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HACCP (Hazard Analysis Critical Control Point) Concept
A preventive strategy that is standardized and formalized to control all
factors affecting the safety and quality of food.
Mainly concerned with manufacturing food that is safe to eat but can be
applied to aesthetic and commercial aspects of quality as well.
The system is based on the assumption that safety and quality hazards exist
at various points from capture/harvest to consumption.
Main elements of the HACCP-System
1. Identification of Potential Hazards
Hazard is anything in the total operation that might contaminate
foodand make it unsafe for the consumers who buy the product, or
that can mislead consumers,making the firm liable to economic
fraud (ASEAN Executing Agency, 1994).
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Steps outlined below identifies the critical control points:
Step 1. Describe the product.
The product must be describe based on raw materials, ingredients,
additives, structure and physical characteristics (solid, liquid, gel, etc.),
processing method and the extent of processing, packaging method and
material, conditions for storage and distribution, shelflife requirement(sell
by date and best before date), instructions for use and the particular
microbiological or chemical criteria.Step 2. State the intended use for the product.
The target consumers and how will they prepare or use the product
mustbe determined. Furthermore, special considerations such as dangers in
use by any vulnerable groupsin the population by particular requirementsprescribed by the importer must be stated.
Step 3. Develop a flow diagram.
All particular steps in the manufacturing process from the time the raw
materials are received until the end-product reaches the market are charted. A
detailed flow chart supported by full technical data is presented.
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Step 4. Confirm the flow diagram and all recorded details.
The flow diagram must be prepared based on accurate and actual
activities in the facility.
Step 5. Identify hazards and establish critical control points (CCP) for every
step involved in making the product.
In each step of production the same question must be asked: Is there
a hazard? If there is a hazard at a particular stage, determine if it can be
controlled. If it can be controlled, it is declared as CCP.
2. Determination of Critical Control Points (CCPs)
CCP- is a point, step or procedure at which control can be applied and a
food safety hazard can be prevented, eliminated or reduced to an
acceptable level (NACMCF, 1992).
3. Establishment of Criteria, Target Levels and Tolerances for each CCP
Critical limits must be set for factors such as temperature, time,
physical dimensions which can influence hazards, moisture and salt
content, pH, and available chlorine content in cleaning water.
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4. Establishment of Monitoring System for each CCP
All data from the monitoring must be recorded on well-designed forms
or charts, and the records checked and evaluated regularly andunannounced by the assigned personnel acting separately of the control
staff (Connell, 1995).
5. Establishment of Corrective Action when CCP is not under Control
A plan is put in place to ensure that corrective action is taken
immediately whenever the monitoring procedures show that there is a
problem at any CCP. Action must be taken before deviation leads to a safety
hazard. Corrective action involves the following activities (Tompkin, 1992):
Using monitoring results to adjust the process in order to maintain
control
Dealing with non-compliance products if control is lost
Fixing or correcting the cause of non-compliance
Keeping records of the corrective actions
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A person must be assigned to be responsible for adjusting the process
and for informing others of what has happened. There are five options for
dealing with non-compliance products:
Release the product (not the wisest option if safety is involved)
Test the product
Divert product to safe use
Reprocess the product
Destroy the product
6. Establishment of Procedures for Verification
Verification and review procedures are set up to ensure that the system
of monitoring is working effectively. Random sampling and analysis can beused to gather additional information in checking whether the HACCP
system is working. Verification can also be undertaken by independent
arties such as government authorities, trade partners, consumer
organizations and others (Huss, 1994).
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7. Documentation and Record Keeping Establishment
A designated person who is responsible for maintaining and keeping
the records must be known to everybody. All documentation and recordsshould be compiled in a manual and accessible at all times for inspection
by regulatory agencies (Devlin, 1996).
Introduction of the HACCP-System
It is proper then to adapt a logical and step-wise order for
introduction of the system (Huss, 1994). The steps involved are:
Commitment
Strong commitment of the top-level management in
introducing the system is very essential.
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Formation of an HACCP-Team and Materials
The most important members of an HACCP-team are the
microbiologists and processing specialists. Other members that may be
included are the chemist, quality assurance manager, engineer, packaging
technologist, sales staff, training and personnel managers.
Initiation of Program
A detailed description and specification of the product must be given tothe team during this time. The specification must contain all technological
matters including preservative criteria, proposed storage temperature,
packaging technology and intended use of the product.
Process Analysis
Analysis of the data must ensure when all the information regarding
product and process has been collected. All hazards must be identified and
CCPs must be established as well. Creation of a decision tree can be very
useful in this process.
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Control Procedures
Equipment and instruments used in control functions must also be
kept uner strict control, and their performance must be inspected
periodically.
Monitoring Procedures
Monitoring and recording of data are key elements of the system. All
alterations to product-formulas or processing lines brought as a result of
the HACCP-study must be on record, as well as corrective actions taken
when something was out of control.
Training of Staff
Training of staff must occur when the HACCP-study is finished and the
programme is set for implementation. Training and refresher courses
must take place periodically and new staff should not be permitted to
start work without undergoing training in HACCP principles and
procedures.
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Application of the HACCP-System in the Fish Processing
Industry
The ultimate use of the HACCP-concept in fish processing is specific
for every process and for every plant. In any case a definite study of process
flow is essential in order to identify the hazards and the CCPs. The application
of the HACCP-system in fish processing technology is discussed below:
Molluscs
Molluscs are a very high-risk food if they are eaten raw or very lightly
cooked since they grow and are harvested in shallow, near-shore estuarine
waters which maybe contaminated with sewage-derived pathogens as
well as those naturally occurring in the overall-environment.
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Hazards and Preventive Measures in Chilled Molluscs
Product Flow Hazard Preventive Measure
Live Molluscs
Contamination with
pathogens, biotoxins,
parasites and chemicals
Monitoring of environment
Chilling Microbial growth Time-temperature control
Transport Microbial growth Time-temperature control
All processing stepsMicrobial growth
Contamination
Time-temperature control
Water quality
Hygiene and sanitation
Chilling Microbial growth Time-temperature control
Distribution Microbial growth Time-temperature control
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Fresh and Frozen Fish
In the manufacture of fresh and frozen products the majority of the
hazards can be controlled in a routine quality assurance programme using very
simple equipment and methods. However, the presence of heat stable toxins canresult in uncontrolled hazards.
Hazards and Preventive Measures in Fresh and Frozen Fish
Product Flow Hazard Preventive Measure
Live Fish
Contamination with pathogens,
biotoxins, viruses, parasites and
chemicals
Monitoring of
environment
Catch and catchhandling
Microbial growth Time-temperature control
Chilling Microbial growth Time-temperature control
Landing Microbial growthTime-temperature control
Hygienic handling
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Raw material (receipt)Poor quality entering
processing
Secure reliable source
Sensory evaluation
Filleting Presence of parasites Candling
All processing stepsMicrobial growth
Contamination
Time-temperature control
Water qualityHygiene and sanitation
Packaging Chemical spoilagePackaging
material/vacuum
Chilling Microbial growth Time-temperature control
FreezingChemical/enzymatic
spoilageTime-temperature control
Dried Products
Dried products usually have a very high salt contentwhich makes them stable at ambient temperature. These products may be
eaten with or without cooking. Processing is usually carried out at ambient
temperature, and if reduction of moisture takes too long, growth and toxin
production by microorganisms could occur.
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Hazards and Preventive Measures in Dried Products
Product Flow Hazard Preventive Measure
Live Fish
Contamination with
pathogens, biotoxins, viruses,
parasites and chemicals
Monitoring of environment
Catch and catch
handlingMicrobial growth Time-temperature control
Chilling Microbial growth Time-temperature control
Landing Microbial growthTime-temperature control
Hygienic handling
Raw material (receipt) Microbial growth Time-temperature control
Salting Improper salt content
Control of salt concentration
in brine and time for fish in
brine (NaCl concentrationand holding time to be
specified)
Drying Microbial growthControl of drying time and
temperature
StorageMicrobial growth
Chemical spoilage
Packaging material
Time-temperature control
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Fermented Products
The use of spoiled fish may cause the formation of toxic substances
such as histamine. The improper handling of raw fish before salting, and high
pH conditions created due to very low salt concentrations may allow the
growth of pathogenic bacteria such as Clostridium botulinum (Virulhakul,
1995). Consumption of these products in raw or partially cooked form may
present hazards due to contamination with parasites.
Hazards and Preventive Measures in Fermented Products
Product Flow Hazard Preventive Measure
Live Fish
Contamination with
pathogens, biotoxins,
viruses, parasites and
chemicals
Monitoring of environment
Catch and catch handling Microbial growth Time-temperature control
Chilling Microbial growth Time-temperature control
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Landing Microbial growthTime-temperature control
Hygienic handling
Raw material (receipt) Microbial growth Time-temperature control
Washing
Presence of extraneous
materials (sand, dirt, etc.) Proper washing procedure
Salting Microbial growth Control of salt : fish ratio
Fermentation Microbial growthControl of fermentation
conditions
Packaging
Microbial
growth/fermentation
persistence
Control of pasteurization
process and packaging
material
Marinated Products
The presence of biotoxins and parasites in raw material for
production of marinated products becomes a hazard depending on the
fishing area and season.
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Hazards and Preventive Measures in Pickled/Marinated
Products
Product Flow Hazard Preventive Measure
Live Fish
Contamination with
pathogens, biotoxins,
viruses, parasites and
chemicals
Monitoring of
environment
Catch and catch
handlingMicrobial growth
Time-temperature
control
Chilling Microbial growthTime-temperature
control
Landing Microbial growthTime-temperature
control
Hygienic handling
Raw material (receipt)Poor quality entering
processing
Secure reliable source
Sensory evaluation
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Salting
Improper salt content in fish
(spoilage and/or survival of
parasites)
Control of salt
concentration in brine and
time of fish in brine (NaCl
concentration and holding
time to be specified)
Pickling/Marinating
Improper NaCl and acetic acid
concentration in fish (taste,
spoilage and/or survival ofparasites)
Control of composition of
marinade and marinating
time.
Holding time to be
specified for pickling.
Packaging in glass jars
in final picklePoor sensory quality
Control of composition of
pickle (concentration of
sugar, acetic acid, spices,
etc.)
Distribution
Microbial growth (bacteria,
yeasts and production of toxin
from C. botulinum type A and B)
Control of temperature
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Smoked Products
Improperly prepared smoked products may be contaminated with
pathogens particularly Clostridium botulinum type E spores.
Hazards and Preventive Measures in Smoked Products
Product Flow Hazard Preventive Measure
Live Fish
Contamination with
pathogens, biotoxins, viruses,
parasites and chemicals
Monitoring ofenvironment
Catch and catch
handlingMicrobial growth
Time-temperature
control
Chilling Microbial growth
Time-temperature
control
Landing Microbial growth
Time-temperature
control
Hygienic handling
Raw material (receipt)
Poor quality entering
processing
Secure reliable source
Sensory evaluation
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Salting
Improper salt content in fish
(spoilage and/or survival of
parasites)
Control of salt
concentration in brine and
time of fish in brine (NaCl
concentration and holding
time to be specified)
SmokingMicrobial growth
Contamination
Time-temperature control
Plant hygiene and
sanitation;
Water quality
Packaging Microbial spoilage; oxidation Time-temperature controlPackaging material
Storage and
distribution
Microbial growth (molds,
bacteria particularly toxin from
C. botulinum type E
Time-temperature control
Minced Products
Minced products are usually heated before consumption. However,
several hazards are present during the preparation of the products.
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Hazards and Preventive Measures in Minced Products
Product Flow Hazard Preventive Measure
Live FishContamination with pathogens,biotoxins, viruses, parasites and
chemicals
Monitoring of
environment
Catch and catch handling Microbial growth Time-temperature control
Chilling Microbial growth Time-temperature control
Landing Microbial growthTime-temperature control
Hygienic handling
Raw material and
ingredients (receipt)
Poor quality entering
processing
Microbial contamination
Ensure reliable source
Sensory evaluation
Time-temperature control
Mincing fish (and
leaching for surimi)Microbial growth
Time-temperature control
Hygiene and sanitation
Grinding minced fish
with ingredientsMicrobial growth
Time-temperature control
Sanitation of equipments
and utensils
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Forming Microbial growthTime-temperature control
Hygiene and sanitation
Battering/breading
Microbial growth;
contamination with foreignmaterials
Time-temperature control
Hygiene and sanitation
Packaging Microbial contamination
Time-temperature control
Hygiene and sanitation
Packaging material
Canned Fish
Canned products are marketed at ambient temperature and
generally stored for months, even years under these conditions. Theseproducts are usually eaten without any heating prior to consumption.
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Hazards and Preventive Measures in Smoked Products
Product Flow Hazard Preventive Measure
Live FishContamination with
pathogens, biotoxins, viruses,
parasites and chemicals
Monitoring of environment
Catch and catch
handlingMicrobial growth Time-temperature control
Chilling Microbial growth Time-temperature control
Landing Microbial growthTime-temperature control
Hygienic handling
Raw material, fish and
cans (receipt)
Poor quality entering
processingSecure reliable source
Filling cansPoor filling affects heat
penetration during retorting
Avoid inclusion of air,control weights of solids,
liquids, product density
and headspace
Exhaustion, seaming RecontaminationControl of closures at
regular intervals
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Retorting Survival of pathogens Time-temperature control
Cooling Bacterial contamination
Control of quality of cooling
water, chlorine level > 1-2
ppm
Handling of wet canned
productsRecontamination
Proper handling procedure
to minimize recontamination
and mechanical shock
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