HACCP PLAN DEVELOPMENT AND ASSESSMENT: A REVIEW

Hazard Analysis and Critical Control Points (HACCP) is a food safety preventive program designed to assure consumers of a safe food supply. Preventive measures adopted for this concept are intended to reduce the need for microbial testing after processing. HACCP plans are designed with the incorporation of good manufacturing practices as a guide to develop sanitation standard operating procedures. Seven principles are followed. The use of preshipment review ensures that the plan has been executed. HACCP plan assessment is needed to determine if a safe product is manufactured consistently. It includes review of the HACCP manual and on-site verification that the HACCP plan is implemented properly. HACCP plan assessment helps to determine if the manufacturer has implemented a sound HACCP system, with appropriate knowledge and support programs to maintain the HACCP plan.     

Development and implementation of hazard analysis and critical control point plans by several U.S. feed manufacturers

The commitment to consumer food safety, global trade, and proposed new regulations by the U.S. Food and Drug Administration Center for Veterinary Medicine has led to increased adoption of hazard analysis and critical control point (HACCP) by the U.S. feed industry. A project supported by the U.S. Department of Agriculture Integrated Food Safety Initiate titled "Development and Implementation of a Voluntary HACCP Program for the US Feed Industry" enabled faculty from three land grant universities to assist individuals from 14 feed companies that collectively manufacture 15 million metric tons of feed in 100 facilities to develop HACCP plans. The process flow in these plans averaged 20 steps, and the most detailed plan included 60 process steps. Chemical hazards were more commonly identified in HACCP plans (average of four hazards per plan) than were biological hazards (average of one per plan). The most prevalent chemical hazards were cross-contamination of type A medicated articles and type B medicated feeds, aflatoxin, and wrong ingredient inclusion in feed. The most common biological hazard was mammalian protein contamination of feed ingredients and finished feed for cattle. An assessment of time and costs associated with developing HACCP plans revealed that approximately 29% of the companies needed additional personnel or additional equipment to implement a HACCP plan, and on average 268 additional person hours were needed to develop and implement a HACCP plan. Plan design, compliance monitoring, and record keeping were the three most time-consuming activities needed for developing and implementing a HACCP plan. The average cost of additional equipment needed to implement a HACCP plan was $250.     

Industry perspectives on the use of microbial data for hazard analysis and critical control point validation and verification

Microbial testing is an essential element in validation of critical limits identified within a hazard analysis critical control point (HACCP) plan. Without appropriate validation there is no assurance that the plan will control the hazards of concern. Once critical control points have been validated to effectively prevent, reduce, or eliminate hazards, application of routine testing for pathogens in finished product becomes an ineffective means to assure process control and therefore safety of the product. The occurrence of a pathogen in a product produced under an effective HACCP plan is so rare that sampling protocols are not capable of finding the needle in the haystack. Quantitative indicators can provide a much more effective tool for verifying that HACCP is properly implemented. Choice of appropriate indicators is product and process specific. In certain applications, finished product testing for even indicator organisms provides no meaningful data for verification of HACCP (e.g., canned products). Tests chosen should provide meaningful information that directs resources toward prevention and improvement of the system.     

Effect of dehairing operations on microbiological quality of swine carcasses

To develop a hazard analysis and critical control point plan for food processing operations, critical control points must be determined. Swine slaughtering and dressing operations were investigated to establish their critical control points. We monitored the microbiology of swine carcasses by surface swabbing carcass bellies at various steps during the process and by quantitating total aerobic plate count (APC) and coliforms. Starting with a dehaired carcass, the sequential steps monitored included presingeing, postsingeing, polishing, and chilling. Initial results indicate that singeing and chilling substantially reduced the levels of APC and coliforms, whereas polishing increased their levels. The hygienic characteristics of individual operations involved in dressing swine carcasses were then evaluated in the second experiment. A set of 40 randomly selected carcasses leaving singeer, polisher, shaver, and washer were sampled. Carcasses were heavily contaminated during the final polishing procedure, and the APC increased threefold compared with prepolishing levels. Washing reduced the bacterial numbers by 69%. To reduce the microbial load on swine carcasses, final polishing and manual shaving steps were not used during the dressing operation on a set of 90 carcasses. APCs on singed carcasses were reduced from 1.34 to -0.15 log10 CFU/cm2 when the final polisher and manual shavers were not used. However, carcasses were subsequently recontaminated with bacteria after evisceration, and the APCs were similar (P > 0.05) regardless of whether the final polishing and manual shaving steps were used, averaging 1.30 and 1.46 log10 CFU/cm2. These results indicated that individual operations can be identified as critical control points, appropriate limits can be set and monitored in a hazard analysis and critical control point system, and steps where further changes to reduce bacterial levels may be needed for swine slaughtering plants.     

The role of microbiological testing in systems for assuring the safety of beef

The use of microbiological testing in systems for assuring the safety of beef was considered at a meeting arranged by the International Livestock Educational Foundation as part of the International Livestock Congress, TX, USA, during February, 2000. The 11 invited participants from industry and government research organizations concurred in concluding that microbiological testing is necessary for the implementation and maintenance of effective Hazard Analysis Critical Control Point (HACCP) systems, which are the only means of assuring the microbiological safety of beef; that microbiological testing for HACCP purposes must involve the enumeration of indicator organisms rather than the detection of pathogens; that the efficacy of process control should be assessed against performance criteria and food safety objectives that refer to the numbers of indicator organisms in product; that sampling procedures should allow indicator organisms to be enumerated at very low numbers; and that food safety objectives and microbiological criteria are better related to variables, rather than attributes sampling plans.     

Validation of acid washes as critical control points in hazard analysis and critical control point systems

A 2% lactic acid wash used in a large meat-processing facility was validated as an effective critical control point (CCP) in a hazard analysis and critical control point (HACCP) plan. We examined the microbial profiles of beef carcasses before the acid wash, beef carcasses immediately after the acid wash, beef carcasses 24 h after the acid wash, beef subprimal cuts from the acid-washed carcasses, and on ground beef made from acid-washed carcasses. Total mesophilic, psychrotrophic, coliforms, generic Escherichia coli, lactic acid bacteria, pseudomonads, and acid-tolerant microorganisms were enumerated on all samples. The presence of Salmonella spp. was also determined. Acid washing significantly reduced all counts except for pseudomonads that were present at very low numbers before acid washing. All other counts continued to stay significantly lower (P < 0.05) than those on pre-acid-washed carcasses throughout all processing steps. Total bacteria, coliforms, and generic E. coli enumerated on ground beef samples were more than 1 log cycle lower than those reported in the U.S. Department of Agriculture Baseline data. This study suggests that acid washes may be effective CCPs in HACCP plans and can significantly reduce the total number of microorganisms present on the carcass and during further processing.     

HACCP体系在夹心海苔生产中的应用

目的 基于夹心海苔生产工艺,结合Z企业生产实际,在夹心海苔生产领域构建危害分析与关键控制点（hazard analysis and critical control point,HACCP）体系,提高夹心海苔生产安全性和产品质量。方法 通过对Z企业夹心海苔生产过程中车间空气、工作人员手部、工作服、设备、工器具、生产物料及内包装材料的卫生情况进行调查,开展危害分析,确定关键控制点并制定和验证HACCP计划。结果 对夹心海苔生产的各道工序进行危害分析,确定原辅材料验收、烘烤、计量包装3个关键控制点,制定并验证了HACCP计划,验证结果表明,成品菌落总数合格率由92%提高至100%,HACCP体系应用效果显著。结论 在夹心海苔生产领域构建HACCP体系能够减少和预防产品不合格率,为夹心海苔终产品提供质量安全保障,降低食品安全风险。     

Use of microbial data for hazard analysis and critical control point verification--Food and Drug Administration perspective

This paper examines the role that the microbiologist and microbiological testing play in implementing hazard analysis and critical control point (HACCP) programs. HACCP offers a more comprehensive and science-based alternative for controlling food safety hazards compared with traditional sanitation programs based upon good manufacturing practices. Controlling hazards under an HACCP program requires a systematic assemblage of reliable data relating to the occurrence, elimination, prevention, and reduction of hazards. These data need to be developed in a transparent environment that will ensure that the best scientific methodologies have been employed in developing the needed data. The two mechanisms used in HACCP to assess the adequacy of the database are validation studies and the verification assessments. Microbiological testing is an important mechanism for collecting data used in developing and implementing an HACCP plan. Microbial sample data can help establish standard operating procedures (SOPs) for sanitation, assess the likelihood of the occurrence of hazards, establish critical limits, and assess the validity of the HACCP plan. The use of a performance standard to assess whether microbiological hazards have been reduced to an acceptable level creates an especially important use for microbial analysis. Microbial testing is also useful in implementing an HACCP plan by helping to monitor the effectiveness of sanitation SOPs, the compliance of incoming ingredients with safety criteria, the safety of product being held for corrective action, and the safety of the finished product. The verification audits demonstrate that all control measures have been applied as designed in the HACCP plan. Although auditing HACCP records is the primary means of verification, microbial sampling can play an important role as well.     

以危机管理掌控食品召回

<正>如今,食品安全已经成为整个社会最 担心的问题,它给食品行业及企业 都带来了很大的影响。但对于食品企业 来说,和其他紧急事务或灾害相比,产品 召回更可能是一种危机,因此如何在召 回发生之前做好准备就显得尤其重要。     

Standardized inspections of food premises during the 2004 Athens Olympic Games: descriptive analysis and risk factors for unsatisfactory results

Standardized inspections of food premises are part of environmental health systems implemented worldwide. The food safety strategy for the 2004 Olympic Games included standardized inspections to ensure uniformity and consistency of procedures and effective electronic management of data. Inspections were carried out by 196 inspectors in the five Olympic cities: Athens, Thessalonica, Volos, Iraklio, and Patra. From January 2003 to September 2004, a total of 1,249 food premises were inspected. An unsatisfactory inspection result (C grade) was received by 347 (27.8%) food premises, a relatively satisfactory result (B grade) was received by 332 (26.6%), and a satisfactory result (A grade) was received by 570 (45.6%). About 16% of inspected premises did not hold a valid permit. Unsatisfactory inspection results were more frequent for premises located in the two largest Greek cities in comparison with the other smaller cities (relative risk = 1.95, 95% confidence interval [CI] = 1.36 to 2.80). Based on logistic regression analysis, unsatisfactory inspection results were positively associated with food premises that were not located on a ground floor (odds ratio [OR] = 2.56, 95% CI = 1.39 to 4.73) and negatively associated with application of hazard analysis critical control point (HACCP) principles (OR = 0.27, 95% CI = 0.10 to 0.71). Food hygiene education through formal training programs should be encouraged to improve compliance of food premises. Food premises located on hotel floors and serving buffet meals are at higher risk for unsatisfactory conditions. Businesses that implemented a HACCP system within their operations to ensure food safety operated under more hygienic conditions. Future inspections by Public Health Authorities should involve elements of audit after the legislation for the application of HACCP principles.     

Use of hazard analysis critical control point and alternative treatments in the production of apple cider.

The purpose of this study was to evaluate the practices of Maryland cider producers and determine whether implementing hazard analysis critical control point (HACCP) would reduce the microbial contamination of cider. Cider producers (n = 11) were surveyed to determine existing manufacturing practices and sanitation. A training program was then conducted to inform operators of safety issues, including contamination with Escherichia coli O157:H7, and teach HACCP concepts and principles, sanitation procedures, and good manufacturing practice (GMP). Although all operators used a control strategy from one of the model HACCP plans provided, only one developed a written HACCP plan. None developed specific GMP, sanitation standard operating procedures, or sanitation monitoring records. Six operators changed or added production controls, including the exclusion of windfall apples, sanitizing apples chemically and by hot dip, and cider treatment with UV light or pasteurization. Facility inspections indicated improved sanitation and hazard control but identified ongoing problems. Microbiological evaluation of bottled cider before and after training, in-line apples, pomace, cider, and inoculated apples was conducted. E. coli O157:H7, Salmonella, or Staphylococcus aureus were not found in samples of in-line apple, pomace, and cider, or bottled cider. Generic E. coli was not isolated on in-coming apples but was found in 4 of 32 (13%) in-line samples and 3 of 17 (18%) bottled fresh cider samples, suggesting that E. coli was introduced during in-plant processing. To produce pathogen-free cider, operators must strictly conform to GMP and sanitation procedures in addition to HACCP controls. Controls aimed at preventing or eliminating pathogens on source apples are critical but alone may not be sufficient for product safety.     

Application of ISO 22000 and comparison with HACCP on industrial processing of common octopus (Octopus vulgaris) – Part I

Critical control points (CCPs) were identified in the risk assessment of octopus ( Octopus vulgaris ) processing and implemented in the hazard analysis critical control point (HACCP) plan. In the hazard analysis worksheet the different hazards were identified at each processing stage, whereas in the HACCP plan each CCP is identified and accompanied with the relevant significant hazard, critical limit, monitoring of the CCP and corrective actions. In this work comparison of ISO 22000 analysis with HACCP is carried out over octopus processing and packaging. ISO 22000 Analysis Worksheet was employed for determination of some prerequisite programmes (PrPs). Comparison between the two systems has been carried out using the hazard analysis worksheet. The PrPs are the main difference between the two systems. The incorporation of PrPs in the ISO 22000 made the system more flexible as a smaller number of CCPs was introduced.     

火腿肠加工过程中微生物风险研究

目的开展火腿肠加工过程中微生物污染风险研究,掌握卫生指示菌、主要食源性致病菌的分布特征和污染途径,为火腿肠加工过程中微生物污染风险控制提供依据。方法 2015—2017年对4家企业的712份产品相关样品(原辅料、中间产品和终产品)和环境样品(包括生产用水、空气沉降菌、人员、工具等)进行监测,选择传统分离培养方法对卫生指示菌和主要食源性致病菌进行检验,并对沙门菌进行血清学鉴定。结果原辅料中菌落总数10~5 CFU/g和大肠菌群10~3 CFU/g的样品比例分别为33.00%(33/100)和29.00%(29/100);中间产品中菌落总数10~5 CFU/g和大肠菌群10~3 CFU/g的样品比例分别为62.86%(66/105)和36.19%(38/105);终产品未检出菌落总数10~4 CFU/g的样品,大肠菌群均10 CFU/g。结论火腿肠加工过程存在微生物污染风险,本研究对掌握火腿肠加工过程的污染分布,确定关键控制点,为制定相关生产质量管理规范、确保终产品的食品安全具有重要意义。     

基于食品防护的出口河豚鱼加工过程控制的研究

基于食品防护和HACCP原理对出口河豚鱼加工过程控制的研究,为出口河豚鱼加工企业科学化控制加工过程提供借鉴。应用危害分析的方法,对出口河豚鱼加工过程中的生物性、化学性和物理性的食品安全危害进行识别和分析,应用关键控制点判断树的方法确定关键控制点并制定控制措施。出口河豚鱼加工过程中的关键控制点如原料验收、挑选、排盘、金属探测可以通过实施HACCP计划加以控制;而对于人为蓄意破坏而引起的危害则通过实施食品防护计划包括企业内外部安全、加工过程安全、贮存和运输过程安全等11个方面加以控制。通过实施HACCP计划和食品防护计划,可对出口河豚鱼加工过程中食品安全危害进行有效地控制,从而确保出口河豚鱼的质量。     

消费者对HACCP认证的支付意愿:基于北京市乳制品市场的调查

调查了北京地区消费者对HACCP认证的认知程度、支付意愿(WTP)以及相关问题,并采用算术平均法和计量方法分别估算了消费者对奶制品的HACCP认证的WTP。调查发现消费者对HACCP认证的认知和信任不足。另外,通过对信息强化前后的比较可知,经过信息强化后,使用算术平均法测算出消费者对HACCP认证的平均WTP为0.13元(占市场价格的8.46%),比信息强化前提高了0.04元。计量结果显示,消费者对该认证的平均WTP为0.11元(占市场价格的7.15%)。可见,加强HACCP认证的宣传能提高消费者对HACCP的认知和接受度。     

HACCP原理在速冻炸猪扒生产中的应用

目的针对速冻炸猪扒,建立一套科学合理的HACCP计划,更好地保障生产过程中食品安全。方法通过文献查阅和工厂实地调研,收集建立HACCP体系的预备信息并建立科学合理的HACCP计划。结果对速冻炸猪扒所涉及的14种原辅料、内外包装材料以及终成品进行描述,并绘制了总流程图与分解流程图,对21个工艺步骤进行描述,并基于物料、生产过程、公共设施(服务)以及过敏原进行危害分析。通过科学的危害评估方法,最终确定3个关键控制点(CCP),分别为挂糊、X光机和金属探测工艺,制定了HACCP计划,并对其有效性进行验证。结论采用HACCP体系对速冻炸猪排的生产过程进行控制,更好地保障了食品安全,且为企业降低了管理成本。     

Practical application of predictive microbiology software programs to HACCP plans

We studied how predictive microbiology models could practically be applied to HACCP plans with two predictive software programs that are currently available. The software programs were the Food Micromodel elaborated by the Ministry of Agriculture, Fisheries, and Food, U.K. and the Pathogen Modeling Program of Eastern Regional Research Center, U.S. Department of Agriculture. They successfully provided useful information on (i) the determination of Critical Control Points (CCPs), (ii) the estimation of critical limits at CCPs, (iii) the decision of abused products, (iv) the assessment of equivalence of HACCP plans, and further (v) the development of new products. With the information simulated by the software programs, HACCP teams could make scientific and objective decisions for developing their individual plans. It was also confirmed that microbiological process standards for food processing are indispensable for the application of the predictive programs to HACCP plans.     

不同屠宰工艺(剥皮和烫毛)对猪胴体表面微生物的多样性影响及关键点的控制研究

应用变性梯度凝胶电泳(Denaturinggradientgelelectrophoresis(DGGE))和经典微生物培养相结合的方法研究了剥皮和烫毛工艺中猪胴体表面污染的微生物数量和细菌多样性的变化以及3.5%乳酸处理后细菌总数和大肠菌群的变化。结果显示:不同猪胴体屠宰工艺中的微生物种类并不完全一致,微生物的污染多是由于前期的屠宰工艺引入;与剥皮工艺相比,烫毛后污染的微生物种类多,初始污染程度也较为严重;乳酸处理显著降低了剥皮工艺中的细菌总数,使出库猪胴体表面细菌总数降低到2.95logCFU/cm2,完全达到HACCP微生物的控制要求,但是没有降低烫毛工艺出库时的细菌总数,因此对不同的屠宰工艺应采取不同的关键点控制措施。     

HACCP在螺旋藻养殖、生产加工中的应用

目的在螺旋藻类的养殖和生产加工中建立和实施HACCP。方法根据GB/T 27341—2009《危害分析与关键控制点(HACCP)体系食品生产企业通用要求》,对螺旋藻养殖、生产加工全过程进行危害分析,确定关键控制点,控制标准和控制方法,提出相应的改进控制措施。样品检测方法和评价标准为GB/T 16919—1997《食用螺旋藻粉》。结果 HACCP在螺旋藻养殖、生产加工中得到建立、实施,并取得良好的效果;探讨了在建立HACCP中存在的问题。结论实施HACCP是一个不断发展的过程,需在实践中不断补充完善。     

Aerobiology of a high-line speed cattle abattoir

The operation of the high-line speed cattle abattoir studied follows a plant-created hazard analysis and critical control point (HACCP) plan that is recognized by the Canadian Food Inspection Agency. Measurement of bioaerosols is not a part of this plan. In this study CFUs in air of selected abattoir processes were enumerated after impinging air onto tryptic soy agar plates with a slit air sampler for 10 to 20 min. The total viable count (TVC) per liter of air was calculated for each sample following incubation at 30 degrees C for 24 h. Monthly samples were collected on the hide removal floor and the carcass dressing floor from March 1998 to April 1999. Mud tag, dirt, and wetness of incoming hides were scored subjectively on the hide removal floor. The other processes were sampled in 3 separate months. The TVC at two locations on the hide removal floor (center of hide removal floor [CHF] and top of hide puller [THP]) had a strong association to each other (r = 0.84; P < 0.001). The mean TVC at the CHF and THP was 10.0 and 11.5, respectively, and the TVC for individual samples ranged from 2 to 42 at these locations. The TVC means for all the other processes ranged from 0.01 to 0.7. Tag and TVC on the hide removal floor had a different seasonal distribution with TVC being highest in the warm months (April to October 1998) and lowest for November to April 1999. No significant relations between TVC and the dirt and wetness variables were evident for the CHF and THP locations on the hide removal floor. It was concluded that the control of aerosols in the hide removal floor should be treated as a critical control point in the HACCP plan.