HACCP AND GOOD MANUFACTURING PRACTICES

2.  Hazard analysis and critical control point
 Concept of HACCP originated in 1960s by NASA.
 The HACCP system – as we know took form in 1971
at national conference on food protection, where risk
assessment was combined with CCP.
 The Pillsbury company first used HACCP for the
assurance of the safety of the U.S food program.
 The United States Department of Agriculture (USDA)
published a final rule in July 1996
 mandating that HACCP be implemented as the
system of process control in all USDA inspected
 meat and poultry plants.

3. Poultry meat is after pork-meat, the world’s
most popular animal food product.
The diversity of available products, its
convenience of preparation combined with
an attractive price, have given poultry
products a ranking above beef and pork
products.
Additional to these positive aspects poultry
meat does not encounter major objections
from religious groups.

4.  Poultry and poultry products have been found
contaminated with Salmonella, Campylobacter
and other potentially pathogenic micro-
organisms and it is for that reason that poultry
products are often named as cause of human
food-borne diseases.
 In poultry Avian Influenza (AI) and New Castle
Disease (NCD) are on the OIE list category A. In
case of AI the present crises show that there is a
serious public health risk.
 In case of NCD vaccination there only can be a
health risk to the workers in case of abuse of the
application.
 With this in mind the information on food safety
aspects in the poultry production chain is
provided.

5.  Hazard: Any biological, chemical, or physical
property that may cause a food to be unsafe
for human consumption.
 Critical control point: A point, step, or
procedure in a food process at which control
can be applied and, as a result, a food safety
hazard can be prevented, eliminated, or
reduced to acceptable levels.
 Critical limit: The maximum or minimum value
to which a physical, biological, or chemical
hazard must be controlled at a critical control
point to prevent, eliminate, or reduce to an
acceptable level the occurrence of the
identified food safety hazard.

6.  Preventive measure: Physical, chemical, or other
means that can be used to control an identified
food safety hazard.
 Process-monitoring instrument: An instrument
or device used to indicate conditions during
processing at a critical control point.
 Responsible establishment official: The
individual with overall authority on-site or a
higher level official of the establishment.

8.  Principle No. 1: Conduct a Hazard Analysis.
Prepare a list of steps in the process where
significant hazards occur, and describe the
preventive measures.
 Principle No. 2: Identify the Critical Control
Points (CCP’s) in the process.
 Principle No. 3: Establish critical limits for
preventive measures associated with each
identified CCP.
 Principle No. 4: Establish CCP monitoring
requirements. Establish procedures for
using the results of monitoring to adjust
the process and maintain control.

9.  Principle No. 5: Establish corrective action to be
taken when monitoring indicates that there is a
deviation from an established critical limit.
 Principle No. 6: Establish effective
recordkeeping procedures that document the
HACCP system.
 Principle No. 7: Establish procedures to verify
that the HACCP system is working correctly.

10. Development of the Plant Specific HACCP Plan:
 The National Advisory Committee on Microbiological
Criteria for Foods (NACMCF) has defined 12 steps
(five preliminary steps listed below and the seven
principles from HACCP) in developing a HACCP
plant-specific plan.
PRELIMINARY STEPS
1) Assemble the HACCP team.
2) Describe the food and its method of distribution.
3) Identify the intended use and consumers of the
food.
4) Develop a flow diagram which describes the
process.
5) Verify the flow diagram.

11.  Description of the Product
 Process Flow Diagram
 Hazard Analysis
 Critical Control Point (CCP) Determination
 HACCP Plan Development

12.  List of Process Models
 Generic HACCP Model for Poultry Slaughter
 Generic HACCP Model for Pork Slaughter
 Generic HACCP Model for Raw, Not Ground Meat and Poultry Products
 Generic HACCP Model for Raw, Ground Meat and Poultry Products
 Generic HACCP Model for Mechanically Separated (Species)/Mechanically Deboned
 Generic HACCP Model for Heat Treated Not Fully Cooked, Not Shelf Stable Meat and
 Poultry Products
 Generic HACCP Model for Meat and Poultry Products with Secondary Inhibitors, Not
Shelf-Stable
 Generic HACCP Model for Not Heat Treated, Shelf-Stable Meat and Poultry Products
 Generic HACCP Model for Fully Cooked, Not Shelf-Stable Meat and Poultry Products
 Generic HACCP Model for Heat Treated, Shelf-Stable Meat and Poultry Products
 Generic HACCP Model for Thermally Processed Commercial Sterile Meat and Poultry
Products
 Generic HACCP Model for Irradiation

14. RECEIVING MEAT
STORAGE OF MEAT
WEIGHING,GRINDING
FINAL GRIND MEAT
PACKAGING/LABELLING
COOLING/STORAGE
SHIPPING

15.  The Hazard Analysis/Preventive Measures Form is used to
review the steps listed in the Process Flow Diagram and
identify where significant hazards could occur and describe
the preventive measures.
 The Hazard Analysis consists of asking a series of questions
which are appropriate to the specific food process and
establishment.
 The potential significance of each hazard should be assessed
by considering its risk and severity.
 A preventive measure is a physical, chemical, or other means
which can be used to control an identified food safety hazard.

16. Step HAZARD PREVENTIVE
MEASURES
CORRECTIVE
ACTION
Chicks
history
Disease carriers. Poultry from
certified sources.
Notify
authority.
Feed and
storage
Product contamination
due to pathogens and
medication misuse.
Feed from certified
sources &
produced under
certified conditions
Reject source,
alternative
supply.
Water and
storage
Pathogens in potable
water.
Clean supply and
protected storage
Upgrade water
source, inform
supplier.
Catching
and
transport
Shedding of pathogens
through stress.
Application of feed
and water
withdrawal,
Cleaning and
disinfection of
transport vehicles
Cleaning and
disinfection of
equipment,
instruction of
farmers.

17. Scalding and
plucking
Cross contamination
during the process.
Sufficient water
supply, cleaning and
disinfection.
Instruction of
management,
cleaning and
disinfection
Evisceration Cross contamination
through equipment and
gut breakage
Cleaning and
disinfection during
processing.
Instruction of
management,
cleaning and
disinfection
Chilling Cross contamination,
(water and air-borne).
Sufficient water
supply, cleaning and
disinfection of
evaporators
Instruction of
management,
cleaning and
disinfection
Cutting Cross contamination,
through equipment.
Cleaning and
disinfection of cutting
equipment
Reject product,
alternative
supply.
Packaging
Contaminated
packaging materials
Visual check, proper
storage

18.  The Critical Control Point (CCP)
Determination form is used to identify
the critical control points in the process.
 Identification of each CCP can be
facilitated by the use of a CCP Decision
Tree
 The Decision Tree asks a series of four,
yes or no, questions to assist in
determining if a particular step is a CCP
for a previously identified hazard.

20. PROCESS
STEP
BIOLOGICAL
CHEMICAL
PHYSICAL
HAZARD
DESCRIPTION
CCP CRITICAL
LIMITS
MONITORING CORRECTIVE
ACTION
HACCP
RECORDS
VERIFICATI
ON
PROCEEDUR
E
The first three columns on the form are transferred from the CCP
Determination Form.
 The fourth column is used to establish critical limits for preventive
measures associated with each identified CCP.
 A critical limit is defined as the maximum or minimum value to which a
physical, biological, or chemical hazard must be controlled at a CCP to
prevent, eliminate, or reduce to an acceptable level the occurrence of the
identified food safety hazard.
 Monitoring is a planned sequence of observations or measurements to
assess whether a CCP is under control and to produce an accurate record
for future use in verification.
 If monitoring indicates that there is a trend towards loss of control, then
action can be taken to bring the process back into control before a
deviation occurs

21.  Column six is used to establish corrective actions to
be taken when monitoring indicates that there is a
deviation from an established critical limit.
 Column seven is used to establish effective
recordkeeping procedures that document the HACCP
system.
 Column eight of the HACCP plan establishes
procedures for verification that the HACCP system is
working correctly.

22. PHYSICAL CHEMICAL BIOLOGICAL
GLASS
METAL
OTHER FOREIGN
MATERIAL
ALLERGENS
DRUG RESIDUES
CLEANING COMPOUND
RESIDUES
NATURAL TOXINS
UN APPROVED
ADDITIVES
CROSS
CONTAMINATION
Raw Ingredients
Raw Storage
Zoonotic Disease
Parasites

23.  Good Manufacturing Practices (GMPs) as
defined by the Food and Drug Administration in
1969 .
 GMPs are the minimum sanitary and processing
requirements for food companies.
 Gmps in the food industry are mentioned in
Part 110: cGMP in Manufacturing, Packing, or
Holding Human Food (1986).
 These GMPs are not designed to control
specific hazards, but are intended to provide
guidelines to help processors’ produce safe
and wholesome products.

24.  Receiving Meat: Incoming meat should be
evaluated. Trucks, containers and carriers of raw
materials should be evaluated to ensure that the
conditions meet plant requirements for
transporting meat.
 Non-Meat Items: such as packaging materials,
seasonings/spices, etc meet the plant
established specifications.
 Storage of Raw Materials : It is recommended
that raw materials be used on a First-In/First-
Out (FIFO) basis
 Tempering/Thawing of Frozen Materials:

25.  Processing : Processing includes the application
of the heat treatment, and it may include
weighing, mixing, blending, grinding, forming,
stuffing.
 An organoleptic evaluation of the raw material
ingredients should be completed prior to adding
the meat to the batch.
 Post-Processing Handling:
 1. Facility Design:it is important that processing
areas meet the “Clean Room Concept”,
 it includes Physical barrier (preferably from floor
to ceiling) for separating raw and cooked
processing areas

26.  Employee traffic flow to prevent cross-over
between raw and cooked areas
 Positive air flow in exposed product packaging
rooms
 Use of footbaths before entrance into a RTE
area, including preparation of
 sanitizing agent, schedule for changing, etc.
 Separate frocks, utensils, etc.
 Proper design, use and cleaning of drains
 Designated equipment and tools for RTE when
possible

27. 2. Sanitation:
- Microbiological monitoring
-Coliform plates
-Standard plate counts
- Environmental testing for Listeria species
- Pre-operational ATP testing
- Visual inspections (organoleptic evaluation)
- Tracking of chemical usage, types,
concentrations and rotation schedules
- Review of sanitation crew training records

28. 3. Employees:
 Development of a written procedure for
employee hygiene and method for training.
-handwashing and/or gloving.
-separate color of frocks. Frock
colors can also be used to
distinguish “product handlers”
from “non-product handlers”
within the RTE area.
-use of appropriate footwear
-Employee traffic flow must be
maintained to prevent cross-
contamination.

29. -Flow should not allow employees to move from
raw to RTE areas.
-All individuals (management, maintenance,
sanitation, inspectors, visitors, etc.) entering the
RTE processing area must follow the established
protocol.

30. Storage of Finished Product: They should be stored
at plant-designated time/temperatures to
maintain product shelf-life.
 Frozen products should be kept frozen.
 A FIFO or a plant specified product
rotation/inventory control schedule should be
maintained for finished products.
 The package/pallet integrity should be
maintained throughout the storage period to
maintain the condition of the finished product.
 Product identity in storage should allow for the
in-plant tracking system to be used for recall
and/or market withdrawal purposes.

31. Loading and Shipping : Finished RTE products
should be handled properly on the loading docks
and during transport to prevent contamination
from raw products and product deterioration by
temperature abuse or improper handling
practices.
 Trucks, containers and carriers of finished
products should be evaluated prior to loading
and shipping to ensure that their condition
meets plant requirements for transporting RTE
products.
 It is recommended that temperature-recording
devices be used when possible for monitoring the
trailer temperature during transportation.

32. Some Important Foodborne Pathogens
 Listeria monocytogenes
 Salmonella
 Escherichia coli O157:H7
 Campylobacter jejuni
 Staphylococcus aureus
 Clostridium perfringens
 Clostridium botulinum
L. monocytogenes: Growth Limitations
Min Optm Max
temp (OC) 1.0 37 45
pH 4.4 7.0 9.4
aW 0.92 0.99 >0.99
NaCl concentration (up to 9.0 %)
oxygen: (facultative)

33.  Salmonella: Growth Limitations
Min Optm Max
temp (OC) 5.2 35-43 46.2
pH 3.8 7-7.5 9.5
aW 0.94 0.99 >0.99
E. coli O157:H7: Growth Limitations
Min Optm Max
temp (OC) 7-8 35-40 44-46
pH 4.4 6.7 9.0
aW 0.95 0.995 ----
E. Coli :
 Easily destroyed by heat
 Low infectious dose (<100 cells)

34. Conditions that allow growth of Clostridium botulinum
 Anaerobic conditions
 pH > 4.6
 salt < 10%
 Temp.
- min. -- 10 OC (50 OF)
- optm. 35-40 OC (95-104 OF)
Clostridium botulinum :
 Factors that control growth in cured meat and poultry
products:
- Salt
- Sodium nitrite
- Refrigeration

35.  Bacillus, C. perfringens, and C. botulinum vegetative cells
killed during the normal cooking processes for RTE meat.
 Microbes on cured meat products:
 Moulds:
◦ Aspergillus, Alternaria, Fusarium, Mucor, Rhizopus, Penicillium.
 Bacteria:
◦ Micrococci are resistant to salt and consequently are most common
where salt levels are high
◦ Lactobacilli are less resistant to salt but more resistant to smoking
◦ These together with Acinetobacter, Bacillus, Pseudomonas and
Proteus may result in the fermentation of sugars in the product to
produce sours of various types

36. a) Lowering water activity
b) Reduction of surface pH
c) Treatment with organic acids
d) Treatment with chlorine and hot water
e) Sodium chloride treatment
f) Sorbate treatment
g) Enzyme inhibitors
h) Cooling
i) Lactic fermentation
j) Irradiation
k) Packaging

37. Product Test n c m M
Raw chicken, fresh or frozen APC 5 3 5x105 107
n = number of samples to be taken from the lot
c = number of samples permitted to fail
m = microbial count below which the sample is
considered to be satisfactory
M = microbial count above which the sample is
considered unsatisfactory

38. Maximum concentration
1 Total coliforms 0 per 100 ml
2 Faecal coliforms 0 per 100 ml
3 Sulphite-reducing clostridia > 1 per 20 ml
4 Faecal streptococci 0 per 100 ml
5 Colony counts No significant increase
over that normally
observed. (Recorded as
the number at 20°C or
37°C)

39. Products Test n c m M
Poultry (Raw) Salmonella 5 0 0 0
Aerobic plate count 5 3 5×10 5 107
Cooked
Poultry
Staph. Aureus 5 7 103 104
Poultry meat Salmonella 10 0 0 0
Dehydrated
poultry
products
Salmonella 10 0 0 0

40. Residues Tolerance Level By
EU (Microgms/ Kg)
Tetracycline Residue (Total) (Including Tetracycline
Hydrochloride, Oxytetracycline Hydrochloride,
Chlorotetracycline)
100
Pencillins
a. Benzylpencillin 50
b. Ampicillin 50
c. Amoxicillin 50
d. Oxacillin 300
e. Cloxacillin 300
f. Dicloxacillin 300
Tylosin 100
Amprolium
Streptomycin sulphate
Streptomycin hydrochloride
Limits to be fixed

41. Number of cans in the lot(N) Number of cans to be
selected(n)
Upto 500 6
500- 1000 7
1001- 5000 8
5001- 10000 9
Above 10000 10

42. - Food and agricultural organisation-u.s
- WPSA
- Ministry of commerce (1995) order-INDIA
- International Commission on Microbiological
Specifications for Foods