Download FEDIAF Code of Practice

FEDIAF Code of Practice
for the Manufacture of Safe Pet Food
TRAINING PACKAGE
Module III
Hazard Analysis and Critical Control Points
Food Safety Management System
CI
Review
measure
HACCP
Food safety management
Prerequisites (GMP)
Food Safety Management System
Food safety management system consists of a prerequisite
programme and a HACCP system
Components of the system:
 Senior management commitment
 Implemented within the quality management system
 HACCP team leader and personnel trained and skilled
 Specific to the application, practical and effective
 Reviewed regularly and validated
 CCPs identified, controlled, monitored and recorded
3. HACCP
What is HACCP?
Hazard Analysis and Critical Control Points is
a technique that identifies, evaluates and
controls hazards significant for food safety
What is a hazard?
A biological, chemical or physical agent in, or
condition of, food or feed with the potential to
cause an adverse health effect
What is pet food safety?
Assurance that, when eaten according to its
intended use, the pet food will not harm the animal
Examples of food borne hazards
Bacteria:
Aeromonas, Clostridium perfrigens,
Clostridium botulinum, Campyloabcter,
pathogenic E.coli, Listeria monocytogenes,
Salmonella, Staphylococcus aureus…
Viruses:
Physical:
Hepatitis A, Rotavirus,
Norwalk-like viruses…
Metal, Glass…
Parasites:
Chemicals:
PCBs, Dioxins, Heavy metals,
Pesticides, Veterinary Drugs,
Mycotoxins, Toxins…
Trichinella spiralis, Taenia,
Fasciola hepatica…
HACCP principles
Step 0
Implement Pre-requisite Programmes
Conduct a hazard analysis
Assemble HACCP Team
Describe product
Identify intended use
Construct Flow diagram
Confirm flow diagram on site
List all potential hazards
Conduct a hazard analysis
Consider control measures
Principle 2
Determine the Critical Control
Points (CCPs)
Use decision tree to determine CCPs
Principle 3
Establish critical limits
Establish action and critical limits for each CCP
Principle 4
Establish CCP monitoring
procedures
Establish monitoring systems for each CCP
Establish corrective action
plans
Establish the corrective action to be taken
when monitoring indicates that a particular
CCP is not under control
Establish verification
procedures
Establish procedures for verification to confirm
that the HACCP system is working effectively
Establish documentation and
recordkeeping systems
Establish documentation concerning all
procedures and records appropriate to these
principles and their application
Principle 1
Principle 5
Principle 6
Principle 7
HACCP study
What is a risk?
Probability of causing an adverse health effect caused
by the occurrence and severity of a hazard in food
Risk assessment to identify hazards:
 Occurrence/severity of hazards and adverse effects
 Qualify/quantify hazards
 Micro-organisms growth
 Toxins, chemicals or physical agents
 Conditions leading to the above
Clostridium botulinum
Ex.: decision tree to identify CCPs
Q1
Preventative control measures exist?
Yes
Modify steps in process
No
Is control necessary?
No
Q2
Yes
Not a CCP
Is the step designed to eliminate or
reduce the likely occurrence of a
hazard to an acceptable level?
Stop*
Yes
No
Q3
Contamination occurs with identified
hazard(s) in excess of acceptable
level(s)?
Yes
Q4
No
Not a CCP
Stop*
Elimination of identified hazard(s) or
reduction to acceptable levels?
Yes
Not a CCP
Stop*
No
Critical
Control
Point
Point, step or
procedure at
which control can be
applied and is
essential to prevent
or eliminate hazards
or reduce it to an
acceptable level
HACCP examples: wet pet food
Critical Control Point
Hazard to be controlled
Typical Control Method
Receiving raw materials
conform spec.
Incorrect or contaminated raw materials
Supplier Assurance + inspection
Metal detection
Metal contamination (e.g. fish hooks)
Permanent magnets, electric metal
Seaming / Sealing
Re-contamination by pathogens
Seam / seal control
Sterilisation
Microbial growth due to under-sterilisation
(Fc0 < 3)
Monitoring Time and Temperature
Cooling
Re-contamination of pathogens due to
contaminated cooling water
Monitoring free and active Chlorine in
cooling water
HACCP examples: semi-moist
Critical Control Point
Hazard to be controlled
Typical Control Method
Receiving raw materials
conform spec.
Incorrect or contaminated raw materials
Supplier Assurance + inspection
Addition of preservatives
Pathogen growth
Monitoring / inspection
Processing
Pathogen or mould growth (due to high
Aw)
Aw Monitoring, monitoring of the right
recipe
Filling
Microbial growth due to condensation
(high filling temp.) + risk moulding
Monitoring / inspection filling temp.
and external temp.
Metal detection
Metal contamination
Electric metal detection device
HACCP examples: dry pet food
Critical Control Point
Hazard to be controlled
Typical Control Method
Receiving raw materials
conform spec.
Incorrect or contaminated raw materials
Supplier Assurance + inspection
Extrusion/ press
Pathogen growth
Control of temp/time or Monitoring
density as a indicator of the cooking
step
Processing
Pathogen or mould growth (high Aw)
Monitoring Aw, moisture,
Filling
Microbial growth due to condensation
Monitoring / inspection filling temp.
and ambient temperature
Metal detection
Metal contamination
Permanent magnets (only Ferrous),
electric metal detection device
Storage of product
Pathogen or mould growth
Warehouse assurance program
HACCP examples: chews
Critical Control Point
Hazard to be controlled
Typical Control Method
Receiving raw materials
conform spec.
Incorrect or contaminated raw materials
Supplier Assurance + inspection
Storage of raw Materials
conform spec.
Deteriorated raw materials
Stocking silo assurance programme
and inspections
Dosing and mixing of
ingredients
Incorrect proportion of ingredients and
additives
Calibration and capability assessment
of dosing and mixing
Processing
Growth of Pathogenic bacteria in process
(e.g. Salmonella due to Aw, time and
temp., cross contamination)
Monitoring / inspection, shelf-life
control
Bag Filling
Condensation (high filling temp.)
Monitoring / inspection filling temp.
Metal detection
Metal contamination
Permanent magnets, electric metal
detection device
HACCP examples: frozen
Critical Control Point
Hazard to be controlled
Control Method
Receiving raw materials
conform spec.
Incorrect or contaminated raw materials
Supplier assurance + inspection
Processing
Growth of pathogenic bacteria
(Salmonella due to AW, time and temp.,
cross contamination)
Monitoring / inspection,
Metal detection
Metal contamination
Permanent magnets (only Ferrous,
electric metal detection device
Cooling / Freezing
Microbiological ingress during cooling
Monitor airflow/temperature
Storage, transport, including
point of sales
Contamination or deterioration
Warehouse assurance and inspection,
temp. monitoring
HACCP examples: fresh / chilled
Critical Control Point
Hazard to be controlled
Control Method
Receiving raw materials
conform spec.
Incorrect or contaminated raw materials
Supplier Assurance + inspection
Processing
Growth of pathogenic bacteria in process
(Salmonella due to AW ,time and temp.,
cross contamination)
Monitoring / inspection,
Metal detection
Metal contamination
Permanent magnets (only Ferrous),
electric metal detection device
Cooling / Chilling
Microbiological ingress during cooling
Monitor airflow/temperature
Storage, transport, including
point of sales
Contamination or deterioration
Warehouse assurance and inspection,
temp. monitoring , shelf life control