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The Hazard Analysis & Critical Control Point System for Food Processors

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The Hazard Analysis & Critical Control Point System for Food Processors RISK MANAGEMENT HACCPAN INTRODUCTION TO The Hazard Analysis & Critical Control Point System for Food Processors By A.V. RISWADKAR ccording to a 1996 U.S. Dept. marily on finished product testing and to distribution. Even potential consumer of Agriculture (USDA) report, general sanitation; these have proven to abuse and misuse can be considered foodborne microbiological be inadequate in controlling many food- under HACCP principles. contamination in the U.S. borne illnesses, such as salmonellosis, With HACCP in place, a food proces- causes an estimated 9,000 e-coli and listeriosis in meat and dairy sor can identify and monitor specific deaths and 33 million human products. Meanwhile, the Food and Drug foodborne hazards that are biological, illnesses annually. The cost of Administration (FDA), USDA and other chemical or physical in nature. A system- AAthese human illnesses and lost productivi- food regulatory agencies are seeking atic hazard analysis is used to identify ty is estimated to be $9.3 to $12.9 billion alternative approaches that will effective- critical control points (CCPs) in the proc- annually (Bacterial Foodborne Diseases). ly and comprehensively evaluate a food ess; these points must be controlled in Recent headlines have reported food plant’s ability to produce consistently order to ensure food safety and prevent safety problems. “Hot dogs blamed for safe, high-quality foods. adverse health impact on the consumer. Listeria outbreak” (AP-Detroit, MI, June This enables the processor to focus con- 1999). “12th death is linked to tainted HAZARD ANALYSIS & CRITICAL CONTROL POINT trol efforts on specific critical points, meat at plant” (New York Times, Jan. 27, The Hazard Analysis and Critical which also prevents the inefficiency asso- 1999). “Armed with E-coli horror stories, Control Point (HACCP) system is one ciated with overapplication of extraordi- consumer groups demand safer meat” such alternative. It focuses on identifying nary sanitation measures. (CNN, Nov. 10, 1999). and preventing hazards that could cause In the drive to ensure food safety, Due to this increased attention, con- foodborne illnesses rather than relying on HACCP is becoming a necessity for all sumer expectations about food quality spot-checks of manufacturing processes food processors; it is now widely accepted and safety have grown, prompting food and random sampling of finished food as an effective part of a total quality pro- processors to seek systems and programs products to ensure safety. Combined with gram. In addition, FDA has incorporated that will both bolster consumer confi- an effective hazard analysis technique, HACCP into its 1999 Food Code, a guid- dence and improve food safety. HACCP allows safety and quality to be ance document that is a model regulation Traditional quality assurance pro- built into each step within the process— for state and local agencies responsible for grams and facility inspections focus pri- from product formulation specifications licensing and inspecting food service AMERICAN SOCIETY OF SAFETY ENGINEERS JUNE 2000 33 HACCP follows a basic risk management philosophy. By identifying critical risk factors, a firm can focus its prevention and mitigation resources to maximize its risk management efforts. establishments, retail food stores and approach to HACCP systems is taking the words, one cannot depend on the advan- vending operations. USDA now requires form of workshops, manuals and training tage of consumer cooking to eliminate all meat and poultry processors to imple- videos developed under the sponsorship remaining microbiological hazards. ment an effective HACCP system and of the International Dairy Foods Assn., Based on these factors, food risk cate- reassess its adequacy at least annually. National Cheese Institute and American gories are assigned as “0” to “VI,” with Butter Institute. Many generic HACCP “VI” being the highest risk. Foods that HISTORY OF HACCP programs have also been developed; for fall into risk factor “A” (e.g., infant for- HACCP emerged as the result of sever- example, FSIS has developed several mula, baby food) automatically become a al joint projects conducted during the generic HACCP models. risk category “VI,” while foods with no 1960s to develop food for the space pro- risk factors (B-F) are categorized as “0.” gram. The approach was presented at the THE SEVEN PRINCIPLES Foods with one risk factor (other than 1971 Conference on Food Protection, Conduct Hazard Analysis & Risk Assessment “A”) are risk category “I.” Those with where it was viewed as a solution to micro- This first principle may be the most two factors (other than “A”) are category biological problems with low-acid canned important. Effective controls cannot be “II” and so on. foods, particularly mushrooms. This led to considered until hazards have been iden- Risk categories can also be assigned to promulgation of Low-Acid Canned Foods tified and their risks assessed. This can be ingredients, incoming raw materials, in- regulation by the FDA in 1974. an involved process, since all potential process foods and finished products. These The original HACCP (1971) was based hazards should be evaluated. Further- categories are useful indicators for priority on three principles: more, failure to recognize a potential haz- identification in the next task—the specific 1) Comprehensive hazard analysis ard can lead to an unacceptable risk, even hazard identification and analysis. and risk assessment. if controls and monitors for identified The focus on consumer safety is funda- 2) Determination and identification of hazards are implemented correctly. mental to HACCP. However, the program CCPs. In 1992, in its “Hazard Principles for can be effectively extended to include other 3) Monitoring of CCPs. Food Production” report, NACMCF de- potential problem types, provided food By 1986, subcommittees of both the fined a hazard as “any chemical, physical safety hazards remain separate and distinct National Conference on Food Protection or biological property that could cause an from those unrelated to food safety. A flow and National Academy of Sciences had unacceptable consumer health risk.” This diagram can be used to document the pro- recommended that the HACCP approach report introduced a food risk categoriza- duction and distribution processes and be adopted by both the U.S. food industry tion process that forms a basis for this first help identify hazards at each step. and regulatory agencies. These recommen- principle. To ensure uniformity, food risk Risk hazard analysis helps identify dations led to formation of the National assessment should encompass the follow- potential types of hazards and their Advisory Committee on Microbiological ing six hazard characteristics. sources. Biological hazards in food proc- Criteria for Foods (NACMCF) in 1987. This A) Food intended for consumption by essing include bacterial, viral, or enteric committee expanded the HACCP protocol at-risk population. This category accounts and parasitic organisms. Chemical hazards to include the seven principles now wide- for risk factors introduced when con- include naturally occurring elements (such ly accepted as the standard. sumers are very young, elderly or other- as mycotoxins from mold), toxic mush- 1) Conduct hazard analysis and risk wise unusually susceptible to potential rooms, plant toxins and chemicals added assessment. hazards of the evaluated food product. during food processing (such as pesticide 2) Identify critical control points in B) Product contains sensitive ingredi- residues, food additives and lubricants). food preparation. ent(s). This accounts for any ingredient Physical hazards come in different forms, 3) Establish critical limits for each CCP. that may be a source of a hazard or might such as glass, stones or metal fragments, 4) Establish procedures for monitoring be a carrier of a microbiological hazard with the most likely outcomes ranging the CCPs. (e.g., eggs). from a chipped tooth to choking. 5) Establish corrective action protocol C) No process step to eliminate haz- for each CCP. ard. For example, raw milk is still sold in Identify CCPs in Food Preparation 6) Establish procedures for effective the U.S. Elimination of the pasteurizing Many points in food processing can be recordkeeping. step is an example of this factor. considered control points, but few are 7) Establish procedures for an effective D) Recontamination potential before critical control points (CCPs). According verification (audit). packaging. Aseptic packaging has sever- to NACMCF, a CCP is any controllable Today, many HACCP programs and al control advantages over traditional point in a specific process where loss of studies are in progress. One of the system’s packaging. One key benefit is the reduc- control may result in unacceptable risk. It greatest strengths is its adaptability to tion of the recontamination potential. is a point, step or procedure in food widely varied processes. For example, E) Potential for product abuse. Does preparation where a food safety hazard USDA’s Food Safety and Inspection Ser- a real potential exist for abuse to the can be prevented, controlled, reduced or vice (FSIS) is applying HACCP principles product during distribution or consumer eliminated. For example, time-tempera- to meat and poultry product safety. These handling that could lead to an unsafe ture relation in pasteurization is a CCP. principles are also the center of an ongoing product? As noted, NACMCF defined CCPs joint seafood inspection program
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