HACCP AND FOOD SAFETY

I INTRODUCTION
II GOOD MANUFACTURING PRACTICES
 Elements of GMP
 Principles of GMP
 Benefits of GMP
 Applications of GMP
III CODEX ALIMENTARIUS
IV HACCP
 History
 Terminologies
 Scope
 Seven principles
 Development of the HACCP plan
V HAZARDS
VI SOURCES OF HAZARDS
VII MEASURES TO CONTROL HAZARDS
VIII HAZARD ANALYSIS
IX CONSUMER PROTECTION
X MANAGEMENT OF THE HACCP PROGRAM
XI BENEFITS
XII APPLICATIONS OF HACCP
XIII CASE STUDIES
XIV OUTBREAKS
XV HAZARD ANALYSIS FORM
XVI REFERENCES
 HACCP AND FOOD SAFETY
"Any process that helps eliminate contamination in our food and beverages is a positive sign,"
Adam Berman

INTRODUCTION

Good Manufacturing Practices

Good Manufacturing Practices (GMPs) lie at the Heart of Quality. GMPs are also
known as current Good Manufacturing Practices (cGMPs), are a series of manufacturing and
administrative procedures aimed at ensuring that products are consistently made to meet
specifications and customer expectations. In relation to food, GMP results in safe and quality
food. The three elements of GMP are Food Safety, Good Practice and Quality

A preventive approach to the safety of foods is more effective than testing or

inspection of processed foods at the final stage. GMP assures food safety through vigilant
measures at the source product design and process control.

Elements of GMP

Food Safety Quality

Manufacturing
practices

1
 Pre-requisites Consistency

HACCP Integrity

Risk Management Wholesomeness

Hazard Awareness Nutrition

CCP Awareness Product attributes

Principles of GMP

1. Organization of personnel
2. Training of personnel hygiene

3. Building and facilities

4. Equipment

5. Control of Components

6. Production and process control

7. Packaging and Label Control

8. Storage and Distribution

9. Laboratory Control

10. Documentation

11. Cleaning and Sanitation

12. Maintenance and Calibration

13. Pest Management

14. Foreign matter control

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 15. Waste Management

16. Reworking Material

17. Audits and Review

18. Customer complaint procedure

19. Recall procedure

Benefits of GMP

1. Create awareness of food quality and safety among the staff

2. Increases confidence in product safety.

3. Provides a starting point for the HACCP program

4. Recognition internationally

5. Prevents regulatory non compliances by meeting regulatory requirements.

6. Prevents expensive failures

7. Reduces customer complaints and recalls and Improve profits.

Applications of GMP

 GMP program ensures favorable conditions for the production of safe food
 Combination with a proper HACCP plan, a robust food safety program can be
developed

 Generic principles behind the management of GMP activities can be conveniently

applied to all food processing operations.

 Control of components, production and processes, packaging and labelling,

storage and distribution may require specific consideration depending on the
nature of the food product.

Codex Alimentarius

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 The Codex Alimentarius is a collection of internationally adopted food standards,
codes of practice, guidelines and recommendations. They have been created for the purpose
of protecting the health of consumers and ensuring fair practices in the food trade.
Recognizing the importance of HACCP to food control, the twentieth session of the Codex
Alimentarius Commission, held in Geneva, Switzerland from 28 June to 7 July 1993, and
adopted Guidelines for the application of the Hazard Analysis Critical Control Point
(HACCP) system. The Codex General Principles of Food Hygiene lay a firm foundation for
ensuring food hygiene. They follow the food chain from primary production through the
consumer, highlighting the key hygiene controls at each stage and recommending an HACCP
approach wherever possible to enhance food safety. These controls are internationally
recognized as essential to ensuring the safety and
suitability of food for human consumption and international trade.

One of the over thirty texts to be adopted this year, the Code of Hygienic Practice for
Powdered Formulae for Infants and Young Children, aims at protecting the most vulnerable
of consumers: infants and small children who for any reason cannot be breastfed . The code,
by setting maximum limits for bacteria in formula and guidance on how to produce, distribute
and prepare powdered formula, will help keeping children safe from potentially serious
infections.

Codex Alimentarius is literally translated from Latin, a "food code". It comprises a

series of general and specific food safety standards that have been formulated with the
objective of protecting consumer health and ensuring fair practices in the food trade. Food
put on the market for local consumption or export must be safe to eat and of good quality. In
addition, food should not carry disease-causing organisms that could harm animals or plants
in importing countries. Codex Alimentarius is run by the Codex Alimentarius Commission,
which is an intergovernmental body where all member countries have a vote. Various
specialist committees are responsible for drafting standards, which are then adopted by the
Codex Commission.

HACCP

HACCP (Hazard Analysis and Critical Control Point) is a systematic approach in

identifying, evaluating and controlling food safety hazards. Food safety hazards are
biological, chemical or physical agents that are reasonably likely to cause illness or injury in

4
the absence of their control. A HACCP system is a preventive system of hazard control rather
than a reactive one. HACCP systems are designed to prevent the occurrence of potential food
safety problems. This is achieved by assessing the inherent hazards attributable to a product
or a process, determining the necessary steps that will control the identified hazards, and
implementing active managerial control practices to ensure that the hazards are eliminated or
minimized.

Essentially, HACCP is a system that identifies and monitors specific foodborne

hazards – biological, chemical, or physical properties – that can adversely affect the safety of
the food product. This hazard analysis serves as the basis for establishing critical control
points (CCPs). CCPs identify those points in the process that must be controlled to ensure the
safety of the food. Further, critical limits are established that document the appropriate
parameters that must be met at each CCP. Monitoring and verification steps are included in
the system, again, to ensure that potential hazards are controlled. The hazard analysis, critical
control points, critical limits, and monitoring and verification steps are documented in a
HACCP plan. Seven principles have been developed which provide guidance on the
development of an effective HACCP plan.

HISTORY OF HACCP

HACCP has become synonymous with food safety. It is a worldwide-recognized

systematic and preventive approach that addresses biological, chemical and physical hazards
through anticipation and prevention, rather than through end-product inspection and testing.

The HACCP system for managing food safety concerns grew from two major
developments. The first breakthrough was associated with W.E. Deming, whose theories of
quality management are widely regarded as a major factor in turning around the quality of
Japanese products in the 1950s. Dr Deming and others developed total quality management
(TQM) systems which emphasized a total systems approach to manufacturing that could
improve quality while lowering costs.

The second major breakthrough was the development of the HACCP concept itself.
The HACCP concept was pioneered in the 1960s by the Pillsbury Company, the United
States Army and the United States National Aeronautics and Space Administration (NASA)
as a collaborative development for the production of safe foods for the United States space
programme. NASA wanted a "zero defects" programme to guarantee the safety of the foods

5
that astronauts would consume in space. Pillsbury therefore introduced and adopted HACCP
as the system that could provide the greatest safety while reducing dependence on end-
product inspection and testing. HACCP emphasized control of the process as far upstream in
the processing system as possible by utilizing operator control and/or continuous monitoring
techniques at critical control points. Pillsbury presented the HACCP concept publicly at a
conference for food protection in 1971. The use of HACCP principles in the promulgation of
regulations for low-acid canned food was completed in 1974 by the United States Food and
Drug Administration (FDA). In the early 1980s, the HACCP approach was adopted by other
major food companies.

The United States National Academy of Science recommended in 1985 that the
HACCP approach be adopted in food processing establishments to ensure food safety. More
recently, numerous groups, including for example the International Commission on
Microbiological Specifications for Foods (ICMSF) and the International Association of Milk,
Food and Environmental Sanitarians (IAMFES), have recommended the broad application of
HACCP to food safety.

TERMINOLOGY

The following terms are used in discussion of HACCP that must be clearly
understood to effectively develop and implement a plan.

1. Acceptable Level means that the presence of hazard which does not pose the
likelihood of causing an unacceptable health risk.
2. Control point means any point in a specific food system at which loss of control
does not lead to an unacceptable health risk.

3. Critical control point, as defined in the food Code, means a point at which loss
of control may result in an unacceptable health risk.

4. Critical Limit, as defined in the Food Code, means the maximum or minimum
value to which a physical, biological, or chemical parameter must be controlled at
a critical control point to minimize the risk that the identified food safety hazard
may occur.

5. Deviation means failure to meet a required critical limit for a critical control point.

6
 6. HACCP plan, as defined in the Food Code, means a written document that
delineates the formal procedures for following the HACCP principles developed
by The National Advisory Committee on Microbiological Criteria in Foods.

7. Hazard, as defined in the Food Code, means a biological, chemical, or physical

property that may cause an unacceptable consumer health risk.

8. Monitoring, means a planned sequence of observations of measurement of critical

limits designed to produce an accurate record and intended to ensure that the
critical limit maintains product safety. Continuous monitoring means an
uninterrupted record of data.

9. Preventive, measure means an action to exclude, destroy, eliminate, or reduce a

hazard and prevent recontamination through effective means.

10. Risk, means an estimate of the likely occurrence of a hazard.

11. Sensitive ingredient, means any ingredient historically associated with a known
microbiological hazard that causes of contributes to production of a potentially
hazardous food as defined in the Food Code.

12. Verification, means methods, procedures, and tests used to determine if the
HACCP system in use in compliance with the HACCP plan.

SCOPE OF HACCP1

a. Aggressive competition required organization to reduce costs while

maintaining quality.
b. Increasing consumer awareness and legal liability to produce safe food

c. Changes in processed technology, increased automation, complex

packaging solutions, new ingredients and improved formulations.

d. Greater emphasis on sensory evaluations and complex distribution

networks leading to reduce delivery times.

SEVEN PRINCIPLES OF HACCP

1
Clarify scope

7
Principle2 1 Conduct a hazard analysis

Identify the potential hazard(s) associated with food production at all stages, from
primary production, processing, manufacture and distribution until the point of consumption.
Assess the likelihood of occurrence of the hazard(s) and identify the measures for their
control.

Principle 2 Determine the Critical Control Points (CCPs).

Determine the points, procedures or operational steps that can be controlled to

eliminate the hazard(s) or minimize its (their) likelihood of occurrence. A "step" means any
stage in food production and/or manufacture including the receipt and/or production of raw
materials, harvesting, transport, formulation, processing, storage, etc.

Principle 3 Establish critical limit(s).

Optical3 limits must be specified and validated if possible for each Critical Control
Point. In some cases more than one critical limit will be elaborated at a particular step.
Criteria often used include measurements of temperature, time, moisture level, pH, A w,
available chlorine and sensory parameters such as visual appearance and texture.

Principle 4 Establish monitoring procedures.

Monitoring is the scheduled measurement or observation of a CCP relative to its

critical limits. Monitoring should ideally provide this information in time to make
adjustments to ensure control of the process to prevent violating the critical limits. Where
possible, process adjustments should be made when monitoring results indicate a trend
towards loss of control at a CCP. The adjustments should be taken before a deviation occurs.
Data derived from monitoring must be evaluated by a designated person with knowledge and
authority to carryout corrective actions when indicated. If monitoring is not continuous, then
the amount or frequency of monitoring must be sufficient to guarantee the CCP in control.

Principle 5 Establish corrective actions.

2
Are they called principles
3
Optical?

8
 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. Deviation and product disposition procedures must be documented in the HACCP
record keeping.

Principle 6 Establish verification procedures.

Verification and auditing methods, procedures and tests, 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. Examples of verification activities include:

- Review of the HACCP system and its records;
- Review of deviations and product dispositions;
- Confirmation that CCPs are kept under control.

Where possible, validation activities should include actions to confirm the efficacy of all
elements of the HACCP plan.

Principle 7 Establish record-keeping and documentation procedures.

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.

Documentation examples are:

- Hazard analysis;
- CCP determination;
- Critical limit determination.

Record examples are:

- CCP monitoring activities;
- Deviations and associated corrective reactions;
- Modifications to the HACCP system.

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DEVELOPMENT OF THE HACCP PLAN

Development of the HACCP plan goes through four distinct stages. The key tasks associated
at each stage are applicable to any food processing operation.

The team

HACCP study begins with the selection of a team consisting of members drawn from various
disciplines in the food processing operation. All the key functions of the organization should
be represented in the team and may include a project leader, a production manager, a
technical expert, an engineer, a secretary and others required. Once the team is formed, the
members will require further training on HACCP principles and they should be provided with
the necessary tools to perform the tasks.

Training

HACCP training has now been accepted as the most cost-effective means of controlling
hazards related to microbiological, physical and chemical contamination of foods.
Implementation of the HACCP plan is a team exercise; thus training and education are
essential if full benefits are to be achieved.

Product description and Intended use

The HACCP team needs to have a complete understanding of the product, its intended use,
the ingredients used, the composition of the product, and the processing steps. It is necessary
to have this information before analyzing for hazards because the food products have to be
assessed in relation to the ability of different pathogens to grow.

The product description should include (i) name of the product (ii) end product features (e.g.,
pH, preservatives, etc.) (iii) How the product is to be used (i.e., ready-to-eat products, further
processing or heated prior to consumption) (iv) packaging details (e.g., packaging materials
and conditions) (v) shelf life (vi) distribution outlets (vii) labeling instructions (viii) shipping
conditions and (ix) target consumer group.

Flow Diagram

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Food processing operation is a continuous flow of food ingredients from “farm to fork”. A
flow diagram breaks up the process into a series of sequential steps that assist further
evaluation. It typically commences at the point where the food is received at the operation.
Thus, the steps in the flow diagram include the entry of ingredients, processing steps,
packaging, storage, distribution and handling by the consumer.

HAZARDS

Biological hazards

Food borne biological hazards include microbiological organisms such as bacteria, viruses,
fungi and parasites. These organisms are commonly associated with humans and with raw
products entering the food establishment. Many of these microorganisms occur naturally in
the environment where foods are grown. Most are killed or inactivated by cooking, and
numbers can be minimized by adequate control of handling and storage practices (hygiene,
temperature and time).

Sources: Bacteria (spore forming and Non spore forming), Viruses, protozoa and parasites.

Chemical hazards

Chemical contaminants in food may be naturally occurring or may be added during the
processing of food. Harmful chemicals at high levels have been associated with acute cases
of food borne illnesses and can be responsible for chronic illness at lower levels.

Sources: Naturally occurring chemicals (allergens and toxins) and added chemicals
(agricultural chemicals, toxic elements, food additives and packaging materials).

Physical hazards

Illness and injury can result from foreign objects in food. These physical hazards can result
from contamination and/or poor practices at many points in the food chain from harvest to
consumer, including those within the food establishment.

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Sources: Bottles, jars, light fixtures, utensils, gauge covers, Packaging, pallets, equipment,
improper processing and employees.

SOURCES OF HAZARDS

Raw Materials

Raw materials are the primary source of contamination. Failure to follow basic quality
assurance procedures (identification and labelling, Storage conditions, Handling requirements,
Preparation and processing and Isolation unsuitable raw materials) on raw materials may lead to food
products that are unsafe for construction.

Processing Steps

Uncontrolled processing operations can lead to hazardous conditions. Failure to maintain

processing conditions such as Temperature or Time delay in processing, incorrect formulations and
procedures and following unauthorized processing techniques may all result in contamination or
microbial growth. Poor cleaning practices may leave excess cleaning chemical residues on plant and
equipments.

Machinery

Unclean and unhygienic equipment can easily promote the growth of microorganisms.
Preventive maintenance of machinery is an important aspect in a safety- management program. If
safety requirements are ignored, the layout of the machinery and equipment can be a potential hazard.
The machinery should be examined at intervals to ensure a safe operation.

Handling of Food

Personal hygiene is extremely important in any food serving establishment. If adequate

precautions are not taken, food handlers can transmit pathogenic bacteria. Personal articles such as
Jewellery can get mixed with foods during preparation.

Environmental Conditions

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 Hazards due to Environmental conditions may affect raw materials, processing and
machinery. Pollution of water and soil can have alarming results through the food chain.
Environmental contamination may also be due to foreign matter, chemicals such as sprays and
contaminants in water.

MEASURES TO CONTROL HAZARDS

1. Measure at the processing and packaging stages (Raw materials, packaging
materials, processing steps, plant and machinery, storage and Distribution, premises
and     personnel).

Method Control parameters

Heat treatment Time, Temperature and Humidity
Filtration Pore, size and filter integrity
Irradiation Dosage and Density of load
Chemical Concentration, pH and Temperature

2. Measures at post processing and packaging stages (Retail and Food service)
3. The consumer (Food preparation and Food usage)

CRITICAL CONTROLS FOR FOODSTUFFS

Fresh juices

Fresh squeezed orange juice, Sparkling apple cider and All-vegetable cocktail4. Americans
quench their thirst with these and other fruit and vegetable juices, and the vast majority of
those juices are not only healthy but safe. Very rarely, however, juice can turn dangerous.

NACMCF (National advisory committee on microbiological criteria for foods)

conclusions for fresh juices5

1. The Committee concludes that while the risks associated with specific juices vary,
there are safety concerns associated with juices, especially unpasteurized juices.

4
5
??

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2. The Committee concludes that the history of public health problems associated with
fresh juices indicates a need for active safety interventions.

3. The Committee concludes that, for some fruit, intervention may be limited to surface
treatment, but for others, additional interventions may be required.

4. The Committee recommends the use of safety performance criteria instead of

mandating the use of a specific intervention technology. In the absence of specific
pathogen-product associations, the committee recommends the use of Escherichia coli
O157:H7 or Listeria monocytogenes as the target organisms, as appropriate.

5. The Committee believes that a tolerable 1evel of risk may be achieved by requiring an
intervention(s) that has been validated to achieve a cumulative 5 log reduction in the
target pathogen(s) or a reduction in yearly risk of illness to less than 10 -5, assuming
consumption of 100 ml of juice daily.

6. The Committee believes that Hazard Analysis Critical Control Points (HACCP) and
safety performance criteria form the general conceptual framework needed to assure
the safety of juices. Control measures should be based on a thorough hazard analysis.
Validation of the process must be an integral part of this framework.

7. The Committee recommends mandatory HACCP for all juice products. Implicit in
this recommendation is that plants have implemented and are strictly adhering to
industry GMPs.

8. The Committee recommends industry education programs addressing basic food

microbiology, the principles of cleaning and sanitizing equipment, GMPs and
HACCP

9. The Committee recommends further study in the following areas:

o Research on the efficacy of new technologies and intervention strategies for

safety.
o Research on the contamination, survival and growth of pathogens on produce
with or without breaks in skin, areas of rot, and within the core.

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 o Research on how produce becomes contaminated with human pathogens
including the relevant microbial ecology during production and processing of
juice. In particular, there is an urgent need for these types of studies on E. coli
O157:H7 in apple juice.
o Baseline studies on the incidence of human pathogens on fruits and
vegetables, particularly those used in juice processing.
o Research on labeling information needed for consumer understanding and
choice of safer juices and juice products.

HAZARD ANALYSIS

Hazard Analysis, the first principle of the HACCP program, is necessary to identify
those hazards that must be eliminated or reduced to an acceptable level to produce safe food.
A hazard analysis serves three purposes: (i) to identify the hazards of significance to food
safety, (ii) to select critical hazards on the basis of risk to the consumer, and (iii) to identify
potential hazards that warrant specific preventive measures. When the same product is
manufactured by different food processing organizations, the hazards will depend upon the
following: (i) sources of ingredients, (ii) product formulations, (iii) processing machinery and
equipment, (iv) processing and preparation procedures, (v) duration of processes, (vi) storage
conditions, and (vii) experience, knowledge, and attitudes of the personnel. Hazard Analysis
form, Hazard identification with inputs and Hazard analysis and CCP determination were
given in table1, 2 and 3.

CONSUMER PROTECTION
The primary objective of an HACCP system is to protect the consumer from the harm caused
by hazards associated with food products.

What Can Consumers Do in the Meantime?

FDA urges high-risk individuals--children, the elderly, and those with weakened immune
systems--to drink only pasteurized juices. And while manufacturers were asked before the
date in the regulation to voluntarily place warning statements on the labels of juices that
haven't been pasteurized, the agency advises people to be aware that a product without a
warning label at this time might still be unpasteurized. A good rule of thumb for high-risk
individuals, says FDA, is if you cannot determine whether a product has been pasteurized, the

15
best choice is to not use the product. Another choice is to bring the juice to a boil to kill any
possible harmful bacteria.
The agency also advises consumers to be aware of the following symptoms commonly
associated with food poisoning: diarrhoea, abdominal pain, cramping, vomiting, fever, and
headache. If you have any of these symptoms, you should contact your physician
immediately.

MANAGEMENT OF THE HACCP PROGRAM

Review
The HACCP program, just like the quality management system, is dynamic. Procedures such
as management responsibility, management review and document approval and issue can be applied
to the HACCP system. The function of the management representative then is to maintain the system
through regular audits and reviews.
Audit
An HACCP audit can be defined as a systematic and independent examination to determine
whether (a) HACCP activities and related results comply with the planned arrangements, (b) these
arrangements are implemented effectively, and (c) the arrangements are suitable to achieve the
objectives. A schedule of audits must be prepared and carried out as planned. There is no international
standard yet for the HACCP system equivalent to the ISO 9000 standard series. HACCP audits should
provided (a) an assessment of the adequacy of the existing system, (b) a bench mark against which
improvements can be made and evaluated, (c) evidence that contractual and legal requirements have
been met, and (d) feedback on safety issues.
The Product Recall system
A reliable and well-tested method of recall should be in place to deal with a food item that has
been established to be contaminated with a harmful ingredient or pathogenic organisms. The recall
team should document the following information: (i) name of the product and pack size, (ii) reason for
recall (iii) cause of the problem, (iv) chronological history of the recall events with actions taken, (v)
effectiveness of the recall, (vi) total cost of the recall, and (vii) corrective actions taken.
BENEFITS
Application of an effective HACCP system has clear benefits for consumers, industry
as well as regulatory bodies.
Benefits of Implementing the HACCP System
Benefits for Consumers
 Lower risk of food borne illnesses
 Greater awareness of food safety

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  Greater confidence in food supply
 Better quality of life through health and socioeconomic benefits
Benefits for Industry
 Greater consumer confidence on product
 Minimizes legal and insurance costs
 Increases market access
 Lower wastage, fewer no recalls, minimum or no reprocessing, and corrective
action
 A consistent product
 Enhanced staff commitment to food safety
 Lower business risk
Benefits for Regulatory Bodies
 Improved health among the community
 More efficient food control
 Lower public health costs
 Trade promotion
 Greater confidence of the community in the food supply

APPLICATION OF HACCP

While the application of HACCP to all segments and sectors of the food chain is
possible, it is assumed that all sectors should be operating according to good manufacturing
practices (GMPs) and the Codex General Principles of Food Hygiene. The ability of an
industry segment or sector to support or implement the HACCP system depends on the
degree of its adherence to these practices.

The successful application of HACCP requires the full commitment and involvement
of management and the workforce. It requires a multidisciplinary approach which should
include as appropriate, expertise in agronomy, veterinary health, microbiology, public health,
food technology, environmental health, chemistry, engineering, etc. according to the
particular situation. The application of the HACCP system is compatible with the
implementation of TQM systems such as the ISO 9000 series. However, HACCP is the
system of choice in the management of food safety within such systems.

CASE STUDIES

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 In1996, case of a 16-month-old child in Colorado who died of heart damage and
kidney failure after drinking contaminated apple juice.

In another 1996 case involving contaminated apple juice, 3 1/2-year-old Amanda

Berman of Chicago was hospitalized for 24 days. In both cases, the apple juice was
unpasteurized and the culprit was E. coli O157:H7, the same microbe that claimed the lives
of four children during a 1993 outbreak from undercooked hamburger.

Because certain food poisoning outbreaks, have been traced to fresh juices that were
not pasteurized or otherwise processed to eliminate harmful bacteria. The Food and Drug
Administration proposed in April measures to reduce the risk of illness from disease-causing
microbes in unpasteurized fruit and vegetable juices.

OUT BREAKS
Foods most likely to be linked to a food poisoning outbreak are seafood, eggs, beef
and produce. Interestingly, three out of these top four high-risk foods are regulated by the
USFDA (US food and drug administration). 682 outbreaks were linked to FDA regulated
foods, as compared to 179 outbreaks linked to USDA regulated foods, as compared to 179
outbreaks linked to USDA regulated foods.
 237 out breaks were linked to seafood, salted whitefish, tuna, buffalo fish, blue
martin, surgeon, grouper, ate, crab up shrimp.
 41 were linked to shellfish, including oysters, clams and mussels.
 170 out breaks were linked to egg and egg dishes (pudding, stuffing, baked and ice
cream) made with shell eggs.
 91 out breaks linked to beef and beef products.
 82 outbreaks were linked to produce (tomatoes, strawberries. Watermelons, potatoes,
lettuce, raspberries, sprouts, basil and parsley)
 52 outbreaks were linked to poultry
 89 outbreaks were linked to dairy products
 31 outbreaks were linked t pork ham and pork sausage
 10 outbreaks were linked to juices
 5 outbreaks were linked to hot dogs, luncheon meat
 130 outbreaks were linked to FDA regulated foods with multiple ingredients.

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FUTURE OF HACCP

New challenges arising from the growing size of the food industry and the diversity of
products and processes have prompted FDA to consider requiring HACCP regulations as a
standard throughout much of the remaining U.S. food supply. If adopted, the regulations
would cover both domestic and imported foods.

HAZARD ANALYSIS

Flow chart for the preparation of milled rice

Disk Huller

Quality Control Sieve

Dryer

Light Impurities Aspirator Aspiration

Other foreign materials Sieve Paddy Separator

Iron & Steel particles Magnetic Separator Whitening cones

Stoner Sieve

Water Soaking Polishing cone

Streaming Sieve

Drying Trieurs (Classifiers)

Packaging

Table 1: Hazard Analysis form- Product name (Milled rice)

Raw material Packaging material Dry ingredients

Paddy Gunny sacs None
Other - -

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 None -

Table 2: Hazard Identification with inputs (Milled rice)

Inputs Description/specification Biological Chemical Physical hazard

hazard (B) hazard (C) (P)

Raw Free from organic and Filth(Rodent Iron and steel Immature grains,
paddy inorganic impurities excrement and particles chaff, Dust and
Dead insects) sand
and Bacterial
spores

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 Table 3: Hazard Analysis and CCP Determination (Milled rice)

Hazard reasonably Q1. Is there a

Process step Inputs Justification control Q2. Is this step a
likely to occur on measure(s) for the CCP?
hazard at this
or in the product step?

at this step If yes, identify the

control measure
and then answer
Q2.

If no, consider
hazard at next
step.

Receiving Freshly harvested None

paddy(18-25%) reduce
to 14% for safe storage
Parboiling

i) Soaking
Paddy None Refer to table 2 Yes- Correct No
( 65-700C, 4hrs) temperature and
time

Yes- Correct

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ii) Steaming Paddy None Refer to table 2 temperature and No
time
(10 mins)

iii) Drying Yes- Correct

Paddy None Refer to table 2 temperature, time
(60-1100C,4-6hrs)
and moisture
No
content

Pre cleaning Paddy None Remove organic and

inorganic impurities

Tempering Cleaned Paddy None

Organic matter;
Hulling(Rubber roll Paddy None
sheller) Milledrice-0.5%m/m max

Milled Parboiled rice-

0.5%m/m max

In Organic matter;

Milledrice-0.1%m/m max

Milled Parboiled rice-

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 0.1%m/m max

Moisture content-15%m/m
max
Polishing
Milled rice None 6-8% Raw and parboiled Yes- Correct time
(Cone polisher) rice given for polishing

Sieving Milled rice None 19-22% Brokens No No

Packaging Milled rice None Hygienic, Nutritional,

technological and
Organoleptic qualities of
food
Name of the product
Labelling Milled rice None No No
Classification

Optional ingredients

Date of Manufacture

Storing Milled rice None

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Specification -Indian long grain white Rice

Broken 20-25% max 25% max

Moisture 14% max 14% max
Damaged/Discolred 2% max 4% max
Yellow Kernels 2% max 2% max
Red & Streaked 1% max 1% max
Chalky grain 5% max 6% max
Foreign matter - 0.5% max
Paddy per kg 30grains max 30grains max
Other varieties 6%max 5%max
Milling Degree Reasonably well milled Reasonably well milled
Size of grain 6.2mm 6mm

REFERENCES
1. Caroline Smith De Wall, 2003. Safe Food from a Consumer Perspective. Food
Control. (14); 75-79.
2. Shafiur Rahman, M.2007. GMP and HACCP. Hand book of Food Preservation
(Second Edition). CRC Press,U.S.A.
3. Sivasankar, B.2005. Food Processing and Preservation. Food Quality. Published by
Prentice-Hall of Indian Pvt Ltd, New Delhi.
4. www.FDA/CFSAN FDA 2001- Food Code.
5. www. wikipedia.org /wiki /Juice
6. www.FAO. org

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