List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

Good Hygiene Practices along the coffee chain

List Potential Hazards;Conduct Hazard Analysis;

Consider Control Measures(Task 6 / Principle 1)

Module 4.6

Module 4.6 – List Potential Hazards;

Conduct Hazard Analysis; Consider Control Measures(Task 6 / Principle 1)

Objectives and contents

Objectives To emphasize the importance of hazard

identification and analysis steps in food safety management

To enable trainees to identify potential hazards in a process and to find appropriate control measures

Contents Examples of hazards Carrying out a hazard analysis Control measures Hazard assessment



Importance of hazard analysis

An accurate analysis of hazards is necessary for an effective HACCP plan

Involves technical and scientific expertise in various domains

Hazard analysis must be reviewed when there is any change in Raw materials Formulation Processing procedures Packaging Distribution Use



Potential hazards

The first step in the development of a HACCP plan is the identification of all potential hazards Biological, chemical and physical At all stages from raw material to

consumption



Biological hazards

Biological hazards include Bacteria and mould (spore-forming) Bacteria (non-spore forming) Viruses Protozoa and parasites



Biological hazards

Commonly associated with humans and with raw products entering the food process

Most have the potential to increase spontaneously if control measures are inadequate

Usually killed or inactivated by heat processing

Fungi include moulds and yeasts Some fungi are beneficial Others produce toxic substances (mycotoxins)



Chemical hazards

Chemical hazards include: Naturally occurring chemicals Added chemicals (intentional and

unintentional) Chemical contaminants may occur at

levels that cause Acute illness Chronic illness



Physical hazards

Examples include Glass, wood, stones, metal, plastic, etc

Hard or sharp foreign objects can cause injury

Poor practices at many points along the food chain can lead to the introduction of physical hazards



Hazard analysis

Sources of information for hazard analysis include Reference texts Company complaints file Scientific research and review papers Epidemiological data Web pages dealing with food safety

issues



Hazard analysis

Objective To determine which hazards need to be

addressed under an effective HACCP plan Overview of approach

Review incoming material Evaluate processing operations Observe actual operating practices Take and analyse measurements



Review incoming material

Review product description form (Form 1) for information that could influence the analysis of hazards Is it ready-to-eat or is further processing

envisaged? Is it intended for a vulnerable group?

For each incoming material (Form 2) write ‘B, C or P’ directly on the form to indicate the nature of all potential hazards



Review of incoming raw material

There is wide variation in practices (on-farm and throughout the marketing chain) that can influence the analysis of hazards in

incoming raw material



Review incoming material

Raw material Packaging material

Coffee fruit (cherry) (B, C, P)

60kg sisal stitched printed sacks or lined / unlined containers (B, C, P)

Date: Approved By:

Potential hazards identified on Form 2 should be fully described on Forms 5, 6 and 7



Incoming material –biological hazards (Form 5)

Identified biological hazards

Controlled at

Ingredients / Materials

Coffee fruit (cherry)Could contain ochratoxin or aflatoxin-producing fungi

Jute bagsCould contain spores of toxigenic fungi that might lead to cross-contamination of product Could contain pathogenic bacteria

(For discussion only)



Incoming material –chemical hazards (Form 6)

Identified chemical hazards Controlled at


Coffee fruit (cherry)Could contain residues of agricultural chemicals (pesticides, fungicides, etc.) Could contain OTA or aflatoxinCould contain heavy metals or other environmental contaminants

Jute bagsCould contain hydrocarbons from batching oilsCould be contaminated by agricultural chemicals depending on previous use




Incoming material –physical hazards (Form 7)

Identified physical hazards Controlled at


Coffee fruit (cherry)Could contain harmful extraneous materials (stones, metal, glass, wood)

Jute bagsCould contain harmful extraneous material, pieces of plastic etc.




Hazards in incoming materials

Sample questions that guide the identification of potential hazards Could pathogenic organisms, toxins, chemicals or

physical objects possibly be present on this material

Are preservatives or additives used in the formulation to kill or inhibit growth of organisms

Are any ingredients hazardous if used excessively or in adequate amounts

Do moisture content and Aw in final product or ingredients affect microbial growth?



Evaluating process operations

Objective Identify all realistic potential hazards related

to each processing operation, the product flow and employee traffic patterns

Review process flow diagram (Form 3) and plant schematic (Form 4)



Hazards associated with process steps

Assign a number to each processing step on Form 3

Examine each step and identify potential hazards (B, C, P)

Use plant schematic to assist in identification of potential hazards



Analysing process steps – guiding questions

Could contaminants reach the product during this operation?

Could micro-organisms of concern multiply to the point where they constitute a hazard?



Process steps – Form 5: biological hazards

Identified biological hazards Controlled atIngredients / Materials

Process steps

1. Harvesting OTA-producers introduced from environmental sources Pathogens introduced from environmental sources, workers

3. Gathering / transporting to beneficio Undue delay in processing after harvest could lead to the proliferation of

OTA-producing fungi

4. Storing sacks OTA-producers introduced from cross contamination of by-products Pathogens introduced from pests

5. Floatation separation Inadequate separation of boia from wetter coffee could cause re-wetting of

the partially dried boia and proliferation of OTA-producers Introduction of water-borne pathogens by contaminated water Cross contamination by OTA-producers if water is overly re-circulated


Should be repeated for chemical and physical hazards



Observe actual operating practices

HACCP team must be familiar with every detail of each operation Observe operation long enough to be

confident of usual practices Observe employees Be attentive of the possibility of cross

contamination after a kill step Identified hazards must be recorded

on appropriate form



Take measurements

Confirm actual processing conditions by taking measurements of important process parameters Physical properties of the product as Aw, temperature,

pH, moisture content Residence time in processing steps Dimensions, volumes Storage conditions

Be sure of accuracy of measuring devices Collect samples for microbial challenge

studies if necessary



Analyse measurements

Qualified individual must analyse and interpret data to determine impact or processing conditions on identified hazards For example, plot Aw / moisture content /

temperature against time as indicated by the circumstances

Compare Aw or pH values with ranges known to support microbial growth

Estimate and evaluate cooling or thawing rates and determine influence on bacterial growth

Evaluate shelf stability of the product



Control measures

Control measures are any actions and activities that can be used to prevent or eliminate a food safety hazard or reduce it to an acceptable level

More than one measure may be required to control a specific hazard and

More than one hazard may be controlled by a specified measure



Controlling biological hazards

Minimize contamination Prevent or minimize growth and toxin

production using heating/cooling, low Aw, low Eh, high acidity, biological processes (e.g. fermentation), preservatives, etc.

Pathogens risk is based on concentration, not just presence / absence

Beware of possible concerted activity of more than one organism together



Controlling chemical hazards

Source control involving raw material specifications and vendor certification

Proper segregation of non-food chemicals during storage and handling

Control of incidental contamination from chemicals

Formulation control and proper use of additives



Controlling physical hazards

Source control – raw material specifications and vendor certification

Processing control – use of magnets, winnowers, screens, etc

Good maintenance of facilities and equipment



Hazard assessment

Use information from hazard analysis to determine Severity of the hazard(s):

• Magnitude of consequences that result when a hazard exists (high, moderate, low, negligible)

Risk of hazard(s): • Probability of an adverse effect (high,

moderate, low, negligible)



Hazard assessment

Use information from hazard analysis to determine Which hazards should be addressed

under HACCP plan • Hazards of a low probability of occurrence

and a low severity should not be addressed in HACCP plan but through GMPs

The points or steps at which control could be applied to prevent eliminate or reduce hazards to an acceptable level (CCPs)



Health risk assessment model

Sa

Sa

Sa

Sa

Sa

Sa

Sa

Mi

Ma

Mi Mi

Mi

Mi Ma

Ma

Cr

Low Medium

High

Negligible

Low

Medium

High

Likelih

ood o

f O

ccurr

ence

Negligible

Severity of Consequences

Key Cr – critical Ma - major Mi – minor Sa - satisfactory



OTA contamination of coffee

A mycotoxin, Ochratoxin A (OTA), produced by different species of Aspergillus and Penicillium Aspergillus niger Aspergillus carbonarius Aspergillus ochraceus Penicillium verrucosum

Control of mould growth from primary production to shipping in order to reduce the risk of OTA contamination

All steps in the process flow chart must be analysed to determine points where control should be exercised to eliminate hazards or control them within acceptable limits



Scientific support forHACCP plan development

Comprehensive identification of potential hazards and sound evaluation of control measures requires availability of good data

‘Scientific support’ for HACCP-based safety management covers: Mycology – ID of OTA-producers; investigation of

conditions of mould growth and OTA- production Evaluation of processing and handling technologies

/ equipment; moisture measurement devices



Summary

What are biological, chemical and physical hazards

Systematically identifying hazards Control measures Deciding which hazards are to be

addressed under the HACCP plan

Next step: Determining thecritical control points in a process

List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

Documents

Transcript of List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)