slide677 principles (logical
way
)
If you
Decide
a
Hazard
is
Critical to food safety then it needs Limits that are Monitored.Monitoring rings the Alarm Bell when it finds
bad
results
Corrective Action
is required to bring things
under
control
once more
.
Everything needs to be
Documented
so we can
prove the food is safe for human consumption.
Slide68HACCP Team
The HACCP Team is the group of people who are
responsible
for
Documenting
and Managing the HACCP system
.
They
do the following tasks:Draw up the HACCP plansTrain Staff in the use of the systemCarry out tasks to check the HACCP plan is
effective
, accurate and is being followed by
staff
The HACCP Team is usually a group of people with
varied
knowledge
, skill and experience so that a better all
roundview
of the hazards and their control is possible.
Slide69Hazard
All Hazards are either
Physical
Allergenic
Chemical
Microbial
Slide70Hazard Anaysis
This is when we .....
Make a LIST of the things that could go wrong
Assess the RISK of each Hazard
WRITE DOWN the Hazards that require
CONTROL
together
with the means of CONTROL
Slide71PROCESS FLOW DIAGRAM
This
is a diagram shows the steps
how a Product is made
or produced,
the Process Flow Diagram should show
how ingredients are
received,stored
, prepared and transformed into a final product, a simple
example is shown below:
Slide72PROCESS STEP
A
Process Step is when an
ingredient
of a product or
the product
itself
changes
in some way. Process Step’s are represented by a “box” on the Flow Diagram, e.g. Chilled Storage and Cook are Process Step’s.
Slide73DECISION TREE
A
Decision Tree is a series of Questions that are asked about a
Hazard
to
determine if the Process Step is a
Critical Control Point
or
CCP.
Slide74Foundation of HACCP -Prerequisite Programs
Slide75CONTROL MEASURE
A
Control Measure is a method of
ELIMINATING
or
REDUCING
a
Hazard
to a safe or ACCEPTABLE level .. for example
Slide76CRITICAL CONTROL POINTS
After
Hazard Analysis we need to decide which Hazards are
CRITICAL
to
FOOD SAFETY. These are called
Critical Control Points
or
CCP’sA Process Step is said to be a CCP When:1. The Process Step is designed to CONTROL theHazard, e.g. Cooking, Chilled Storage or Metal
Detection
2.
A LATER Process Step will NOT Eliminate or Reduce
the Hazard to an acceptable level
.
e.g. Once food is Cooked that’s the
LAST
chance
to destroy harmful bacteria.
Slide77CRITICAL LIMIT
When we have identified a
Critical Control Point
using the
Decision
Tree
we need to set
Critical Limits
. These are values at which theazard is known to be reduced to a safe or acceptable level. Some examples are given below;•
Temperature of food in fridge 1-5oC
•
Cooking temperature 75oC for
a
minimum
of 2 minutes
Slide78MONITORING PROCEDURE
A
Monitoring Procedure is a
planned
and
documented
method
forchecking
that the all CCP’s are within their Critical Limit’s.• Check and record temperature of food infridge every 4 hrs.• Check and record cooking temperatureeach batch made.
Monitoring Procedure’s result in
records
that
prove
food is
safe for
human
consumption
.
Slide79CORRECTIVE ACTION
A
Corrective Action is a
pre-planned
and
documented
method for
regaining“Control
” when Monitoring detects values
outside their Critical Limit’s.Check and record temperature of food in fridge every 4 hrs.
Examples
;
Corrective Action
: Remove food to alternative
fridge, discard suspect food, repair fridge
.
All Corrective Actions should be
logged
in the HACCP Manual and
procedures
reviewed
as a result of the intervention
.
Slide80VALIDATION
Validation
is a way of checking the
EFFECTIVENESS
of the HACCP
Plan, i.e.
Is the HACCP Plan VALID
?
Check samples of food after Cooking to ensurethere are no harmful bacteria in the food.Proof of Validation should be from a combination of external and internal sources and it should be logged in the HACCP Manual.Examples:
EFFECTIVENESS: Having an absence of dangerous
bacteria proves that the Control Measure “Cooking”
is effective.
Slide81VERIFICATION
Verification
is a way of
checking
that the
HACCP plan is being
used
and
followed as intended.Example:•Review the Process Flow and Hazard Analysisto ensure that it remains accurate.Checks: “Walk through” the Process Flow and
ensureit
is correct and look for any new hazards
Verification is a way of making sure
the HACCP plan is correct
and that
staff
are
using it correctly
.
Slide82SUMMARY
•
HACCP stands for Hazard Analysis Critical Control Points
• A HACCP Team normally produces and manages the HACCP system
• The SEVEN Principles of HACCP mean that we need to IDENTIFY and
MONITOR CRITICAL HAZARDS in order to PROVE we are making SAFE
FOOD
• HACCP is based on SEVEN Principles
• Critical Control Points require Monitoring to ensure the food is SAFE
• A HACCP Plan needs to be regularly VALIDATED for EFFECTIVENESS• A HACCP System needs to be VERIFIED to ensure it remains UP TO DATE
Slide83Prerequisite Programs
Universal programs / procedures for controlling operational conditions of the plant
Create an environment suitable for the production of safe products.
Must be adequate and effective.
Must be monitored (requires documentation and records) – Internal Audit.
Repeated failure of a prerequisite program may indicate that decisions made in a Hazard Analysis are not supported.
Slide84Raw Materials Control
Slide85Sanitation
Slide86Sanitation
Effective cleaning procedures for equipment and facility.
Documented – SSOP (Sanitation Standard Operating Procedures)
Defined frequency
Chemicals approved for use in food facilities.
Records – concentrations, times, temperatures.
Sanitation monitoring – visual inspections, chemical or microbiological testing.
Corrective actions for deficiencies.
Slide87Employee Training
Slide88Employee Training
Records of training required.
Hygienic Practices
Disease Control
Cleanliness – outer garments, hand-washing, unsecured jewelry and other objects, use of gloves, hair and beard nets, eating, drinking, tobacco use, nail polish, etc.
Manufacturing Controls
Traffic flow to prevent cross contamination
Ingredient / product handling to protect product
Control measures (pH, cook time / temp, moisture, etc)
Scheduling sequential runs to prevent cross contamination (as for allergens)
Food Defense
Slide89Facility Design and Control
Slide90Facility Design and Control
Grounds
Eliminate pest harborage areas
Properly grade roads, yards, parking lots
Building
Provide sufficient space for placement of equipment and storage of materials
Prevent cross contamination
Slide91Facility Design and Control
Floors, walls and ceilings cleaned and in good repair.
Prevent condensate
Adequate lighting
Adequate ventilation
Water Quality (potable, steam, ice, reclaimed water, cooling water, backflow prevention)
Employee welfare / sanitary facilities
Waste control
Environmental monitoring
Slide92Equipment Design and Maintenance
Slide93Equipment Design and Maintenance
Designed and of materials and workmanship as to be adequately cleanable – meets standards
Installed
with adequate space to allow for proper cleaning and maintenance and to prevent cross contamination.
Properly maintained (records).
Slide94Pest Control
Slide95Pest Control
Prevention is key (design, maintenance and sanitation)
Rodent control
Insect control
Bird / Bat Control
Slide96Traceability and Product Recovery
Slide97Traceability and Product Recovery
Documented program with written procedures to meet federal requirements.
Program should include
Product Identification / Lot coding
Finished product distribution records retained beyond shelf life of product
Responsible individuals and their roles
Identification of Key Contacts – Internal, supplier customer
Mock Recovery Program
One step forward, one step back
Slide98Steps to
HACCP Implementation
Assemble the HACCP Team
Describe the food and its distribution
Describe the intended use and consumers of the food
Develop a flow diagram which describes the process
Verify the Flow Diagram
Slide99Multidisciplinary HACCP Team
Quality Assurance
Sanitation
Engineering
Microbiology
Production
Outside experts (if necessary)
Slide100Describe the Food / Distribution: Cheddar Cheese
Formal Product name:
Cheddar Cheese
Food Safety Characteristics:
pH (4.9 to 5.4)
Packaging type:
42# Block, Vacuum sealed in ploy bag and stored in corrugated box
Length of shelf life/storage temperature:
3-12 months when stored below 45°FWhere it will be sold:
Food Manufacturer
Intended Consumers:
Consumers of all ages
Labeling instructions:
Keep Refrigerated
Intended use:
Ready to eat product. May be used as ingredient. May be further processed into chunks or shredded.
Slide101Develop a Flow Diagram
Slide102Verify the Flow Diagram
HACCP Team should perform an on-site review of the operation to verify the accuracy and completeness of the flow diagram.
Take the diagram out to the production floor and walk through the steps.
Review periodically, modify and update as necessary (annual review or when change to process occurs).
Slide1031 - Conduct a Hazard Analysis
Identify hazards at each processing step and for each ingredient and material used.
Biological – such as pathogen
Chemical – such as toxin
Physical - such as glass
Evaluate hazards to determine severity and likelihood to occur
The hazard evaluation provides a basis for determining control measures such as CCP’s
Slide1042 - Determine Critical Control Points
A critical control point (CCP) is defined as a step at which control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level.
Information from the hazard analysis should enable the HACCP team to identify which steps in the process are CCPs.
Slide1053 – Establish Critical Limits
A critical limit must be scientifically based and is a maximum and / or minimum value to which a biological, chemical or physical parameter must be controlled at a CCP to prevent, eliminate or reduce the food safety hazard to an acceptable level.
Examples: Temperature, time, Water Activity, pH, safe tolerance level for drug residues
Slide1064 – Establish Monitoring Procedures
Monitoring is a planned sequence of observations or measurements used to assess whether a CCP is under control.
Monitoring should produce an accurate record for use in verification.
Where there is loss of control (a CCP limit is exceeded) there must be documented corrective action.
Slide107Monitoring
Continuous is desirable (recording chart) but where not possible, frequency for monitoring must be established.
Responsibility for monitoring must be assigned - Position title / work station
Slide1085 - Establish Corrective Actions
Corrective actions are procedures to be followed when a deviation occurs.
Corrective actions must be specific.
Halt production of product
Isolate the affected product
Return the process to control
Determine the disposition of the product
Records must be kept for a reasonable period after the shelf life of the product
Slide1096 _ Establish Verification Procedures
Establish procedures to verify that the system is working properly
.
Might include calibration and testing of monitoring equipment, demonstration of system performance, documented record review
Slide1107 - Records
Identify records that are being used to monitor control points
Records of training
Records at process step (recording charts, temperature records, etc)
Deviation logs
Verification and Validation Records
Records to show changes to the HACCP Plan
Slide111Consider our example
Slide112Identify hazard at each step and for each material
Slide1131 – Conduct Hazards Analysis
Identify the hazards for each step of the process:
Raw milk / receiving
Identify the type of hazard: chemical, biological or physical
Chemical –
β
-lactam (antibiotic)
residue, pesticide
Biological – Vegetative Pathogens, viruses, spoilage organismsPhysical – Metal
Slide114Determine severity of each hazard and likelihood of occurrence
Severity:
Enteric pathogens such as E. coli 0157H7 and Salmonella cause severe health effects including death among children and elderly
.
Likelihood to occur:
L
ikely that they will occur in raw milk supply
Using this information, determine if this potential hazard is to be addressed in the HACCP Plan
Slide115Hazards Analysis (severity)
Is the hazard identified at this step severe and of sufficient likelihood of occurrence to warrant it’s control? If
Yes,
go to next question.
If no,
identify the prerequisite program or procedure step, which reduces the likelihood or severity of the hazard to ensure that control at this step is not necessary.
Slide116Hazards Analysis (control)
Does a control measure exist at this step to prevent, reduce or eliminate the likely occurrence of the hazard to an acceptable level?
If yes, this step is a CCP.
If no, identify where control exists. (Pasteurization Step – This step is a CCP).
Slide117Hazards Analysis (justify)
Justification - Research or Reference Document that gives credence to your assumptions.
Pasteurized Milk Ordinance, 2003 Revision, WDATCP 80.48
Slide1182 - Determine Critical Control Points
Slide1193 - Establish Critical Limits
Critical Limits
HTST Limits for raw milk pasteurization are defined in the PMO –
minimum 161
˚F / 15 seconds
Slide1204 - Establish Monitoring Procedures
Continuous chart monitoring of temperature and flow rate.
Performed by Pasteurizer Operator in the Pasteurizer Room.
Slide1215 - Establish Corrective Actions
When minimum time or temperature requirement is not met, product automatically diverts to back to the balance tank prior to the HTST Pasteurizer. Forward flow is prevented.
Product diversion must be indicated on Pasteurizer Recording chart. These instances should be carefully reviewed by Licensed Pasteurizer Operator.
Slide1226 _ Establish Verification Procedures
Daily: Proper performance of HTST is demonstrated after sanitation and before product (Cut In / Cut Out) and recorded on the continuous chart. Charts verified Licensed Pasteurizer Operator.
Six months: Representative from WDA Tests Pasteurizer / time (maximum allowable flow for specified distance) and temperature. All controls are sealed. Records are retained by facility and state.
Daily: Seal check – verify that all seals are intact. Record reviewed by Licensed Pasteurizer Operator.
Slide1237 – Establish Records
Pasteurizer Charts
Seal Check Record
WDA Pasteurizer Time / Seal Record.
Other Equipment Calibration and testing records.
Slide124Identify CCP on Flowchart
Slide125HACCP Description Chart
Slide126The International Organization for Standardization (ISO) creates many different types of standards
ISO is made up of standards institutes from 154 different countries
Member countries work together to develop and approve standards
What is ISO?
International Standards for Business, Government and Society
www.iso.ch
Slide127INTRODUCTION OF ISO 22000
By
the early 2000s, a number of standards have been developed by different private and national organizations around the world. This led to complications when companies started using their own in-house developed codes to audit their suppliers. Different audit criteria made it nearly impossible for suppliers to fulfill all requirements in the global market.
In 2001, the International Organization for Standardization (ISO) started working on an auditable standard for Food Safety Management System (FSMS). This international FSMS standard, known as ISO 22000, was finally published on September 1, 2005. It is a framework that combines prerequisite programs, the HACCP principles and application steps as described by the Codex
Alimentarius
Commission and elements of the ISO 9001:2000 standard.
Within two years, the standard has been implemented by organizations in more than 50 countries as an alternative to more than 20 food safety schemes developed by individual companies in the sector for auditing their suppliers.
Slide128What is ISO 22000?
It is a Food Safety Management System (FSMS) that uses a management systems approach as well as a HACCP process.
The goal of ISO 22000 is to provide one internationally recognized standard for a food safety management system that can be applied to any organization in the food chain.
Slide129129
Introduction
In order to understand the significance of ISO 22000
we must first understand what ISO 22000 is about and
how is it applicable to the food industry. To achieve
these objectives we must ask the following questions:
What ISO 22000 means?
-ISO 22000 means consensus agreements between all the economic stakeholders concerned: suppliers; users; government regulators; other interest groups, such as consumers
Slide130130
How ISO 22000 benefit society?
For businesses, the widespread adoption of ISO 22000 means that suppliers can base the development of their products and services on specifications that have wide acceptance in their sectors;
This, in turn, means that businesses using ISO 22000 are increasingly free to compete on many more markets around the world
Slide131131
How ISO 22000 benefit consumers?
For consumers:
- conformity of products and services to International
Standards
-provides assurance about:
-quality
-safety
-reliability
Slide132132
How ISO 22000 benefit trade officials?
For trade officials negotiating the emergence of regional and global markets, IS0 22000 create "a level playing field" for all competitors on those markets;
The existence of divergent national or regional standards can create technical barriers to trade, even when there is political agreement to do away with restrictive import quotas and the like;
International Standards are the technical means by which political trade agreements can be put into practice
Slide133133
How ISO 22000 benefit developing countries?
For developing countries, ISO 22000 represents an international consensus and constitute an important source of technological know-how;
By defining the characteristics that products and services will be expected to meet on export markets;
International Standards give developing countries a basis for making the right decisions when investing their scarce resources and thus avoid squandering them
Slide134134
How ISO 22000 benefit governments?
For governments, ISO 22000 provides:
-technological and scientific know-how
-bases for developing health, safety and environmental legislation
-education of food regulatory personnel
Slide135135
How ISO 22000 benefit governments? (Cont’d)
-certification or registration
-international acceptance of standards used globally
-economic benefits
-social benefits
-trade liberalization
-food quality
-food safety
-food security
Slide136136
What are the benefits of ISO 22000 for other stakeholders?
Confidence that organizations implementing ISO 22000 have the ability to identify and control food safety hazards;
International in scope;
Provides potential for harmonization of national standards;
Provides a reference for the whole food chain;
Provides a framework for third party certification;
Slide137ISO 22000:2005
Slide138Slide139Slide140What is FS22000?
FS22000 is a Food Safety Certification Scheme that uses ISO 22000 and PAS 220
PAS 220 specifies requirements for Prerequisite Programs for food manufacturers
This document was added to ISO 22000 to create a system that could be benchmarked by the Global Food Safety Initiative
FS22000 was originally called
FSSC 22000.
It has been shortened
To
FS22000
for simplicity
Slide141Slide142FS22000 or ISO 22000?
Manufacturers can choose ISO 22000 or FS22000
If your customers want a
GFSI
(
Global
Food
Safety
Initiative
)
registration scheme then you will use FS22000
You will need to evaluate your market and determine which standard is most appropriate
FS22000 applies only to food manufacturer, so if you are not a manufacturer, you will use ISO 22000
Slide143ISO 22000 for the food safety
Is
related to the presence of and levels of food-borne hazards in food at the point of consumption
As
food safety hazards may be introduced at any stage of the food chain, adequate control throughout the food chain is essential
Is
a joint responsibility of all parties participating in the food chain
Failures
in food supply can cause human suffering, death, poor reputation, violations, poor nutrition, poor quality products and decreased profits
Slide144Key elements
Standard specifies the requirements for a food safety management system that combines the following generally recognized key elements to ensure food safety along the food chain, up to the point of final consumption:
interactive
communication
system
management
prerequisite
programmes
HACCP principles
Slide145Slide146ISO 22000 intends to define the Food Safety Management System requirements that companies need to meet in order to comply with food safety regulations all over the world.
ISO 22000:2005 takes a food chain approach to food safety. It defines a set of general food safety management requirements that apply not only to food producers and manufacturers, but to all the organizations that participate in the food supply chain.
ISO 22000 specifies the requirements for an FSMS that combines the following key elements to ensure food safety along the food chain:
Slide147Difference between HACCP and ISO 22000
Besides
the fact that HACCP is a food safety system, and ISO 22000 is a food safety management system standard, differences between these two include the following:
• ISO 22000 allows the development of a food safety management system by external experts for any company, and this includes implementation and verification of all or part of activities involved in the system
• ISO 22000 also refers to good practices in sectors and general hygiene rules published by Codex
Alimentarius
.
• Besides the internal communication, external communication is also a condition for establishing, implementing and updating the FSMS according to ISO 22000.
• ISO 22000 demands risk analysis to evaluate each food safety hazards identified.
• ISO 22000 demands documentation of PRPs.
• HACCP uses the traditional concept of dividing control measures into two groups: prerequisites and measures applied at critical control points (CCPs). In the case of ISO 22000, these concepts are reorganized in a logical order by adding a group of control measures named operational prerequisite programs (
oPRPs
).
Slide148Difference between HACCP and ISO 22000
• ISO 22000 demands monitoring system and planning of corrective actions for operational PRPs, as for CCPs.
• ISO 22000 demands analysis and improvement according to the outcome of monitoring of
oPRPs
and HACCP plan.
• ISO 22000 also requires the review and identification of specifications, formulation and origin for input and end-products.
• ISO 22000 separates and clarifies verification activities and validation activities.
• Allergen control is a required prerequisite program in ISO 22000; however it is not mentioned in HACCP.
• ISO 22000, new terms have been developed, such as “potentially unsafe product” and the term “withdrawal” for product recall and product recollection activities.
• ISO 22000 requires continual improvement and updating of the management system.
Slide149149
This International Standard specifies the requirements for a food safety management system that combines the following generally recognized key elements to ensure food safety along the food chain, up to the point of final consumption; these elements are:
interactive communication;
system
management;
process control (ISO 9001);
HACCP
principles;prerequisite programs
.
Slide150150
Communication along the food chain is essential to ensure that all relevant food safety hazards are identified and adequately controlled at each step within the food chain.
This implies communication of the needs of the organization to both organizations upstream in the food chain and organizations downstream in the food chain.
This implies communication of the needs of the organization to both organizations upstream in the food chain and organizations downstream in the food chain.
Slide151151
Communication with customers and suppliers, based on the information generated through systematic hazard analysis, will also assist in substantiating customer and supplier requirements with regard to their feasibility, need
and impact on the end product.
Recognition of the organization's role and position within the food chain is essential to ensure effective interactive communication throughout the chain in order to deliver safe food products to the final consumer.
The possible scope of the communication channels among typical interested parties of the food chain is schematically exemplified in Figure 1.
Slide152152
Figure 1 – Example for communication along the food chain
Slide153153
This International Standard integrates the principles of the Hazard Analysis and Critical Control Point (HACCP)
system and application steps developed by the Codex Alimentarius Commission and dynamically combines it with prerequisite programs (PRP(s)) necessary to control and reduce any food safety hazards identified for the end products delivered to the next step in the food chain to acceptable levels.
Hazard analysis is the key to an effective food safety management system, as it organizes the knowledge required to design an effective combination of control measures.
Slide154154
This International Standard requires that all hazards that may be reasonably expected to occur in the food chain, including hazards that may be associated with the type of process and facilities used, are identified and assessed, resulting in a clear determination of those to be controlled within the organization and those that are to be controlled (or are already controlled) by other organizations within the food chain and/or by the final consumer.
Thus, this standard provides the means to document and justify both inclusions and omissions in setting control measures.
Slide155155
Infrastructure and maintenance programs are used to address basic requirements of food hygiene and accepted good (manufacturing, agricultural, hygienic, etc.) practices of a more permanent nature; whereas operational PRP(s) are used to control or reduce the impact of identified food safety hazards in the product or the processing environment.
The HACCP plan is used to manage the CCP(s) identified to eliminate, prevent or reduce specified food safety hazards from the product, as determined during hazard analysis.
During hazard analysis the organization determines the strategy to be used to ensure hazard control by combining the PRP(s) and the HACCP plan.
Slide156156
This International Standard requires that organizations identify, monitor, control and routinely update both the PRP(s) and the HACCP plan.
To facilitate the application of this International Standard, it has been developed as an auditable standard.
However, individual organizations are free to choose the necessary methods and approaches to fulfill the requirements of this International Standard.
To assist individual organizations with development and implementation of this International Standard an informative explanation and guide for its use are provided in Annex A.
Slide157157
This International Standard recognizes that there are differences amongst organizations within the food chain. It specifies a mechanism that will allow a small and/or less developed organization, such as a small farm, a small packer-distributor, a small retail or food service outlet, to implement an externally developed and designed combination of PRP(s) and HACCP plans, if
a) it is demonstrated that it has been developed in compliance with the requirements of this International Standard specified for the hazard analysis, PRP(s) and HACCP plan,
b) specific measures have been undertaken to adapt the externally developed system to the organization, and
Slide158158
c) it has been implemented and is operated in accordance with the other requirements of this International Standard.
The most effective food safety systems are designed, operated and updated within the framework of a structured management system and incorporated into the overall management activities of the organization. This
provides
maximum
benefit for the organization and interested parties.
This International Standard has taken due consideration of the provisions of ISO 9001:2000 in order to enhance compatibility of the two standards.
Slide159159
The correspondence between ISO 9001:2000 and this International Standard is provided in Annex B.
This International Standard may be applied independently from other management system standards.
Its implementation can be aligned or integrated with existing related management system requirements while organizations may utilize existing management system(s) to establish a food safety management system that complies with the requirements of this International Standard.
Slide160160
How ISO 22000 benefits everyone?
ISO 22000 can contribute to the quality of life in general by:
-ensuring safe food
-
reducing foodborne diseases
-better quality and
safer
jobs in the food industry
-better utilization of resources
-more efficient validation and documentation of
techniques, methods and procedures
-increased profits
-increased potential for economic growth and development
Slide161Quiz Questions
Write a
brief
description
for
food
quality. What are the important components
of
the
food
quality
?
Give
an
example
for
food
safety
concern
and
make
suggestion
to
prevent
or
eliminate
it.
3.Write
long
form of
following
terms
HACCP,GMP,GHP,ISO,BRC
and
ISO.
4.Write seven
principles
in HACCP
system
approach
5. Write 2
difference
between
HACCP
and
ISO22000