Transcript FEDIAF Code of Practice

FEDIAF Guide to Good Practice
for the Manufacture of Safe Pet Food
TRAINING PACKAGE
Module III
Hazard Analysis and Critical Control Points
Food Safety Management System
CI
Review
measure
HACCP
Food safety management
Prerequisites (GMP)
Food Safety Management System
Food safety management system consists of a prerequisite
programme and a HACCP system
Senior management commitment as first condition
Components of the HACCP system:
 Implemented within the quality management system
 HACCP team leader and personnel trained and skilled
 Specific to the application, practical and effective
 Reviewed regularly and validated
 CCPs and OPRPs identified, controlled, monitored and
recorded
Pre-Requisite Programmes
Prerequisite programmes are basic conditions and activities
(good practices)
Examples:
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Exterior/Interior conditions
Cleaning
Storage conditions
Handling of toxic materials
Training
Pest control
Calibration
Supplier control
Good Laboratory Practice
etc
Food and Non food grade
Lubricant storage
Calibration status
3. HACCP - definitions
What is HACCP?
Hazard Analysis and Critical Control Points is
a technique that identifies, evaluates and
controls hazards significant for food safety
What is a hazard?
A biological, chemical or physical agent in, or
condition of, food or feed with the potential to
cause an adverse health effect
What is pet food safety?
Assurance that, when eaten according to its
intended use, the pet food will not harm the animal
Examples of food borne hazards
Bacteria:
Aeromonas, Clostridium perfrigens,
Clostridium botulinum, Campyloabcter,
pathogenic E.coli, Listeria monocytogenes,
Salmonella, Staphylococcus aureus…
Viruses:
Physical:
Hepatitis A, Rotavirus,
Norwalk-like viruses…
Metal, Glass…
Parasites:
Chemicals:
PCBs, Dioxins, Heavy metals,
Pesticides, Veterinary Drugs,
Mycotoxins, Melamine, Toxins…
Trichinella spiralis, Taenia,
Fasciola hepatica…
Ex.: decision tree to determine
inspection plans based on the source
Feed material/Ingredient/
Additive/packaging/Wet product/Finished
Products
Trader does
not separate
supplies
Is your supplier a trader?
yes
Trader
separates
supplies
no
EU/EFTA origin or of third
country with equivalent
safety/hygiene standards?
Third country origin with
occurrence or doubts as to
safety/hygiene concerns?
Does supplier has the
quality assurance system in
place ?
Does supplier has the
quality assurance system in
place ?
no
yes
Follow frequency for Low
Risk ( A)
yes
no
Follow frequency for
Medium Risk ( B)
Follow frequency for
High Risk (C)
HACCP principles
Step 0
Implement Pre-requisite Programmes
Conduct a hazard analysis
Assemble HACCP Team
Describe product
Identify intended use
Construct Flow diagram
Confirm flow diagram on site
List all potential hazards
Conduct a hazard analysis
Consider control measures
Determine the Critical Control Points
(CCPs) and Operational Pre-Requisite
Programs (OPRPs)
Use decision tree to determine CCPs and OPRP’s
Establish critical limits
Establish action and critical limits for each CCP
and OPRP
Establish CCP monitoring procedures
Establish monitoring systems for each CCP and
OPRP
Establish corrective action plans
Establish the corrective action to be taken when
monitoring indicates that a particular CCP or
OPRP is not under control
Establish verification procedures
Establish procedures for verification to confirm
that the HACCP system is working effectively
Establish documentation and
recordkeeping systems
Establish documentation concerning all
procedures and records appropriate to these
principles and their application
Establish Validation
Validation of control measures
Codex Principle 1
Codex Principle 2
Codex Principle 3
Codex Principle 4
Codex Principle 5
Codex Principle 6
Codex Principle 7
HACCP study
What is a risk?
Probability of causing an adverse health effect caused
by the occurrence and severity of a hazard in food
Risk assessment to identify hazards:
 Occurrence/severity of hazards and adverse effects
 Qualify/quantify hazards
 Micro-organisms growth
 Toxins, chemicals or physical agents
 Conditions leading to the above
Clostridium botulinum
Ex.: decision tree to identify CCPs and
OPRPs (1)
Q1
Do preventative control measure(s)
exist for the identified hazard (including
control measures upstream)?
Yes
No
Modify steps in the
process or product
Is control at this
step necessary for
safety?
No
Q2
Yes
Not a CCP
Is the step specifically designed and essential
to eliminate or reduce the likely occurrence of a
hazard to an acceptable level by it self?
No
No
Q3
Point, step or procedure
at which control can be
applied and is essential to
prevent or eliminate
hazards or reduce it to an
acceptable level
Stop*
Yes
Is control measure at this step essential, in
combination with other control measures, but
out of control does not automatically implicate
there is an immediate food safety risk?
Is the step specifically designed to eliminate or
reduce the likely occurrence of a hazard to an
acceptable level?
Critical
Control
Point
OPRP
Ex.: decision tree to identify CCPs and
OPRPs (2)
Q3
Point, step or
procedure at
which control can be
applied and is
essential to prevent
or eliminate hazards
or reduce it to an
acceptable level
Could contamination occur, with
identified hazard(s) in excess of
acceptable level(s), or could this
increase to unacceptable levels?
Yes
Q4
No
Not a CCP
Stop*
Will a subsequent step eliminate
identified hazard(s) or reduce likely
occurrence to acceptable levels?
Yes
OPRP
No
Critical
Control
Point
HACCP examples: wet pet food
The following is an example of an HACCP outcome when applied to wet pet food
e.g: cans, trays, pouches.
It is not intended to be complete. Manufacturers should use this for guidance only
Critical Control
Point/OPRP depending
on your HACCP
Hazard to be controlled
Typical Control Method
Transport / storage
Contamination or deterioration (e.g. temp)
Assurance and inspection programme
Raw Materials conform
spec
Incorrect or contaminated raw materials (e.g. SRM)
Supplier Assurance programme and
incoming inspection
Processing
Microbial growth due to incorrect processing
Monitoring time and temperature inspection,
shelf-life control
Metal detection
Metal contamination (e.g. fish hooks)
Permanent magnets, electric metal detection
device
Filling
Microbial growth due to under-sterilisation (caused by overfilling of
chunks)
100% inspection by headspace
control/weight control
Gravy addition
Microbial growth due to under-sterilisation (caused by overfilling of
chunks)
100% inspection by headspace
control/weight control
Seaming / Sealing
Growth micro-organisms (e.g. product inclusion in seal, damaged
flanges)
Seam / seal control
Sterilisation
Microbial growth due to under-sterilisation (e.g. due to low initial
temperature, low sterilisation time or low sterilisation temperature)
which leads to a F0 less than 3
Calibration and monitoring
Cooling
Microbiological ingress during cooling (e.g. due to lack of Chlorine)
Calibration and monitoring (of dosing
equipment and water quality)
Handling of primary
package
Contamination or deterioration due to loss of packaging integrity
Visual control
HACCP examples: semi-moist
Critical Control
Point/OPRP depending
on your HACCP
Hazard to be controlled
Typical Control Method
Transport / storage
Contamination or deterioration (e.g. temp)
Assurance and inspection programme
Raw Materials conform
specification
Incorrect or contaminated raw materials (e.g. SRM)
Supplier Assurance programme and
incoming inspection
Addition of preservatives
Microbiological growth
Monitoring / inspection
Processing
Microbial or mould growth (e.g. due to high Aw)
Aw monitoring / inspection, shelf-life
control
Filling
Microbial growth due to condensation (caused by too high filling
temperature) and risk moulding
Monitoring / inspection filling temperature
and external temperature
Metal detection
Metal contamination
Electric metal detection device
Handling of primary
package
Contamination or deterioration due to loss of packaging integrity
Visual control
HACCP examples: dry pet food
Critical Control
Point/OPRP depending
on your HACCP
Hazard to be controlled
Typical Control Method
Transport / storage
Contamination or deterioration (e.g. humidity)
Assurance and inspection programme
Raw Materials conform
spec.
Incorrect or contaminated raw materials (e.g. SRM)
Supplier Assurance programme and incoming
inspection
Heating
Bacterial growth caused by lethality too low, e.g. low
time/temperature (less than 90°C) of product during
extrusion/pressing/baking)
Control of temp/time and monitoring/
inspection, shelf-life control
Processing
Microbial or mould growth (e.g. due to high Aw)
Aw, moisture, monitoring / inspection, shelf
life control
Filling
Microbial growth due to condensation (caused by too high filling
temperature)
Monitoring / inspection filling Temperature
and external temperature
Metal detection
Metal contamination
Permanent magnets, electric metal detection
device
Storage of product
Microbial or mould growth
Aw/Warehouse assurance program
Handling of primary
package
Contamination or deterioration due to loss of packaging integrity
Visual control
HACCP examples: chews
Critical Control
Point/OPRP depending
on your HACCP
Hazard to be controlled
Typical Control Method
Transport / storage
Contamination or deterioration (e.g. temp))
Assurance and inspection programme
Raw Materials conform
spec.
Incorrect or contaminated raw materials (e.g. SRM)
Supplier Assurance programme and
incoming inspection
Processing
Growth of spoilage bacteria in process (e.g. High number of
Salmonella due to poor processing conditions; Aw, time and
temperature, cross contamination)
Monitoring / inspection, shelf-life
control
Bag Filling
Condensation (due to high filling temperature)
Monitoring / inspection filling
temperature and external temperature
Metal detection
Metal contamination
Permanent magnets, electric metal
detection device
Handling of primary
package
Contamination or deterioration due to loss of packaging integrity
Visual control
HACCP examples: frozen
Critical Control
Point/OPRP
depending on your
HACCP
Hazard to be controlled
Control Method
Transport / storage
Contamination or deterioration (e.g. temp))
Assurance and inspection programme
Raw Materials conform
spec.
Incorrect or contaminated raw materials (e.g. SRM)
Supplier Assurance program and incoming
inspection
Processing
Growth of spoilage bacteria in process (e.g. High number of
Salmonella due to poor processing conditions; AW, time and
temperature, cross contamination)
Monitoring / inspection, shelf life control
Metal detection
Metal contamination
Permanent magnets, electric metal
detection device
Cooling / Freezing
Microbiological ingress during cooling
Storage, transport,
including point of sales
Contamination or deterioration, Growth of micro-organisms
Warehouse assurance and inspection
program, temperature monitoring
Handling of primary
package
Contamination or deterioration due to loss of packaging integrity
Visual control
HACCP examples: fresh / chilled
Critical Control
Point/OPRP
depending on your
HACCP
Hazard to be controlled
Control Method
Transport / storage
Contamination or deterioration (e.g. temp)
Assurance and inspection programme
Raw Materials conform
spec.
Incorrect or contaminated raw materials (e.g. SRM)
Supplier Assurance program and
incoming inspection
Processing
Growth of spoilage bacteria in process (e.g. High number of Salmonella
due to poor processing conditions, AW, time and temperature, cross
contamination )
Monitoring / inspection, shelf life control
Filling
Microbiological ingress
Temperature monitoring / inspection /
shelf life control
Metal detection
Metal contamination
Permanent magnets, electric metal
detection device
Cooling / Chilling
Microbiological ingress during cooling
Storage, transport,
including point of sales
Contamination or deterioration, Growth of micro-organisms
Warehouse assurance and inspection
program, temperature monitoring ,
shelf life control
Handling of primary
package
Contamination or deterioration due to loss of packaging integrity
Visual control
HACCP examples: small pets
Critical Control
Point/OPRP
depending on your
HACCP
Hazard to be controlled
Typical Control Method
Transport / storage
Contamination or deterioration (e.g. humidity)
Assurance and inspection programme
Raw Materials conform
spec.
Incorrect or contaminated raw materials (e.g. SRM)
Supplier Assurance programme and
incoming inspection
Cooling of raw
materials
Contamination or deterioration, growth of micro-organism
Transport assurance, temperature
monitoring, shelf life control
Heating
Bacterial growth caused by lethality too low, e.g. low
time/temperature (less than 90°C) of product during
extrusion/pressing/baking)
Control of temp/time and Monitoring /
inspection, shelf-life control
Mixing
Homogeneous basic produkt
Manufacturer´s declaration, personal
training, visual control
Processing
Microbial or mould growth
Aw, moisture monitoring / inspection,
shelf life control, personal hygiene
Metal detection
Metal contamination
Permanent magnets, electric metal
detection device
Storage of product
Microbial or mould growth
Aw/Warehouse assurance program
Handling of primary
package
Contamination or deterioration due to loss of packaging integrity
Visual control, personal training