Exploring Idiosyncrasies and Potentialities of HACCP Team ...

Exploring Idiosyncrasies and Potentialities of HACCP Team

Across the Sharjah Food Industry, UAE

by:

Yassir Mohamed Osman Al Mahi

B.Sc. in Public and Environmental Health, University of Khartoum (1994)

M.Sc. in Public and Environmental Health (Food Hygiene and safety)

University of Khartoum (2006)

A Thesis

Submitted to the University of Gezira in Fulfillment of the

Requirements for the Award of the Degree of Doctor of

Philosophy

in

Public and Environmental Health

Department of Food Hygiene and Safety

Faculty of Health and Environmental Sciences

August, 2013


Across the Sharjah Food Industry,UAE

by:


Supervision committee:

Name Position Signature

Prof. Abdel Moneim E. Sulieman Main Supervisor

Prof. Abdelelah Mohamed El-Hassan Co-supervisor

Dr.Mayalagu Pandian Regds Pandian

Co-supervisor

Date: August/2013



by:


Examination committee:

Name Position Signature

Prof. Abdel Moneim E. Sulieman Chair Person

Prof. Ahmed Alawad Alfiki External Examiner

Prof.Awad Mohammed Abderahim Internal Examiner

Date of Examination: 18 / August /2013

ii

Dedication

To my parents

To my sisters & Brothers

To my wife

To my son

To my family

And to the people I love

YASSIR

iii

أعوذ بالله من الشيطان الرجيم

بسم الله الرحمن الرحيم

ارِ وَالْفُلْكِ وَالنَّهَ اللَّيْلِ السَّمَاوَاتِ وَالْأَرْضِ وَاخْتِلَافِ خَلْقِ فِي إِنَّ مِنْ السَّمَاءِ مِنَ اللَّهُ أَنْزَلَ وَمَا النَّاسَ يَنْفَعُ بِمَا فِي الْبَحْرِ تَجْرِي الَّتِي وَتَصْرِيفِ دَابَّةٍ كُلِّ مِنْ فِيهَا وَبَثَّ مَوْتِهَا بَعْدَ الْأَرْضَ بِهِ فَأَحْيَا مَاءٍ

لِقَوْمٍ لَآيَاتٍ وَالْأَرْضِ سَّمَاءِال بَيْنَ الْمُسَخَّرِ وَالسَّحَابِ الرِّيَاحِ . يَعْقِلُونَ

164: البقرة

اللهم صلي ، اللهم صلي على سيدنا محمد )ص( ما ذكرك الذاكرون اللهم، ص( ما غفل عن ذكرك الغافلون) وسلم على سيدنا محمد

وسلم صلي اللهم نجوم السماء عدد المصطفى حبيبك على وسلم صلياللهم صلى في الصحراء الرمل حبات دعد المصطفى حبيبك على

على سيدنا محمد وعلى آل محمد صلاة تنجينا بها من جميع الأهوال والآفات وتقضى لنا بها جميع الحاجات وتطهرنا بها من جميع السيئات وترفعنا بها عندك أعلى الدرجات وتبلغنا بها أقصى

تك يا الغايات من جميع الخيرات فى الحياة وبعد الممات وبرحم .أرحم الراحمين

iv

Acknowledgements

First one should pay gratitude to almighty God the most Gracious and

most Merciful who granted me the mind, health, strength and patience to

conduct this study and helping me in all my life.

I am very much thankful and grateful for my research supervisor, Prof.Dr.

Abdel Moneim E.Sulieman and Co-supervisor, Pro.Dr.Abdelah Mohamed

Elhassan those who have assisted me throughout the research with full

support, proper guidance and well planned paces in determination to have

this work come out true. I also feel so honored to have this opportunity to

thank, Co- supervisor Dr. M.Pandian, who have really worked hard with us

since we started taking on this study in 2010. I would like also to thank Dr.

Mustafa shazel, University of Nile Valley for his full support and assistance

during the writing of this research. A word of thanks also to the dedicated my

friends and family for their encouragement and support throughout this study.

v

Last but not least, I wish to thank my parents for all the love, support

and words of wisdom that have guided me from the halls of academia straight

into the fast-paced world of employment and opportunity.



Yassir Mohammed Osman Al Mahi

Ph.D. In Public and Environmental Sciences Augut, 2013

Department of Food Hygiene and Safety

Faculty of Health and Environmental Sciences

University of Gezira

Abstract

HACCP team is a group of people selected to undertake food safety and tackle all its

related issues. This study was based on standard interview in order to explore HACCP

teams' idiosyncrasies and potentialities across Sharjah-UAE food industry, quantitative

and qualitative techniques were of use to conduct the analysis. There were 61 accessible

HACCP certified businesses from which 11 businesses were selected randomly in order to

carry out the interviews. Most businesses have a reasonable and a sufficient number of

HACCP team members ranged between 5-10 members. Generally, total of 10 (90.9%)

businesses out of 11(the total sample), have either an ideal number of HACCP team or

close to this number which is recommended or stipulated in the regulation. Regarding HACCP team qualifications and expertise, the study had discovered that most of the HACCP team members were qulifed, it noticed that 7(63.6%) HACCP team among their members who have got high education degrees (M.Sc. and B.Sc.). And almost 3 (27%) HACCP team whom they were competely education with B.Sc., expect one HACCP team that was trained by formal training.

HACCP teams were with various disciplines and multidisciplinary approach was existing

to a certain extent in some HACCP teams whereas inter-hierarchical approach was not

being known but surprisingly it appeared to exist in some HACCP teams. Finally study

recommended as the HACCP team should be multidisciplinary; it also needs to be inter-

hierarchical. Multidisciplinary represents the breadth/horizontal aspect of the organization,

which mainly refers to differing knowledge and expertise, while inter-hierarchical refers

vi

to the length/vertical side of the organization represented by all levels within the

organization.

غذيةصناعة الأفريق الهاسب عبر ل والإمكانات الصفات الذاتية ستكشافإ

مارات العربية المتحدةدولة الأ ,بمدينة الشارقة

ياسر محمد عثمان الماحى

( 2013أغسطس, ) يئة الصحة العامة وصحة الب ةدكتورا

وسلامة الغذاءقسم صحة

كلية العلوم الصحية والبيئية ، جامعة الجزيرة

اسةالدرملخص

غذية ومعالجة لحرجة مجموعة من الناس مختارة للإضطلاع بسلامة الأا التحكمنقاط تحليل الخطورة و فريق

الصفات الذاتية جل إستكشاف أهذه الدراسة بنيت على المقابلة القياسية من جميع المسائل المتصلة بها.

دولة –بمدينة الشارقة غذيةلأصناعة اعبر تحليل الخطورة ونقاط التحكم الحرجةفريق ل والإمكانات

شركة 11 عدد تم إختيار وشركة مطبقة نظام الهاسب 61 عدد كان هنالك مارات العربية المتحدة.الأ

معظم المؤسسات أن ووجد .جراء التحليلخدام التقنيات الكمية والنوعية لإستوتم إ عشوائيا لتنفيذ المقابلات

10. بصورة عامة مجموع اعضو 10-5لهاسب يمتد بين لديها عدد كافى ومعقول من أعضاء فريق ا

مؤسسة )العينة الكاملة( لديها عدد مثالى من أعضاء الفريق أو بالقرب من هذا الرقم وهو 11( من 90.9%)

ات فرق الهاسب ، الدراسة أكتشفت أن معظم أعضاء . وفيما يتعلق بمؤهلات وخبر موصى به فى اللوائحال

على درجات تعليمية ا عضاء فرق الهاسب قد حصلومن بين أ )%63(7ن نسبة حظ أفرق الهاسب مؤهلين ولو

كملوا تعليمهم بدرجة البكالريوس ماعدا من فرق الهاسب قد أ )%27( 3( ونسبة وس وماجستير عليا )بكالري

فريق الهاسب يتكون من مختلف التخصصات ويطبق أن جد كما و فريق واحد تم تدريبه بتدريب رسمى.

لى حد ما، ولكن تطبيق المدخل الهرمى للفريق كان غير إة فى بعض فرق الهاسب التخصصات المتعدد مدخل

وصت الدراسة بأن يتم أ ا وأخير فى بعض فرق الهاسب الى حد ما. ه رومعروف ولكن من المدهش ظه

لتخصصات ا مدخل .تكوين فريق الهاسب بمدخل النظام متعدد التخصصات ومدخل النظام الهرمى للمؤسسة

vii

لى المعرفة والخبرات المختلفة، فىإساسا أفقى للمؤسسة والذى يشير تساع الجانب الأألفريق يمثل المتعددة ل

.كل المستويات بالمؤسسةلى الجانب الرئسى للمؤسسة التى يمثلها إالمدخل الهرمى للفريق يشير أن حين

List of Contents

Item Page No.

Dedication i

Acknowledgements iii

English Abstract iv

Arabic Abstract v

List of Contents vi

List of Tables xi

List of Figures xiv

List of Abbreviations xvi

Chapter One

1. Introduction 1

1.1. HACCP system 5

1.2. HACCP legislation in Sharjah 6

1.3. Research background 8

viii

1.4. Significance and justification of the study 9

1.5. Research problem 10

1.6. Assumptions 10

1.7. Thesis organization 11

1.8. Research questions 12

1.9. Research objectives 13

1.9. 1 General objective 13

1.9.2 Specific objectives 13

Chapter Two

2. Literature Review 14

2.1. HACCP 14

2.2. Structure of HACCP 17

2.3. Prerequisite program for HACCP 19

2.3.1. Good manufacturing practices 20

2.4. Preparation of HACCP application 24

2.5. Contents of HACCP plan 27

2.6. The HACCP principles 28

2.7. Development and implementation of HACCP 35

2.8. Areas of application of HACCP in the food

industry

52

ix

2.9. HACCP benefits 53

2.10. Drawbacks of HACCP 54

2.11. Team work 55

2.12. Rules for effective team work 56

2.13. HACCP and team work 58

2.13.1. Complexity of the production process 58

2.13.2. HACCP team as a requirement 59

2.13.3. The HACCP team 60

2.13.4. HACCP team size 62

2.14. Multidisciplinary team 67

2.15. Inter-hierarchical team 69

2.16. Food borne diseases in the African Region

and Sudan

70

Chapter Three

3. Materials and Methods 72

3.1. Study area 72

3.2. Research methods 73

3.3. Preparation for the interview 78

3.4. Implementation of interview 79

3.5. Interpreting data 80

x

3.6. Qualitative approach 80

3.6.1 Strength of qualitative approach 81

3.6.2 Weaknesses of qualitative approach 81

3.7 Population and sampling 82

3.8. Materials and research tools 83

3.9. Research process 83

3.10. Research limitations 84

3.11. Research analysis 85

Chapter Four

4. Results and discussion 87

4.1. Results 87

4.2. The number of HACCP team members 89

4.3. Qualification of HACCP team members 93

4.4. A multidisciplinary team 95

4.5. Inter-hierarchical team 100

4.6. Source of HACCP team 114

4.7. History of HACCP teams 114

4.8. HACCP team changes 115

4.9. HACCP team meeting 115

4.10. Positive experiences gained from HACCP 119

xi

team

4.10.1. Positive experiences that relate specifically

to teams

119

4.10.2. Positive experiences that relate to HACCP

generally

134

4.10.3. Negative experiences that relate

specifically to teams

136

4.10.4.Negative experiences that relate to HACCP

generally

148

4.11. Interviewees profile 151

4.12. Businesses in the case to be contacted again

regarding this project

153

Chapter Five

5. Conclusions and Recommendations 154

5.0.1.Findings of the study 154

5.1 Conclusions 155

5.2 Recommendations 157

References 160

Appendices 170

xii

List of Tables

Table No. Title Page No.

2.1 Publications on a team approach 56

2.2 Number of articles mentioning HACCP team 65

3.1 Interviews in food safety publications by

Emerald

76

3.2 Initial analysis 87

4.1 Businesses interviewed profile 87

4.2 Businesses' HACCP teams compared to the

regulation

92

4.3 Qualifications of HACCP team members of 11

selected food businesses (firms) in Sharjah

93

4.4 Initial anaylsis of company (J) 95

4.5 Difficulties or challenges relating to HACCP

team as quoted from company (G)

96

4.6 Positions that HACCP team is mostly selected

from

99

4.7 Job title of HACCP team members and their

level in company A

101


level in company B

102


level in company C

103

xiii


level in company D

105


level in company E

106


level in company F

107


level in company G

108


level in company H

109


level in company I

110


level in company J

111


level in company K

112

4.18 Initial analysis of company A 119

4.19 Initial analysis of company B 120

4.20 Initial analysis of company C 121

4.21 Initial analysis of company D 122

4.22 Initial analysis of company E 123

4.23 Initial analysis of company F 125

4.24 Initial analysis of company G 126

xiv

4.25 Initial analysis of company H 128

4.26 Initial analysis of company I 129

4.27 Initial analysis of company J 131

4.28 Initial analysis of company K 133

4.29 Initial analysis of the difficulties and challenges

related to HACCP team (company A)

136


related to HACCP team (company B)

137


related to HACCP team (company C)

139


related to HACCP team (company D)

140


related to HACCP team (company E)

141


related to HACCP team (company F)

142


related to HACCP team (company G)

143


related to HACCP team (company H)

144


related to HACCP team (company I)

146

4.38 Initial analysis of the difficulties and challenges 147

xv

related to HACCP team (company J)


related to HACCP team (company K)

148

List of Figures

Figure

No.

Title Page

No.

2.1 Flow diagram for production of frozen cooked

beef patries …………………………………….

26

2.2 The HACCP decision tree..................................... 31

2.3 The HACCP Logical sequence............................ 48

2.4 Steps in implementing a HACCP plan................. 49

2.5 Four benefits of team working.............................. 57

2.6 Logical sequence for the application of HACCP... 47

4.1 HACCP team member’s aganist number of

employees................................................................

90

4.2 Regular periods of HACCP teams meeting.......... 117

xvi

List of Abbreviations

CAC Codex Alimenturias Commission

CCPs Critical Control Points

CSA Canadian Standards Association

CFTs Cross-Functional Teams

EPA Environmental Protection Agency

EU European Union

FAO Food and Agriculture Organization

FMEA Failure, Mode, and Effect Analysis

FDA Food and Drug Administration

GAP Good Agricultural Practices

GMP Good Manufacturing Practices

GHP Good Hygiene Practices

HACCP Hazard Analysis Critical Control Points

HEW Health, Education &Welfare

ICMSF International Commission of Microbiological Specification of Food

ISO International Standard Organization

NAS National Academy of Science

NASA National Aeronautic and Space Agency

NACMCF National Advisory Committee on Microbiological Criteria for Food

PRPs Pre-requisite programmes

QA Quality Assurance

USFDA United State Food and Drug Administration

xvii

UAE United Arab Emirate

U.S United State

SOP Standard Operation Procedure

SSOP Sanitation Standard Operation Procedure

SPS Sanitary and Phytosanitary Measures

TBT Technical Barriers to Trade

WHO World Health Organization

WTO World Trade organization

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CHAPTER ONE

1. INTRODUCTION

Rapid urbanization and reform in developing countries have changed

the market for food commodities. Countries like UAE now find themselves

participating in a global trade dealing in a wide range of food products. Even

perishable products such as raw seafood and fresh vegetables can be

transported over long distances and producers increasingly experience

competition from faraway competitors.

Consumers consequently are faced with food or food ingredients that

may derive from distant countries or continents, and with a less transparent

food supply. This has led to food quality and safety concerns.

In most of the developing world basic food safety rules accommodate

these risks, through buying, cooking, preserving and social pressure on food

processors and marketers. However, with increasing globalization of the

food supply the transparency of short market chains may be lost, and

consumers are increasingly dependent on specialized services to guarantee

safe food. For international trade, the Hazard Analysis and Critical Control

Point (HACCP) system has now firmly established itself as an important

component of safety assurances for food products sold in the worldwide

market.

The European Union (EU) first initiated the requirement for HACCP for

the import and export of fish and fish products to the EU countries in 1996.

The United States likewise had also required HACCP for imported fish and

fishery products to the country in 1997 (FDA, 1999). Development in food

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safety requirements motivated exporting countries to consider the

implementation of HACCP for their food products. Although the

implementation of HACCP is on a voluntary basis, the future of UAE food

products in the international trade is highly linked with our ability to comply

with the food safety requirements imposed by the importing countries. As an

exporting country, UAE must be able to meet the mandatory requirements of

importing countries.

The Food and Agriculture Organization (FAO) and the World Health

Organization (WHO) of the United Nations support the continual

development of national policies for protecting consumer’s health and

furthering economic development (FAO/WHO, 2004).

Food- borne diseases continue to be one of the largest public health

problems worldwide, and these also important causes of reduced economic

productivity. There are a number of reasons for this (Motarjemi and

Wallace, 1997) including:

1.The proportion of the population who has increases susceptibility to food

borne illness is increasing, for example, the elderly, the immune

compromised and the malnourished.

2.Changing life styles have resulted in a number of changes to our eating

habits:

a/ More people now eat out, which has led to an increased demand for

catering establishments of varying types;

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b/ Many women work outside the home and rely on processed foods for fast

meals preparation, this has meant that knowledge of how to handle and

prepare foods has decreased in recent years;

c/ Increased mass production of foods, has increased the potential for large

numbers of consumers to be affected in the event of an outbreak of food

borne disease.

d/ Increased tourism has ment that people are exposed to food borne hazards

from others areas.

3.Emerging pathogens, such as verocytoxin- producing E.coli.

4.New technologies and processing methods.

Although food-borne illness is a common occurrence, there is no

effective surveillance mechanism in place. Thus in the absence of such data,

realistic risk assessment is difficult to carry out and also consumer

perception of the risk of food-borne illness is very low indeed. Unless this is

corrected, there will never be complete acceptance of any food safety

management system (Marthi, 1999).

On the same path of trying to lay hands on a system that could assure

practical assurance for food to be safe enough for human consumption, and

since early days of hazard analysis and critical control points concept which

was adopted in the late 1960s when the Pillsloury company in cooperation

with the National Aeronautic and Space Army (NASA) came together to

work out a safety system to protect astronaut from food poisoning and food-

borne infections (Engel, 2000). Hazard Analysis Critical Control Points

(HACCP) was initially developed as a mean of obtaining increased

- 4 -

confidence over the microbiological safety of the foods used in the space

program (Mayes and Mortimore, 2003).

At this time, most food safety systems were based on "Snap-Shot"

inspection and end product testing. This kind of testing could not assure

I00% safety of the product. Consequently, there was a need for a new

method- a preventive system to guarantee safe food.

In 1970, except for the low acid- canned industry and large corporation,

the HACCP concept was not widely adopted into daily food operations. The

HACCP system as our know today took place from 1971 The National

Conference on Food Protection (Corlette, 1998). During the 1980, the

concept evolved and gained acceptance throughout the world (Panisello and

Quatick, 2001).

The HACCP concept was endorsed by WHO/FAO Expert Committee as

an effective way of controlling food-borne diseases in 1983 when the joint

FAO/WHO Committee on food Safety advised that HACCP should reduce

traditional end product testing approach to food safety assurance (Mayes and

Mortimore, 2003).In 1985 the implementation of HACCP was officially

recommended by the National Academy of Science (NAS) (Corlette,1998).

On November 28, 1989, the National Advisory Committee on

Microbiological Criteria for Food (NACMCF) gave final approach to its first

major documents, “Hazard Analysis Critical Control Points System”. And

was forworded to cabinet secretaries of the Department of Agriculture,

Health and Human services, commerce, and Defense (Corlette, 1998). In

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1990, HACCP re –emerged to become the primary approach to assure the

safety of food supply (Panisello and Quatick, 2001).

Since then, there have been considerable attention to harmonize the use

of HACCP from national and international institution to manage food safety

hazard in the food industry world-wide (Panisello and Quatick, 2001).

HACCP is a proven system which, if properly applied, will give

confidence that food safety is being managed effectively. It will enable you

to focus on product safety as the top priority, and all for planning to prevent

things going wrong, rather than waiting for problems to occur before

deciding how to control them (Mortimore and Wallance, 1998).

In summary, it is clear that international legislation is moving more and

more towards making HACCP a mandatory requirement in the food

industry. This will lead to greater regulatory assessment of HACCP system

as governments take up their responsibility with regards to confirming that

the business operators are properly complying with requirements (WHO,

1999).

1.1. HACCP system

HACCP is defined as a system which identifies, evaluates, and controls

hazards which are of significant for food safety (CAC, 2003).

According to CAC (2003) HACCP system consists of the following seven

principles:

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Principle1

Conduct a hazard analysis.

Principle 2

Determine the Critical Control Points (CCPs).

Principle 3

Establish critical limit(s).

Principle 4

Establish a system to monitor control of the CCP.

Principle 5

Establish the corrective action to be taken when monitoring indicates that a

particular CCP is not under the control.

Principle 6

Establish procedures for verification to confirm that the HACCP system is

working effectively.

Principle 7

Establish documentation concerning all procedures and records appropriate

to these principles and their application (CAC, 2003).

- 7 -

1.2. HACCP legislation in Sharjah

Extensive scientific research in the area of food safety and hygiene has

resulted in establishing many food safety systems. One of the most well-

known and recognized systems is HACCP. HACCP is a system used by the

food industry to ensure that, all food consumed is safe to eat (Sharjah

Municipality, 2005).

HACCP uptake in Sharjah started in 2000 and plans for its

implementation throughout the food industry were effective since then.

Sharjah Municipality took the initiative of addressing the system via

different methods such as seminars, ceremonies of appreciation and through

training sessions (Sharjah Municipality, 2008).

Food Control Section as it is the enforcement authority in the Emirate of

Sharjah, started to assess food companies if they embrace HACCP system,

the section started to set out essential requirements and follow up the

progress of the system uptake gradually.

“It is the responsibility of the food industry to develop and implement

HACCP plans and for regulatory agencies to facilitate this

process.”(NACMCF, 1992).

The Director went on noting that the Food Control Section of Sharjah

Municipality, being a leader in the region in the food safety issues, was the

first to mandate this system in the food factories, which is considered a

revolution in food inspection and food safety (Sharjah Municipality, 2007).

- 8 -

Regarding HACCP team in Sharjah Legislation; Assemble HACCP team

is the first step in the implementation, fully to understand the process and be

able to identify all likely hazards and CCPs, it is important that the HACCP

team is made up of people from a wide range of disciplines (Sharjah

Municipality, 2005).

1.3. Research background

Over the past 6 years there has been an increase in the number of

UAE food manufacturers with HACCP certification. HACCP is becoming a

major issue in the UAE food industry primarily due to demands from

importing countries such as the United States and the European Union (EU).

As of December 1997 (FDA, 1999), the United States government has been

requiring seafood processors to develop and implement HACCP systems for

imported fish and fishery products. The European Union has similarly issued

Directive 91/493/EEC (22/7/1991) and Directive 94/356/EC (20/5/1994),

requiring all manufacturers exporting seafood products to the EU to

implement HACCP systems. UAE food manufacturers as such are

compelled to respect the demands of importing countries or risk rejection of

their seafood products.

Since April1996, UAE has been a member of the World Trade

Organization (WTO), which currently has a membership of 148 members,

and has attached to it several Agreements and Ministerial Decisions and

Declarations including the Agreement on the Application of Sanitary and

Phytosanitary Measures (SPS Agreement) and the revised Agreement on

Technical Barriers to Trade (TBT Agreement). Both those Agreements are

- 9 -

related to the trade in food with the SPS Agreement specifically related to

human health and safety.

For successful development of the HACCP you need to define the

HACCP system presented a totally new approach in quality assurance. The

development of such system was of great importance since every kind of the

contamination would lead either to space mission Failure, Mode, Effect

Analysis which are crucial points in the process could potentially go wrong.

To date, no large-scale study has been conducted to study the

idiosyncrasies and potentialities of HACCP teams and to which extent they

have been built up multidisciplinary and inter hierarchical having in mind

their ultimate goal to implement and maintain HACCP system so as to

produce safe food across the food Industry.

This research attempted to explore the information about the HACCP

team structure of the food industry in Sharjah providing an insight of

Sharjah food safety program.

1.4. Significance and justification of the study

Research about the exploring idiosyncrasies and potentialities of

HACCP team is important and useful. This study is expected to contribute

to the theory and evidence based practices of HACCP. The proposed

questions in this study are important for at least 3 reasons.

1. This study offers to explore the information about the HACCP team

structure of the food industry in Sharjah providing an insight of Sharjah food

safety program.

- 10 -

2. This study is also vital because it discusses and assesses the performance

of the HACCP team. It is hoped that this study can contribute to the body of

knowledge on HACCP team and HACCP as a whole.

3. The study will somehow highlight the level of HACCP System in

developing contries through the output of HACCP team study.

1.5. Research problem

The problem can be discussed according to different viewpoints.

1. HACCP has been implemented by the Sharjah Municipality - UAE since

2000 (Sharjah Municipality, 2008). Yet no significant research has so far

been conducted on the HACCP uptake in the exploring idiosyncrasies and

potentialities of HACCP Team across the Sharjah –UAE Food Industry.

2. its contribution to the current knowledge of HACCP is summed up in the

following:

- As there is no much of this selected topic in the literature, therefore, this

will work as an expansion or certainly enrichment to the literature in this

area.

- Studying the HACCP team members' structure could lay hands on

standardized parameters that could be part of the requirements.

1.6. Assumptions

The following assumptions were taken in consideration in this study:

1. the respondent to the questionnaire of in-depth knowledge of HACCP

team.

- 11 -

2. the perception of the respondents are representatives of the organization.

1.7. Thesis organization

The thesis is divided into five chapters. The first chapter gives a brief

description of the research. It provides an overview of the research

background, research problems, research questions, objectives of the thesis,

scope of the study, its assumptions, justifications and significance.

The second chapter provides an extensive literature related to HACCP

in UAE and elsewhere. It also discusses the HACCP team structure as well

as prerequisite programmes for HACCP such as GMP and Sanitation

Standard Operating Procedures (SSOP).

Chapter three describes the research methodology. This includes

research design, population and sample, questionnaire development,

secondary data collection, interpreting data, material and research tools and

research analysis.

Chapter four shows the results, analysis and discussion of the study.

This includes descriptive statistics and the results of questionnaire as well as

comparisons between questionnaire response and actual recorded audit data.

Chapter five presents conclusion and recommendation of the whole

study. A brief review and summary of the research objectives and the

accomplishments and main conclusions were provided. The developed

framework, limitations, implications of the research and recommendations

for future study were further explained

- 12 -

1.8. Research questions

Based on an extensive literature review, the following research

questions have been proposed related to the exploring idiosyncrasies and

potentialities of HACCP team across the Sharjah –UAE food manufacturing

companies:

Question 1:What is the HACCP team composition across the Sharjah –UAE

Food Industry?

Question 2: What are the positive and negative experience gained, related

specifically to HACCP teams and to HACCP in general?

Question 3: What are the HACCP team’s education backgrounds in the food

industry experience?

Question 4: What are the difficulties or challenges relating to HCCP team?

- 13 -

1.9. Research objectives

1.9.1. The general objective

The primary purpose of this study was to explore the idiosyncrasies

and potentialities of HACCP teams and to what extent they have been built

up multidisciplinary and inter hierarchical having in mind their ultimate goal

to implement and maintain HACCP system so as to produce safe food.

1.9.2. Specific objectives

In addressing the research problem and answering the research

questions, this study seeks to achieve specific research objectives:

1- To explore the HACCP team composition across the Sharjah –UAE Food

Industry.

2- To investigate the positive and negative experience gained, related

specifically to HACCP teams and to HACCP in general.

3- To identify the HACCP team’s education backgrounds in the food

industry experience?

4- To explain the difficulties or challenges relating to HCCP team?

- 14 -

CHAPTER TWO

2. LITERATURE REVIEW

2.1 HACCP

HACCP is an abbreviation for Hazard Analysis and Critical

Control Points system. Hazard analysis and critical control point is a

preventive approach to food safety management. It designed to control

significant food safety hazards, i.e. those hazards that are likely to cause an

adverse health effects when products were consumed. Hazard analysis and

critical control point requires development of the HACCP plan, a document

that states how food safety hazards will be controlled in the operation. It is

normally developed by a multidisciplinary HACCP team, including several

personnel from the food operations. The HACCP system comprises the

HACCP plan plus associated monitoring and verification records, which

demonstrate that the HACCP plan is working in practice at all times.

HACCP systems were developed through the application of the international

agreed HACCP principles (CAC, 2003).

It is frequently written about and talked about at conferences and

within companies, but it also often misunderstood and poorly applied in real

situations. The HACCP concept has been around in the food industry for

some time, yet it continues to be debated rigorously at international level.

Developments in HACCP over the past 10 years or so have been fairly

major, and some governments now see its implementation as a remedy for

all of their country’s food safety issues. In reality, use of the HACCP

approach may well offer a practical and major contribution to the way

- 15 -

forward, but only if the different authorities are willing to apply it effectively

, they should have to obtain proper knowledge and expertise to answer that

formal purpose. HACCP is a technique and it needs people to operate it

(Mortimore and Wallance, 1998).

Those who are not familiar with HACCP often hold the

misconceived belief that it is a difficult, complicated system which must be

left to experts, and can only be done in large companies with plentiful

resources. True, you do need a certain level of expertise to carry out

HACCP, but this expertise includes a thorough understanding of your

product, raw materials and process, along with an understanding of the

factors that could cause a health risk to the logical system of control, based

on the prevention of problems- a common- sense an approach to food safety

management. With good training, every one ought to be able, to understand

the concept, given that; it is based on sound reasoning. HACCP will be a key

element of abroad product management system (Mortimore and Wallance,

1998).

The HACCP technique itself is a straightforward and logical system

of control based on prevention of problems- a common sense approach to

food safety management. In reality, the use of HACCP approach may well

offer a practical and major contribution to the way forwarding in food safety

management, but only if the people in charge are expertise to apply it

effectively.

In brief, HACCP is applied by taking a number of straight forward

steps: Look at your process/product from start to finish, identify potential

hazards and decide where they could occur in the process; put in controls

- 16 -

and monitor them; write it all down and keep records and the lastly ensure

that it continues to work effectively.

The Hazard Analysis and Critical Control Points (HACCP) is a well

known and widely accepted management system initially implemented in the

food industry. It is the systematic approach to control potential hazards in an

operation. The target of the HACCP is to identify the problems (hazards)

before they occur. The system establishes mechanisms to control all stages

of a particular process. This control is proactive which means the

identification of potential hazards, preventive measures, and the

establishment of monitoring and remedial actions thereby avoiding the

occurrence of hazards in advance. HACCP is described as a “concept of zero

error (Mortimore and Wallance, 1998).

A hazard is defined by Codex (1997) as a biological, chemical or

physical agent in, or condition of, food with the potential to cause an adverse

health effect. Hazards affect the safety rather than the quality of food.

Biological hazards are concerned with the presence, cross-contamination,

multiplication and survival of micro-organisms. Chemical hazards involve

the presence or contamination of foods with toxic chemicals or allergens and

physical hazards are items that might enter food that are either sharp, hard or

of dimensions that can cause choking. Causing consumer burns due to

extreme high temperatures of food/drink served may also be considered as

an example of a physical hazard in a catering operation.

Hazards is controlled by control measures, defined by Codex (2003)

as actions or activities required to prevent or eliminate a food safety hazards

or reduce it to an acceptable level. Control measures may take a wide variety

- 17 -

of forms and may be part of HACCP, where they control food safety

hazards, or part of prerequisite programs, where they control the general

operational conditions that provide a foundation for food safety. When

developing prerequisite programs for HACCP, it is necessary to consider the

most appropriate control measures. In many catering and retail operations,

the majority of controls for chemical and physical hazards will be in the

prerequisite programs. This is also true in manufacturing, although online

control systems such as sieving and metal can also be used.

2.2 Structure of HACCP

The first category of the hazards, the biological or microbiological

source, is divided into three classes: bacterial, viral and parasitic. Many of

the HACCP programmers were developed around these hazards

(Rhodehamel, 1992).

A hazard is defined by the National Advisory Committee on

Microbiological Criteria for Foods (NACMCF) as “a biological, chemical,

or physical agent that is reasonably likely to cause illness or injury in the

absence of its control” (NACMCF, 1989).

The International Commission of Microbiological Specification for

Food (ICMSF) has classified these hazardous microorganisms according to

their severity of risk (NACMCF, 1998).These bacterial hazards can result

either in food-borne infection or intoxications. The source, the symptoms of

the resulting disease and the food associated vary significantly and can be

caused by a large variety of pathogens. An implemented HACCP program

with regard to these hazards has three basic targets;

- 18 -

The first one should reduce, eliminate or destroy the hazard. The Second

is that, the program should be able to prevent a recontamination and the third

aim is to inhibit the growth and toxin production. The second category

describes hazards of chemical origin. All food products contain chemicals,

and as any chemical substance, they can be toxic at a certain dosage.

However, there are chemicals which are prohibited in food and others which

are allowed only in limited amounts. There are two types of chemical

hazards in foods, naturally occurring and supplementary chemicals. The

formal limits for naturally occurring toxins have been established in the

Code of Federal Regulation, title 2. The informal maximum allowable limits

have been described in the Compliance Policy Guidelines of the Food and

Drug Administration.

The added chemicals are inserted in foods during the time of growing,

harvesting, processing, storage and distribution. These chemicals are

allowed only within the permitted limits. They include agricultural

chemicals, like pesticides or herbicides regulated by the Environmental

Protection Agency (EPA), further the prohibited substances listed in Title

21, Part 189 of the Code of Federal Regulations and finally toxic elements,

like lead, mercury or arsenic. The latter are either not allowed in food or

only within established maximum limits. Finally, added chemicals also

include color additives, preservatives and substances improving flavor or

nutritional fortification. In addition, there are substances which occur or

belong to the production process of food, like cleaning chemicals and

sanitizer which do not belong to food but might probably be incorporated.

The Good Manufacturing Practices (GMP) has set the limits for these

substances.

- 19 -

The third category, the physical hazards, include hazard as extraneous

matter or foreign objects. These physical matters not normally found in food

may lead to illness or injury of a person (NACMCF, 1992). One of the most

common objects complaints of in food is glass (Rhodehamel, 1992). These

physical hazards demonstrate a gap in the production process which can lead

to an unacceptable health risk. Methods to control these kinds of hazards

include the raw material specification and inspections of suppliers’

certification and guarantees as well as education and training of employees.

2.3 Prerequisite program for HACCP

In order to successfully implement HACCP, food businesses should, as

part of pre-requisite programmes (PRPs), already be operating a ccording to

codex general principles of food hygiene, that applicable codes of practice,

and according to food safety legislation (Codex,2009) .

Evolving HACCP-based methodologies: Merge both the general (i.e.

prerequisite) and specific (i.e. HACCP) hazards in a way that businesses can

understand and therefore control (FAO/WHO, 2006).

HACCP cannot stand alone; it is a part of a larger system of control

procedures. HACCP implementation depends on the competence of people

who develop and operate it and the prerequisite programmes. Prerequisite

programmes may impact on the safety of food; they also are concerned with

ensuring that foods are wholesome and suitable for consumption. Formal

prerequisite program are increasingly and successfully used to support the

implementation of HACCP in food processing (Mortimore and Wallace

1998).

- 20 -

Some countries have already identified prerequisites. For example, in

North America the US Department of Agriculture Food Safety Inspection

Service required not only HACCP, but also Good Manufacturing Practice

and Sanitation Standard Operation Procedures (SSOPs) (NACMCF, 1997).

Similarly, the Food and Drug Administration required HACCP and the

prerequisite of GMP as a specific requirement for seafood production. As

previously mentioned, UAE currently requires GMP as a prerequisite before

HACCP implementation. Pre-requisite programmes such as GAP (Good

Agricultural Practices), GMP (Good Manufacture Practices) and GHP

(Good Hygiene Practices) must be working effectively within a commodity

system before HACCP is applied. If these pre-requisite programmes are not

functioning effectively then the introduction of HACCP will be complicated,

resulting in convenience, over-documented system.

2.3.1 Good manufacturing practices

A GMP programme may cover NACMCF, (1997):

1. Establishment Design and Facilities:

Codex, (2009) stated that the potential sources of contamination must be

considered when deciding where to locate food establishments, as well as

effectiveness of any reasonable measures that might be taken to protect food.

The structure and location of a processing plant needs to be considered in

relation to the nature of operations and risks associated with them. Food

premises should be designed to minimize possibilities of contamination of

commodity or product.

- 21 -

• Design and layout should permit maintenance, cleaning and disinfection of

the site to minimize airborne contamination.

• All surfaces that come into contact with food should be non toxic, as well

as being easy to maintain and clean in order to prevent any additional

contamination.

• Suitable facilities should exist for temperature and humidity control, when

required.

• Effective measures should exist to prevent access by pests.

2. Control of operation:

Effective control measures should be in place to reduce the risk of

contamination of the commodity or food supply such that it is safe and fit for

purpose:

• Adequate time, temperature or humidity controls

• Food grade packaging

• Potable water supplies

• Maintenance of equipment

- 22 -

3. Maintenance and sanitation:

Procedures and work instructions should exist to demonstrate an

adequate level of maintenance of an establishment as well as efficient

practices for cleaning, waste management, and pest control. Overall, these

operations will support the ongoing control of potential food hazards that

may contaminate food.

4. Personnel hygiene:

Measures need to be in place to ensure that food handlers do not

contaminate food. This objective can be attained by maintaining an

appropriate level of personal cleanliness and following guidelines for

personal hygiene.

5. Transportation:

The method of transportation should be such that measures are taken to

prevent any contamination or deterioration of the commodity. Commodities

or product that need to be transported in certain environments should be

appropriately controlled, e.g. chilled, frozen, or stored under specific

humidity levels. Containers and conveyors used for transporting food need

to be maintained in good condition and be easy to clean. Containers used for

bulk transfer should be designated and marked specifically for food use

only.

- 23 -

6. Training:

Training is intended to modify or develop knowledge, skills and

attitude through learning experience and to achieve effective performance in

activity or range of activities. Although ignorance may be a factor , most

food poisoning incidents are caused by a failure of managers and food

handlers to implement good hygiene practice. Consequently, food becomes

contaminated, pathogenic bacteria are produced with the opportunity to

multiply or they survive inadequate cooking or processing.

All food handlers should be trained in personal hygiene, as well as in

the specific operation with which they are working, to a level commensurate

with their duties. Food handlers should also be supervised by trained

supervisors. An ongoing training programme for food handlers is paramount

to the success of a Food Safety Management System.

7. Product information and consumer awareness:

The end product should be accompanied by adequate information to

ensure that personnel at the next stage in the food chain will handle, store,

process, prepare and display the product safely. Since the consumer may be

responsible for performing the ultimate control measure, the cooking of raw

meat or fish, they should have all the relevant information required to carry

out this step effectively. All batches of food should be easily identified, by a

batch or lot number, to allow traceability of the commodity if required.

In the prerequisite programmes, cleaning and sanitation plays an

important role. When it is in place, HACCP can be more effective because it

can be concentrated on the hazards associated with the food or processing

- 24 -

and not on the processing plant environment. In some situation, it may

reduce number of critical control points in HACCP plans (Marthi, 1999).

2.4. Preparation of HACCP application

The term “prerequisite programmers”, “good manufacturing practice”

and “good hygiene practice “ is used interchangeably in different parts of the

world but have the same meaning. The NACMCF, (1997) defined

prerequisite programmers as (procedures, including good manufacturing

practice (GMP) that address operational conditions, providing the foundation

for the HACCP system.

The NACMCF has recommended establishing a prerequisite program

before the application of the HACCP principles. This program describes the

basic environmental and operating conditions of the process. The principles

should be developed and managed separately from the HACCP plan and

regularly audited to ensure the existence and effectiveness of these

programs.

An essential part for the successful implementation and realization of a

prerequisite program is the education and training of the staff involved. The

employees should learn the skills necessary to make the process successful

and also should be enabled to appreciate the sense and benefit of this

method. This includes precise training activities specific to the product or

process. Therefore, it is recommended to develop a HACCP plan which

includes a variety of different tasks.

The first task describes the assembly of a HACCP team. This team

consists of people with specific expertise concerning to the product or

- 25 -

process. The composition of the group should be multidisciplinary and

incorporate people from various areas involved.

The next task illustrates the product or process itself. This description

should include all general information. A complete specification enables the

team to get a comprehensive picture of the process and consequently they

are able to identify the expectations of the end user or consumer. The final

task includes the development of a flow diagram of the process. This is a

diagrammatic description of the steps of the process. Each step or sequence

requires specific flow chart. The flow diagram could be a easy block-type

diagram (Figure 2.1) or highly complex depending on the extent on the

procedure (Figure 2.2). The HACCP team should carry out an on-site review

of the flow diagram to confirm its suitability and usefulness. If required,

modifications should be implemented and documented respectively. After

completing these preliminary tasks the so called “seven principles of

HACCP” can be applied. These principles demonstrate the establishment,

implementation and maintenance of the HACCP. The principles have

international acceptance and details of this approach have been published by

the Codex Alimentarius Commission (1991) and the NACMCF in (1992).

- 26 -

1. Receiving (Beef)

↓

2.Sorage

↓

3. Grinding

↓

4. Mixing

↓

5. Forming

↓

6. Cooking

↓

7. Freezing

↓

8. Boxing

↓

(Figure 2.1) Flow diagram for the production of frozen cooked beef patries1.

9. Distributing

- 27 -

2.5. Contents of HACCP plan

The system should be a written plan based on the individual operation’s

menu, equipment, facilities, customers and processes (Arduser and Robert,

2005).

A successful HACCP plan will contain the following,

- The Good Manufacturing Practice (GMPs)

- Standard Operation Procedure (SOPs)

- List of HACCP team members.

- List of individual products and their intended uses.

- A flow chart of the individual products through the system.

- Hazard analysis.

- Critical Control Points (CCPs)

- Critical limits (procedures) for each control point.

- CCP monitoring procedures.

- Corrective an actions to be taken if a critical control point infraction

occurs,

- Recording procedures.

- Verification procedures.

- 28 -

2.6 The HACCP principles

Principle 1: Conduct a hazard analysis

To prepare a list of specifying steps where significant hazards can occur

and describe the preventative measures. This require the team to look at all

process steps individually, consider which hazards might occur and how pest

to control them.

After developing the flow diagram the potential hazards with regard to

the biological, chemical or physical risks in the process must be determined.

These hazards could occur at each step of the process from the very

beginning to the end. A potential hazard is included in the list if the

elimination or reduction of this hazard is essential for the safety and quality

of the (product) process. Hence, the HACCP team describes a preventative

measure in order to control each hazard. It is possible, that more than one

preventative measure is necessary to control one specific hazard, and that

more than one hazard could be controlled by a single preventative measure.

Principle 2: Determine the critical control points (CCPs)

Determine the points, procedures and operational steps (critical control

points – CCPs) that can be controlled to eliminate the hazards or minimize

their likelihood of occurrence. At this stage the points that are critical to

product safety are identified. This can be done through judgment and

experience or by using the Codex decision tree (Figure 2.2)

Critical control points have to be identified for each model. They should

guarantee the safety or quality of a product or process. The identification of

these points is very often a point of discussion within companies or

- 29 -

institutions building their own individual HACCP plan. To determine a

suitable number of critical control points might be very complex because too

many points could make the system unmanageable. On the other hand, too

few points would not ensure entirely the safety or quality of the product or

process. An approach to identify critical control points is to use a decision

tree.

A decision tree was published by the codex in 1997 to illustrate the

complex process of decision making to be under taken by the HACCP team.

However, this training tool was not designed to replace the knowledge and

experience of the team, or to be used in a regimented way.

Research shows that over -reliance on this tool is a feature of poorly

constructed HACCP plans with subsequent, compromising food safety. A

"common sense" approach to decision make can be far more effective.

Figure 2.2 shows the codex decision tree, which was designed to facilitate

decision making rather than be used as sole means.

The codex decision tree can be used for training and to support CCP

decision making. It may not be applicable in all situations and is not a

mandatory approach to making CCP decisions.

The determination of a CCP in the HACCP system can be facilitated by

the application of a decision tree, which indicates a logical reasoning

approach. Application of a decision should be flexible, given whether the

operation is for production, slaughter, processing, storage, distribution or

other. This example of a decision tree may not be applicable to all situations,

other approaches may be used.

- 30 -

By applying the HACCP decision tree. (Figure 2.2) the team is able to

define those steps which are critical to the product or process. They can set

targets and the acceptable tolerances for each critical control point and

determine how, when and by whom the critical control point is to be

measured and observed.

In addition, there have to be instructions and procedures for dealing with

deviations from the acceptable tolerance. The monitoring of the critical

control points is carried out by record keeping and continuous

documentation.

- 31 -

Q1 Do control preventive measure(s) exist?

Is control at this step necessary for safety?

Q2 Is the step specifically designed to eliminate or reduce the

likely occurrence of a hazard to an acceptable level?

Q3 Could contamination with identified hazard(s) occur in excess of acceptable

level(s) or could this increase to an unacceptable level(s)?

Q4 Will a subsequent step eliminate identified hazard(s) or reduce the likely

occurrence to an acceptable level?

Figure (2.2): The HACCP decision tree (CAC. 1997).

Yes No

No Not a ccp Stop

Modify step, process or product

Yes

Yes

No

Yes

Yes No

No

Stop

Not a ccp

Critical Control Point

Not a ccp

Stop

- 32 -

Principle 3: Establish critical limit(s)

To establish target levels and tolerances which must be met to ensure

the CCP is under Control.

Target levels and tolerances describe the difference between safe and

unsafe products or processes at a critical control point. They determine the

acceptable maximum and minimum of each level. Each critical control point

of the sequence will have one or more control measures. These control

measures should prevent, eliminate or reduce the potential hazards, and each

of these control measures has one or more associated critical limits. These

limits must be measurable and scientifically based.

Establish critical limits must be specified and validated for each CCP. In

some cases, more than one critical limit will be elaborated at a particular

step. Where HACCP guidance developed by experts has been used to

establish the critical limits, care should be taken to ensure that limits fully

applied to specific operation, product or groups under consideration (Codex,

2009).

Principle 4: Establish a system to monitor control of the CCP

To establish a monitoring system to ensure control of the CCP by

scheduled testing or observation.

Monitoring is the scheduled measurements or observation of a CCP

relative to its critical limits. The monitoring procedures must be able to

detect loss of control at the CCP. Further, monitoring should ideally provide

this information in time to make adjustments to ensure control of the process

to prevent violating the critical limits (Codex, 2009).

- 33 -

The regular and effective monitoring of a sequence is very extremely and

necessary. The establishment of this tool includes the answer of the

questions what, why, how, where, who and when have to be monitored and

observed. The question “what is monitoring” elucidates that monitoring is an

action. It is not something that is set up, turned on and then ignored. It is a

continuously ongoing procedure. The question “why monitoring” includes

not only the collection of data and information of the process. Monitoring

includes observation and measurement. It also includes the fast and

appropriate reaction to a possible deviation. Observation leads to qualitative

indices and measurement leads to quantitative indices. It depends on the

established critical limit which index is the most suitable. By applying the

question “where do we monitor” the team should consider where it is ideal

to monitor with minimal or without interruption of the production flow.

Personnel who monitor must be trained in the monitoring process for which

they are responsible. They must have a full understanding of the purpose and

importance of monitoring. In addition, they must be unbiased in monitoring

and reporting. Moreover, it is essential that the management responsible has

confidence in the employees who are responsible for the monitoring process.

Lastly, regarding the question “when do we monitor” also the question

includes “how often”. As mentioned above, monitoring is a continuous

process; therefore a permanent monitoring must be implemented. The

frequency of monitoring can be handled differently depending on the

amount of acceptable risk.

- 34 -

Principle 5: Establish the corrective action to be taken when monitoring

indicates that a CCP is not under control.

The HACCP system is developed to discover potential hazards in a

process and to set up strategies to prevent reduce or eliminate their

occurrence. A corrective action is necessary and should include guidance on

how to identify and correct the cause of noncompliance, how to determine

the disposition of the noncompliant product and how to record the corrective

actions that have been taken. These specific corrective actions should be

developed in advance for each critical control point. The responsibilities

must be distributed and every person involved in the process as well as in

the corrective action should be properly informed.

Specific corrective actions must be developed for each CCP in the

HACCP system in order to deal with deviations when they occur. The

actions must ensure that the CCP has been brought under control. Actions

taken must also include proper disposition procedures and must be

documented in the HACCP record-keeping (Codex,2009) .

Principle 6: Establish procedures for verification, including supplementary

tests and procedures to confirm that HACCP is working effectively.

Verification and auditing methods, procedures and test, including random

sampling and analysis, can be used to determine if the HACCP system is

working correctly. The frequency of verification should be sufficient to

confirm that the HACCP system is working effectively.

- 35 -

Verification describes activities that determine the validity of the HACCP

plan and the operation procedures. Apart from monitoring, processes like

auditing are essential. They should be established during the process of

designing and implementing the HACCP plan. Such activities could be the

review of the HACCP system, its records and deviations. Further it can

include procedures to observe if critical control points are under control and

also examine the validation of the established targets and tolerances. The

verification activities are screened by individual unbiased experts within a

company, an institution, third party experts or regulatory agencies.

Principle 7: Establish documentation concerning all procedures and records

appropriate to these principles and their application.

The overall success of the application of the HACCP system strongly

depends on the efficient and accurate record keeping. A careful and precise

documentation demonstrates that the system is under control. The

documentation covers the entire HACCP plan including all points mentioned

in the other principles and should include a summary of the hazard analysis

with the description of the potential hazards and the resulting control

measures.

2.7. Development and implementation of HACCP

Prior to the introduction of HACCP, it was common for business to

test the safety of their products via "end-product testing", namely the

measurement of physical properties, chemical analysis and microbiological

testing in a sample of the finished product. However, a number of limitations

were recognized with this approach :( Taylor et al., 2012)

- 36 -

- Cost: The number of samples, personnel involved and laboratory costs are

high if adequate sampling plans are followed. Also, the cost of products

"lost” to testing can be significant.

- Retrospective: The food is already manufactured with limited opportunities

to recover costs through re-work, etc.

-Time: It can take several days before results are available and in many cases

the food is consumed or sold before results are obtained.

-Unreliable: The chances of finding a hazard are variable, but most often

they are very low. False positives and false negatives are common.

- False sense of security: The hard work of sampling and testing can give a

sensation of "being in control" and create a strong but false sense of security.

- Technical requirements: It requires technical abilities to design statistically

valid sampling plans, follow sampling procedures and interpret results.

One of the major problems with end-product testing is that the number,

size and nature of the samples taken for analysis greatly influence the results

of testing. In some instances it is possible for the analytical sample to be

truly representative of the lot that is sampled. This applies to liquids such as

milk and water where the contents are homogenous. However, in cases of

lots or batches of solid food this is not the case, and a food lot may easily

consist of units with wide differences in microbiological contaminants. Even

within the individual unit (i.e. a retail pack) the hazard (i.e. the presence of

pathogen) can be very unevenly distributed, and the probability of detecting

it may be very low.

- 37 -

This is one of the reasons why a new approach was needed by NASA.

They were not willing to accept the low levels of probability in assuring

safety derived from end -product testing.

One of the main benefits of the HACCP methodology is that it is a

proactive, preventive approach to managing risks within food businesses.

Control is taken out of the laboratory and into food system. HACCP moves

away from testing the final product and instead emphasizes the importance

of controlling significant hazards throughout the food production system.

Modern food safety management includes the development and

implementation of a risk - based preventative system to control specific

significant hazards (i.e. HACCP). However, to be effective this must be

based on a firm foundation of food safety controls that ensure the continual

mitigation of general food safety hazards (Taylor et al., 2012).

Today, the Hazard Analysis and Critical Control Points, initially

implemented in the food industry is a well known and widely accepted

management system. HACCP was developed in 1959 by the Pillsbury

Company in cooperation with the National Aeronautics and Space Agency

(NASA), the Natick Laboratories of the U.S. Army and the U.S. Air Force

Space Laboratory Project Group. The aim was to develop a microbiological

safety system for food consumed by the astronauts (Codex Alimentarius

Commission, 1997).

At this time, most food safety systems were based on “snapshot”

inspection and end product testing. This testing could not assure a 100%

safety of the product. Consequently, there was a need for a new method – a

- 38 -

preventive system- to guarantee safe food. The successful development of

the HACCP system presented a totally new approach in quality assurance.

The development of such system was of considerable importance since

every contamination would lead either to a space mission failure or a

catastrophe (Mortimore and Wallance, 1998). The new approach, the

HACCP, was developed on the basis of an engineering system: Failure,

Mode, and Effect Analysis (FMEA). The system analyses which crucial

points in a process could potentially go wrong (Lambiri. et. al, 1995).

In 1971, the National Conference on Food Protection (U.S. Dept.

HEW, 1972) presented the HACCP system to the public, and in the same

year the Pillsbury Company implemented the method in their company.

After, this convention the Food and Drug Administration (FDA) offered

Pillsbury Company a contract to conduct classes for FDA personnel on this

method. In addition, the ICMSF recommended the HACCP to the food

industry (Eisenberg et al., 1975).

In 1985, the implementation of HACCP was officially recommended

by the National Academy of Science (NAS) (Hedberg et al., 1992). Later

the NAS advised the foundation of an institution, the National Advisory

Committee on Microbiological Criteria for Foods (NACMCF) (NACMCF,

1992 ( which should guarantee a continuous improvement and development

of the system beyond the microbiological risk analysis. Further, the Codex

Alimentarius Commission, founded in the 1960s by the Food and

Agricultural Organization (FAO) and the World Health Organization

(WHO) described the “seven principles of the HACCP” taking into

consideration the developments over the last 20 years (Majewski, 1992).

- 39 -

Since then, the HACCP has been further advanced and modified by

different reviews in 1992, 1995 and 1997 by the NACMCF. The committee

made the principles concise. They revised and added definitions and also

included a section on prerequisite programmers, education and training, as

well as on implementation and maintenance of the HACCP plan. In addition,

they provided a more detailed application of the HACCP principles and also

a decision tree for identification of the critical control points (CCP).

Furthermore, the FAO/WHO in 1998 established guidelines for the

regulatory assessment of HACCP and the WHO included these guidelines in

their recommendation ensuring the supply of safe water (Lufthansa, 2005).

Implementing HACCP requires careful preparation of the workforce and

effective management. Depending on the maturity of the operation this may

be a straightforward implementation of the HACCP requirement or may

require a culture change, e.g. to include more fundamental prerequisite

requirements.

The implementation stage is where the HACCP plans are handed over

from the HACCP team that has worked on the development process, to the

operations personnel who will manage the CCPs on a day-to-day basis.

Training for personnel who will monitor CCPs and take corrective action is

essential, and HACCP awareness training for the operations workforce is

advisable. HACCP monitoring personnel need to understand the monitoring

procedures and frequency, as well as, who to record results and when

corrective action must be taken.

- 40 -

Implementation does need to be carefully planned, with responsibility

for the various actions given to appropriate people. Large, more complex

businesses will need detailed discussion with key people, whereas smaller

businesses may find implementation more straightforward, as the key people

may already have been involved in the development of HACCP plans.

The implementation of a HACCP according to the original Codex

sequence involve a 12- step approach. This 12 step include the five steps

shown under " Preliminary Procedures" in Figure 2.3 and the seven steps

required for principles one to seven in the Figure. Each step is explained

below (Taylor et al., 2012).

- 41 -

requisite Programmes-Pre

↓

Preliminary Procedures: Assemble team, describe

product, identify intend use, construct flow diagram,

confirm flow diagram

↓

Principle one

Conduct a hazard analysis

↓

Principal tow

Determine critical control points

Principle three

limits Establish critical

↓

Principle four

Establish monitoring system

↓

Principle five

Establish corrective action

↓

Principle six

Establish verification

↓

Principle seven

keeping-Establish documentation and record

Figure (2.3): HACCP Logic Sequence adapted from (Taylor et al., 2012).

- 42 -

Step 1: Assembling the HACCP team

Assembling the HACCP team (Codex, 2009): The food operation

should ensure that the appropriate product specific knowledge and expertise

is available for the development of an effective HACCP plan. Optimally,

this may be accomplished by assembling a multidisciplinary team.

Step 2: Describe product

A full description of the product should be drawn up, including

relevant safety information such as: Composition, physical, chemical

structure (including aw, PH, etc), microcidal / static treatments (heat-

treatment, freezing), (Codex, 2009).

Step 3: Identify intended use

Identify intended use (Codex, 2009):The intended use should be

based on the expected uses of the product by the end user or consumers. In

specific cases, vulnerable groups of the production, e.g. institutional feeding,

may have to be considered.

Step 4: Construction a flow diagram

The flow diagram should be constructed by the HACCP team and

should cover all steps in the operation for specific product. The same flow

diagram may be used for a number of products that are manufactured using

similar processing steps.

- 43 -

Step 5: On- site flow diagram

On- site confirmation of a flow diagram (Codex, 2009): Step must be

taken to confirm the processing operation against the flow diagram during

all the stages and hours of operation and amend the flow diagram where

appropriate. The confirmation of the flow diagram should be performed by a

person or persons with sufficient knowledge of the operation

Step 6: Coduct a hazard analysis

The term " hazard analysis" was initially used within HACCP to

describe the process of identifying hazards and assessing risk. The term was

later expanded to company control measures for each hazard identified. This

step could therefore, be more accurately described as :" identified

significant hazards and control measures ". The HACCP team should list all

of the hazards that may be reasonably expected to occur each step according

to the scope and then identify which hazards are of such a nature that their

elimination or reduction to acceptable levels is essential to the product of a

safe food ( Codex, 2009).

Consideration should be given to what control measures, if any exist, can

be applied to each hazard. More than one control measure may be required

to control a specific hazard(s) and more than one hazard may be controlled

by a specific control measure (Codex, 2009).

In conducting the hazard analysis, wherever possible, the following should

be including:

1- The likely occurrence of hazards and severity of their adverse health

effects,

- 44 -

2- The qualitative and/or quantitative evaluation of the presence of hazards,

and

3- The survival or multiplication of micro-organisms of concern and the

production or persistence in foods of toxins, chemicals or physical agent (

Codex, 2009).

Step 7: Determine critical control points

There may be more than one CCP at which control is applied to

address the same hazard. If a hazard has been identified at a step where

control is necessary for safety, and no control measure exists at this step, or

any often, then the product or process should be modified at that step, or at

any earlier or later stage, to include a control measure.

There are often discussions as to whether there are CCPs in the

primary productions of foods that are later to be cooked and made safe by

the consumer. HACCP should look at in the context of the operational

process, for examples CCPs are identified that if not controlled would results

in an unacceptable level of contamination entering the supply chain.

The determination of a CCP in the HACCP system can be facilitated

by the application of a decision tree, which indicates a logical reasoning

approach. Application of a decision tree should be flexible, given whether

the operation is for production, slaughter, processing, storage, distribution or

other. This example of a decision tree may not be applicable to all situations

other approach may be used (Codex, 2009)

- 45 -

Step 8: Establish critical limits

Critical limits must be specified and validated for each CCP. In some

cases, more than one critical limit will be elaborated at a particular step.

Where HACCP guidance developed by experts has been used to establish

the critical limits, care should be taken to ensure that these limits fully apply

to specific operation, product or groups of product under consideration

(Codex, 2009).

Critical limits must be measured in real time. this means that most

microbiological testing will not be an appropriate parameter (at least until

rapid and sufficiently cost-effective methods of detection exist). The critical

limits to be monitoring the control of pathogens therefore usually relate to

operational practice, e.g. cooking times and temperatures.

Step 9: Developing monitoring systems

Monitoring is the scheduled measurement or observation of a CCP

relative to its critical limits; the monitoring procedures must be able to detect

loss of control at the CCP. Future, monitoring should ideally provide this

information in time to make adjustments to ensure control of the process to

prevent violating the critical limits (Codex, 2009).

Step 10: Developing corrective actions

Specific corrective actions must be developed for each CCP in the

HACCP system in order to deal with deviations when they occur. The

actions must ensure that the CCP has been brought under control. Actions

taken must also include proper disposition of the affected product.

- 46 -

Deviation and product disposition procedures must be documented in the

HACCP record-keeping.

Step 11: Establish procedure for verification

Verification and auditing methods, procedures and test, including

random sampling and analysis, can be used to determine if HACCP system

is working correctly. The frequency of verification should be sufficient to

confirm that the HACCP system working effectively.

Step 12: Documentation and record-keeping

Efficient and accurate record-keeping is essential to the application

of an HACCP system. HACCP procedures should be documented.

Documentation and record-keeping should be appropriate to the nature and

size of the operation and sufficient to assist the business to verify that the

HACCP controls are in place and being maintained.

Documentation and record-keeping is the last step in the HACCP

development process. By now the team should have an effective HACCP

system that, if applied and implemented correctly, will manage food safety.

However, this is not the end of the line for HACCP team. The team should

still meet on a regular basis to assess and review the HACCP plan(s).

The management of any HACCP system it will require continuous

improvement. The HACCP system must be kept up date.( Taylor et. al.,

2012).

- 47 -

According (Taylor et. al., 2012) the There are many potential triggers for a

HACCP study and system update, including:

- The introduction of new products or ingredients.

-The adoption of new or amended processes.

-The installation of new equipment.

- News about emerging pathogens.

- 48 -

Figure (2.4) logical sequence for the application of HACCP (FAO and

WHO, 2004, P.42)

- 49 -

Steps in implementing a HACCP plan (adapted from Mortimore and Wallace,1998)

↓

Step 1: Determine the approach to implementation

Step 2: Agree activities and timetable

Step 3:

Training Step 4: Set up monitoring systems

Step 5: Complete modifications and prerequisites

Step 6: Confirm monitoring system in place

Step 7: Confirm implementation actions complete-review and audit

Corrective Action

- 50 -

Figure (2.5). Steps in implementing a HACCP plan adapted from

(Mortimore and Wallace, 1998).

Step1: Determine the approach to implementation

The two approaches to implementing HACCP plans are to use a

phased approach, doing a bit at a time, or to implement everything at once.

Most companies choose to phase the implementation of HACCP to make

sure that each part works smoothly before moving on to the next.

Step2: Agree activities and timetable

It is helpful to construct a detailed activity list that can be ticked off as

each task is completed. This can include details of whom is responsible and

deadlines to make an implementation timetable. The main implementation

activities will be setting up monitoring systems and training personnel.

Step3: Training

All staff in the operation will need some awareness training about the

HACCP system and food safety requirements. Personnel who carry out

monitoring and corrective action will need more detailed training about their

roles. Specifically, they will need to understand the monitoring procedure

(i.e. exactly what they have to do), the frequency, where they should record

results and what to do if the results show that the CCP is out of control, i.e.

there is a deviation. Training can be done by HACCP team members or

managers who have been involved in the HACCP process. Alternatively,

external training support may be sought.

- 51 -

Step 4: Set up monitoring systems

Setting up monitoring systems involves getting all the required

equipments and facilities together in the right place for monitoring to occur.

This might mean purchasing extra equipments such as temperature probes,

as well as providing written/pictorial instructions and appropriate forms to

record the results. If you already have work record sheets in the processing

area, it is normally easiest to amend these to add in the CCP monitoring

requirements rather than developing new record sheets.

Step 5: Complete modifications and prerequisites

This simply requires each responsible person to complete their

actions so that the list can be ticked off.

Step 6: Confirm monitoring systems in place

Once the systems have been set up and the monitoring personnel

trained, this is just a check to make sure the monitoring requirements are

satisfactory.

Step 7: Confirm implementation actions complete – review and audit

The act of implementing HACCP is when the monitoring of CCPs

starts, with recording of results and corrective actions for any deviations. It

is a excellent idea to carry out a review or mini-audit in the first few days of

implementation to confirm that everything is working as planned. In this

way, any practical problems with the system can be quickly rectified, e.g. by

additional training or amending procedures and record sheets.

- 52 -

2.8 Areas of application of HACCP in the food industry

The HACCP has been successfully implemented in different areas in

the food industry, for several years and became a extremely powerful tool in

food control. The control of a process is based on prevention. This approach

differs from the traditional regulatory measure of food control (Lambiri et

al., 1995) ,which was based, on the observation and testing of samples. It

was more a “snapshot” inspection and end product testing. The control of the

food took part at the end of the production chain; consequently the

procedure of troubleshooting was always retrospective.

This system provided little health protection, particularly regarding

contamination (Codex Alimentarius Commission, 1997). The HACCP

method describes a preventative approach which helps to identify potential

hazards before they occur. It is possible to use this system as a method of

food safety assurance. The method is able to guarantee a safe processing-line

from “farm to fork” in the production of a product. The resources necessary

can be concentrated on the critical control points rather than being spread

across the whole process. An increase of effectiveness is only possible

through training and education of the staff. This training strategy differs

from the traditional approach where only parts of the staff were involved.

The HACCP system requires the entire staff at all levels to be coached. This

strategy represents a new approach for the staff not only to react in case of a

hazard but to prevent a hazard. This involves a broader view in the

identification of problems in the production or process-line regarding the

potential risks. Evaluating the whole concept of HACCP, Mortimore and

Wallance, ( 1998) , described the technique as flexible and possible to apply

- 53 -

in a variety of areas such as product quality, work practices and also to

products outside the food industry. Primarily used in the traditional food

industry, different sectors within this industry have started to implement this

management system, such as catering services.

2.9. HACCP benefits

HACCP is a proven system which, if properly applied, will give

confidence that food safety is being managed effectively. It will enable you

to focus on product safety as the top priority, and allow for planning to

prevent things going wrong, rather than waiting for problems to occur before

deciding how to control them.

Because HACCP is recognized, effective methods, it will your customers

confidence in the safety of your operation and will indicate that you are a

professional company that takes its responsibilities seriously. HACCP will

support you in demonstrating this under the food safety and food hygiene

legislation, and in many countries, it is a legislative requirement.

When implement a HACCP system, personnel from different disciplines

across the company need to be involved, and this ensure that everyone has

the same fundamental objective to produce safe food. This is often

otherwise difficult to achieve in the real world where there is constant

pressure from a number of different areas, e.g. customer/ commercial

pressures, brand development, profitability, new product development,

health safety, environment/ green issues, head count restriction, etc.

The primary area where HACCP will help is in processing of safe

food. It helps people to make informed judgments on safety matters and

- 54 -

removes bias, ensuring that the right personnel with the right training and

experience are making decisions. As HACCP is a universal system, it can be

passed on to your suppliers to assist in assuring raw material safety, and will

also help to demonstrate effective food safety, and will also help to

demonstrate effective food safety management through documented

evidence, which can be, used in the event of litigation.

HACCP is the most effective method of maximizing products safety. it

is a cost- effective system that targets resource to critical areas of

processing, and in doing so reduces the risk of manufacturing and selling

unsafe products. Users of HACCP will almost certainly find that there are

additional benefits in the area of product quality. This is primarily due to

increased awareness of hazards in general and the participation of people

from all areas of operation.

2.10. Drawbacks of HACCP

If HACCP is not properly applied, then it may not result in an effective

control system. This may be due to improperly trained or untrained

personnel not following the principles correctly; it may be that the outcome

of the HACCP study is not implementing system fails through lacks of

maintenance, e.g. if a ccompany implements a system and stop there, paying

little or no heed to changes that occur in the operation, then new hazards

may be missed. The effectiveness may also be lost if company carries out

the hazard analysis and then tries to make its findings fit with existing

control. As our will see HACCP is a compatible with existing quality

manage- met systems, but you must ensure the product safety is always

- 55 -

given priority and that HACCP findings are not changed because they differ

from existing operation limits.

Other problems may rise if HACCP is carried out by only one person,

rather than a multidisciplinary team, or where it is done the corporate level

with little or no input from the processing facility. Some critics may say that

HACCP is too narrow in that it focuses only on food safety; others say that it

should only be used for microbiological safety. HACCP was designed for

food safety, and as our have outlined, safety should always come first, but

the HACCP can be applied beyond food safety, but the key issue is to make

sure you don't try to do too much at once and end up either with a

complicated system which is difficult to control, or with a system that covers

many areas but lacks depth in each individual issue. So it is better apply the

principles to each area separately, and then link together the management

systems.

2.11. Teamwork

"Take my people away, but leave my factories, and soon grass will grow

on the factory floors. Take my factories away, but leave my people, and

soon we will have a new and better factory." (Carnegie, 2001).

The success of a HACCP is dependent upon both people and facilities.

Management and employees must be properly motivated and trained if a

HACCP program is successfully to reduce the risk of food-borne illness.

Education and training in the principles of food safety and management

commitment to the implementation of a HACCP system are critical and must

be continuously reinforced (Arduser and Robert, 2005).

- 56 -

A team is a small number of people with complementary skills who are

committed to a common purpose, performance goals, and approach for

which they are mutually accountable (Proehl, 1997).

Although interest in work groups began in the 1920s, the use of the

word a team as applied to work groups was not widely used until the 1970s

Ingram and Desombre, (1999). The literature shows a lot of publications on

team approach as per the data quoted from CSA Illumine database (Table 2.

1) on 08 April 2008:

Table (2.1): publications on a team approach (the data quoted from CSA

Illumine database on 08 April 2008)

Published

works

Journals Peer-

reviewed

Conferences Books Scholars Web

sites

60013 37308 13313 3469 3044 8101 67

2.12. Rules for effective teamwork

There are many models/ theories for teamwork, and this is just one of

the models which have set some rules for teamwork in order to be effective:

- Identify a leader.

- Meet regularly.

- Respect others: agree to disagree.

- Listen to one another.

- 57 -

- Be open to constructive criticism.

- Be honest.

- Know respective abilities and limitations.

- Understand respective roles and responsibilities (Bilchik, 1998).

There is evidence that, work teams can help to address increasingly

complex problems and that they are being used as a primary strategy for

continuous improvement Ingram and Decomber, )1999); See Figure 2.5

Figure(2.6): Four benefits of team working (Ingram and Decomber, 1999)

Recognizing that, teams often serve a variety of constituents, many

models in the organizational literature propose a multifaceted approach to

team effectiveness, capturing features of healthy internal functioning such as

team process, conflict, communication, or motivation and indicators of team

- 58 -

effectiveness gathered from sources external to the team including customer

satisfaction, innovation, market share, or external reputation (Tyran and

Gibson, 2008).

The data of the research done by (Higgs et. al., 2005) which was

designed to explore the interrelationship between team diversity and task

complexity in terms of its impact on performance, does support the

hypotheses that diversity is beneficial in teams with high complex tasks and

detrimental in teams with less complex tasks.

Bringing a cross-functional perspective to organizational problems

helps build understanding, problem-solving capabilities, coordination,

communication and, ultimately, improved quality and productivity (Proehl,

1997).

2.13. HACCP and teamwork

2.13.1. Complexity of the production process

Food production processes differ in many ways e.g. the number of

process steps, specificity of production processes, and the heterogeneity of

raw materials due to seasonal harvesting and natural variation. This diversity

is called complexity of the production process. The complexity causes

variation during manufacturing, which makes demands on quality

management to control food production quality (Spiegel et al., 2003).

Additionally, operation and design of the production processes differ.

For example, the ratio between batch and continuous processes affect quality

management activities. Besides, the number of closed and open processes

differ which affect risks and actions during production. Automatic and

- 59 -

manual operations also influence risks, speed and actions of the production

process. Therefore, complexity of the production process is expected to

affect performance of quality management and/or production quality. The

diversity of food production processes may explain why food quality

systems differ in the realized production quality (Spiegel et al., 2003).

HACCP is focused on the primary process and aims to assure the

production of safe food products by identifying and controlling the critical

production steps (Spiegel et al., 2003).

However, the relation between Quality and food safety systems in

such multifaceted working environment, they are combined or integrated to

assure more aspects of food quality. For example, HACCP and ISO are

combined to take technological and management measures for assuring food

safety and food quality (Spiegel et al., 2003). The new ISO norm, especially,

with requirements for food safety could be helpful for the application of

HACCP (Spiegel et. al., 2003).

2.13.2 HACCP team as a requirement

The team-based approach to problem solving, with involvement

across the whole organization, is an explicit part of the HACCP system

irrespective of company size. This approach, of utilizing fully the human

resources across the company to develop solutions through teams, can offer

a powerful guide to future action in other areas of the business operation

(Taylor, 2001).

- 60 -

HACCP team; the group of people who are responsible for

developing, implementing and maintaining the HACCP system (NACMCF,

1997).

A HACCP team should include operations supervisors and line

operators, quality control staff, and persons from departments such as

purchasing, receiving, and distribution (Corlette, 1998). Further HACCP is a

team approach that involves all members of staff in food safety (Mitchell,

1992).

2.13.3 The HACCP team

The HACCP system relies on a team approach to the management of

food safety.whilst this was once quite a revolutionary concept. It is now

commonplace in most industrial context.

However, using teams of people rather than individuals is still seen as

a high cost activity within the food industry with few, if any benefits. Thus,

the first step to achieving HACCP often becomes the first stumbling block.

Many companies expect technical staff to design and implement

HACCP or use external consultants to do so. From a theoretical perspective

this will not produce an effective system; there is increasing practical

evidence that support this.

There are a number of reasons why team work is necessary to achieve

HACCP, (Taylor, et al., 2012)

1. A key requirement for HACCP is the understanding that it will be a

"journey" that it will require the commitment of the entire workforce.

Everyone in the organization will need to understand the part they play in

- 61 -

achieving safe food and they all must become engaged in the process. this

involvement is best gained through the active participation of as many

people as possible in the HACCP system development.

2. HACCP requires detail, systematic study of all parts of a food operation;

it is unlikely that, except in very small business, any one person has all this

information. The more complex the operation, the less likely this becomes.

3. Whilst technical staff may be relied upon to identify many significant

hazards it is the production workers who contribute most to identify

appropriate controls; they have the experience to know what will work in

practice.

It is important that HACCP is not carried out by one person alone but

is that result of a multi-disciplinary team effort-the HACCP team. It is

recommended that HACCP team consists of experts (“experts” meaning

having knowledge and expertise) from the following area:

1- Quality Assurance/Technical-providing expertise in microbiological,

chemical and physical hazards, and understanding of the risks, and

knowledge of measures that can be taken to control of hazards.

2- Operation or Production- the person who has responsibility for a detailed

knowledge of the day-to-day operational activities required in order to

produce the product.

3- Engineering- able to provide a working knowledge of process equipment

and environment with respect by hygienic design and process capability.

- 62 -

4- Additional expertise-may be provided both from within the company and

from external consultancies. The following areas should be considered:

- Supplier Quality Assurance – essential in providing details of supplier

activities and in assessment of hazard and risk associated with raw materials.

The person responsible for auditing suppliers will have aboard knowledge of

best practicing gained through observing a wide range of manufacturing

operations.

- Research and development-if the company is one where new products and

process development is a continuous activity, then input from this area will

be essential.

- Distribution – for expert knowledge of storage and handling throughout

the distribution chain. This is particularly important if distribution condition,

e.g. strict temperature control, is essential to product safety.

- Purchasing – could be useful in accompany involved in purchasing

factored goods for on word sake or in a food services operation, or where

technical and purchasing personnel will mean that they are made fully aware

of the risk associated with particular products or raw materials and can assist

with early recommendation of a proposed change in supplier.

2.13.4 HACCP team size

Within the HACCP team itself, consideration the range of disciplines

required. In smaller companies, the same person may be responsible for both

QA and operations. In terms of team size, four to six people are a good

range. This is small enough for communication not to be a problem, but

large enough to be designate specific tasks.

- 63 -

In a large organization, three may be more than one HACCP team. It

was stressed earlier that the members of the team must have a good working

knowledge of what actually happens in practice. In large companies the

“experts” and senior people in the three main disciplines of QA, production

and engineering may not be closed enough to the operation. It may then be

more effective to have a serious of smaller department factory teams, still

make up of the three main disciplines but at least senior level. The

departmental teams there carry out the HACCP study for their own areas

and, when satisfied with the resulting HACCP plan, pass it up to a more

senior level for approval. This ensures that the true working knowledge of

activities is captured and subsequently reviewed by appropriate experts in

each area.

The number of people needed in addition to HACCP team will, be

dependent upon the type of operation and number of controls that needed to

be monitored. There should always be a sufficient number of people to

ensure that the critical points are monitored effectively, and that records are

reviewed.

A HACCP team is critical for the development of the HACCP plan

and for the implementation of the HACCP system in the company (Corlette,

1998).

The HACCP plan implementation is generally vested upon the efforts

of a team in an establishment rather than on the commitment of a single

individual (Asania and Zamora, 2005).

- 64 -

Colette (1998) , stresses in his book 'HACCP User's Manual' that the

first task in developing a HACCP plan is to assemble HACCP team

consisting of individuals who have specific knowledge and expertise

appropriate to the product and process.

Assemble HACCP team is the first recommended step in the logic

sequence (see Figure 2.6) for application of HACCP format recommended

by Codex Alimentarius Commission (CAC). The Codex Alimentarius

Commission implements the Joint FAO/WHO Food Standards Programme,

the purpose of which is to protect the health of consumers and to ensure fair

practices in the food trade. The Codex Alimentarius (Latin, meaning Food

Law or Code) is a collection of internationally adopted food standards

presented in a uniform manner CAC, (1999).

Most HACCP initiatives start with the appointment of a HACCP team

and HACCP team leader. HACCP is best done as a team (five or six people

at the maximum) the HACCP team needs to be multi-functional and have

the knowledge that has depth and breadth across the enterprise (Mayes and

Mortimore, 2003).

In building a food safety management system, the U.S. Food and Drug

Administration has initially recommended in its proposed manual to

assemble HACCP team, use of this manual is most effective when a team

approach is used (USFDA, 2006).

However, on the basis of all guidance we come to a conclusion that, to

have a successful HACCP you need to have a multidisciplinary and inter-

hierarchical team.

- 65 -

The literature shows a lot of work has been on the team in general but

little was done about "HACCP team" as a keyword being part of the title and

as discounted using Scopus database, below (Table2.2) is the result:

Table (2.2): Number of articles mentioning HACCP team (Scopus Database,

2008)

No. of articles in hazard analysis and critical control point 3621

No. of articles mentioning HACCP 3044

No. of articles mentioning team in title 21,594

Articles with hazard analysis and critical control point team 141

No. of articles mentioning HACCP team 55

No. of articles with HACCP team in title. one article

There is just one article investigating HACCP team structure by having

it in its title and nothing of the sort has ever studied the issue in-depth to

discover the multidisciplinary and inter-hierarchical basis of the team.

However, whatever is published in this area seems to be on HACCP

implementation generally.

Nevertheless, the only approach which shares a good deal of the

sought information is 'Barriers of HACCP team members to guideline

adherence' by (Asania and Zamora, 2005) in which the authors assure the

success of their study by interviewing or questioning ideal HACCP team

members, mentioning in their results that the survey respondents belonged to

- 66 -

HACCP teams comprising of 4–10 members representing various work

divisions in their companies. Ideally, HACCP team members should be

multidisciplinary consisting of individuals who have the appropriate

technical skills and expertise about the product and its processes (Asania and

Zamora, 2005).

The research method used for the above study was using a

questionnaire designed basically on the developed cognitive-behavior barrier

model to HACCP principle adherence. The HACCP team members were

individually asked to respond to the questionnaire using the face-to-face

narrative interview technique (Asania and Zamora, 2005). Here are some

points regarding their findings:

The study establishes the need for food processor management to

understand that teams must be multidisciplinary to ensure guideline

adherence.

There was some sort of resentment and unsatisfactory reaction to the

teams interrogated who were not diverse, we find that in the section of

HACCP team profile saying " The apparent inappropriate constitution of the

meat HACCP teams may have been mainly based on the decision of their

respective managements" and by saying " The sect oral skewdness of the

group composition for the HACCP teams for meat processors lends itself to

a limited perspective and lack of technical expertise to all significant aspects

of the product and its processes that might be pertinent to the HACCP plans"

(Asania and Zamora, 2005).

- 67 -

On the other hand the study supports the beverage team saying "The

memberships of the beverage HACCP teams were more appropriately

assembled as multidisciplinary groups. The respondents from HACCP teams

of the beverage industries were from various disciplines including personnel

from: the research and development, production, quality control and, sales

and marketing. The multidisciplinary membership of the beverage HACCP

teams might not be again based on the critical view of the responsible

management on the appropriate constitution of the teams but rather more as

a consequence of the diminutive nature of the company (Asania and Zamora,

2005).

In their recommendation, they go by saying "It is evident that the

management responsible for the HACCP team membership needs to fully

appreciate the fundamental concept of the group to be multidisciplinary".

The research does not study the HACCP team structure in-depth as it is

not its objective. The research serves its purpose and its goal of discovering

the barriers hindering HACCP team to adhere with the guidelines but it does

not go further with the study that this paper is all about (Asania and Zamora,

2005).

2.14 Multidisciplinary team

The food operation should assure that the appropriate product

knowledge and expertise is available for the development of an effective

HACCP plan (CAC, 2003). Optimally, this may be accomplished by

assembling a multidisciplinary team (CAC, 2003).

- 68 -

The successful application of HACCP requires the full commitment and

involvement of management and the work force. It also requires a

multidisciplinary approach; this multidisciplinary approach should include,

when appropriate, expertise in agronomy, veterinary health, production,

microbiology, medicine, public health, food technology, environmental

health, chemistry and engineering (CAC, 2003).

The team should at least have representation from all areas of the

operation that will be involved in the implementation process. This includes,

but is not limited to, the owner, the managers, chefs, cooks, dishwashers,

waiting staff, and other individuals who might be actively involved in the

preparation and service of the food (USFDA, 2006).

A multidisciplinary team arises from grouping together people of

different disciplines who belong to a same organization and who have to

collaborate with each other in order to respond to the needs of previously

selected customers (Freyens and Martin, 2007).

Cross-functional teams (CFTs), also known as multidisciplinary teams

(Lichtenstein, 2004), are being hailed as the cure for companies; the chief

benefit of CFTs is that they provide a manageable way to bring together

diverse resources for a project (Webber, 2002).

Working in a multidisciplinary team therefore puts various areas of

knowledge into contrast; it generates new types of behavior, creativity, risk

sharing (Freyens et. al., 2007).

In general literature, an article has been written to discover how a

multidisciplinary team approach can improve safety practices of entreat

- 69 -

feeding preparation by Gibbons et al.,( 2006). Even though the article might

have no direct link to study in hand, but it does support the approach in

general and, as a result, the main finding here is that a multidisciplinary team

approach is recommended to promote safe administration of entreat feeding.

Under the subheading of HACCP team formation and training the

author (Surak and Wlison, 2007) declares: effective companywide

implementation of HACCP is a multidisciplinary task that requires an effort

equal to that supporting any significant organizational change or

improvement initiative.

Another says HACCP is a multidisciplinary science-based approach to

the issue of food safety (Creswell, 2007).

The team should be multidisciplinary and include individuals from

areas such as engineering, production, sanitation, quality assurance, and food

microbiology (Corlette, 1998). The team should include local personnel who

are more familiar with the variability and limitations of the operation

(Corlette, 1998).

Assemble HACCP team (Codex, 2009): The food operation should

ensure that the appropriate product-specific knowledge and expertise is

available for the development of an effective HACCP plan. Optimally, this

may be accomplished by assembling a multidisciplinary team.

2.15. Inter-hierarchical team

Inter-hierarchical approach to HACCP team is not mentioned in

Codex Alimentarius, but it is recommended by some HACCP experts

notably Professor Taylor, Sanford University, where the professor's

- 70 -

perception and explanation comes from the theory that multidisciplinary

represents the breadth/ horizontal aspect of the organization which is mainly

referring to the different knowledge and expertise, the inter-hierarchical

refers to the length/ vertical side of the organization represented by the

different held positions.

A combination of cross-functional and natural work team is the best

formation to thoroughly implement HACCP. For larger companies, a

hierarchy of at least two tiers of teams is recommended in HACCP

implementation. The author of this statement refers to steering team and

operations team and declares that the selection of these individuals is among

the most significant considerations in implementing HACCP. Cross-

functional representatives will include site quality assurance, engineering/

maintenance, and production management personnel (Surak and Wlison,

2007)

2.16. Food borne diseases in the African region and Sudan

Food borne illnesses are prevalent in all parts of the world, and the toll

in terms of human life and suffering is enormous. Contaminated food

contributes to 1.5 billion cases of diarrhea in children each year, resulting in

more than three million premature deaths, according to the World Health

Organization (WHO). Those deaths and illnesses are shared by both

developed and developing nations. For example, in the United States, the

Centers for Disease Control and Prevention (CDC) estimates that food borne

diseases cause approximately 76 million illnesses annually among the

country’s 290 million residents, as well as 325,000 hospitalizations, and

5,000 deaths.2 In South East Asia, approximately one million children under

- 71 -

five years of age die each year from diarrheal diseases after consuming

contaminated food and water.

Even if data regarding food borne diseases in the African region are

extremely scarce, studies have shown that the following pathogens are

prevalent: Campylobacter, Salmonella, Shigella, Hepatitis, Brucella,

Staphylococcus aureus, Bacillus cereus, Escherichia coli, and rotavirus.

In the 30 years since its conception, the HACCP system has grown to

become the universally recognized and accepted method for food safety

assurance. The recent and growing concern worldwide about food safety on

the part of public health authorities, the food industry and consumers has

been the major impetus in the application of the HACCP system. This

concern has been substantiated by a significant increase in the incidence of

food borne diseases in many countries during recent years.

The World Health Organization has recognized the importance of the

HACCP system for prevention of food borne diseases for over 20 years and

has played an important role in its development and promotion.

- 72 -

CHAPTER THREE

3. MATERIAL AND METHODS

3.1 The study area

Sharjah is the oldest emirates coast of Oman, and mediates the other

emirates. The area of Sharjah 2,600 km² and this space is equivalent to

3.3% of the total area of the UAE.The length of the coastline of the

Arabian Gulf about 20 kilometers, and the inside of about 80 kilometers of

the Gulf of Oman. Sharjah is the capital of Sharjah emirate located on the

Arabian Gulf and in the south-west lies, the village of Alkhan then twist that

separates the creek from Sharjah, built on the Gulf coast along three miles,

was one of the most important centers for import and export, and industries

are thriving.

There are currently over 2,775 stand-alone restaurants in Sharjah,

serving both residents and tourists. Dining outlets range from high-end

restaurants and buffets, to fast food chains and cafés. These restaurants serve

multinational cuisine including traditional Arabic, European, American,

Chinese, Thai, Indian, Pakistani, among others, to meet the demands of a

diverse pool of consumer groups. Dining out is becoming increasingly

fashionable in Sharjah and new dining facilities are opening every year to

meet the rising demand. There are also 61 certified HACCP company

distributed in Sharjah city and industries area obtain from sharjah

Municipality database.

- 73 -

The study was carried out in Sharjah the third largest Emirate of

United Arab Emirates in June 2010. The following are some information

about Emirate of Sharjah:

Sharjah: The third largest Emirate of United Arab Emirates.

Language: Arabic.

Area: 2,600 km².

Climate: Hot & Humid (most of the year).

Summer: Max - 113°F | Min-72°F.

Winter: Max - 74°F | Min-55°F.

Also known as: Cultural Capital of UAE & the Pearl of the Gulf

3.2 Research methods

The research method employed in this work was standard

interview. Standardized open interview: It is usually made of a questionnaire

that contains questions to be asked in the same formulation to all the

interviewees. It serves to make comparisons of answers by different people

(Amann and Reiterer, 2003).

As common with quantitative analyses, there are various forms of

interview design that can be developed to obtain thick, rich data utilizing a

qualitative investigational perspective (Creswell, 2007). For the purpose, of

this examination, there are three formats for interview design that will be

explored which are summarized by Gall et al. (2003): (a) informal

- 74 -

conversational interview, (b) general interview guide approach, and (c)

standardized open-ended interview.

The standardized open-ended interview is extremely structured in

terms of the wording of the questions. Participants are always asked

identical questions, but the questions are worded so that responses are open-

ended Gall et al., (2003) This open-endlessness allows the participants to

contribute as much detailed information as them desire and it also allows

the researcher to ask probing questions as a means of follow-up.

Standardized open-ended interviews are likely the most popular form

of interviewing utilized in research studies because of the nature of the open-

ended questions, allowing the participants to fully express their viewpoints

and experiences. If one were to identify weaknesses with open-ended

interviewing, he would likely identify the difficulty with coding the data

(Creswell, 2007). Since open-ended interviews in composition call for

participants to fully express their responses in as much detail as desired, it

can be quite difficult for researchers to extract similar themes or codes from

the interview transcripts as them would with less open-ended responses.

Although the data provided by participants are rich and thick with qualitative

data, it can be a more cumbersome process for the researcher to sift through

the narrative responses in order to fully and accurately reflect an overall

perspective of all interview responses through the coding process. However,

according to Gall et al. (2003), this reduces researcher biases within the

study, particularly when the interviewing process involves many

participants.

http://ed.grammarly.com/editor/content?page.paperReportKey=

- 75 -

Over the past 100 years, the interview has received much attention. It

is agreed that, the interview is modest in terms of reliability or validity

(Buckley et al., 2000). Research has shown that, structured interviews are

more reliable than unstructured interviews (Buckley et al., 2000).

Few strides have been taken toward creating a new and better

selection tool to replace the interview (Buckley et al., 2000). Many scholars,

including a number of recent meta-analytic researchers, have attempted to

encourage the use of structured interview, citing its higher validity and inter

rater agreement (Buckley et al., 2000).

By the early 1920s, the interview in a recognizably modern form, both

structured and unstructured, had become established as a data collection

method in sociology (Lee, 2004).

New concepts about how interview should be conducted surfaced in

1929 and 1930 (Buckley et al., 2000). This concept of standardized

interview formats was gaining popularity in the late 1930s and early 1940s

(Buckley et al., 2000).

Researchers have used interviews for their studies in the context of

food safety and HACCP as shown below (Table 3.1) based on the

information provided by Emerald database on 10 May 2008:

- 76 -

Table 3.1: Interviews in food safety publications by Emerald database on 10

May 2008

Research method No. of articles

Interview in food safety 723

Interview in HACCP 31

Standardized interview in food safety 61

Standardized interview in HACCP 5

Standardized interview is the chosen research tool for this study that

appeared to be logical and focused since the research problem is already

defined "the composition of HACCP teams", and because a little is known

about the problem and no clear previous research has been carried out, that’s

why some qualitative and/or exploratory research may be necessary (Frazer

and Lawley, 2000).

The questions used for this study were predetermined and designed

beforehand (see Appendix (3) , and the following points work as

justification for the number of the sample selected as well as for the

selection of the research method used for this study:

Having open-ended questions in the research tool made the thought

difficult or, perhaps, quite risky using other methods other than interview

since the time was short and therefore, crucial for the researcher to make

- 77 -

ends meet. The Interviews come into their own when we need to ask

numerous open-ended questions or open-ended probes (Oppenheim, 1992).

Response rate is better with the face to face interviews. Perhaps the

most significant determinant both of response rate and the quality of the

responses is the subject's motivation (Oppenheim, 1992).

With the interview, the researcher is able to inquire more that clear out

more thoughts. The researcher tried to increase the number of samples

considering the predominant factors time and cost, but eleven was the

achievable number in such a limited time.

Interviews can give a prepared explanation for the purpose of the study

more convincingly than a covering letter can (Oppenheim, 1992).

Interviews build up a rapport (Oppenheim, 1992).

Many research workers feel that interviewers are more valid in some

sense (Oppenheim, 1992).

As the research tool contains both open-ended and closed questions,

the study then took the direction of being qualitative and quantitative at a

time. Therefore, the data collection from those closed questions were

numbers which gives the study a form of being quantitative but for those

open-ended questions; words and themes were extracted from the answers of

the respondents; giving the research the other side of the coin to be

qualitative.

Research may be categorized into two distinct types: qualitative and

quantitative, the former concentrates on words and observations to express

- 78 -

reality and attempts to describe people in natural situations. In contrast, the

quantitative approach grows out of a strong academic tradition that places

considerable trust in numbers that represent opinions or concepts

(Amartunga et al., 2002).

3.3 Preparation for the interview

Probably the most helpful tip with the interview process is that of

interview preparation. This process can help make or break the process and

can either alleviate or exacerbate the problematic circumstances that could

potentially occur once the research is implemented. McNamara (2009)

suggests the importance of the preparation stage in order to maintain an

unambiguous focus as to how the interviews will be erected in order to

provide maximum benefit to the proposed research study. Along these lines,

Chenail, ( 2009 ) provides a number of pure-interview exercises researchers

can use to improve their instrumentality and address potential biases.

McNamara, (2009) applies eight principles to the preparation stage of

interviewing which includes the following ingredients:

1- Choose a setting with little distraction;

2- Explain the purpose of the interview;

3- Address terms of confidentiality;

4- Explain the format of the interview;

5- Indicate how long the interview usually takes;

6- Tell them how to get in touch with you later if they want to;

- 79 -

7- Ask them if they have any questions before you both get started with the

Interview, and

8- Don't count on your memory to recall their answers (Preparation for

Interview section, para. 1).

3.4 Implementation of interviews:

As with other sections of interview design, McNamara, (2009) made

some excellent recommendations for the implementation stage of the

interview process. He included the following tips for interview

implementation:

1. Occasionally verify the tape recorder (if used) is working;

2. Ask one question at a time;

3. Attempt to remain as neutral as possible (that is, don't show strong

emotional reactions to their responses;

4. Encourage responses with occasional nods of the head, "uh huh"s, etc.;

5. Provide transition between main topics, e.g., "we've been talking about

(some topic) and now I'd like to move on to (another topic);”

6. Don't lose control of the interview (this can occur when respondents

stray to another topic, take so long to answer a question that times begins to

run out, or even begin asking questions to the interviewer) (Conducting

Interview section, para 1).

- 80 -

3.5 Interpreting data

The final constituent in the interview design process is that of

interpreting the data that was gathered during the interview process. During

this phase, the researcher must make “sense” out of what was just uncovered

and compile the data into sections or groups of information, also known as

themes or codes (Creswell, 2003, 2007). These themes or codes are

consistent phrases, expressions, or ideas that were common among research

participants (Kvale, 2007). How the researcher formulates themes or codes

vary. Many researchers suggest the need to employ a third party consultant

who can review codes or themes in order to determine the quality and

effectiveness based on their evaluation of the interview transcripts

(Creswell, 2007). This helps alleviate researcher biases or potentially

eliminate where overanalyzing of data has occurred. Many researchers may

choose to employ an iterative review process where a committee of

nonparticipating researchers can provide constructive feedback and

suggestions to the researcher(s) primarily involved with the study.

3.6 Qualitative approach

To operate in qualitative mode is to trade in linguistic symbols and by so

doing, attempt to reduce the distance between indicated and indicator,

between theory and data, between context and action (Maanen, 1979).

- 81 -

3.6.1Strengths of gualitative approach

A strong emphasis on exploring the nature of a phenomenon, instead of

testing hypotheses (Ekanem, 2007). A tendency to work primarily with

unstructured (and semi structured) data (Ekanem, 2007). Investigation, of a

small number of cases in detail (Ekanem, 2007).

Analysis of data that involve explicit interpretation of the meanings and

functions of human actions, the product of which mainly takes the form of

verbal descriptions and explanations (Ekanem, 2007). to gain, high

credibility and face validity (The University of Arizona, 2006).

To have the flexibility to use one's own knowledge, expertise, and

interpersonal skills to explore diverting or unexpected ideas or themes raised

by participants (The University of Arizona, 2006).

Qualitative research appears invaluable for the exploration of subjective

experiences (Carr, 1994).

3.6.2Weaknesses of qualitative approach

Amartunga et al., (2002) outlined four main perceived constraints for

weaknesses of Qualitative Approach: Volume of data; data collection can be

tedious and require more resources; Complexity of analysis; analysis and

interpretation of data may be more difficult; Details of classification record;

and harder to control the pace, progress endpoints of the research process.

Flexibility and momentum of analysis besides that, policy makers may

give low credibility to results from qualitative approach. Interviews are

expensive and time-consuming to conduct (Oppenheim, 1992).

- 82 -

Further, it has long been recognized that purely qualitative research

may neglect the social and cultural construction of the variables studied

Amartunga et al., (2002).

3.7 Population and sampling

Eleven companies were selected randomly from a sample universe of 61

companies, which were, obtained from Food Control Section of Sharjah

Municipality database.

Before the selection; the entire sample had to be grouped into different

categories based on their business activities as follows, 1.Dairies, 2.Juices &

Beverages, 3.Bakeries, 4.Meat & Sea Foods, 5.Cereals 6.Mineral Water,

7.Oil, Sugar & flour 8.Seafood, 9.Meat. 10. Chocolates and 11.

Miscellaneous.

Following that and by using the electronic randomizer

(http://www.randomizer.org/form.htm), the researcher had to select

randomly one company from each group.

These businesses are all HACCP certified companies and based in Sharjah

Emirate, some of these companies are based within the city and some are in

the Sharjah industrial area.

http://www.randomizer.org/form.htm

- 83 -

3.8 Materials and research tools

The questions used in this study were designed by Katherine Clark at

the University of Salford (Clark, 2007). It has been chosen as it was

designed to generate data about the composition, level of expertise and

experiences of HACCP teams.

The interviews were recorded using a portable MP3 recorder. Since

transcription is exact time consuming in qualitative research, many

researchers have been intrigued by the possibilities of using voice

recognition technology for transcription purposes (Lee, 2004). The use of a

recording device allowed the researcher to listen attentively and avoided the

distractions that writing notes can present to both interviewer and

interviewee.

A pen and paper were at hand in order to record details of each

participant for use in compiling a profile and also to note down any points to

be clarified later in the interview.

3.9 Research process

Following the selection of the companies detailed in the sampling

section the researcher started to contact the concern persons of those

companies by telephone. After getting their consent in the study, the email

of the University was forward to them with the letter of the student. Each

participant was visited at his office /place of work in order to carry out with

them a face-to-face interview.

- 84 -

A face-to-face interview was carried out with the quality assurance

managers/food safety controllers/ HACCP leaders of the selected food

businesses. The participants represented their companies as HACCP team

leaders. The researcher started the interview with a brief introduction to the

subject highlighting the aim and the objective of the research explaining the

way they have been selected for that purpose.

The participants were promised, and reassure of anonymity throughout

the research declaring the following statement to each participant "no

material, which could personally, identify you will be used in any reports on

this study" and the information collected will only be used for the purposes

of the investigation and will be held confidential.

Participants were informed that their participation is totally voluntary,

and they can withdraw or stop the interview at any moment they feel so.

For open-ended questions, responses were transcribed into texts where

the texts have been kept in italic, and the following punctuation took place

while transcription: Questions needed for transcription put in brackets [ ].

Quotation marks ( " " ) were used for interviewee responses

Ellipsis (…..) used for longer pauses

For hesitations and repetitions, certain remarks were also included such as

(err ...em… um...)

- 85 -

3.10 Research limitations

Time was the main factor that this work couldn’t be expanded more,

but choosing interview research method was extremely helpful in meeting

the deadline.

The relationship between the researcher as an enforcement officer and

participants may be significant, but that did not affect the study at any stage

because the researcher's work in Dubai Municipality and the companies in

Sharjah Municipality.

Moreover, that the researcher used to go for the interview on casual

dress introducing himself as a student only. However, for those who

recognize the researcher as an enforcement officer, assurances have been

placed that nothing of the results would be passed to the municipality.

3.11 Research analysis

Analysis in this study has taken the same analysis technique that was

first used by Taylor et al., (2004) in their study titled perception of "the

bureaucratic nightmare" of HACCP'. The Table (3.2) below contains an

extract from an interview transcript and provides an example of how the

initial analysis process was carried out. This was later followed by a second

stage which consisted of a theme analysis, in order to identify whether any

of the feelings uncovered in the initial analysis could be grouped together.

Themes were then compared to those found in the other interviews.

- 86 -

Table (3.2): Initial analysis

Transcription Initial analysis

"….I could just say we are much

more aware of the various

department than when we were not a

team …may be I was just bothered

about my job, he is bothered about

his job….he never thought ..Ok….we

got to go..and we have got to be

collective ..u know ..so.. if it is a

maintenance department ..They are

more what you call ….aware..That

they have to get a preventative

maintenance in place…you got to

know the importance of it ..so …u

know ..it is more of an awareness. I

think it is more of awareness ..it is a

healthy discussion and change of

ideas….more heads sitting together it

is more ideas otherwise ..I think ..its

communication and .awareness

should be the most positive aspects I

think .it .does affect our production

also in finance way…"

Awareness of what is the system all

about that even other departments

understood the point such as

maintenance and they are trying to

do their work accordingly.

Everyone has become aware of the

work of others and knows much

about it.

Believe that more heads sitting

together made the work go easy and

productive.

- 87 -

CHAPTER FOUR

4. RESULTS AND DISCUSION

4.1 Results

Eleven food businesses were actively involved in the process, some of

the key milestones and discussed briefly below: Table (4.1) presents the

business activity, number of employee and number of HACCP team

members of 11 selected food businesses (firms) in Sharjah.

Table ( 4.1): Businesses interviewed profile

No. Company

Name

Business Activity No.of

Employees

No.of

HACCP team

members

1 Company A Poultry products 350 10

2 Company B Dairy products 250 6

3 Company C Bakery and sweets 450 21

4 Company D Seafood 85 9

5 Company E Mineral water 255 5

6 Company F Biscuits and cakes 300 9

7 Company G Ready meals 300 6

8 Company H Juices and fresh fruits 227 5

- 88 -

9 Company I Meat and poultry products 90 7

10 Company J Meat products. 60 5

11 Company K Chocolates 200 7

All these businesses had their HACCP implemented either by

themselves or through approved institutions and HACCP implementation

remains subject to be accredited and renewed annually by Food Control

Section of Sharjah Municipality through the final reports of audits.

These businesses have employees from 60 to 450 employees, in fact,

8 (72.7%) businesses have more than 200 employees and three (27.2%)

businesses only were run with 60, 85 and 90 employees as illustrated in

(Table 4.1). Number of HACCP team should not be taken against the

number of employees but rather to the number of different activities and

processes carried out on the factory floor; therefore the number of

employees given in (Table 4.1) is just for illustrating the size of businesses

which the research had been carried out at.

Effective companywide implementation of HACCP is multidisciplinary

task that require an effort equal to that supporting any major organization

change or improvement initiative. Team formation and training an important

aspect of HACCP implementation. A combination of cross- function and

natural work teams is the best formation to thoroughly implementation of

HACCP. For large companies, hierarchy of at least two tires of team is

recommended in HACCP implementation.

- 89 -

4.2 The number of HACCP team members

In Sharjah Municipality 2005 guidelines for food manufacturers,

emphasis had been placed on businesses to retain a list of HACCP team

along with their responsibilities as part of the business record keeping and

documentation. However, in the Eleven food businesses interviewed there

was a total number of HACCP team members ranged from 5-10 members

with the exception of one company that had 21 members (Table 4. 1). This

indicates that total of 10 (90.9%) businesses out of 11, have either an ideal

number of HACCP team (5 to 6 members) or close to this number which

was recommended by FAO, (1998), Mayes and Mortimore, (2003).

The HACCP team will identify the members and will write their names,

designations, qualifications, experiences, training attended and their tasks

(Sharjah Municipality, 2005). All the business illustrated this as mentioned

in (Table 4.1).

- 90 -

Number of HACCP team members against total

Number of Employees

0

5

10

15

20

25

350

250

450 85 25

530

030

0+ 227 90 60 20

0

Total Number of employees

HA

CC

P t

ea

m m

em

be

rs

Series1

Figure (4. 1): HACCP team members against number of employees

Figure (4.1) shows the number of HACCP team members for the

entire sample was within 10 members, but one company only had more and

it is again the same company that had more employees than the rest.

Ideally the team should not be larger than six, although for some

stages, of the study it may be necessary to enlarge the team temporarily with

personnel from other departments, e.g. marketing, research and development

or purchasing and finance (FAO, 1998). HACCP is best done as a team (five

or six people at the maximum) Mayes and Mortimore, (2003).

Internet (2001), in the book, of Agriculture and Resource Management

Council of Australia and New Zealand, the size of the team to be a

maximum of five, but a minimum of three (obviously, small operators will

- 91 -

be limited in the number of people available, and outside assistance may be

required).

In smaller establishments, one person may fulfill several roles or even

constitute the whole team (FAO, 1998). In the latter case, the use of external

consultants or advice may be necessary (FAO, 1998).

Wallace and Powell,( 2005), also mention that the normal practice is to

have HACCP teams of four to six individuals.

Based on the above guidelines the number of HACCP team members is

maximum six people and one person at the minimum.

The first company (A) have 10 members of their HACCP team and

probably this number could be acceptable since it is selected from two

different plants; hatching and meat processing plants from which they had to

have representatives to make HACCP team and as their brilliant

understanding tells them that HACCP is about continuity; starts from farm

to fork and the two plants complement each other that is why a blend of

expertise was necessary.

ATCHING; To produce young of poultry by incubation Merriam and

Webster, (2008), so this hatching is quite specific and far in knowledge from

other processes that only professionals in the same field could understand

what is going on the farm; therefore they have to have members from the

hatching plant sufficiently because the selection is not going to be flexible

that is why the HACCP team had more members than the stipulated in the

regulation of the FAO, (1998), Mayes and Mortimore, (2003).

- 92 -

Apparently, the company (C), having formed a solid HACCP team of 21

members, seems to be trying to cover up the entire processes carried out on

its factory floor and by referring to their job titles (Appendix 1). The

company seemed to be obliged to appoint those members to represent both

quality and safety issues at a time but under the name of HACCP team.

Well, the company had to be more focused to have HACCP team separate.

Table (4. 2): Businesses' HACCP teams compared to the regulation

HACCP team in businesses Total of businesses

No. of businesses that their HACCP team is

matching the regulation

5 (45.4 %)

No. of businesses that have more members of

HACCP team than in the regulation

6 (54.5 %)

No. of businesses that have HACCP team close to

the number stipulated in the regulation

5 (45.4%)

No. of businesses have huge number of HACCP

team.

1 (9.1%)

The findings in Table (4. 2) discover that there are 5 (45.4 %)

businesses that their HACCP teams have 5 to 6 members in number which is

as same as recommended or stipulated in the regulation.

On the other hand, there are 6 (54.5 %) businesses as illustrated in the

Table 4. 2 that had more members of their HACCP teams than the stipulated

- 93 -

in the regulation. Only one business (9.1 %) that had an extremely large

number of HACCP team than usual.

Total of 10 (90.9%) businesses out of 11, have either an ideal number of

HACCP team (5 to 6 members) or close to this number which was

recommended by FAO (1998), Mayes and Mortimore (2003). and other

HACCP theorists.

As a result, almost half of the entire sample 5 (45.4 %) businesses; their

number of HACCP team members is matching the one stipulated in the

regulation.

4.3 Qualifications of HACCP team members

Table (4. 3): Qualifications of HACCP team members of 11 selected food

businesses (firms) in Sharjah.

No Company Qualification %

Ph.D. M.Sc. B.Sc. Dip. Formal

training

Experience

1 Company A 100%

2 Company B 100%

3 Company C 33% 38% 29%

4 Company D 33% 22% 22% 22%

5 Company E 100%

6 Company F 22.2% 55.6% 22.2%

- 94 -

7 Company G 33.3% 16.7% 33.3% 16.7%

8 Company H 80% 20%

9 Company I 28.6% 28.6% 42.9%

10 Company J 20% 60% 20%

11 Company K 14.3% 71.4% 14.3%

Table (4.3) ; illustrates how HACCP teams are qualified, it is noticed that 7

(63.6 %) HACCP teams, among their members there are members who have

got high educational degrees (M.Sc. and B.Sc.) and almost 3 (27%)

HACCP teams whom they were completely educated with B.Sc. Except one

HACCP team that was trained by formal training.

In terms of the qualifications and expertise findings; most of the

HACCP team members throughout the sample were qualified and have

various disciplines, which vary between, B.Sc, M.Sc., Diploma and formal

training in addition to long experiences that, some members have got which

add considerably to their knowledge.

The HACCP team shall identify the members and shall write their

names, designation, qualification, experience, training attended and their

tasks (Sharjah Municipality, 2005).

The food operation should assure that the appropriate product

knowledge and expertise is available for the development of an effective

HACCP plan (CAC, 2003).

- 95 -

4.4 A multidisciplinary team

During the interviews, food businesses were very much aware of the

approach that the HACCP team is effective when it is made up from

different related sections of the industry; therefore, their responses were

always within that context.

Table (4.4) Initial analysis of Company (J)


"….I could just say we are much more

aware of the various departments

when we were not a team …may be I

was just bothered about my job , he is

bothered about his job….he never

thought ..ok….we got to go ..and we

have got to be collective ..u know

..so.. if it is a maintenance department

..they are more what you call

….aware ..that they have to get a

preventative maintenance in

place…you got to know the

importance of it ..so …u know ..it is

more of awareness. I think it is more

of awareness ..it is a healthy

discussion and change of








work of others and know much about

it.


- 96 -





also in finance way…"


productive.

The company J has responded to the question of (What have your most

positive experiences been with this HACCP team?) as quoted; (Table 4.4)

"….I could just say we are much more aware of the various departments

than when we were not a team …may be I was just bothered about my job,

he is bothered about his job….he never thought ..Ok….we got to go ..and we

have got to be collective ..u know"

Table (4.5) Difficulties and challenges relating to the HACCP team as

quoted from Company (G).


No …. Because they were all

trained and have the knowledge ..

that made HACCP easy

Nothing

Company G as part of their response to the question of, [Have there been

any difficulties or challenges relating to the HACCP team?] have explained

- 97 -

that HACCP team selection was not a problem to them as the company had

the right expertise,

"No …. Because they were all trained and have the knowledge... that

made HACCP easy… HACCP system see …eh.., usually for a HACCP

team, the team number should be multidisciplinary team; the number should

have knowledge about microbiology ; food processing; maintenance as

there are a lot of automatic machineries; then purchase….here they know

how to make HACCP team … they have that knowledge ..so it was not

difficult for them ..."

Once the HACCP had become mandatory, the companies have

committed themselves to obtain knowledge in that through training.

Therefore, these businesses have probably read about the multidisciplinary

requirement in the regulations and guidance such as codex. All the HACCP

members shall undergo the HACCP training courses (Sharjah Municipality,

2005).

By going through the job titles of HACCP team members for each business

interviewed we are able to identify the amltidisciplinary approach clearly,

below are the findings:

Company (A)'s HACCP team consists of members from quality control,

diagnostic lab, maintenance, hatching, processing plant and sales.

Company (B)'s HACCP team consists of top management, quality

assurance, control, production, purchase and maintenance.

Company (C)’s HACCP team consists of a wide range of specialties the

number of the team (21) could explain that (Appendix 1).

- 98 -

Company (D)'s HACCP team consists of top management, technologist,

quality, production and maintenance.

Company (E)'s HACCP team consists of production, quality and distribution

Company (F)'s HACCP team includes staff from quality, production,

maintenance, store and technologists

Company (G)'s HACCP team includes members from top management,

quality, production, purchase, and maintenance.

Company (H)'s HACCP team includes members from quality, production,

maintenance and chemists

Company (I)'s HACCP team includes members from quality, production,

purchasing, maintenance and store.

Company (J)'s HACCP team includes members from top management,

quality, production and maintenance.

Company (H)'s HACCP team includes members as technologist,

microbiologist, quality, production, maintenance, new product development.

The team shall consist of individuals with different specialties. Several

specialties may involve in the team, each with an understanding of particular

hazard and associated risks, e.g. a microbiologist, chemist, QC manager, a

process engineer etc. people such as packaging specialists, raw material

buyers, distribution staff or production staff who are involve with the

process and have a working knowledge of it, may be brought into the team

temporarily in order to provide relevant expertise (Sharjah Municipality,

2005).

- 99 -

However, It is noticed throughout the entire selected sample that three

locations in the business Table ( 4.6) are considered dominant for HACCP

team members to be selected from, these locations are Quality control,

Production and maintenance (Appendix 1).

Table (4.6): Positions that HACCP team is mostly selected from

Location No. of Businesses Precentges

Quality control 11 100%

Maintenance 10 90.9%

Production 11 100%

The above findings could be considered a solid foundation for

addressing multidisciplinary approach throughout the businesses

interviewed.

Even though that these three departments are well related, moreover,

HACCP team should also be selected from further departments based on

how far those departments are involved in the processing lines and how

imperative their impact on the control of CCPs in the factory.

It is essential to assemble the right blend of expertise and experience,

as the team will collect, collate and evaluate technical data and identify

hazards and critical control points (FAO, 1998).

To analyze and develop the resources available within the organization,

it is recommended that the HACCP team be multidisciplinary (Surak and

- 100 -

Wilson, 2007). This helps ensure that primary and shared responsibilities are

not overlooked or heavily loaded onto one department, for example, the

quality department (Surak and Wilson, 2007).

4.5 Inter-hierarchical team

Below are the HACCP teams of the businesses interviewed listed as

per the job titles so as to discover how they relate or comply with Inter-

hierarchical approach (Table 4.7-4.17).

Generally, HACCP team members are all documented in the business's

HACCP manual by names along with their job titles and qualifications

- 101 -

Table (4.7): Job title of HACCP team members and their level in the

company (A).

No. Job title of HACCP team members and their level in the company

1 Food Processing Plant Manager

2 Processing Plant Manager

3 Quality Control & Diagnostic Lab Manager ( HACCP team leader)

4 Hatching Manager

5 Maintenance Manager

6 Quality Manager

7 Quality Controller



10 Sales Man

It does not seem to be an ideal team when looking at it from an inter-

hierarchical structure as it has to include persons from the production line as

well as from top management, besides that a sales man could be considered

of quality team rather than a safety one.

- 102 -


company (B).


1 Deputy General Manager

2 Production Manager


4 Purchase Manager

5 Quality Assurance Supervisor ( HACCP team leader)

6 Quality control Supervisor

Here, there is a need for someone from the bottom lines of production as

the responsibility has been placed on the managers it seems.

- 103 -


company (C).


1 Executive Manager-HACCP leader


3 Distribution Manger

4 HACCP In-charge

5 ISO In-charge

6 Bun line Administrator

7 HACCP implementer & Recorder

8 Statistical Officer

9 Hygiene Officer

10 Lab Technician

11 Mechanic

12 Store Keeper

13 Delivery In-charge

14 Hygiene Officer

15 Lab. Technician

- 104 -

16 Hygiene Officer

17 HACCP/ISO Implementer

18 Slice Bread Supervisor

19 Record Keeper

20 Record Keeper

21 Record Keeper

Studying this team from the prospect of being inter-hierarchical, of

course the team has included positions from different places but lacks top

management involvement.

- 105 -


company (D).


1 Managing Director

2 General Manager

3 Operation Manager & HACCP Manager

4 Factory Manager


6 Quality Assurance

7 Fish Technologist ( HACCP leader)

8 Assistant Quality Controller

9 Machinery In-charge

Well, this team could possibly be inter-hierarchical as it descends from

the top management to those who are on the shop floor such as quality

assurance, assistant QC and fish technologist.

- 106 -


company (E).


1 Quality Assurance Manager

2 Assistant Plant Manager ( HACCP leader)

3 Assistant Distribution Manager

4 Lead Production Operator

5 not provided

Here, it seems that the team members have been picked up from almost

the same level of job positions; therefore it could not be considered inter-

hierarchical.

- 107 -


company (F).


1 General Manager Production

2 Quality Assurance Manager ( HACCP leader)

3 Shift Manager

4 Store Keeper

5 Quality Officer

6 Mechanical Engineer

7 Hygiene Technician

8 Quality Officer

9 Quality Officer

The team has included persons from top management but it lacks people

from within the production lines whereas quality has taken a bigger portion

among the HACCP team members, therefore, inter-hierarchical approach

partially exists in this team.

- 108 -


company (G).


1 General Manager

2 Operational Manager


4 Purchase Manager


6 Quality Assurance Officer (HACCP leader)

Well, in this team, top management is available and has an ideal number

of members but it lacks people from the bottom line of processing plant.

Besides that the team seems to be within the managers only. Therefore it is

not appropriate and it has to be looked at again.

- 109 -


company (H).




3 Quality Assurance Officer (HACCP leader)

4 Laboratory Chemist

5 Laboratory Chemist

The team could be redesigned in a better way to include persons from

the production line.

- 110 -


company (I).


1 Managing Director


3 Quality Controller (HACCP leader)

4 Purchasing & Administration

5 Maintenance Engineer

6 Store Keeper

7 Supervisor

Team has included persons from top management and descended to

include others from lower related positions, therefore; inter-hierarchical

approach could be considered as existing in this team.

- 111 -


company J


1 General Manager


3 Assistant Production Manager

4 Head of Maintenance

5 Quality Controller (HACCP leader)

Team has included persons from top management descending to include

others from lower related positions but lacks the consideration of production

line workers which could positively complete the whole structure.

- 112 -


company (K).


1 Quality and Food Safety Technologist(HACCP leader)

2 Microbiologist

3 Quality & Vendor Assurance

4 Production Coordinator

5 Maintenance Technician

6 New Product Development (NPD)

It is not inter-hierarchical team as HACCP team is not structured to be

descending from top to bottom positions.

- 113 -

Since the inter-hierarchical approach is neither a requirement in codex

nor the legislation of Sharjah but merely a proposition by some experts, so it

is not surprising that not all businesses are inter-hierarchical, as a matter of

fact, it is quite an entertaining finding that some businesses have

incorporated an inter-hierarchical element to their team composition despite

this not being a requirement.

The HACCP team needs to be multifunctional and have the knowledge

that has depth and breadth across the enterprise (Mayes and Motimore,

2003).

In some of the legislations such as the one of Australia and New

Zealand (ARMCANZ ,2001), the people that HACCP team should be made

of (General Manager, QA Manager, Inspector, Forman and an understudy (

i.e. a motivated worker), such an order ,which is descending, from top to

bottom levels is an inter-hierarchical structure.

It is advocated that there is a need for a HACCP team that will represent

the "breadth" and "depth" of a company (Taylor, 2002). The former would

require representations from all areas of company (e.g. quality control,

production, engineering etc.) and is often referred to as the multidisciplinary

element of management, supervisors, food-operatives etc.) And can be

referred to as inter-hierarchical nature of the team (Taylor, 2002).

HACCP experts suggest that teams should be inclusive of different

positions starting from the top management to the ordinary workers whose

work is related to the subject (Taylor, 2006).

- 114 -

4.6 Source of HACCP team

All the HACCP teams were from within the companies themselves

except one company, which had 2, of its members from the parental

company; this explains the commitment of the companies to implement and

maintain HACCP system by providing training to their HACCP team in

order to carry out such notable duties and not necessarily depend on external

sources (Appendix, 1).

4.7 History of HACCP teams

HACCP system became mandatory for food factories in Sharjah on

2005. HACCP teams of 5 companies (45.4%) were formed on 2003 that is

when the HACCP system was still at its early stages when the authorities

started to divert its regulation towards HACCP by asking the food

businesses to have a food safety system in their premises.

It is noticed that 9 companies (81.8%) out of 11 (the entire selected

samples) had their HACCP team before it was mandatory, and just 2

companies (18.1%) had formed their HACCP team at the time of HACCP

system has become mandatory as part of their HACCP system

implementation.

However, that explains the enthusiasm and prompt movement of the

authorities towards HACCP implementation and that time could be looked at

as HACCP era in Sharjah.

- 115 -

4.8 HACCP team changes

All the businesses interviewed answered yes to whether the HACCP

team has changed by either joining new members or vice versa and such an

answer is more credible and transparent.

The question was [since this HACCP team formed has members

left/joined?, If so please give details].

The company (A)'s HACCP team changed drastically on 2003 as their

old team was established on 1995, but it seems they had to put new members

and rebuilt it again.

Seven businesses had suffered changes in their HACCP teams where

all those businesses teams formed a long time ago; the last was on 2004 and

two businesses only had recorded changes in their HACCP team by one

person leaved the job and replaced by another.

One business, which is, company (K) had formed new Quality

Assurance Team on 07/2006 instead of one before; this would represent food

safety and quality issues.

4.9 HACCP team meeting

[How often does your HACCP team meet?] That was the question

asked by the researcher and the responses could be categorized into four (4)

groups according to the different schedules of HACCP teams meeting

(Figure 4.2).

The first group had 3 (27.2%) businesses who have stated that their

HACCP team meeting takes place once in every 6 months, these businesses

- 116 -

are D, F and G who are dealing with frozen seafood, biscuits and frozen

meals, respectively.

The second group also had 3 (27.2%), businesses that refer to their

regular HACCP team meeting as once in every 3 months, these businesses

are A, C and E, their main activities are poultry products, pastries and

mineral water, respectively.

The group three had as a similar number of businesses as former groups,

which is 3 (27.2%), food businesses but in this group, they have set their

HACCP team meeting once a month; the businesses are H, J and K, their

activities include fresh fruits products, frozen meat products, chocolates,

respectively.

Finally, the fourth group had just the remaining 2 (18.1 %) businesses

of those held for interviews and here it seems they have narrowed the gap to

have the meeting twice a month, and these businesses are B ,and I and their

main activities are milk products and meat products, respectively.

- 117 -

Figure (4.2): Regular periods of HACCP teams meeting.

But despite the differences among the four groups of their scheduled

HACCP team meeting they have all stated that HACCP team meeting would

take place whenever changes, deviations or modifications in the processing

lines occurred.

The differences in team meeting schedules among the four groups could

be explained as follows:

The first group has one business, which is dealing, with mineral water,

and in this, there are less frequent changes in production as well as, the size

of the business is not quite large so it is quite reasonable for the team to meet

at such pace in every six months, but in the case of the other two businesses

HACCP team

meeting

1st Group

Group nd2

Group rd3

Group th4

3 Businesses

Once in 6

months

3 Businesses

Once in 3

months

3 Businesses

Once a month

2 Businesses

Twice a month

D, F and G

A, C and E

H, J and K

B and I

- 118 -

which are dealing with pastries and poultry products, besides that they are

both a bit big in business size, so perhaps they will have to reconsider the

period of the meeting.

In the second group, businesses main activities are frozen seafood and

biscuits which are considered less risky in addition to their less frequent,

changes in production, hence the meeting schedule in every 3 months is

good.

Third and fourth groups which their main activities are with milk, meat

products and juices which are considered high risk products, therefore, such

meeting schedule is quite good.

The HACCP team members shall assemble periodically to discuss issues

related to the HACCP system & develop or modify or verify or implement

the HACCP system (Sharjah Municipality, 2005).

The number of meetings will depend on the scope of the study and the

complexity of the operation. For efficiency, each meeting should have

objective, a planned agenda and a limited duration. Meetings should be of

sufficient frequency to maintain momentum, but spaced out enough so there

will be time between meetings for the gathering of any necessary

information (FAO, 1998).

- 119 -

4.10 Positive experiences gained from HACCP team

4.10.1 Positive experiences that relate specifically to teams

Themes were extracted from the responses of the interviewees to summarize

the positive impacts gained from HACCP team (Table 4.18-4.28).

Table (4.18) Initial analysis of company (A)


"…..Since we started working as a

team we begin to know all the

specifications of our products, the

associated pathogens such as

salmonella spp. and the total

account of bacteria that each

product might have. Working

together we succeeded in gaining

customer confidence in our

products As team also we

composed the HACCP manual…"

Increase knowledge by having it

shared

Business enhanced

Complied with legislation

Final analysis of company A:

Members' knowledge improved

Company A quoted as saying in this regard " ..Since we started working as a

team we began to know all the specifications of our products, the associated

- 120 -

pathogens such as salmonella spp, and the total account of bacteria that each

product might have"

Table (4.19) Initial analysis of company (B)


"…definitely na ..with the form I

can say that, after implementing

haccp there are lot of things we

have implemented and things are

going on very smooth there are not

any problems because with HACCP

.. you know .. basically there are

ccps in the HACCP so that with ccp

we made the ccp and we are

monitoring the ccp, we are

controlling the ccp all the things it

is totally giving good life, good

awareness to the employees, all are

contributing to this HACCP

especially this personal hygiene

they have increased their level of

standard, it is good for the

organization also and individual

also …basically…"

Believe that working as a team they

have gained a lot of experiences and

have become aware of the importance

of CCPs and what they stand for.

Working as team have increased the

standard of personal hygiene among

the staff

The reward is dual for the organization

as well as for the employees.

- 121 -

Final analysis of company B:

Here the company B explains how much knowledge they have gained in

implementing and maintaining HACCP system

"…definitely na ..with the form I can say that, after implementing HACCP

there are a lot of things we have implemented and things are going on very

smooth there are not any problems because with HACCP .. you know ..

basically there are CCPs in the HACCP so that with CCP our made the CCP

and we are monitoring the CCP, we are controlling the CCP all the things it

is totally giving good life,…."

Table (4.20) Initial analysis of company (C)


"….Positive experiences that after

the implementation of …..HACCP ..

I think that we are more safe ..we

are more safe and er… actually if

we follow …they give us all the

details ..or the critical or what are

the hazards and they differentiate

each and every thing and we follow

the study… according to the study

the products are safe..."

Being a team they were able to

implement HACCP system which

made them feel safe

- 122 -

Final analysis of company C:

Here the company C explains how much knowledge they have gained in

implementing and maintaining HACCP system

"….Positive experiences that after the implementation of …..HACCP .. I

think that we are more safe ..we are more safe and er… actually if we follow

…they give us all the details ..or the critical or what are the hazards and they

differentiate each and every thing and we follow the study… according to

the study the products are safe..."

Table (4.21) Initial analysis of company (D)


..yah I think the most important

thing is the awareness ..its a.....that

u know ..like a ..its a quality is very

important especially in the food

industry ..i mean it’s in the same

for any other industry but

especially for the food safety

…quality and safety so that

awareness I think is the most

important thing with the team

because it’s …a …from various

levels may be excluding the

workers but for that every year

there is training…given I would say

believe that awareness of safety and

quality have been increased among the

team as well as the entire workforce

Gained more training and felt more

responsible.

- 123 -

it’s a shared responsibility.

Final analysis of company D:

Company D explains in this situation as saying;

"..yah I think the most important thing is the awareness with the team

because it’s …a …from various levels may be excluding the workers, but for

that every year there is training given I would say it’s a shared

responsibility.."

Table (4.22) Initial analysis of company (E)


By having …lets say the HACCP

team you have… lets say

distribution of responsibilities is

better ..it will assigned when you

have haccp team.. the distribution

of responsibility assign clearly to

each member and cascading later

on this is responsibility to staff who

comes beneath .. like for the lead

operator he have..10 helpers and

10 helpers for each shift .. 20

helpers …so wherever you are

assigned for a job we cascade this

Assigning responsibilities have become

easier.

- 124 -

responsibility for helpers bellow

..of course ..in the HACCP all they

have training and refreshing course

also ..so ..they are aware in a way

or another of their contribution to

the product safety ..like how

important their job is and why they

should do it perfectly even if you

have automatic machines, human

interference is important ..so they

can

Awarness is better .. commitment

towards the company is better

because all they receive training

courses not less than three courses

..so when member or…..lets say an

employee who gets such train ..see

his company went to invest on

him…then our return investments

will be the loyality to the company,

the ownership of this employee

Being a team that enhanced the

awareness, commitment.

Gaining more training courses that

increases knowledge and in return

make increase the ownership among

the employees towards the company.

- 125 -

Final analysis of company E:

Members' awareness and commitment increased

Company E also explained this by saying;

"…Awareness is better ... Commitment towards the company is better

because all they receive training courses not less than three courses ...so

...they are aware in a way or another of their contribution to the product

safety ..like how important their job is and why they should do it perfectly

even if you have automatic machines, human interference is important…"

Table (4.23) Initial analysis of company (F)


We did some

..modifications….alterations on the

flow charts very recently we

introduced new ccps so when we

meet next one ccp we are going to

remove and include one ccp…. We

could proper assessment of the

system

Being a team they are able to maintain

HACCP system themselves and keep it

updated.

- 126 -

Final analysis 0f company F:

Company, F also explains saying

"….We did some ...modifications….alterations on the flow charts very

recently we introduced new CCPs so when we meet next one CCP we are

going to remove and include one CCP…. We could proper assessment of the

system…"

Table (4.24) Initial analysis of company (G)


See.. experiences means ..all our people

….they all got good experience in the

industry ..all are trained in haccp and

ISO then they got enough knowledge in

the system already …see …er ..all have

haccp training .. ISO knowledge .. they

know what are the subjects ….if the

situation has come .. they know what are

the potential efforts ..and then what are

quality measures .. all the things….all this

have a good impact on the food and

implementation

..u see… they were all understanding ..all

are cooperative ..if you say something

Working as a team enabled them

to gain more experience, know

more about HACCP and ISO as

well.

Working as a team enabled them

to handle difficult situations

properly and better than before as

they have become aware of the

critical points

Believe that they have become

cooperative, responsive to

- 127 -

about haccp .. we will have a good

discussion and good contribution also..

usually .. you see … is not a one man

show is always a group work

HACCP issues as they are now

familiar with its topics that also

made their discussions useful.

Final analysis of company G:

Company G also explains how the company team as well as the other

staff gained more knowledge saying;

"….See.. experiences mean ..all our people ….they all got good experience

in the industry ..all are trained in HACCP, and ISO then they got enough

knowledge in the system already …see …er ….if the situation has come ..

they know what are the potential efforts ..and then what are quality measures

.. all the things….all this have a good impact on the food and

implementation…"

Company G also adds;

"....u see… they were all understanding ...all are cooperative ...if you say

something about HACCP ... we will have a good discussion and good

contribution also.. Usually... you see … is not a one man show is always a

group work…."

- 128 -

Table (4.25) Initial analysis of company (H)


First of all … the group work is

always a momentum for the person

…when all of them sit down to

discuss a situation and share the

thoughts from different angles

every one will benefit from that ..

and this affects the quality

tremendously … we say here that

the quality is not the responsibility

of Quality Dep. But it is the

responsibility of the all.

Haccp team is very important

because, one person can not do

everything … and also you need to

know from others …and from their

experiences and disciplines….

Believe that team work is always a

momentum for the individuals to work

hard and discuss issues with different

perspectives

Believe that everyone needs the

assistance of others in terms of

exchanging ideas, experiences which is

very helpful.

- 129 -

Final analysis of company H:

Employees’ performance improved

Company H explains how teamwork can be momentum for the workforce

saying;

"…..First of all … the group work is always momentum for the person

…when all of them sit down to discuss a situation and share the thoughts

from different angles everyone will benefit from that .. and this affects the

quality tremendously … we say here that the quality is not the responsibility

of Quality Dep. But it is the responsibility of the all…."

Table (4.26) Initial analysis of company (I)


Positive experiences that first I told

….since I am a person .. I am .with

less experience ..even though I

know much .. I am very much into

microbiology ..since we do not have

lab.. we are sending our samples to

SGS or to some other labs ..but I

am very much experience in

microbiology more than any one

..because I worked as a

microbiologist in India ..so I know

Realizing a fact that a team work has

helped all members share their

knowledge, experiences and everyone

has become knowledgeable of what's

happening in other departments.

- 130 -

about the organisms which are

causing food poisoning .. what are

the organisms which are producing

toxins.. I know the organisms which

affect the food ..about all things I

have idea ..so since we are going to

start new lab I can give my full …..

but regarding the processing or

other things I am not much

experience but I am learning from

this ..so I have learnt many things

from this people ..even though

…see .. I have learnt many things

from the production because I have

to know each and everything which

is going on like ..suppose we'll be

having some fifty products, sixty

products .. so I must know about

each product…even I am interested

what is happening in the

purchasing ….though I am part of

the quality but I have to know

..even from the store

keeper…....even if he is not well

educated but his experience , he is

seen this company for more than

- 131 -

10 years…….he is seen whats

happening in food processing ..but

I can learn from him.. so by talking

by having conversation with this

people by having interaction with

this people .. so as team I am

learning

Final analysis of company, I:

Company I explains the experiences gained through the team

".. I am very much into microbiology …. but regarding the processing or

other things I am not much experience but I am learning from this.. I have

learnt many things from the production …even I am interested what is

happening in the purchasing ….though I am part of quality, but I have to

know..even from the store keeper …."

Table (4.27) explicate the Initial analysis of company (J)



aware of the various departments when we

were not a team …may be I was just

bothered about my job , he is bothered

Awareness of what is the

system all about that even other

departments understood the

point such as maintenance and

- 132 -

about his job….he never thought ..ok….we

got to go ..and we have got to be collective

..u know ..so.. if it is a maintenance

department ..they are more what you call

….aware ..that they have to get a

preventative maintenance in place…you

got to know the importance of it ..so …u

know ..it is more of awareness. I think it is

more of awareness ..it is a healthy

discussion and change of ideas….more

heads sitting together it is more ideas

otherwise ..I think ..its communication

and .awareness should be the most

positive aspects I think .it .does affect our

production also in finance way…"

they are trying to do their work

accordingly.

Everyone has become aware of

the work of others and know

much about it.


together made the work go easy

and productive.

Final analysis 0f company J:

Company J explains how they have become more aware and how important

that is for their business since they have started working as a team saying;

"…em……..I could just say we are much more aware of the various

departments when we were not a team …may be I was just bothered about

my job , he is bothered about his job….he never thought ..ok….we got to go

- 133 -

..and we have got to be collective ..u know ..so.. if it is a maintenance

department ..they are more what you call...aware, .that they have to get a

preventative maintenance in place…you got to know the importance of it

..so …u know ..it is more of awareness...it is a healthy discussion and

change of ideas….more heads sitting together it is more ideas otherwise ..I

think ..its communication and awareness should be the most positive aspects

I think .it .does affect our production also in finance way….."

Table (4.28) Initial analysis of company (K)


The benefits are the learning the

learning is very important …the

issue what happened …u know…

this is a factory …. Nothing is

perfect in the world …things

happened and that’s how you learn

from what happened …we do risk

assessment we learn ..and then….

To prevent it from happening again

and again ..

Believe that working as team has

helped increase their knowledge

- 134 -

Final analysis of company K:

Company K contributes to this saying;

"….The benefits are the learning is very important …the issue what

happened …u know… this is a factory …. Nothing is perfect in the world

…things happened and that’s how you learn from what happened …we do a

risk assessment we learn..and then…. To prevent it from happening again

and again …."

4.10.2 Positive experiences that relate to HACCP generally

The following themes were extracted from the responses of the interviewees;

Business improved

Company A quoted saying; “...working together we succeeded in gaining

customer confidence in our products as a team"

Business secured

Company C explains how they have become safer after implementing

HACCP system in their premise.

"… after the implementation of …..HACCP... I think that we are more safe".

Management improved

Company E explains how their management has become tidy and organized:

"…..By having …lets say the HACCP team you have… lets say distribution

of responsibilities is better ..it will assign when you have HACCP team.. the

- 135 -

distribution of responsibility assign clearly to each member and cascading

later on this responsibility to staff who comes beneath .."

Company J explains how reporting has become effective than it used to be;

"..so.. reporting has become more effective.. .that one nice .ok ..they were

checks in place I haven’t said no but it was not specific ..if I have the raw

material supervisor asked him now what material has you got today and at

what time ..he would be able to tell me specifically …ok….this is it and I

made so and so checks".

Compliance with the legislation

Company (A) an explained how they were able to achieve organized work

by producing HACCP manual saying;

"………… working together we succeeded in gaining customer confidence

in our products…..as a team also we composed the HACCP manual ......."

Company C explains how their company has become safe in terms of any

complaints or penalties saying;

"……Positive experiences that after the implementation of …..HACCP .. I

think that we are more safe ..we are more safe and er… actually if we follow

…they give us all the details ....or the critical or what are the hazards and

them differentiate each and every thing and we follow study….er …um…

according to the study the products are safe…."

- 136 -

Healthy working environment emerged

Company J have expressed their experiences towards HACCP by

experiencing its positive impacts on their working situations

"..it is a healthy discussion and change of ideas….more heads sitting

together it is more ideas otherwise ..I think..its communication and

.awareness should be the most positive aspects I think.."

4.10.3 Negative experiences that relate specifically to teams;

The starting steps were a challenge.

Table (4.29) Initial analysis of the difficulties and challenges related to the

HACCP team (company A)


There was no difficulties because

the team was qualified, the one who

is not well qualified will get the

knowledge from the other team

members

When we joined the company we

are all specialized in different

HACCP was not well understood at

the beginning but as a team being

- 137 -

subjects but HACCP concept was

not really focused in our minds, we

had just general idea about it that’s

why we had to be enrolled in

training courses so as to strengthen

our knowledge and know about it

much.

trained HACCP become known to

them.

Company A an explained when they first joined; they actually were not

much knowledgeable of HACCP saying;

"…when we joined the company we are all specialized in different subjects

but HACCP concept was not really focused in our minds, we had just

general idea about it that’s why we had to be enrolled in training courses so

as to strengthen our knowledge and know about it much…."


HACCP team (company B)


So far no … no .. we ..even in the beginning

we having a proper ..we going …..we made a

manual we've submitted our maneuver outside

agency then Dubai municipality they've gone

through all the manuals and we got HACCP in

- 138 -

first audit, in the very first audit we got

HACCP .. no.. see.. marmum farm is a small

farm is not a very big dairy, we've a small

system here .. so within the limitations we've

taken to choose our best team.. because.. see..

as far as long am here as far for the quality

assurance only Laxmikant is there ..and the

production manager, he is the only key person

in that so we've taken key persons from every

and each department .... so for us there was no

any problems because I told this is not a very

big dairy it is a small dairy and we've a small

system and within the limitation we've done

and what we can say is a great achievement

that it was great challenge for us we have

taken the … in the first audit ..and while…

this… choosing these ccps…. we've studied in

details until the points we are facing… while

maximum time that we've chose the ccps so

mentoring and this controlling it is very easy

by practice .. and the awareness of people and

this… employees involvement in this systems

helps increase the moral of the employee

also… it helps in the system also…

Working hard at the

beginning to have HACCP

implemented which was

approved by the first audit

from a third party.

- 139 -

Company B also pointed out to how they have struggled to complete

HACCP manual at the beginning saying;

",…. we've a small system and within the limitation we've done and what we

can say is a great achievement that it was a great challenge for we have

taken the HACCP… in the first audit .. ….."


HACCP team (company C)


…no .. I think when we were

implementing ..we start ..at the

start of the implementation ..then

we face some problems ..we face

some …like this ..their

requirements that …er.. certified

suppliers ..we were facing like this

problem ..but now we take all our

raw materials ..we have the

certified suppliers now ..because

..but at the beginning we had the

problem

Understanding the requirements of

HACCP system made them face the

problem of getting approved and safe

suppliers.

- 140 -

Company C explained the situation they had at the beginning saying;

"..…no .. I think when we were implementing ..we start ..at the start of the

implementation ..then we face some problems ..we face some …like these

..their requirements that …er.. certified suppliers ...."


HACCP team (ompany D)


..Difficulties..There have been in the sense

like a.. we were having with ..its sea world

as u see…… like ……the program is sea

world from 2000 till date there having

been many changes to the program…some

times as per the inspection of the

municipality staff or sometimes from third

party audit or internal audit so there have

been corrections to the program basic

programs so which I think…..i wouldn’t

say that yahh…its…i wouldn’t call them

challenges but then been improvements

with the initially plan ..i think there have

been changes systematic ..continuous

changes to the programme ..verious

infractions between the team the auditors

the factory activities…..the challenges may

Facing changes in the system by

auditors as well as by

enforcement authority that

require amendments

There was a delay in getting the

recommended changes or

modification done immediately

due to financial problems.

- 141 -

be will be in the sense of budgetary

concerns ..yahh ..because sudden changes

requires sudden budget commitment ..so

..which at times it was not available but

then they … manage that ..


HACCP team (company E)


In the haccp team .. the challenge

was earlier to develop skills for the

staff who were earlier not involved

,, you have to gradually build up

their skills .. er … they can not in

the haccp team directly you have to

work out invest lot of many in them

to get certain training

Developing skills that qualify them to

be a HACCP team by training which is

costly and the company has to pay for

that.

Company E also contributes to this saying;

"………In the HACCP team .. the challenge was earlier to develop skills

for the staff who were earlier not involved ,, you have to gradually build up

their skills .. er…"

- 142 -


HACCP team (company F)


Yah .. see.. actually ..Some challenges

from the Municipality, some challenges

from the certification companies …so ..

they didn’t accept our flow chart once ..

we had to modify that …when we learnt

something from them ….municipality

challenges said that you are wrong .. we

proved what we were doing was

right…so…..when we went for re-

certification 2006 municipality…one

person ..what is his name..

Harold….yah…so and so ..was putting

me in some challenges that you should

cancel this ccp ..and I have to tell him if

cancel this ccp I will have a problem

..so… I tried to convince him and he

finally agree ..this kind of problems we

had.. from the certification companies

….sometimes they will just say this is not

correct …


auditors as well as by

enforcement authority that

require amendments at the

beginning.

HACCP as a controversy

- 143 -

Company F explained in this regard as saying;

"…Yah .. see.. actually ..Some challenges from the Municipality, some

challenges from the certification companies …so .. they didn’t accept our

flow chart once .. we had to modify that …"


HACCP team (ompany G)




that made haccp easy

Nothing


HACCP team (company H)


One of the difficulties we have got is

the haccp team meeting … we are

trying to intensify the meeting to be

weekly not even monthly so that any

member who couldn’t attend the

During the meeting that requires

everyone to be present but that

never realized as someone would be

absent therefore there is a need to

- 144 -

meeting the first week can attend it

the second one.. but when it is

monthly if any member failed to

attend ….then he will have to wait

for another month to meet again and

that’s not practical..,

Other difficulties could be

considered administrative ……such

as the place that we wanted to meet

in …. Sometimes it is occupied by

other group or needed by the

General Manager.

overcome this problem by adjusting

the meeting schedule.

Lack of space in the company to

arrange the meeting in.

Lack of time

As company H was referring to as saying; "…One of the difficulties we have

got is the HACCP team meeting … we are trying to intensify the meeting to

be weekly not even monthly so that any member who couldn’t attend the

meeting the first week can attend it the second one.."

Lack of Space is an obstacle for conducting HACCP

Company H arose this issue as saying; "….Other difficulties could be

considered administrative such as the place that we wanted to meet in …

- 145 -

Sometimes it is occupied by other group or needed by the General

Manager….."

In a fast-moving environment such as a processing plant or a catering

establishment, time is always limited. Therefore it is not surprising that

people always priorities tasks according to their own perception of

importance Panisello and Quantick,(2001).

Therefore, managers should be aware of the limitations of their operations

and realistically design monitoring procedures and schedules commensurate

with their operations Panisello and Quantick,(2001).


HACCP team (company I)


Difficulties means ok…suppose every

people ..because I told before …since I

am the person who….since I am holding

the haccp team leader… ..first of all I

must know what are the…work ..things

that should be done in the factory….so

my responsibility is to hold all this

people ..really I have faced a lot

challenges in this company….because

our company since we have lack of

space it is difficult to …it is very hard

work ..i think after we go for the

Lack of space is an hurdle that

affect the team to work

harmoniously

- 146 -

expansion things will be much easier..we

lack some one more from the quality

control but our company is intending to

hire a quality control manager who must

be having more experience than me ….he

might not know much about our company

but he definitely have experience then

only we can work hand in hand …

Personal difficulty that he needs

someone else to assist him so as

to alleviate some of the work load

assigned to him.

Company I demonstrates their difficulties as saying;

"…..really I have faced a lot challenges in this company….because our

company since we have a lack of space it is difficult to …it is very hard

work ..i think after we go for the expansion things will be much easier….."

Food factory layout must be designed to achieve a smooth flow of

operations keeping the amount of handling of food materials to the minimum

possible Panisello and Quantick,(2001).


HACCP team (company J)


Yes….ya….initial….financial

aspects….because we had made a lot

Things were not tidy enough,

team had to work hard to make

- 147 -

of changes when we were introduced

into haccp .. the manual writing ..and

having certain checks in place

…having people come to do certain

duties then also may be the splitting

your duties ..earlier if you had a

supervisor who is just looking into

everything you couldn’t really pin

point and ask him to do this at this

time ..but.. u know ..so.. reporting has

become more effective.. .thats one

nice .ok ..they were checks in place I

haven’t said no but it was not

specific ..if I have the raw material

supervisor asked him now what

material have you got today and at

what time ..he would be able to tell

me specifically …ok….this is it and I

made so and so checks.

ends meet such as taking more

duties, writing HACCP manual.


HACCP team (company k)


"….Yaah.. I would call them Lack of scientific evidence or proof

- 148 -

challenges not difficulties .. yeah

.they had been a lot .especially .in

terms of a.. …convincing people

that these are the right things to do

and why we are right …u know .. to

prevent issues …etc. challenges

again….I can say ..that ..er .. what

really happen is certain issues are

challenging things when we have…

suspect of a.. may be …a foreign

object contamination or any

contaminant ..etc…..and we have

taken decision for example …these

are the challenging……"

of a plan being valid so as to

convince others about it.

Lack of tools to make things sure

happening so that right decision could

be taken.

Company K quoted as saying "…Yaah.. I would call them challenges not

difficulties .. yeah .they had been a lot .especially .in terms of the a..

…convincing people that these are the right things to do and why we are

right …u know .. to prevent issues …etc…"

- 149 -

4.10.4Negative experiences that relate to HACCP generally

The following themes were extracted from the interviews responses;

Financial difficulties

Company D explained the difficulties sometimes ago faced the HACCP

team to carry out corrective actions ;

"…..the challenges may be will be in the sense of budgetary concerns ..yahh

..because sudden changes requires sudden budget commitment ..so ..which

at times it was not available but then they … manage that ….."

Company E also adds;

"……..you have to gradually build up their skills .. er … they can not be in

the HACCP team directly you have to work out invest a lot of many in them

to get certain training……"

Company J quoted saying in this context;

"…Yes….ya….initial….financial aspects….because we had made a lot of

changes when we were introduced into HACCP … the manual writing ..and

having certain checks in place …having people come to do certain duties

then also may be the splitting our duties ..."

HACCP as distortion

This was implied by many responses as quoted while interview;

Company D explains how many changes or modifications their company

had received since the implementation and these changes are still going on

- 150 -

in spite of the simple nature of business as him referred to it as sea world (

meaning seafood business),

"…difficulties….There have been in the sense like a.. we were had with ..its

sea world as u see…… like ……the program is sea world from 2000 till date

there having been many changes to the program…some times as per the

inspection of the municipality staff or sometimes from third party audit or

internal audit…"


This was implied in some responses that there are no clear and cut

answers regarding HACCP elements even from the authorities or

certification institutions;

"….municipality challenges said that you are wrong .. we proved what we

were doing was right…so…..when we went for re-certification 2006

municipality…one person ..what is his name.. so and so….yah….so and so

..was putting me in some challenges that you should cancel this CCP ..and I

have to tell him if cancel this CCP I will have a problem ..so… I tried to

convince him and him finally agree ..this kind of problems we had.. from the

certification companies ….sometimes they will just say this is not correct

…"

The adoption of HACCP will be impeded unless there is mutual

understanding and agreement between the food industry and the enforcement

authorities Panisello and Quantick,(2001).

- 151 -

4.11 Interviewees profile

Company A

A man who is in his mid 50's, an expatriate who have come to the country

(UAE) long time ago in the eighties, he lives along with his family in the

company's accommodation in the farm. He is always on call for any

situation that might occur in the farm. He is a veterinary doctor, holds

Quality Control & diagnostic Lab Manager ( HACCP team leader) in the

company, has nearly 25 years of experience, has got a good knowledge in

HACCP implementation through training courses and on site experience.

Company B

A male in his 40's, works as a quality control supervisor, had been working

in Oman before, his educational background is B.Sc. in dairy, has gotten a

good knowledge of HACCP implementation which he applied it to his

current company. While implementing HACCP they haven’t got assistance

from outside experts but himself and his team tried to work their system out

and them got it approved by first audit from the municipality.

Company C

A man is in his late 40's, who has been assigned to look after HACCP

maintenance in the company, his educational background is basically on

chemistry and he has got M.Sc. in the same subject.

- 152 -

Company D

A man in his early 40's, expatriate, has got M.Sc. In industrial fisheries and

he is working as a fish technologist and HACCP leader at a time, seems to

be very conversant with his role.

Company E

A man in his mid 30's, an expatriate single, who is working as an auditor

besides to his current job as an assistant plant manager, his educational

background is chemistry science, he has got a good knowledge in TQM as

well as in HACCP through experience and training courses.

Company F

A man in his early 40's, working as a quality assurance manager in his

current job, his educational background is BSc. Chemistry, has got

experience in HACCP from his previous job and through training.

Company G

A man who is 34 years old, living with his family of a wife and two kids,

used to work in Oman before he joined his current job, holds M.Sc. In Fish

Industries, has got experience in HACCP and ISO through courses.

Company H

A man in his 40's, working as quality assurance officer in his current job as

well as a HACCP leader, he is a graduate of biochemistry besides that he

got Diploma in food science,

- 153 -

Company I

A man in his early 30's has finished M.Sc. In microbiology and worked as a

microbiologist in his previous job in India, in his current company he works

as quality controller as well as a HACCP leader.

Company J

A lady in her late 20's, single, she had finished MSc. In microbiology, very

much dedicated to her position, has got a sense of humor, she seemed a

prominent figure in the company regarding food safety besides that she is

the HACCP leader.

Company K

A man who is 35 years old, graduate of food science a technology, worked

as a consultant and a third party auditor in his previous job, he has got a

good knowledge of legislation as well as TQM guidelines, he joined his

current job before 3 months and him is the team leader as he is the quality

and food safety technologist.

4.12 Businesses in the case to be contacted again regarding this project:

Are you happy to be contacted again regarding this project? That was the

last question among the questions designed for the interview and all the

businesses interviewed has responded YES, in fact, warmly welcomed to

participate in any further inquiries.

- 154 -

CHAPTER FIVE

5. CONCLUSIONS AND RECOMMENDATIONS

5.1 Findings of the study

The primary purpose of this study was to explore the idiosyncrasies and

potentialities of HACCP teams and to which extent they have been built up

multidisciplinary and inter-hierarchical taking into consideration the outmost

and ultimate goal of how could that be beneficial and invaluable for HACCP

implementation and maintenance so as to produce safe food.

From the results obtained and from the interviewees' responses the

research had revealed the most positive experiences being with HACCP

team, and the difficulties encountered by the HACCP teams as in the

following Findings:

1. Positive experiences that relate specifically to teams:

- Members' knowledge improved.

- Members' awareness and commitment increased.

- Employees performance improved.

2. Other positive findings about HACCP in general.

- Business improved.

- Business secured.

- Management improved.

- Compliance with the legislation.

- 155 -

- Healthy working environment emerged.

3. Negative experiences that relate specifically to teams:

- The starting steps were a challenge.

- Lack of time.

- Lack of space is an obstacle for conducting HACCP.

4. Negative experiences that relate to HACCP

- Financial difficulties.

- HACCP as distortion.

- HACCP as a controversy.

5.2 Conclusions:

1. From the above results. It is clear that, the good advantages of assembling

a team and how beneficial that is on team individuals themselves which in

turn has its positive influence on HACCP system generally.

2. The study indicated a HACCP system that really works in practices will

depend on the competency of the people who both developed it and who

operated it, and the prerequisite programmes, which support it. If it is to be

truly successful, then there must be an overriding internal belief in the

HACCP approach and what it can do for the business once properly

implemented. The critical success factors will thus be:

- Proper preparation and planning.

- Trained and educated people.

- 156 -

- Belief in the approach by all personnel.

- A shared commitment to food safety.

3. The company has implemented HACCP for its own benefits rather than

for HACCP certification. The company’s quest for continuous quality

improvement is significantly enhanced with improving product safety under

the HACCP system. As yet, acquiring a HACCP certification is not a

condition of a good sale. However, achievements from HACCP

implementation would promote the product in the eyes of customers.

4. In order to strengthen its HACCP implementation, the company should

broaden qualitative hazard assessments to quantify consumer risk and

potential hazard reduction (Notermans et. al., 1995).

5. Most businesses have a reasonable and a sufficient number of HACCP

team members ranged between 5-10 members. Almost half of the entire

sample which are 5 (45.4 %) businesses; their number of HACCP team

members is matching the number recommended or stipulated in the

regulation.

6. Generally, total of 10 (90.9%) businesses out of 11(the total sample), have

either an ideal number of HACCP team (5 to 6 members) or close to this

number which is recommended by FAO (1998), Mayes and Mortimore,

(2003) and other HACCP theorists.

7. Regarding HACCP team qualifications and expertise, the study had

discovered that most of the HACCP team members were educated with

various educational backgrounds; M.Sc, B.Sc, Diploma, formal training and

long experiences in the same field.

- 157 -

8. Therefore the study show, the composition of the teams was

multidisciplinary to some extent, positively the businesses seemed to be

aware of multidisciplinary approach, and that appeared very clear through

their responses during the interviews. On the other hand, businesses seemed

to be not aware of inter-hierarchical approach that the HACCP team should

also be addressed with as recommended by some HACCP theorists, however

the approach sometimes exists concurrently and unintentionally.

9. To implement an effective food safety management system, managers will

require an understanding of all aspects of food hygiene, including basic

microbiology and food science, together with the last information on causes

of food borne illness, food vehicles and preventive measure.

5.3 Recommendations:

1. HACCP team in the food industry in Sharjah is positively considered as

an important step towards HACCP implementation, and therefore, it is an

essential element of HACCP system in Sharjah, often, however, HACCP

requires to be more focused, well trained and properly structured so as to

comply with the multidisciplinary and inter-hierarchical approaches.

2. There is a need for the HACCP team should be aware of hazards and

control and controls relating to their food business, especially in relation to

temperature and microbiology, physical and chemical contamination. They

should be able to identify points that are critical to food safety and

implement effective control and monitoring procedures at these point. If

monitoring reveals that a problem has occurred at critical control point, a

- 158 -

system must be in place to ensure timely and appropriate corrective action is

taken.

3. A comprehensive effort by governments and businesses is necessary and

data should be collected and used to evaluate and adapt the HACCP plan.

The HACCP system must also be revised to reflect ongoing changes to

operating systems, plant, facilities, workforce and environment, as these will

have an impact on the safety of the consumer’s end product. As changes

occur, each employee must be retrained, kept aware of his role and held

accountable for a clean workspace and safe product at his stage of the

process. Moreover, consideration should be given to the value and

application of control charts in maintaining process control in the Production

and Laboratory areas, as this will allow continuous tracking of process

parameters at CCP.

4. The Ministry of Health in Developing countries should took the initiative

of address the HACCP system and plans for its implementation throughout

the food industries via different methods such as seminars, ceremonies of

appreciation and through training sessions.

5. The Ministry of Health as it is enforcement authority in Developing

countries . it must starts to assess food companies if are embrace the

prerequisite programme of HACCP such as Good Manufacture Practice

(GMP), Good Hygiene Practice (GHP),Good Agriculture Practice (GAP), so

as to implement the HACCP system and to set out the essential requirement

and follow up the progress of the HACCP system uptake gradually.

- 159 -

6. The responsibility of the food industry in Developing countries to

develop and implement HACCP plans and for regulatory agencies to

facilitate this progress.

7. Finally study recommended as the HACCP team should be

multidisciplinary; it also needs to be inter-hierarchical. Multidisciplinary

represents the breadth/horizontal aspect of the organization, which mainly

refers to differing knowledge and expertise, while inter-hierarchical refers to

the length/vertical side of the organization represented by all levels within

the organization.

8. Suggestions for Further Studies: The above study was carried in a very

small area (Sharjah emirate) compared to the total area of United Arab

Emirate (UAE) country,. Therefore, Further in -depth research is

recommended in this sector in order to investigate and highlight the

importance of HACCP team being multidisciplinary and inter- hierarchical

and how invaluable those approaches for effective HACCP implementation.

- 160 -

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- 170 -

APPENDICES

Appendix 1: HACCP Team Questionnaire

How many people are in your HACCP team?

2. Who are the key members of your current HACCP team? (add to table

below)

3. What are their qualifications/if any? (add to table below)

Name Job Title Qualifications

4. Are any of these people from outside the business? If yes what is their

function and/or area of expertise?

- 171 -

5. When was this HACCP team formed?

6. Since this HACCP team formed have members left/joined? If so please

give details.

7. How often does your HACCP team meet?

8. What have your most positive experiences been with this HACCP team?

9. Have there been any difficulties or challenges relating to the HACCP

team?

10. Are you happy to be contacted again regarding this project?

Business details

Business name

Contact name

Contact telephone number

Business address

Number of employees

- 172 -

Products

Other Not

Appendix 2: Sharjah City Map

Sharjah is the oldest emirates coast of Oman, and mediates the other

emirates. The area of Sharjah 2,600 km², and this space is equivalent to

3.3% of the total area of the UAE. The length of the coastline of the Arabian

Gulf about 20 kilometers, and the inside of about 80 kilometers of the Gulf

http://www.google.ae/url?sa=i&rct=j&q=sharjah+map+with+area&source=images&cd=&cad=rja&docid=h_y_aPn8XquewM&tbnid=Jmi6SEazRVOewM:&ved=0CAUQjRw&url=http%3A%2F%2Fwww.destination360.com%2Fmiddle-east%2Funited-arab-emirates%2Fash-shariqah%2Fholiday-inn-sharjah%2Fhotel-map&ei=eGAzUZHNFo2BkwWU94DADg&psig=AFQjCNEV7BzN0dz1ve9Qe2I_Ti9SBcHr1Q&ust=1362407768927379

- 173 -

of Oman. Sharjah is the capital of Sharjah emirate located on the Arabian

Gulf and in the south-west lies the village of Alkhan then twist that separates

the creek from Sharjah, built on the Gulf coast along three miles, was one of

the most important centers for import and export, and industries were

thriving.

Appendix 3: Interviews transcription

Eleven companies selected were HACCP certified companies with which the

research was carried out and their responses are shown below as per the

questions sequence on the questionnaire,

The question was

How many people are in your HACCP team

No. Company Name No. of Employees No. of HACCP

team

1 Company A 350 10

2 Company B 250 6

3 Company C 450 25

4 Company D 85 9

5 Company E 255 5

6 Company F 300 9

7 Company G 300+ 6

- 174 -

8 Company H 227 5

9 Company I 90 7

10 Company J 60 5

11 Company K 200 7

Every company has enclosed the name of their HACCP team members, their

job titles and qualifications as asked through the question no. 2 and 3 in the

questionnaire.

Here are the interviews for each company separately

Company (A).

Q1. [How many people are in your HACCP team?]

10 people

Q2. [Who are the key members of your current HACCP team? (add to table

below)]

Q3. [What are their qualifications/if any? (add to table below)]

No. Job title Qualification

1 Quality Control & diagnostic Lab

Manager ( HACCP team leader)

BSc. In veterinary

2 Maintenance Manager Mechanical Engineer

- 175 -

3 Processing plant Manager Vet

4 Hatching Manager Agricultural Engineer

5 Quality Controller Vet


7 Sales man Veterinary Institute


9 Quality Manager Veterinary Institute

10 Food Processing Plant Manager Food Technologist

Q4. [Are any of these people from outside the business? If yes what is their

function and/or area of expertise?]

A4. No, all of them are from within the company itself.

Q5. [When was this HACCP team formed?]

A5. 1995

Q6. [Since this HACCP team formed have members left/joined? If so please

give details.]

A6. Yes many left and new joined but the current HACCP team is fixed

since 2003.

- 176 -

Q7. [How often does your HACCP team meet?]

A7. Once in every 3 month and on emergencies

Q8. [What have your most positive experiences been with this HACCP

team?]

A8. "….Since we started working as a team we begin to know all the

specifications of our products, the associated pathogens such as salmonella

spp. and the total account of bacteria that each product might have.

Working together we succeeded in gaining customer confidence in our

products. As team also we composed the HACCP manual……"

Q9. [Have there been any difficulties or challenges relating to the HACCP

team?]

A9. There was no difficulties because the team was qualified, the one who is

not well qualified will get the knowledge from the other team

members…….When we joined the company we are all specialized in

different subjects but HACCP concept was not really focused in our minds,

we had just general idea about it that’s why we had to be enrolled in training

courses so as to strengthen our knowledge and know about it much….."

Q10. [Are you happy to be contacted again regarding this project?]

A10. Yes

- 177 -

2. Company (B)


A1. 6 people


below)]

Q3. [What are their qualifications/if any? ( add to table below)]


1 Q. Assurance Supervisor (HACCP leader) Dairy Science

2 Q. control Supervisor Dairy Science

3 Deputy General Manager Engineering

4 Production Manager Dairy Science

5 Purchase Manager Engineering

6 Maintenance Manager Engineering



A4. NO


- 178 -

A5. On 2003


give details.]

A6. Yes


A7. Twice a month


team?]

"……definitely na ..with the form I can say that, after implementing haccp

there are lot of things we have implemented and things are going on very

smooth there are not any problems because with HACCP .. you know ..

basically there are ccps in the HACCP so that with ccp we made the ccp and

we are monitoring the ccp, we are controlling the ccp all the things it is

totally giving good life, good awareness to the employees, all are

contributing to this HACCP especially this personal hygiene they have

increased their level of standard, it is good for the organization also and

individual also …basically,….."


team?]

"……So far no … no .. we ..even in the beginning we having a proper ..we

going …..we made a manual we've submitted our maneuver outside agency

then Sharjah municipality they've gone through all the manuals and we got

HACCP in first audit, in the very first audit we got HACCP .. no.. see..

- 179 -

marmum farm is a small farm is not a very big dairy, we've a small system

here .. so within the limitations we've taken to choose our best team..

because.. see.. as far as long am here as far for the quality assurance only

Laxmikant is there ..and the production manager, he is the only key person

in that so we've taken key persons from every and each department .... so for

us there was no any problems because I told this is not a very big dairy it is a

small dairy and we've a small system and within the limitation we've done

and what we can say is a great achievement that it was great challenge for us

we have taken the … in the first audit ..and while… this… choosing these

ccps…. we've studied in details until the points we are facing… while

maximum time that we've chose the ccps so mentoring and this controlling it

is very easy by practice .. and the awareness of people and this… employees

involvement in this systems helps increase the moral of the employee also…

it helps in the system also…"


A10. Yes

- 180 -

3. Company(C).


A. 25 people


below)]



1 Executive Manager-HACCP leader MBA, BSc. & food

hygiene Dip.

2 Production Manager MSc. Chemical Sci.

3 Distribution Manger BSc.

4 HACCP In charge (HACCP leader) M.Sc. chemistry

5 ISO In charge B.Sc.

6 Bun line Administrator MA economics

7 HACCP implementer & Recorder B.Sc. Chemistry

8 Statistical Officer B. com+ M.Sc.

9 Hygiene Officer BA

10 Lab Technician M.Sc.

- 181 -

11 Mechanic SSC

12 Store Keeper B.com

13 Delivery In charge Graduation

14 Hygiene Officer M.Sc. Chemist

15 Lab. Technician M.Sc.

16 Hygiene Officer MBA-Finance

17 HACCP/ISO Implementer B.Sc.Chem & zoology

18 Slice Bread Supervisor BA.

19 Record Keeper SSC





A4. NO


A5. 2003

- 182 -


give details.]

A6. Yes


A7. On quarterly basis and at any deviation occurs in the factory


team?]

A8. "….Positive experiences that after the implementation of …..HACCP ..

I think that we are more safe ..we are more safe and er… actually if we

follow …they give us all the details ..or the critical or what are the hazards

and they differentiate each and every thing and we follow the study…

according to the study the products are safe…."


team?]

A9."…no .. I think when we were implementing..we start ..at the start of the

implementation ..then we face some problems ..we face some …like this

..their requirements that …er.. certified suppliers ..we were facing like this

problem ..but now we take all our raw materials ..we have the certified

suppliers now ..because ..but at the beginning we had the problem…"


A10. Yes

- 183 -

4. Company (D).


A. 9 members


below)]



1 Managing Director 30 yrs experience in

seafood

2 General Manager B. Tech in Food Tech.

3 Operation Manager & HACCP

Manager

M.Sc. in Microbiology

4 Fish Technologist MSc. Industrial fisheries

5 Quality Assurance M.Sc. in Microbiology

6 Factory Manager Over 25 yrs experience in

sea food

7 Production Manager Diploma in refrigeration &

B. Com

8 Asst. QC B.Sc. Fisheries

- 184 -

9 Machinery In-charge Diploma in Refrigeration &

Air Conditioning.



A4. NO


A5. 2000


give details.]

A6. Yes


A7. Twice a year


team?]

A8. "....yah I think the most important thing is the awareness ..it's a.....that u

know ..like a ..it's a quality is very important especially in the food industry

..i mean it’s in the same for any other industry but especially for the food

safety …quality and safety so that awareness I think is the most important

thing with the team because it’s …a …from various levels may be excluding

- 185 -

the workers but for that every year there is training…given I would say it’s a

shared responsibility…."


team?]

A9. "…difficulties..there have been in the sense like a.. we were having with

..its sea world as u see…… like ……the program is sea world from 2000 till

date there having been many changes to the program…some times as per the

inspection of the municipality staff or sometimes from third party audit or

internal audit so there have been corrections to the program basic programs

so which I think…..i wouldn’t say that yahh…its…i wouldn’t call them

challenges but then been improvements with the initially plan ..i think there

have been changes systematic ..continuous changes to the programme

..various infractions between the team the auditors the factory

activities…..the challenges may be will be in the sense of budgetary

concerns ..yahh ..because sudden changes requires sudden budget

commitment ..so ..which at times it was not available but then they …

manage that …."


A10. Yes

- 186 -

Company (E)


A1. 8 people


below)]



1 Asst. Plant Manager HACCP workshop

Intermediate food Hygiene ( CIEH UK

Certified

Internal auditing

2 Q.A. Manager HACCP workshop

Intermediate food Hygiene ( CIEH UK

Certified

Internal auditing

3 Ass. Distribution Manager HACCP workshop

4 Lead Production Operator HACCP workshop

Cleaning disinfection of water Tanks

Food hygiene training

- 187 -

Basic food hygiene

5 Not provided



A4. NO.


A5. 03/2005


give details.]

A6. Yes (one person and new one is joined)


A7. Once every 3 months and at any changes


team?]

A8."….By having …let's say the HACCP team you have… let's say

distribution of responsibilities is better ..it will assigned when you have

haccp team.. the distribution of responsibility assign clearly to each member

and cascading later on this is responsibility to staff who comes beneath ..

like for the lead operator he have..10 helpers and 10 helpers for each shift ..

20 helpers …so wherever you are assigned for a job we cascade this

- 188 -

responsibility for helpers bellow ..of course ..in the HACCP all they have

training and refreshing course also ..so ..they are aware in a way or another

of their contribution to the product safety ..like how important their job is

and why they should do it perfectly even if you have automatic machines,

human interference is important ..so they can…..Awarness is better ..

commitment towards the company is better because all they receive training

courses not less than three courses ..so when member or…..lets say an

employee who gets such train ..see his company went to invest on

him…then our return investments will be the loyality to the company, the

ownership of this employee….."


team?]

A9. "….In the HACCP team .. the challenge was earlier to develop skills for

the staff who were earlier not involved ,, you have to gradually build up their

skills .. er … they can not in the haccp team directly you have to work out

invest lot of many in them to get certain training…."


A10. Yes

- 189 -

6. Company (F)


A1. 9 people


below)]

Q3 [What are their qualifications/if any? ( add to table below)]


1 QA Manager B.Sc. Chemistry

2 G.M. Production M. Tech foods

3 Mechanical eng. Mechanical eng.

4 Store Keeper B.com

5 Q. Officer B.Sc. Chemistry

6 Shift Manager M.Sc.in food

7 Hygiene Tech B.Sc. In chemistry

8 Quality Officer B.Sc. In chemistry

9 Quality Officer M.Sc. Microbiology



- 190 -

A4. NO.


A5. 2003


give details.]

A6. yes 3 persons


A7. Once in every 6 months


team?]

A8. "….We did some ..modifications….alterations on the flow charts very

recently we introduced new ccps so when we meet next one ccp we are

going to remove and include one ccp…. We could proper assessment of the

system…."


team?]

A9. "…..Yah .. see.. actually ..Some challenges from the Municipality, some

challenges from the certification companies …so .. they didn’t accept our

flow chart once .. we had to modify that …when we learnt something from

them ….municipality challenges said that you are wrong .. we proved what

- 191 -

we were doing was right…so…..when we went for re-certification 2006

municipality…one person ..what is his name.. Harold….yah….Harold ..was

putting me in some challenges that you should cancel this ccp ..and I have

to tell him if cancel this ccp I will have a problem ..so… I tried to convince

him and he finally agree ..this kind of problems we had.. from the

certification companies ….sometimes they will just say this is not correct

…"


A10. Yes

Company (G)


A1. 6 people


below)]



1 Quality A. Officer( HACCP leader) M.Sc. in IF industrial fisheries

2 G.M Diploma in hotel admin.& food

Tech.

3 Operational Manager Dip. Hotel Admin.& food Tech.

- 192 -

4 Purchase Manager BSc. Food Science

5 Maintenance Manager BE Electrical& Dip. In Business

6 Production Manager MSc. in Fish processing



A4. NO.

Q5. When was this HACCP team formed?]

A5. 2004


give details.]

A6. Yes.


A7. Once in every 6 months .. and at any changes


team?]

A8. "…..See.. experiences means ..all our people ….they all got good

experience in the industry ..all are trained in haccp and ISO then they got

enough knowledge in the system already …see …er ..all have haccp training

.. ISO knowledge .. they know what are the subjects ….if the situation has

come .. they know what are the potential efforts ..and then what are quality

- 193 -

measures .. all the things….all this have a good impact on the food and

implementation…..u see… they were all understanding ..all are cooperative

..if you say something about haccp .. we will have a good discussion and

good contribution also.. usually .. you see … is not a one man show is

always a group work….."


team?]

A9.

"….No …. Because they were all trained and have the knowledge .. that

made haccp easy… HACCP system see …eh.., usually for a haccp team,

the team number should be multidisciplinary team, the number should have

knowledge about microbiology , food processing , maintenance as there are

a lot of automatic machineries , then purchase….here they know how to

make haccp team … they have that knowledge ..so it was not difficult for

them .."


A10. Yes

8. Company (H)


A1. 5 people

- 194 -

Q2. [Who are the key members of your current HACCP team? (Add to table

below)]



1 Q.A. Officer( HACCP leader) Higher Dip. In Food Tech. &

B.Sc. biochem.

2 Production Manager Food Technology

3 Maintenance Manager B. Eng.

4 Laboratory Chemist Microbiology

5 Lab. Chemist B.Sc. In Food



A4. 3 persons from within the Branch comp. and 2 are from the mother

company.


A5.2002


give details.]

- 195 -

A6. Yes just one.


A7. Once in a month


team?]

A8. "…..First of all … the group work is always a momentum for the person

…when all of them sit down to discuss a situation and share the thoughts

from different angles everyone will benefit from that .. and this affects the

quality tremendously … we say here that the quality is not the responsibility

of Quality Dep. But it is the responsibility of the all…..Haccp team is very

important because, one person cannot do everything … and also you need to

know from others …and from their experiences and disciplines…."


team?]

A9. "…..One of the difficulties we have got is the haccp team meeting … we

are trying to intensify the meeting to be weekly not even monthly so that any

member who couldn’t attend the meeting the first week can attend it the

second one.. but when it is monthly if any member failed to attend ….then

he will have to wait for another month to meet again and that’s not

practical..,

- 196 -

Other difficulties could be considered administrative ……such as the place

that we wanted to meet in …. Sometimes it is occupied by other group or

needed by the General Manager….."

Q10. Are you happy to be contacted again regarding this project?

A10. Yes

9. Company (I)

Q1. How many people are in your HACCP team?

A1. 7 people


below)]


No. Name Job title Qualification

1 Q. Controller (HACCP leader) M.Sc. Biotech

2 Production Manager Industrial Training

3 Managing Director M.Sc. in

Management

4 Purchasing & Admin B.Sc. Arts

5 Maintenance Eng. B.Sc. Physics

6 Store Keeper High Secondary

- 197 -

7 Supervisor Intermediate



A4. NO


A5. 2003


give details.]

A6. Yes just one.


A7. Twice a month


team?]

A8. "….. Positive experiences that first I told ….since I am a person .. I am

.with less experience ..even though I know much .. I am very much into

microbiology ..since we do not have lab.. we are sending our samples to

SGS or to some other labs ..but I am very much experience in microbiology

more than anyone ..because I worked as a microbiologist in India ..so I know

about the organisms which are causing food poisoning .. what are the

organisms which are producing toxins.. I know the organisms which affect

- 198 -

the food ..about all things I have idea ..so since we are going to start new lab

I can give my full ….. but regarding the processing or other things I am not

much experience but I am learning from this ..so I have learnt many things

from this people ..even though …see .. I have learnt many things from the

production because I have to know each and everything which is going on

like ..suppose we'll be having some fifty products, sixty products .. so I

must know about each product…even I am interested what is happening in

the purchasing ….though I am part of the quality but I have to know ..even

from the store keeper…....even if he is not well educated but his experience ,

he is seen this company for more than 10 years…….he is seen what's

happening in food processing ..but I can learn from him.. so by talking by

having conversation with this people by having interaction with this people

.. so as team I am learning…."


team?]

A9. "….Difficulties means ok…suppose every people ..because I told before

…since I am the person who….since I am holding the haccp team leader…

..first of all I must know what are the…work ..things that should be done in

the factory….so my responsibility is to hold all this people ..really I have

faced a lot challenges in this company….because our company since we

have lack of space it is difficult to …it is very hard work ..i think after we

go for the expansion things will be much easier..we lack some one more

from the quality control but our company is intending to hire a quality

control manager who must be having more experience than me ….he might

- 199 -

not know much about our company but he definitely have experience then

only we can work hand in hand …"


A10. Yes

10. Company (J)


A1. 5 people


below)]



1 Q. Control (HACCP leader) M.Sc. microbiology

2 Production Manager B.Sc.

3 G.M Chartered

Accountant

4 Ass. Production M B.Sc. Food tech.

5 Head of Maintenance Dip. in eng.

- 200 -



A4. NO


A5. 2003


give details.]

A6. Yes, the G.M.


A7. Once in a month


team?]

A8. "….I could just say we are much more aware of the various departments

than when we were not a team …may be I was just bothered about my job ,

he is bothered about his job….he never thought ..ok….we got to go ..and we

have got to be collective ..u know ..so.. if it is a maintenance department

..they are more what you call ….aware ..that they have to get a preventative

maintenance in place…you got to know the importance of it ..so …u know

..it is more of awareness. I think it is more of awareness ..it is a healthy

discussion and change of ideas….more heads sitting together it is more ideas

otherwise ..I think ..its communication and .awareness should be the most

- 201 -

positive aspects I think .it .does affect our production also in finance

way….."


team?]

A9. "…..Yes….ya….initial….financial aspects….because we had made a lot

of changes when we were introduced into haccp .. the manual writing ..and

having certain checks in place …having people come to do certain duties

then also may be the splitting your duties ..earlier if you had a supervisor

who is just looking into everything you couldn’t really pin point and ask

him to do this at this time ..but.. u know ..so.. reporting has become more

effective.. .that's one nice .ok ..they were checks in place I haven’t said no

but it was not specific ..if I have the raw material supervisor asked him now

what material have you got today and at what time ..he would be able to tell

me specifically …ok….this is it and I made so and so checks…."


A10. Yes

- 202 -

11. Company (H)


A1. 7 people


below)]



1 HACCP

Leader

QFS Technologist B.Sc. In food

Science

2 Microbiologist M.Sc. microbiology

3 Q & Vendor Assurance Cemical Eng.

4 Production Coordinator B.Sc. Chemistry

5 Maintenance Technician Dip. Electrical Eng.

6 New Product Development

(NPD)

B.Sc. Food Science

7 Engineering B.Sc. Eng.

- 203 -



A4. NO


A5. 2006


give details.]

A6. Yes.


A7. "Once in a month"

- 204 -


team?]

A8. "…The benefits are the learning the learning is very important …the

issue what happened …u know… this is a factory …. Nothing is perfect in

the world …things happened and that’s how you learn from what happened

…we do risk assessment we learn ..and then…. To prevent it from

happening again and again …."


team?]

A9. "….Yaah.. I would call them challenges not difficulties .. yeah .they had

been a lot .especially .in terms of a.. …convincing people that these are the

right things to do and why we are right …u know .. to prevent issues …etc.

challenges again….I can say ..that ..er .. what really happen is certain issues

are challenging things when we have… suspect of a.. may be …a foreign

object contamination or any contaminant ..etc…..and we have taken

decision for example …these are the challenging….."


A10. Y

- 205 -

Appendix 4: Initial Analysis

1. Company (A)

What have your most positive experiences been with this HACCP team?


"…..Since we started working as a

team we begin to know all the

specifications of our products, the

associated pathogens such as

salmonella spp. and the total

account of bacteria that each

product might have. working

together we succeeded in gaining

customer confidence in our

products As team also we

composed the HACCP manual…"

Increase knowledge by having it

shared

Business enhanced

Complied with legislation

- 206 -

Have there been any difficulties or challenges relating to the HACCP team?


There was no difficulties because

the team was qualified, the one who

is not well qualified will get the

knowledge from the other team

members

When we joined the company we

are all specialized in different

subjects but HACCP concept was

not really focused in our minds, we

had just general idea about it that’s

why we had to be enrolled in

training courses so as to strengthen

our knowledge and know about it

much.

HACCP was not well understood at

the beginning but as a team being

trained HACCP become known to

them.

- 207 -

2. Company (B)



"…definitely na ..with the form I

can say that, after implementing

haccp there are lot of things we

have implemented and things are

going on very smooth there are not

any problems because with HACCP

.. you know .. basically there are

ccps in the HACCP so that with ccp

we made the ccp and we are

monitoring the ccp, we are

controlling the ccp all the things it

is totally giving good life, good

awareness to the employees, all are

contributing to this HACCP

especially this personal hygiene

they have increased their level of

standard, it is good for the

organization also and individual

also …basically…"

Believe that working as a team they

have gained a lot of experiences and

have become aware of the importance

of CCPs and what they stand for.

Working as team have increased the

standard of personal hygiene among

the staff

The reward is dual for the organization

as well as for the employees.

- 208 -



So far no … no .. we ..even in the

beginning we having a proper ..we

going …..we made a manual we've

submitted our maneuver outside

agency then Dubai municipality

they've gone through all the

manuals and we got HACCP in first

audit, in the very first audit we got

HACCP .. no.. see.. marmum farm

is a small farm is not a very big

dairy, we've a small system here ..

so within the limitations we've

taken to choose our best team..

because.. see.. as far as long am

here as far for the quality

assurance only Laxmikant is there

..and the production manager, he is

the only key person in that so we've

taken key persons from every and

- 209 -

each department .... so for us there

was no any problems because I told

this is not a very big dairy it is a

small dairy and we've a small

system and within the limitation

we've done and what we can say is

a great achievement that it was

great challenge for us we have

taken the … in the first audit ..and

while… this… choosing these

ccps…. we've studied in details

until the points we are facing…

while maximum time that we've

chose the ccps so mentoring and

this controlling it is very easy by

practice .. and the awareness of

people and this… employees

involvement in this systems helps

increase the moral of the employee

also… it helps in the system also…

Working hard at the beginning to have

HACCP implemented which was

approved by the first audit from a third

party.

- 210 -

3. Company (C)



"….Positive experiences that after

the implementation of …..HACCP ..

I think that we are more safe ..we

are more safe and er… actually if

we follow …they give us all the

details ..or the critical or what are

the hazards and they differentiate

each and every thing and we follow

the study… according to the study

the products are safe..."

Being a team they were able to

implement HACCP system which

made them feel safe

- 211 -



…no .. I think when we were

implementing ..we start ..at the

start of the implementation ..then

we face some problems ..we face

some …like this ..their

requirements that …er.. certified

suppliers ..we were facing like this

problem ..but now we take all our

raw materials ..we have the

certified suppliers now ..because

..but at the beginning we had the

problem

Understanding the requirements of

HACCP system made them face the

problem of getting approved and safe

suppliers.

- 212 -

4. Company (D)



..yah I think the most important

thing is the awareness ..its a.....that

u know ..like a ..its a quality is very

important especially in the food

industry ..i mean it’s in the same

for any other industry but

especially for the food safety

…quality and safety so that

awareness I think is the most

important thing with the team

because it’s …a …from various

levels may be excluding the

workers but for that every year

there is training…given I would say

it’s a shared responsibility.

believe that awareness of safety and

quality have been increased among the

team as well as the entire workforce

Gained more training and felt more

responsible.

- 213 -



..Difficulties..There have been in the sense like

a.. we were having with ..its sea world as u

see…… like ……the program is sea world from

2000 till date there having been many changes

to the program…some times as per the

inspection of the municipality staff or

sometimes from third party audit or internal

audit so there have been corrections to the

program basic programs so which I think…..i

wouldn’t say that yahh…its…i wouldn’t call

them challenges but then been improvements

with the initially plan ..i think there have been

changes systematic ..continuous changes to the

programme ..verious infractions between the

team the auditors the factory activities…..the

challenges may be will be in the sense of

budgetary concerns ..yahh ..because sudden

changes requires sudden budget commitment

..so ..which at times it was not available but

then they … manage that ..

Facing changes in the

system by auditors as well

as by enforcement

authority that require

amendments

There was a delay in

getting the recommended

changes or modification

done immediately due to

financial problems.

- 214 -

5. Company (E)



By having …lets say the HACCP

team you have… lets say

distribution of responsibilities is

better ..it will assigned when you

have haccp team.. the distribution

of responsibility assign clearly to

each member and cascading later

on this is responsibility to staff who

comes beneath .. like for the lead

operator he have..10 helpers and

10 helpers for each shift .. 20

helpers …so wherever you are

assigned for a job we cascade this

responsibility for helpers bellow

..of course ..in the HACCP all they

have training and refreshing course

also ..so ..they are aware in a way

or another of their contribution to

the product safety ..like how

Assigning responsibilities have become

easier.

Being a team that enhanced the

awareness, commitment.

- 215 -

important their job is and why they

should do it perfectly even if you

have automatic machines, human

interference is important ..so they

can

Awarness is better .. commitment

towards the company is better

because all they receive training

courses not less than three courses

..so when member or…..lets say an

employee who gets such train ..see

his company went to invest on

him…then our return investments

will be the loyality to the company,

the ownership of this employee

Gaining more training courses that

increases knowledge and in return

make increase the ownership among

the employees towards the company.

- 216 -



In the haccp team .. the challenge

was earlier to develop skills for the

staff who were earlier not involved

,, you have to gradually build up

their skills .. er … they can not in

the haccp team directly you have to

work out invest lot of many in them

to get certain training

Developing skills that qualify them to

be a HACCP team by training which is

costly and the company has to pay for

that.

- 217 -

6. Company (F)



We did some

..modifications….alterations on the

flow charts very recently we

introduced new ccps so when we

meet next one ccp we are going to

remove and include one ccp…. We

could proper assessment of the

system

Being a team they are able to maintain

HACCP system themselves and keep it

updated.

- 218 -



Yah .. see.. actually ..Some challenges

from the Municipality, some challenges

from the certification companies …so ..

they didn’t accept our flow chart once

.. we had to modify that …when we

learnt something from them

….municipality challenges said that

you are wrong .. we proved what we

were doing was right…so…..when we

went for re-certification 2006

municipality…one person ..what is his

name.. Harold….yah…so and so ..was

putting me in some challenges that you

should cancel this ccp ..and I have to

tell him if cancel this ccp I will have a

problem ..so… I tried to convince him

and he finally agree ..this kind of

problems we had.. from the

certification companies ….sometimes

they will just say this is not correct …


auditors as well as by enforcement

authority that require amendments

at the beginning.


- 219 -

7. Company (G)



See.. experiences means ..all our

people ….they all got good

experience in the industry ..all are

trained in haccp and ISO then they

got enough knowledge in the system

already …see …er ..all have haccp

training .. ISO knowledge .. they

know what are the subjects ….if the

situation has come .. they know

what are the potential efforts ..and

then what are quality measures ..

all the things….all this have a good

impact on the food and

implementation

..u see… they were all

Working as a team enabled them to

gain more experience, know more

about HACCP and ISO as well.

Working as a team enabled them to

handle difficult situations properly and

better than before as they have become

aware of the critical points

Believe that they have become

cooperative, responsive to HACCP

issues as they are now familiar with its

topics that also made their discussions

useful.

- 220 -

understanding ..all are cooperative

..if you say something about haccp

.. we will have a good discussion

and good contribution also..

usually .. you see … is not a one

man show is always a group work





that made haccp easy

Nothing

- 221 -

8. Company (H)



First of all … the group work is

always a momentum for the person

…when all of them sit down to

discuss a situation and share the

thoughts from different angles

every one will benefit from that ..

and this affects the quality

tremendously … we say here that

the quality is not the responsibility

of Quality Dep. But it is the

responsibility of the all.

Haccp team is very important

because, one person can not do

everything … and also you need to

know from others …and from their

experiences and disciplines….

Believe that team work is always a

momentum for the individuals to work

hard and discuss issues with different

perspectives

Believe that every one needs the

assistance of others in terms of

exchanging ideas, experiences which is

very helpful.

- 222 -



One of the difficulties we have got is

the haccp team meeting … we are

trying to intensify the meeting to be

weekly not even monthly so that any

member who couldn’t attend the

meeting the first week can attend it

the second one.. but when it is

monthly if any member failed to

attend ….then he will have to wait

for another month to meet again and

that’s not practical..,

Other difficulties could be

considered administrative ……such

as the place that we wanted to meet

in …. Sometimes it is occupied by

other group or needed by the

General Manager.

During the meeting that requires

everyone to be present but that

never realized as someone would be

absent therefore there is a need to

overcome this problem by adjusting

the meeting schedule.

Lack of space in the company to

arrange the meeting in.

- 223 -

9. Company (I)



Positive experiences that first I told

….since I am a person .. I am .with

less experience ..even though I

know much .. I am very much into

microbiology ..since we do not have

lab.. we are sending our samples to

SGS or to some other labs ..but I

am very much experience in

microbiology more than any one

..because I worked as a

microbiologist in India ..so I know

about the organisms which are

causing food poisoning .. what are

the organisms which are producing

toxins.. I know the organisms which

affect the food ..about all things I

have idea ..so since we are going to

start new lab I can give my full …..

but regarding the processing or

other things I am not much

Realizing a fact that a team work has

helped all members share their

knowledge, experiences and everyone

has become knowledgeable of what's

happening in other departments.

- 224 -

experience but I am learning from

this ..so I have learnt many things

from this people ..even though

…see .. I have learnt many things

from the production because I have

to know each and everything which

is going on like ..suppose we'll be

having some fifty products, sixty

products .. so I must know about

each product…even I am interested

what is happening in the

purchasing ….though I am part of

the quality but I have to know

..even from the store

keeper…....even if he is not well

educated but his experience , he is

seen this company for more than

10 years…….he is seen whats

happening in food processing ..but

I can learn from him.. so by talking

by having conversation with this

people by having interaction with

this people .. so as team I am

learning

- 225 -



Difficulties means ok…suppose every

people ..because I told before …since I

am the person who….since I am holding

the haccp team leader… ..first of all I

must know what are the…work ..things

that should be done in the factory….so

my responsibility is to hold all this

people ..really I have faced a lot

challenges in this company….because

our company since we have lack of

space it is difficult to …it is very hard

work ..i think after we go for the

expansion things will be much easier..we

lack some one more from the quality

control but our company is intending to

hire a quality control manager who must

be having more experience than me ….he

might not know much about our company

but he definitely have experience then

only we can work hand in hand …

Lack of space is an hurdle that

affect the team to work

harmoniously

Personal difficulty that he needs

someone else to assist him so as

to alleviate some of the work load

assigned to him.

- 226 -

10. Company (J)




aware of the various departments

when we were not a team …may be I

was just bothered about my job , he is

bothered about his job….he never

thought ..ok….we got to go ..and we

have got to be collective ..u know ..so..

if it is a maintenance department ..they

are more what you call ….aware ..that

they have to get a preventative

maintenance in place…you got to

know the importance of it ..so …u

know ..it is more of awareness. I think

it is more of awareness ..it is a

healthy discussion and change of












work of others and know much

about it.



- 227 -

also in finance way…" productive.



Yes….ya….initial….financial

aspects….because we had made a

lot of changes when we were

introduced into haccp .. the manual

writing ..and having certain checks

in place …having people come to

do certain duties then also may be

the splitting your duties ..earlier if

you had a supervisor who is just

looking into everything you

couldn’t really pin point and ask

him to do this at this time ..but.. u

know ..so.. reporting has become

more effective.. .thats one nice .ok

..they were checks in place I

haven’t said no but it was not

specific ..if I have the raw material

supervisor asked him now what

material have you got today and at

what time ..he would be able to tell

me specifically …ok….this is it and

Things were not tidy enough, team

had to work hard to make ends

meet such as taking more duties,

writing HACCP manual.

- 228 -

I made so and so checks.

11. Company (K)



The benefits are the learning the

learning is very important …the

issue what happened …u know…

this is a factory …. Nothing is

perfect in the world …things

happened and that’s how you learn

from what happened …we do risk

assessment we learn ..and then….

To prevent it from happening again

and again ..

Believe that working as team has

helped increase their knowledge

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"….Yaah.. I would call them

challenges not difficulties .. yeah

.they had been a lot .especially .in

terms of a.. …convincing people

that these are the right things to do

and why we are right …u know .. to

prevent issues …etc. challenges

again….I can say ..that ..er .. what

really happen is certain issues are

challenging things when we have…

suspect of a.. may be …a foreign

object contamination or any

contaminant ..etc…..and we have

taken decision for example …these

are the challenging……"

Lack of scientific evidence or proof

of a plan being valid so as to

convince others about it.

Lack of tools to make things sure

happening so that right decision could

be taken.

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Appendix 5: Plates of food businesses (firms) in Sharjah

- 231 -

Plate No (1): Shows clean wash hand basin (not use for food or equipment)

which must be as long as, provided by hot and cold water (mixed 40°C)

,tissuse paper,waste container, liquid soap and hand sanitazier.

Plate No (2): Shows the receiving area. Food must be inspected on arrival

and immediate storage. All ingredients and materials should be bought

from reputable,approved suppliers and reject unsatisfactory deliveries.

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Plate No (3): shows the high standards of personal hygiene and good

hygiene practices of the employees during the prepration process. Its also

shows hairnet completely covers the head and wears hand gloves , arm

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gloves , masks and protective clothing. protective clothing it must be clean,

easy to clean ,comfortable, smart and no extternal pockets.

Plate No (4): shows the good design, workflow, adequate and suitable

equipments. Maintenance and cleaning are important to keep the

environment, facilities and equipments in agood state of repair where they

- 234 -

can both function as intended and prevent cross-contamination with food

residues and micro-organisms.

Plate No (5):shows the process area, and well -designed and proper use of

suitable equipment/utensils which made from stainless steel and effective

cleaning and disinfection. As a general guideline, a center temperature of

- 235 -

at least 75°C is recommended for raw, frozen and chilled food, and this

should be checked with a disinfected prope thermometer. Pans should

always be covered when not stirring to avoid contamination.

Plate No (6): Shows adequate numbers from refrigerators, which made

from stainless steel.Storing food out of the danger zone, food should be

kept below 5°C e.g.in refrigerator or kept above 63°c e.g. in abain marie.

- 236 -

Plate No (7): shows the good design of double sink in the premises,well -

designed and proper use of suitable equipment/utensils and effective

cleaning and disinfection.

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Plate No (8): Shows the good design of premises and equipments and all

equpiments from stainless steel . Businesses should operate preventive

maintenance programmes and mangers should ensure that breakdowns and

faults are dealt with immediately.

- 238 -

Plate No (9): Shows the utensils cleaning area. utensils must be wash and

sanitize after every use to prevent cross contamination.Cleaning methods

need to be developed that are suitable for the item to be clean, including

the use of appropriate chemical cleaning agents, disinfectants, hot/cold

water and cleaning tools. e.g brushes.

- 239 -

Plate No (10): Shows the different colours of cutting boards. cutting boards

and handles of knives and brushes may be made from polypropylene or

other suitable synthetic material. The use of different colours or shapes as

code to ensure equipment used for raw food is not used for high-risk food

is recommended. Red is usually used for raw food, bule for cooked food

and green for salad vegetables

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Plate No (11):Shows the inspection of dry food store, all food should be

inspected before placing in storage. As far as practicable, external

packaging should not be brought into food preparation areas. Unloading

should be compllted as quickly as possible. The dry food store should be

dry, cool,well lit and well ventilated. Effective pest control measures,

storage of food at least 15cm above the floor and stock rotation systems are

essential.Food should be stored away from the walls and pipes affected by

condensation and on suitable shelves such as tubular stainless steel racks.

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Plate No (12): Shows food product in side refegratre. Refrigerated must be

dry, cool well ventilated and clean. Units should normally operate between

1°C and 4°C. A thermometer should be permanently positioned in the

warmest part of the refrigerator and the temperature checked and recorded,

preferably three times a day.

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Plate No (13): Shows the verification procedures , which is there

compliance with food safety reqirements defined in the HACCP plan i.e. is

it working in practice?

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Plate No (14): Shows frozen polturty in side freezer . Commercial freezers

should operate at -18°C or slightly below.At this temperature food will

keep for a reasonable time with no bacterial growth. the important in

operational control are hygienic cotrol of water,ice and steam that may be

used in avariety of processes; apporopriate mangement and supervision;

and the need to keep adequate documentation and records.

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Plate No (15): Shows the label of food products.. Most food must be

labelled "use-by" for high risk foods with short shelf life or "best before"

for foods with longer shelf life.

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Plate No (16): Shows the label of food products. Satisfactory rotation of

stock, to ensure that older food is used first, is essentional to avoid spoilage

and ensure food is of good quality and safe. Shelf life always depends on

satisfactory storage conditions (FIFO- First In First Out).

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Plate No (17): Shows the high standards of personal hygiene and good

hygiene practices of the employees during the prepration process.Raw food

must always be kept separate from high-risk food at all stage of storage

and preparation. Separate equipment, working surfaces and food handlers

should be used to avoid cross-contamination from raw to high- risk food.

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Plate No (18): Shows the cilled storage of food ingredients and sutible

food storage containers and facilities. Food should be stored on suitable

shelves such as tubular stainless steel racks.

- 248 -

Plate No (19): Shows the good design, adequate, suitable storage and

seprate looked chemical store.which must be clean, ventilated and afar

from the food. Staff must be trained to "clean as they go" and never clean

from raw areas with the same equipment.Chemicals must always separated

from food and should never be empited into unmarked or food containers,

espescially bottles.

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Plate No (20): Shows the good design for bathroom (toliet), which must be

clean and disinfection.

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