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Hazard Analysis Critical Control Point (HACCP)

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Hazard Analysis Critical Control Point (HACCP) R E T A I L FS-4 FOOD SAFETY HACCP is an acronym for the Hazard Pillsbury Company, the National Analysis and Critical Control Point Hazard Analysis and Aeronautic and Space Agency system. HACCP is a preventative (NASA), the Natick Laboratories of system that is used in the food industry Critical Control the U.S. Army, and the U.S. Air Force to help ensure food safety. The basis for Space Laboratory Project Group worked HACCP is to identify potential hazards Points together on a project in food produc- associated with food production and tion for the NASA space program. The preparation, and to develop mecha- (HACCP) pathway of HACCP started in 1959 nisms to eliminate or control these when Pillsbury was asked to produce a hazards. HACCP can be applied to all for Foodservice food that could be used under zero areas of food production, from the farm gravity conditions in space capsules. In to the homes of consumers. HACCP is and Food Retail 1959, they began the project knowing important to all segments of the food Operations basically nothing about how foods industry. might react under zero gravity condi- tions. The most difficult and perhaps During the past twenty years, most Dr. Richard Linton, most important aspect of the project HACCP programs have been dedicated Extension Specialist was to develop a system to assure that to food processing plants which are in Department of Food Science food products would not be contami- the “middle” of the food production nated with biological, chemical, or chain. More recently, the food industry physical hazards. Such hazards might has realized the importance of establish- Dr. Barbara Almonza, result in an aborted or catastrophic ing HACCP principles for the end of mission. the food production chain: retail food Associate Professor and foodservice operations. Department of With these problems in mind, the Restaurant, Hotel, Institutional, and research groups concluded it was The use of HACCP can complement Tourism and Management necessary to develop a preventive food quality control programs. When safety system that would reduce the measures are taken to assure food safety, Purdue University likelihood of biological, chemical, and this generally results with better food physical hazards. In doing so, control quality. HACCP is not a stand-alone could be achieved over all aspects of system! Effective cleaning and This publication was reviewed by the food production including raw material, sanitizing programs and maintaining following outside reviewers: processing, environmental conditions, the health and cleanliness of the food Dr. Joseph Eifert, Ph.D. personnel, storage, distribution, and handler are also important for assuring a Manager of Microbiology, Nestle transport. This approach, referred to as safe, high-quality food. These programs USA, Inc HACCP, worked well for the NASA are typically not part of HACCP Dr. Jeff Rhodehamel, Ph.D. space program, and was quickly adapted programs because they are difficult to Microbiologist by the food industry. monitor, and safe limits have not been U.S. Food and Drug Administration clearly established. Dr. Cameron Hackney, Ph.D. A Systematic Study Professor of Food Microbiology HACCP involves a systematic study of History of HACCP Virginia Polytechnic Institute and the ingredients, the food product, the The concept of HACCP was initiated State University conditions of processing, handling, by the Pillsbury Company. The Department of Food Science • Purdue Cooperative Extension Service storage, packaging, distribution, and consumer use. The complete analysis Figure 2. Common hazards in foodservice and food retail operations. allows for the identification of the Biological: “sensitive” areas in the process flow Pathogenic bacteria (i.e Salmonella spp., Staphylococcus aureus) which might contribute to a hazard. Viruses (i.e. Hepatitis A) From this information, “Critical Parasites (i.e. Trichinella spiralis) Control Points” (CCP’s) can be Rodents and insects (can carry bacteria, viruses, parasites) determined. Areas identified as CCP’s Chemical: are monitored and limits are deter- Naturally occurring (i.e. seafood toxins) mined to control potential hazards. Added chemicals (i.e. cleaning agents, pesticides) When properly applied, HACCP can be used to control any area or point in Physical: the food system which could contribute Inherent to food (i.e. bone particles) to a hazardous situation whether it be Non-inherent to food (i.e. glass, stone, wood) contaminants, disease-causing microor- ganisms, physical objects, chemicals, raw materials, an unsafe process, CCP’s to control biological hazards in package labeling, or storage conditions. Determine CCP’s This step identifies critical areas or foodservice and food retail operations There are seven principles which are points of the flow of a food product that are usually time and temperature related used to develop and implement a are required to control the identified since they can be easily monitored. HACCP program (Figure 1). hazards. For an area to be considered a Time and temperature are also the most CCP, loss of control would mean the important factors permitting growth of likelihood of an unacceptable health bacteria. Occasionally, a measurement Figure 1. Seven principles of hazard. In HACCP programs, some- in pH (acidity of a food) may also be HACCP. times “control points” (CP’s) will also used as a critical limit. Although 1) Analyze hazards be identified. A CCP is different from a important, limits for chemical and physical hazards are used less often in 2) Determine CCP’s CP (Figure 3). A CCP indicates a high food safety risk (likely to occur) and a HACCP plans for foodservice and food 3) Establish critical limits for CCP’s CP indicates a low food safety risk (not retail. Chemical and physical hazard 4) Monitor CCP’s likely to occur). Food safety relies on levels are usually more easily monitored 5) Take corrective action identification and control of CCP’s, and controlled prior to receipt at a foodservice and/or food retail establish- 6) Do record keeping while, CP’s may be used for quality specifications. ment. For chemical hazards, it will be 7) Verify that the system is working important to ensure that chemicals (cleaning agents) are separated from Figure 3. CCP or CP ? foods. A visual inspection can be used Hazard Analysis for physical hazards. In the first step of HACCP, it is If control is lost, is it LIKELY that a health Time and temperature limits can be set important to identify potential hazards risk will occur? for various areas of retail food produc- that might be associated with growing, If the answer is YES, this is considered a tion. They include receiving, cold harvesting, raw materials and ingredi- CCP. storage, thawing, cooking, cooling, ents for processing, manufacturing, If the answer is NO, this is considered a CP. reheating, hot-holding, and cold- distribution, marketing, preparation, holding of foods. Some suggested and consumption of the food. critical limits are included in Figure 4. The purpose of hazard analysis is to identify all potential hazards (biologi- Establish Critical Limits for Monitoring CCP’s cal, chemical, and physical) that may CCP’s Monitoring CCP’s includes the be associated with the flow of a given This step establishes upper and/or lower recording of data (temperature, time) food. Some potential hazards of concern limits for each CCP. CCP’s are set for for limits which have been set for each in foodservice and retail foods are foods that can naturally carry and/or CCP in the HACCP plan. Data identified in Figure 2. The types of support the growth of a foodborne collection is important to assure that hazards depend on the type(s) of foods hazard. These types of foods are called CCP limits are being met. The and preparation practice(s) involved. potentially hazardous foods. Limits for procedures and frequency for monitor- 2 ing CCP’s will differ depending on the type of food(s) and the preparation Figure 4. Temperature/time critical limits for retail food preparation. practices used. Receiving: Internal temperature should be <41°F for all potentially hazardous foods. Corrective Action Cold Storage: Internal temperature should be maintained at <41°F for all potentially If monitoring shows that a limit for a hazardous foods. CCP has been exceeded, corrective Thawing: Refrigerator thawing at <41°F is suggested. Microwave thawed foods action procedures must be in place to must be cooked immediately after thawing. Cool water thawing must be done at <70°F for assure the safety of the food. Corrective <2 hours from a continuously running potable water supply. Thawing at room temperature action procedures may range from is not acceptable. discarding the product to simply Preparation of Food: Preparation of potentially hazardous foods should be done so cooking the product to a higher that food is held not between 41-140°F whenever possible. If food must be prepared temperature. Corrective action between 41°-140°F, it can only be exposed in this temperature range for 4 hours total time, procedures will differ depending on the however, <2 hours total time is preferred. type of foods and the preparation practices used. Cooking: Food type Internal temperature* Holding time Record Keeping Beef roast (rare) 130°F 121 minutes Keeping records of the HACCP plan Beef roast (rare) 140°F 12 minutes and for monitored CCP’s is extremely Eggs, meat, fish 140°F 15 seconds ° important. It is a good idea to have Pork, game animals, 155 F 15 seconds records available for 1 year on location, ground beef Poultry, stuffed meats 165°F 15 seconds and for 3 years total. Good record *Microwave cooking Add 25°F ——— keeping helps to assure proper use of the HACCP program and the safety of Cooling: Potentially hazardous foods must be cooled from 140°F to 70°F within 2 foods that are served.
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