4. Science
&
Advisory
Unit
4
What will I gain from this training?
Following this presentation you should have
an understanding of:
– the basics of what HACCP and HACCP-based
programs are and how they work
– how HACCP can improve food safety
– the components of an effective HACCP system
– what implications HACCP will have for OMAF
5. Science
&
Advisory
Unit
5
• Estimated effect of food-borne illness U.S.
– 76 million cases
– 325,000 hospitalizations
– 5,000 deaths
• Assuming Canada has ~ 10% population size
– 7.6 million cases
– 32,500 hospitalizations
– 500 deaths
What’s happening?
6. Science
&
Advisory
Unit
6
Why do we hear more about
food-borne illness?
• Changes in technology and scientific knowledge
• Increase in consumption of fresh and ready-to-
eat products
• Change in consumer demographics - population
more at risk
• Changes in food-borne pathogens
• Globalization of food supply
• Increased surveillance
7. Science
&
Advisory
Unit
7
• As improved food safety systems become more
common, many buyers are requiring them of
their suppliers
• Manufacturers are in-turn requesting their
suppliers have documented food safety systems
• Food safety evolution all along the food-chain
Market Access?
8. Science
&
Advisory
Unit
8
• To both food-borne illness and market access
problems?
• For a food-safety system that focuses on
preventing problems before they occur rather
than rely on end-product testing to detect
failures?
• For an industry-led program used to improve
and verify food safety?
What’s the answer….
9. Science
&
Advisory
Unit
9
What is HACCP?
• HACCP stands for:
azard nalysis ritical ontrol oints
• HACCP is:
– preventative
– science-based
– a food safety system
• A properly functioning HACCP system will
result in the production of a safer food
product.
10. Science
&
Advisory
Unit
10
Is HACCP Standardized?
• HACCP methodology has been
standardized internationally by the Codex
Alimentarius commission
• This commission was set-up by the World
Health Organization to develop
internationally recognized food safety
standards
11. Science
&
Advisory
Unit
11
Where could I find HACCP now?
• Canadian Food Inspection Agency
– Federally registered food plants
• Australia/New Zealand
• European Union
• United States
• Japan
• Malaysia
• Cuba
• Iceland
• Many others
12. Science
&
Advisory
Unit
12
Is HACCP called anything else?
• There are various food safety programs world-
wide that incorporate HACCP
• These include:
– FSEP: Food Safety Enhancement Program (CFIA)
– QMP: Quality Management Program (CFIA)
– Pathogen Reduction Final Rule (USDA)
– SQF: Safe Quality Food (International)
– and many others
14. Science
&
Advisory
Unit
14
A Short History...
• 1960’s - Pillsbury developed HACCP with the
U.S. Army and NASA.
• 1974 - HACCP principles used in low acid
canned food regulation.
• 1980’s - Used for pathogen control by major
food companies.
• 1990’s and into the new millenium - Widely
accepted by governments and many multi-
national food manufacturers.
15. Science
&
Advisory
Unit
15
HACCP is not:
– a food quality system
– a government implemented program
– maintenance free
– the solution to every problem
– zero risk
– automatically functional
16. Science
&
Advisory
Unit
16
Where can HACCP be used?
HACCP can be used in any food sector from
production to retail or “Field - to - Fork”
Processing
Retail & Foodservice
Production
Transport
17. Science
&
Advisory
Unit
17
How does HACCP
improve food safety?
• Focuses on problem prevention
• Sequentially examines all processes and
products, and determines where hazards can
be controlled
• Promotes ownership for food safety to food
handlers and operation owners
• Outcome-based, non-prescriptive
• 40 % reduction in Salmonella
contamination in U.S. meat plants
18. Science
&
Advisory
Unit
18
Does HACCP have any
other benefits?
A properly designed HACCP program can
have the following benefits:
• Increased buyer confidence
• Reduced operational costs
• Improved product quality
• Increased market access
• Business liability protection
• Permits efficient oversight
• Organization development
19. Science
&
Advisory
Unit
19
Well what’s the catch?
There are potential barriers to HACCP
implementation.
– Cost of implementation
– Difficulty of implementation
– Lack of awareness and understanding -
inadequate knowledge and training
– Belief that there is no need for HACCP
– Lack of time/resources
– No recognition system by provincial
government
20. Science
&
Advisory
Unit
20
How does HACCP work?
• There are two main components:
– Prerequisite Programs
• control the overall plant environment
• control factors not directly related to the food
– HACCP Plans
• specific to a certain product or process
• control factors directly related to food production
21. Science
&
Advisory
Unit
21
Prerequisite Programs
• Ensure that the manufacturing environment
does not present sources of contamination.
• Must be implemented prior to the HACCP
plan(s)
• Address certain hazards so that they do not
need to be accounted for at each step in a
HACCP plan
23. Science
&
Advisory
Unit
23
• Items that might be monitored as part of this
pre-requisite program include:
– composition of plant construction materials
– maintenance of the facility itself
(housekeeping)
– proper product, people, and garbage flow
– adequate storage areas and procedures
– adequate facility lighting, ventilation, lack of
condensation, etc.
Plant Premises and Layout
24. Science
&
Advisory
Unit
24
Water Quality
• Items that might be monitored as part of this
pre-requisite program include:
– water quality testing and monitoring program
(e.g. chlorination testing, microbiological
testing, etc.)
– ice quality testing and monitoring program
– water filter maintenance program
– water testing equipment
calibration program
25. Science
&
Advisory
Unit
25
• Items that might be monitored as part of this
pre-requisite program include:
– ensuring proper storage of product (e.g. raw and
cooked separated, allergens and non-allergens
separated, food and chemicals separated)
– first in, first out product rotation procedures (FIFO)
– monitoring of product storage temperatures
(refrigerated, frozen product)
– inspection of incoming product
– inspection of transport vehicles
Transportation and Storage
26. Science
&
Advisory
Unit
26
• Items that might be monitored as part of this
pre-requisite program include:
– equipment is easily cleanable, smooth, and non-
porous
– adequate calibration programs
Equipment
– adequate preventive
maintenance programs
equipment specific training to
ensure proper use
27. Science
&
Advisory
Unit
27
• Items that might be monitored as part of this
pre-requisite program include:
– master cleaning schedule
– documented cleaning procedures
– inspection/testing/audit of program
– sanitation chemical strength monitoring
– environmental sampling
Sanitation
28. Science
&
Advisory
Unit
28
• Items that might be monitored as part of this
pre-requisite program include:
– personal hygiene
– HACCP and GMP (Good Manufacturing Practices)
– sanitation
– allergen, cross-contamination, etc.
– specific programs for other food safety related
programs and procedures
Employee Training
29. Science
&
Advisory
Unit
29
• Items that might be monitored as part of this
pre-requisite program include:
– Documented, effective recall procedures
– Adequate mock recall frequency
– Adequate product coding
– Traceability, both forwards and backwards
– Adequate held-product procedures
Recall Program
31. Science
&
Advisory
Unit
31
What about HACCP plans?
• Control factors directly related to food
product or production process
• Determine food safety hazards likely to
occur during manufacturing
• Once hazards are identified, control
measures are implemented
32. Science
&
Advisory
Unit
32
What are the hazards?
• There are 3 types of hazards
– Biological
– Chemical
– Physical
• Don’t forget cross-contamination
– microbiological, allergens
33. Science
&
Advisory
Unit
33
Biological Hazards
• Biological hazards can cause illness and
include:
– bacteria: E.coli, Salmonella, Listeria,
Campylobacter, Shigella
– viruses: cold viruses, Hepatitis A, Norwalk virus
– parasites: Giardia, Cryptosporidium,
Trichinella, tapeworms
– yeasts and molds
• Important to remember that any toxins
produced by microbiological organisms are
also biological hazards (e.g. verotoxin)
34. Science
&
Advisory
Unit
34
Chemical Hazards
• Chemical hazards can cause injury or
poisoning and include:
– Naturally occurring substances: allergens (e.g.
peanuts, fish, etc.), plant specific toxins and
naturally occurring poisons (rhubarb leaf,
nightshade, etc.)
– Excessive, intentionally added chemicals:
antibiotics, pesticides, herbicides, fungicides,
nitrates
– Accidentally added chemicals: cleaning
chemicals, paint, pest control chemicals
36. Science
&
Advisory
Unit
36
That’s a lot of HACCP Plans!
• A unique HACCP plan is not necessary for
every single product produced.
• Products can be grouped into categories
based on:
– commodity group
– processing steps
– hazards
– etc.
37. Science
&
Advisory
Unit
37
Implementing HACCP
• Codex recommends 12 steps to
implementing a HACCP plan
– first 5 steps are required to gather the resources
and information needed
– last 7 steps are the 7 principles of HACCP
• Successful completion of all 12 steps will
result in a properly functioning HACCP
plan
38. Science
&
Advisory
Unit
38
Step #1:
Assemble the HACCP Team
• Group of people that will oversee the
implementation and maintenance of the
HACCP program
• Multi-disciplinary (i.e. production, sanitation,
management, etc.)
• If necessary, can be one person
• The ‘HACCP Co-ordinator’
oversees the entire process.
39. Science
&
Advisory
Unit
39
Step #2:
Describe the Product(s)
• Full description of the product(s) being
manufactured under the program including:
– name
– ingredients including allergens
– chemical traits (e.g. pH, aw, salinity, etc.)
– shelf life
– labelling requirements
– storage and transport conditions
• This info will assist with hazard analysis
40. Science
&
Advisory
Unit
40
Step #3:
Identify Intended Use & Consumers
• Which group(s) will be consuming the food
product
– Products consumed by the elderly, immuno-
compromised or the very young may require
more stringent controls
• Where will the product be sold
• How will it be prepared
41. Science
&
Advisory
Unit
41
Step #4:
Flow Diagram & Plant Schematic
• The flow diagram should:
– Outline all processing steps
– Include all major processing steps
• The plant schematic should:
– Outline where all of the processing steps occur
– Display the movement of products, people, and
refuse.
• Points of potential cross-contamination should
be highlighted.
42. Science
&
Advisory
Unit
42
Step #5:
Verify Flow Diagram & Schematic
• The HACCP team should:
– Conduct an on-site inspection to verify and
check the accuracy of the flow diagram and
schematic created in step #4
– Physically follow normal product flow from
receiving to shipping to ensure no major
processing or contamination points have been
missed
43. Science
&
Advisory
Unit
43
Step #6:
Conduct a Hazard Analysis
• HACCP Principle #1
– Evaluate information regarding potential
hazards associated with the manufacturing
process and ingredients
– Determine which hazards are significant to food
safety
– Consider:
• probability of occurrence
• severity of consequences
44. Science
&
Advisory
Unit
44
• For example:
– During the manufacture of a cooked meat pie,
the raw meat may contain pathogenic bacteria
that may cause severe illness
– This is a biological hazard
– Other hazards may also exist (physical - metal
contamination, chemical - antibiotics, etc.)
Step #6:
Conduct a Hazard Analysis
45. Science
&
Advisory
Unit
45
Step #7:
Determine CCPs
• HACCP Principle #2
• Critical Control Points (CCPs) are:
– a point, step, or procedure at which a control
measure is essential to prevent,eliminate, or
reduce a food safety hazard
• CCPs are not:
– necessarily located where the hazard occurs,
they may be located at a subsequent step
• Some hazards cannot be controlled by the
operator
46. Science
&
Advisory
Unit
46
• Using the cooked meat pie example:
– Cooking the meat to an adequate internal
temperature will ensure that all pathogenic
bacteria present on the meat are destroyed,
thereby controlling the hazard
Step #7:
Determine CCPs
47. Science
&
Advisory
Unit
47
Step #8:
Establish Critical Limits
• HACCP Principle #3
• A critical limit:
– is the maximum and/or minimum value to
which a parameter must be controlled at a CCP
– separates acceptability from unacceptability
– must be clearly defined and measurable
48. Science
&
Advisory
Unit
48
• Using the cooked meat pie example:
– At the meat cooking CCP, the internal
temperature must reach a minimum of 74°C to
ensure the destruction of pathogenic bacteria
– Critical limits can be any scientifically valid
measurement
Step #8:
Establish Critical Limits
49. Science
&
Advisory
Unit
49
Step #9:
Establish Monitoring Procedures
• HACCP Principle #4
• Monitoring:
– is the process of conducting a planned
sequence of measurements to
determine if a CCP is under control
– results must be recorded
• If monitoring shows that Critical Limits are
not met, then the process is out of control and
the food may be unsafe.
50. Science
&
Advisory
Unit
50
• Using the cooked meat pie example:
– At the meat cooking CCP, the internal
temperature of at least 2 meat pies, located in
the “cold spots” of the oven, will be taken
from each batch of meat pies
– The temperature must be a minimum of 74°C.
– Temperatures must be taken by the oven
operator with a calibrated thermometer and
will be recorded on the “cooking report”
Step #9:
Establish Monitoring Procedures
51. Science
&
Advisory
Unit
51
Step #10:
Establish Corrective Actions
• HACCP Principle #5
• Corrective Actions
– are pre-determined activities that must occur when
monitoring indicates that a deviation has occurred.
– must:
• regain control of the process
• locate and hold affected product
• determine disposition of affected product
• prevent a recurrence
52. Science
&
Advisory
Unit
52
• Using the cooked meat pie example:
– if the internal temperature of the meat pie does
not reach 74°C, then the product may contain
viable pathogenic bacteria
– the product in question must be held and
condemned or properly re-cooked
– the reason why the product did not achieve
74°C must be determined and corrected
Step #10:
Establish Corrective Actions
53. Science
&
Advisory
Unit
53
Step #11:
Establish Verification Procedures
• HACCP Principle #6
• Verification
– ensures the HACCP plan is being properly followed
– confirms the plan is operating according to written
procedures
• Validation
– ensures the HACCP plan is complete and valid
– ensures the plan is effective in achieving expected
food safety outcomes
54. Science
&
Advisory
Unit
54
• Using the cooked meat pie example:
– At the end of each day, the HACCP Coordinator
will review the “cooking report” to confirm that
specified temperatures were achieved for each batch
– Once per month, the coordinator will perform an
on-site verification to confirm that the temperatures
of every batch are being taken as specified using a
calibrated thermometer
– Once every 6 months a random sample of 2 meat
pies will be taken and sent to a laboratory for
outside analysis
Step #11:
Establish Verification Procedures
55. Science
&
Advisory
Unit
55
Step #12:
Establish Record Keeping Procedures
• HACCP Principle #7
• Record keeping must be complete and
accurate and include:
– documentation pertaining to all 12 steps,
including the HACCP principles
– appropriate record storage procedures
– a log book to keep track of changes
56. Science
&
Advisory
Unit
56
• Using the cooked meat pie example:
– All “oven report” records must be maintained
and stored for pre-determined period of time
– A record of the verification activities must also
be maintained including:
• on-site inspection report
• semi-annual meat pie microbiological analysis
– All additional documents used to develop this
CCP must also be maintained.
Step #12:
Establish Record Keeping Procedures
57. Science
&
Advisory
Unit
57
HACCP System Summary
• To summarize, there are 2 parts to most
functioning HACCP systems
– Prerequisite Programs
• implemented prior to HACCP programs
• control the overall plant environment
• control factors not directly related to the food
– HACCP Plans
• implemented following pre-requisite programs
• specific to a certain product or process
• control factors directly related to food production
60. Science
&
Advisory
Unit
60
Why does industry need HACCP?
There are numerous consequences for some
businesses if HACCP is not implemented.
• Not using the best food safety system available - adversely
affects credibility
• Industry now relies mainly on government inspection for
food safety assurance - limited sense of responsibility for
food safety
• Industry stakeholders threatened by shrinking market
access (especially SMEs) as market place increasingly
requires that food be produced under recognized HACCP
systems
• Ontario’s food processing industry is falling behind other
jurisdictions - adversely affects competitiveness
61. Science
&
Advisory
Unit
61
What is industry’s current stance?
• Larger industry players are implementing HACCP
systems
• Industry strongly stresses the need for a
government recognition system
• Pressure to develop pilot projects
• Pressure from non-regulated as well as regulated
industries
• Owner/operators of small operations are confused/
overwhelmed/less aware
62. Science
&
Advisory
Unit
62
OMAF faces new and exciting challenges in
designing a science-based food safety system
that is:
Feasible for Ontario’s industry to implement,
Capable of controlling the food-safety hazards within
Ontario,
Acknowledged by other government bodies and
players in the food industry, and
Accepted in the market place by buyers.
What is OMAF’s Strategy?
63. Science
&
Advisory
Unit
63
Hired 2 HACCP Advisors
Completed initial background policy analysis
Assisted with the development of a national HACCP
recognition protocol with CFISIG (Canadian Food
Inspection System Implementation Group)
HACCP working group
FID - Processing, ARD - On-farm
representatives from various commodity areas
Where are we now?
64. Science
&
Advisory
Unit
64
Received policy direction on 4 key issues:
Approach to HACCP implementation
Scope of HACCP implementation
Mandatory vs. Voluntary HACCP systems
Recognition of HACCP systems
Received feedback on these issues at
industry discussion sessions held in June
Continue with economic analysis &
HACCP plan development
Where are we now?
65. Science
&
Advisory
Unit
65
– Pre-requisites + 7 HACCP principles = HACCP
– Interpretation, delivery, and implementation can vary
(i.e. FSEP, QMP, Codex, SQF, etc.)
– In selecting an approach we must consider:
• level of food safety delivered
• reception in other jurisdictions
• integration with other food safety systems
• practicality of implementation
• acceptance by stakeholders
• cost to government
Issue #1: HACCP Approach
66. Science
&
Advisory
Unit
66
Issue #2: Recognition
– Without government recognition:
• Little value for a plant to implement HACCP
• Unlikely that HACCP systems would be accepted by
buyers
– Costs must be considered
– OMAF recommends a 3rd party recognition system
• OMAF would accredit
independent 3rd parties
• Independent 3rd parties would
recognize individual facilities
67. Science
&
Advisory
Unit
67
Issue #3: Mandatory/Voluntary
– HACCP can be implemented as:
• mandatory requirement through regulation
• voluntary program
• mandatory for high risk commodities, voluntary for others
• staged approach from voluntary to mandatory
– Benefits and drawbacks to each
– A voluntary or staged approach seems most suitable
68. Science
&
Advisory
Unit
68
Issue #4: Scope of Recognition
– Scope of facilities targeted is potentially large
– All non-federally registered food processing facilities.
– Total could number in the thousands
– May be practical to use a staged transition based on:
• inherent risk with the food product
• presence of an established government infrastructure
• readiness and willingness of the sector to adopt HACCP
– OMAF is recommending the availability of HACCP
recognition to all non-federally registered food
processing facilities
70. Science
&
Advisory
Unit
70
On-Farm Food Safety Programs
• Have been or are in the process of being
developed by commodities in response to these
market demands.
OFFS Program Adoption Continuum
General
awareness
Best
management
practices
manual
Peer review
program
Industry
recognized on-
farm food
safety program
Government
recognized
HACCP-based
on-farm food
safety
programs
71. Science
&
Advisory
Unit
71
Risk-based Food Safety
• Some products are higher risk than others.
• Commodities assess their needs to
determine where best to position themselves
with regard to on-farm food safety
programs.
72. Science
&
Advisory
Unit
72
What Does This Mean For
Primary Producers?
HACCP-based programs will help primary
producers to:
– identify which hazards are most likely to be
introduced at the farm level
– identify which production practices best control
them
– monitor hazard controls points
– keep appropriate records to demonstrate program
compliance
73. Science
&
Advisory
Unit
73
What is OMAF’s On-farm Strategy?
For on-farm food safety systems, OMAF
intends to:
• Contribute to their continuous improvement
• Promote the adoption of effective science-
based initiatives.
• Support efficient implementation
74. Science
&
Advisory
Unit
74
OMAF is Ready for the
Challenge
• To encourage producers to adopt on-farm
food safety initiatives that will be continually
improving food safety, OMAF will focus on:
– identifying and eliminating barriers to
implementation
76. Science
&
Advisory
Unit
76
At The End Of The Day...
• OMAF will continue Ontario’s legacy as an
innovative leader in safe, high quality
agricultural products.
– An efficient and effective on-farm food safety
system for Ontario
– A feasible and effective recognized HACCP
system for the food processing industry
77. Science
&
Advisory
Unit
77
Are there any other HACCP-related
questions or issues?
We hope that you have found this information
session useful and informative
Supporting documentation of the presentation
can be found in the booklets provided
Thank-you for your time, input and
patience!
Conclusion
