TAIEX MUGLA 7 8 March Workshop on Food Borne Poisoning and Outbreaks

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1 TAIEX MUGLA 7 8 March 2013 Workshop on Food Borne Poisoning and Outbreaks Dr. Jan Van Seghbroeck Federal Agency for the Safety of the Food Chain Belgium

2 Dr. Jan Van Seghbroeck - FASFC Basic HACCP Principles for catering establishments, hotels and restaurants: HACCP implementations and identifying critical control points in these establishments

3 Content Introduction Background to HACCP Prerequisite Programmes Practical Implementation of HACCP

4 Introduction What is HACCP? Have A Cup of Coffee & Pray??? NO Hazard Analysis Critical Control Points

5 Introduction Did you know... HACCP was first developed for use in America s space program HACCP is a prevention plan, not a testing program HACCP was scrutinized and endorsed by both industry and regulators HACCP is the application of common sense and scientific principles to food processing

6 Background to HACCP Background to EC Regulations Food hygiene requirements in the European Union are based upon: Regulation 852/2004 on the hygiene of food stuffs Regulation 853/2004 on specific hygiene rules for products of animal origin

7 Background to HACCP Regulation 852/2004 on the hygiene of foodstuffs Came into force across the whole of the EU on the 1st January 2006 General principles for the hygienic production of foodstuffs, throughout the food chain Primary objective - to ensure a high level of consumer protection with regard to food safety

8 Background to HACCP Regulation 852/2004 on the hygiene of foodstuffs Preamble: The HACCP system is an instrument to help food business operators attain a higher standard of food safety The HACCP requirements should take account of the principles contained in the Codex Alimentarius. They should provide sufficient flexibility to be applicable in all situations, including in small businesses.

9 Background to HACCP Regulation 852/2004 on the hygiene of foodstuffs Article 5 Food business operators shall put in place, implement and maintain a permanent procedure or procedures based on the HACCP principles. requires a full documented HACCP system applies to food businesses at any point after primary production

10 Background to HACCP Regulation 852/2004 on the hygiene of foodstuffs The HACCP principles referred to in paragraph 1 consist of the following: (a) identifying any hazards that must be prevented, eliminated or reduced to acceptable levels; (b) identifying the critical control points at the step or steps at which control is essential to prevent or eliminate a hazard or to reduce it to acceptable levels;

11 Background to HACCP (2) The HACCP principles referred to in paragraph 1 consist of the following: (c) establishing critical limits at critical control points which separate acceptability from unacceptability for the prevention, elimination or reduction of identified hazards; (d) establishing and implementing effective monitoring procedures at critical control points; (e) establishing corrective actions when monitoring indicates that a critical control point is not under control;

12 Background to HACCP (2) The HACCP principles referred to in paragraph 1 consist of the following: (f) establishing procedures, which shall be carried out regularly, to verify that the measures outlined in subparagraphs (a) to (e) are working effectively; (g) establishing documents and records commensurate with the nature and size of the food business to demonstrate the effective application of the measures outlined in subparagraphs (a) to (f).

13 Background to HACCP Regulation 853/2004, laying down specific hygiene rules for products of animal origin Contains detailed hygiene rules for products of animal origin (fresh meat, meat products, dairy products, fish, eggs, etc) recognising the specific microbiological and chemical hazards associated with such foods Products of animal origin also subject to the general hygiene rules in Regulation 852/2004 and thus the requirement for procedures based on the HACCP principles Also came into force across the EU on the 1st January 2006

14 Background to HACCP Other relevant EC Regulations include: Regulation 854/2004, on the organization of official controls on products of animal origin intended for human consumption Regulation 882/2004, on official controls performed to ensure the verification of compliance with feed and food law, animal health and animal welfare rules Regulation 2073/2005 on Microbiological Criteria for foodstuffs Regulation 178/2002 on the general principles and requirements of food law

15 Prerequisite programmes Terminology Mandatory Food hygiene requirements (Prerequisite food hygiene requirements EC DG SANCO Guidance) Commercial SSOP (Sanitation standard operating procedure) GMP (Good manufacturing practices) GHP (Good hygiene practices)

16 Prerequisite programmes EC DG SANCO HACCP Guidance Prior to the application of HACCP to any business, the FBO should have implemented the prerequisite food hygiene requirements The prerequisite requirements provide the foundation for effective HACCP implementation Food hygiene is the result of the implementation of prerequisite requirements and procedures based on HACCP principles Specific requirements of 178/2002 e.g. traceability

17 Prerequisite programmes Guides to Good Practice Sector Specific Advice, set out in National and Community Guides to Good Practice, developed under Regulation 852/2004 (Articles 7, 8,9) Not legally binding, a business may demonstrate compliance with the legislation in other ways Collated list of industry guides from the member states

18 Prerequisite programmes Codex and Prerequisites Prior to the application of HACCP to any sector of the food chain, that sector should have in place Prerequisite Programmes HACCP Prerequisite Programs GMP GHP SOP SSOP Structure of buildings, equipment

19 Prerequisite programmes General Principles of Food Hygiene Primary production Design and facilities Control of operation Maintenance and sanitation Personal hygiene Transportation Product information and consumer awareness Training (Codex AlimentariusFood Hygiene Basic Texts)

20 Prerequisite programmes Regulation 852/2004 Annex II General Hygiene Requirements for all FBOs (Except when Annex I applies) Premises: General requirements for food premises (e.g. layout, design, construction, siting, size, lavatories, washbasins, ventilation) Specific requirements in rooms where food is prepared, treated or processed (floors, walls, ceilings, windows, doors, surfaces) Equipment requirements

21 Prerequisite programmes Regulation 852/2004 Annex II General Hygiene Requirements for all FBOs (Except when Annex I applies) Personnel: Personal hygiene The health of staff Training

22 Prerequisite programmes Regulation 852/2004 Annex II General Hygiene Requirements for all FBOs (Except when Annex I applies) Product/Raw Materials: Transport Food waste Water supply Provisions applicable to foodstuffs (pests, chill-chain, thawing) Provisions applicable to wrapping and packaging of foodstuffs Heat treatment in hermetically sealed containers

23 Practical Implementation of Pre-Pro Example: Reporting Employee Illness and Injury SOP Policy: All employees will report illness and injury, and will be restricted from working with food, as necessary to prevent the contamination of food. Procedures: employees must report a. vomiting, diarrhea, jaundice, sore throat with fever b. exposure to or diagnosis of foodborne illness caused by: Salmonella Typhi, Shigella spp., Shiga toxin-producing E. coli, Hepatitis A virus, Norovirus c. any cuts, burns, boils, sores, skin infections or infected wounds

24 Practical Implementation of Pre-Pro Example: Reporting Employee Illness and Injury SOP Corrective Action: a. Restrict the employee from working with or around food b. Exclude the employee from the establishment c. Exclude the employee and notify when diagnosed with a foodborne illness d. Cover any open wounds with a clean, dry and leak proof bandage (gloves) e. Discard food that may have become contaminated due to employee illness and Injury f. Retrain any employee not following procedures in this SOP Verification and Record Keeping: a. Record corrective action in Personnel File b. Record product name and reason for discarding food on Production Record

25 Practical Implementation of Pre-Pro Example: Receiving Food SOP Policy: All food and non-food deliveries will be checked prior to storing in the facility to help ensure food quality and safety Procedures: employees in charge must a. Only accept deliveries if authorized to accept, reject and sign for deliveries, and have been trained to check product for proper temperatures, expired code date, signs of thawing and refreezing, pest damage, etc. b. Plan ahead for shipments (storage space, cleaning..) c. Accept deliveries during times allowing for adequate inspection d. Inspect deliveries immediately; check for correct product, quantities, damaged or mishandled product,weights e. Measure temperature of products, of delivery truck f. Label the product with the receiving date

26 Practical Implementation of Pre-Pro Example: Receiving Food SOP Corrective Action: a. Reject food that: is not the correct product, is damaged, shows signs of mishandling (thawing and refreezing), shows signs of insect infestation, has damaged packaging (tears, leaks, flawed seals, rust, swollen ends, etc.) is past the expiration date b. Reject refrigerated food that is above 5 C (41ºF) c. Reject frozen food that is above 18 C (0 ºF) and shows signs of thawing or refreezing d. Send (if immediate action is required) to purchasing agent Verification and Record Keeping: a. verify that food has been safely received by monitoring employees and reviewing temperature logs daily b. Record of temperatures on the Truck Receiving Temperature Log and details of products rejected

27 Practical Implementation of Pre-Pro Example: Monitoring Visitors SOP Policy: Visitors will follow all food safety procedures Procedures: employees involved in escorting visitors must: a. Limit the number of unnecessary visitors in food preparation areas: students, vendors b. Ensure that visitors wash hands and wear hair restraints properly c. Ensure that visitors follow all other food and equipment safety and sanitation practices

28 Practical Implementation of Pre-Pro Example: Monitoring Visitors SOP Corrective Action: 1) Remove visitors not following safety and sanitation procedures from food preparation areas 2) Discard food if contamination likely occurred 3) Record product name and reason for discarding 4) Clean food-contact surfaces if contamination likely occurred Verification and Record Keeping: a. verify that food safety and sanitation are not compromised by visitors b. record product name of discarded items and reason for corrective action taken

29 Obtain management commitment Define terms of reference/scope of the study Select the team Describe the product Identify intended use Flow diagram/define process Confirm flow diagram Identify and list potential hazards

30 Conduct a hazard analysis Specify control measures Determine CCPs Establish critical limits Establish monitoring system Establish corrective action plan Validation, verification & review Establish documentation and records

31 The Scope of the HACCP Plan Should be identified Should describe which segment of the food chain is involved, which process of the business the general classes of hazards to be addressed (biological, chemical and physical) Can also be called Terms of Reference (Based on EC DG SANCO HACCP Guidance Document)

32 Regulation 178/2002 Definitions Risk means a function of the probability of an adverse health effect and the severity of that effect, consequential to a hazard Hazard means a biological, chemical or physical agent in, or a condition of, food or feed with the potential to cause an adverse health effect

33 HACCP Team Should involve all parts of the food business concerned with the product Needs to include the whole range of specific knowledge and expertise appropriate to the product under consideration. Where necessary, the team will be assisted by specialists. (Based on EC DG SANCO HACCP Guidance Document)

34 Principle 1 List all hazards associated with each process step Analyse the hazards List of measures which will eliminate, prevent or reduce hazards: i.e. control measures

35 Principle 1 Recognize the flow of food - the path that foods travel in your operation. The sequence may include the following: Development of recipe Purchase of ingredients and supplies Delivery of ingredients and supplies Storage of ingredients and supplies Preparation -- thawing, processing and cooking Holding or display of food Service of food Cooling and storing of food Reheating for service

36 Product description/ Intended use Prepare a full description of the product, including relevant safety information: Composition Structure and physico-chemical characteristics Processing Packaging Storage/distribution conditions Required shelf-life Instructions for use Any microbiological or chemical criteria Intended use and consumer target group (Based on EC DG SANCO HACCP Guidance Document)

37 Flow Diagram Defines all operational steps (of the process) in sequence Raw material intake to, at least, product dispatch Include delays, return loops or product reworking Correct for all operational times/shifts Confirmed as correct by team during operating hours Supplementary information may also be required: site plan, equipment layout, technical parameters of operations, segregation of clean/dirty or high/low risk areas/site product/staff/material flows

38 Identify hazards such as: Bacterial contamination Survival of bacterial contaminants Biological, physical and chemical contamination Cross-contamination

39 Estimate risks If you serve a large number of potentially hazardous foods, several factors can increase the chance of food borne illness: 1. Type and age of customer young, elderly, or immune suppressed 2. Resistance to food borne illness; 3. Vendors/distributors approved; 4. Equipment and facilities (must be in good working condition Employees (must be trained in safe food handling and preparation procedures).

40 Control Measure Actions and activities that can be used to prevent or eliminate food safety hazards or reduce their impact or occurrence to acceptable levels (Based on EC DG SANCO HACCP Guidance Document)

41 Principle 2 Critical Control Point 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 Use professional judgement Application of a decision tree may be useful (Based on EC DG SANCO HACCP Guidance Document)

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43 Principle 3 Critical Limits Establish critical limits at critical control points which separate acceptability from unacceptability for the prevention, elimination or reduction of identified hazards Correspond to the extreme values acceptable with regard to product safety. Target levels are more stringent levels that can be used to ensure that critical limits are met. A deviation is a failure to meet a critical limit (Based on EC DG SANCO HACCP Guidance Document)

44 Principle 4 Monitoring A program of observations or measurements performed at each CCP to ensure compliance with specified critical limits Observations or measurements must be able to detect loss of control at critical points in time for corrective actions to be taken (Based on EC DG SANCO HACCP Guidance Document;)

45 Monitoring Records Records associated with monitoring CCPs must be signed by the person(s) doing the monitoring and when records are verified, by a responsible reviewing official(s) of the company (Based on EC DG SANCO HACCP Guidance Document;)

46 Principle 5 Corrective Action Establish corrective actions when monitoring indicates that the critical control point is not under control Planned in advance Followed when there is a deviation from the critical limit or a trend towards loss of control (Based on EC DG SANCO HACCP Guidance Document)

47 Corrective Action Records Corrective actions should include a written record of measures taken indicating all relevant information - for example: date time type of action persons taking the action subsequent verification check (Based on EC DG SANCO HACCP Guidance Document;)

48 Principle 6 The HACCP team should specify the methods and procedures to be used for determining if the HACCP is working correctly. Validation (where possible) Verification Review (EC DG SANCO HACCP Guidance Document)

49 Codex Key Terms VALIDATION Obtaining evidence that a control measure or combination of control measures, if properly implemented, is capable of controlling the hazard to the specified level VERIFICATION The application of methods, procedures, tests and other evaluations, additional to monitoring, to determine whether a control measure is or has been operating as intended (based on the definition in CAC/GL )

50 Microbiological Criteria for Foodstuffs Regulation (2073/2005/EC) To protect public health and provide harmonized reference points for FBOs Recital 5 of MCR states: The safety of foodstuffs is mainly ensured by a preventative approach such as implementation of GHP and HACCP principles. Microbiological criteria can be used in validation and verification of HACCP procedures and other hygiene control measures.

51 Review Scheduled (at least annually) Triggered (before change) Internal factors External factors

52 Principle 7 Documentation Holding an accurate record is essential for the implementation of HACCP and HACCP procedures should be documented. The establishment of a documentation and record keeping should be appropriate to the nature and extent of the operation and sufficient to assist the company to verify that the HACCP controls are in place and are maintained. (EC DG SANCO HACCP Guidance Document)

53 Flow chart: centralized food service

54 Critical control point COLD FOOD MUST BE MAINTAINED AT 4ºC (41ºF) OR BELOW WHILE HOLDING AND SERVING.

55 Observation Mediterranean salad was held at 11ºC. CORRECTIVE ACTION - If the salad has remained between 5ºC and 21ºC for less than two hours, serve the product immediately (within 30 minutes) or chill product quickly to reach safe product temperature. Record action. - If the item has been held at this temperature or higher for more than two hours, discard immediately. Record action.

56 Critical control point RAW FOOD IS COOKED TO CORRECT MINIMUM INTERNAL TEMPERATURE

57 Observation Hamburger has not been cooked to minimum internal temperature of 74ºC. CORRECTIVE ACTION Continue cooking process until hamburger has reached correct internal temperature. Temperature must register on thermometer for 15 seconds. The hamburger may not be served until it has reached the required internal temperature. Record action.

58 Critical control point FOOD THAT IS COOKED, COOLED AND REHEATED FOR HOT HOLDING IS REHEATED RAPIDLY (WITHIN TWO HOURS) TO 74ºC (165ºF) FOR 15 SECONDS.

59 Observation Leftover hamburger has been reheated too slowly and reached an internal temperature of only 65ºC. CORRECTIVE ACTION Rapidly bring temperature to 74ºC for 15 seconds and serve the hamburger immediately (within one hour). Record action.

60 Critical control point HOT FOOD MUST BE MAINTAINED AT A MINIMUM TEMPERATURE OF 60ºC (135ºF) OR ABOVE WHILE HOLDING AND SERVING.

61 Observation Pasta was held at a temperature of 49ºC for ONE hour. CORRECTIVE ACTION Rapidly reheat pasta to 74ºC for 15 seconds and hold above 60ºC or serve immediately (within one hour). Record action.

62 Observation Pasta was held at temperature below 49ºC. CORRECTIVE ACTION - If pasta has been held at this temperature for less than two hours, rapidly reheat to 74Cº for 15 seconds and hold above 60Cº. Record action. - If the item has been held at this temperature for more than two hours, discard immediately. Record action.

63 Critical control point FOOD IS COOLED QUICKLY AND SAFELY TO 21ºC (70ºF) WITHIN TWO HOURS AND THEN TO 4ºC (40ºF) OR BELOW WITHIN AN ADDITIONAL TWO HOURS (TOTAL COOLING TIME FOUR HOURS).

64 Observation After four hours of cooling leftover meat sauce/gravy, the product temperature was above 15ºC. CORRECTIVE ACTION Discard meat sauce/gravy immediately. Record action.

65 Critical control point REFRIGERATION EQUIPMENT MUST BE MAINTAINED AT 4ºC (40ºF) OR BELOW.

66 Observation Refrigeration thermometers register ambient temperature of 11ºC or above. CORRECTIVE ACTION - Immediately check product temperature. Discard all potentially hazardous foods immediately if product temperature is10ºc or above. Remove other foods to safe refrigerated storage area immediately. Record action. - Contact the appropriate maintenance department for repair and document request in writing. Follow up as necessary. Record action.

67 Thank you!