Post on 03-Mar-2021
HACCP IN FISH PROCESSING SECTOR
Ferrahi SARACOGLU (MSc)
Government Provided Staff
Fisheries and Aquaculture Expert
Food and Agriculture Organization of
the United Nations (FAO) Subregional Office For
Central Asia (SEC)
Ferrahi.Saracoglu@fao.org
Office : (+90) 312 207 5000/6466
Mobile : (+90) 542 473 0407
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Outline• Introduction
• What is the HACCP System?
• History
• Why we need HACCP in Fish Processes
• What is the hazards
• HACCP Principles
• HACCP Implementation to The Fish Processes
• Prerequisite Programs
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Introduction▪ According to data published in 2015 by FAO, 17 percent of the world supply of animal proteins derived from Fish.
▪ With capture fishery production relatively static since the late 1980s, aquaculture has been responsible for the continuing impressive growth in the supply of fish for human consumption.
▪In per capita terms, food fish consumption grew from 9.0 kg in 1961 to 20.2 kg in 2015, at an average rate of about 1.5 percent per year.
▪The highest per capita fish consumption, over 50 kg, is found in several small island developing States (SIDS), particularly in Oceania, while the lowest levels, just above 2 kg, are in Central Asia and Caucasus
▪Fish is an exceptionally important component of the human diet and an enormous industry exists to provide a huge variety of consumer products in which fish is a major component.
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
What Is The HACCP?
HACCP
PROACTIVE
EFFECTIVE
RISK ASSESMENT
BASED
FULLY DOCUMENTE
D
SYSTEMATIC
SCIENCE BASED
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Food Safety And Quality Pyramid
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Continuous
Quality Improvement
HACCP
Prerequisite Programs
Management Commitment
TrainingEducation
History
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
1950
1951: Dr Deming and others developed total quality
management (TQM) systems
19701960 200019901980
1961: NASA and Pillsbury first developed HACCP
(3 Principles)
1971: HACCP Presented at 1th National Food
Safety Conference
1974: A regulation for low acid canned food was published by FDA and HACCP
became mandatory.
1980: WHO/ICMSF Published a report on
HACCP
1983: WHO Europe recommended HACCP
1985: National Academy of
Science recommended
HACCP
1992: NACMCF issues a revised documents, The first document
with 7 principles
of HACCP.
1993: Codex AlimentariusComission published first
guideliness
1994: HACCP was introduced into EU
Legislation.
1986: FAO Fishery Industries Division
(FAO/FII) adopted the HACCP approach to
fish quality assessment
1995: FDA NACMCF issues a revised
documents, The first document with 7
principles of HACCP.
1997: FDA issued its final rule to mandate HACCP
for use in seafood
processing plants.
2005: ISO 22000 Food Safety Management
System formed.
Why We Need HACCP?
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Prevention Cure
Risky
Cheap
Safe Time Consuming
Expensive
Difficult
Healthy
Easy
Advantages Of The HACCP▪It focuses on those critical points in food processing and handling required for safe food production
▪Science based and systematic allowing for the specific identification of food safety hazards
▪Requires the implementation of measures to control these hazards where significant
▪Employs the principle of risk assessment allowing prevention to be based on the control program rather than inspection and testing
▪Better use of resources
▪Standardization of hazard management allowing for easier auditing and inspection by second and third parties
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
HACCP Implementations In Fish Processing
Stunning
Grading
Scaling Washing
Beheading
Gutting Filleting
Skinning
Meat-Bone Seperating
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Preliminary Processing Of Fish
Implementation Steps of HACCP
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Step 1: Assemble HACCP Team▪Gather as many materials and documents related to food safety as well as assemble a team to represent different sectors within the industry.
▪One HACCP coordinator with HACCP skills should be chosen.
▪The team should represent engineering, production, sanitation, and quality assurance.
▪Larger companies can have teams of seven or eight people while small companies may have teams as small as two or three people.
▪The HACCP coordinator should have responsibility for the whole HACCP program and be the team leader
▪Obtain management commitment
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Step 2:Describe Product▪ Product name (common name) or group of product names (the grouping of like products is acceptable as long as all hazards are addressed)
▪ Important end-product characteristics: properties or characteristics of the food under review that are required to ensure its safety (e.g. pH/preservatives)
▪ How the product is to be used (i.e. ready-to-eat/further processing required, heated prior to consumption)
▪ Type of package, including packaging material and packaging conditions (e.g. modified atmosphere)
▪ Shelf-life, including storage temperature and humidity if applicable
▪ Where the product will be sold (e.g. retail, institutions, further processing)
▪ Labelling instructions (e.g. handling and usage instructions)
▪ Special distribution control (e.g. shipping conditions)
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Step 3: Identify Intended Use▪Describe the normal expected use of the food
▪Who are the customers?
▪Who might misuse or abuse the product?
▪Ensure clear instructions on the label.
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Step 4: Construct Flow Diagram
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
▪A flow diagram is a graphical representation of the process steps involved in making the food product and is developed by the HACCP team. It should be comprehensive and cover all the steps in the processes and the defined scope of the HACCP study.
Fresh Fish Flow Diagram Example
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Receiving*
Storage*Scale
HeadWash
Fillet
Skin
RinseFillet/
Candle/ Bone*
Weight/ Pack/ Label
Refrigerated Storage*
Shipping
* Denotes that one or more CCPs have been identified
Step 5: Verification of Flow Diagram
▪After the flow diagram has been drawn up, the multidisciplinary team should confirm it on site during operating hours.
▪Any observed deviation must result in an amendment of the original flow diagram to make it accurate.
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
7 Principles of HACCP
Conduct A Hazard Analysis
1
Determine The Critical Control Points (CCPs)
2
Establish Critical Limits
3
Establish Monitoring Procedures
4
Establish Corrective Actions
5
Establish Verification Procedures
6
Establish Record keeping and Documentation
Procedures 7
Step 6: Conduct a Hazard Analysis-Principle 1▪ List all potential hazards associated with each step
▪Conduct a hazard analysis
▪Determine whether there are hazards that are reasonably likely to occur
▪Identify preventive measures to control the identified hazards
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Potential HazardsHazard: A biological, chemical or physical agent in, or condition of,food with a potential to cause an adverse health effect (Codex,2009b)
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Agents
▪Bacteria
▪Viruses
▪Moulds
▪Parasites
▪Toxins
▪Chemicals & Allergens
▪Foreign material
Adverse Health Effects
▪ Choking
▪ Vomiting
▪ Fever
▪ Kramps
▪ Chronic Infections
▪ Damage of Organs
▪ Cancer
▪ Death
Biological Hazards
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
▪Foodborne 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)
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Chemical Hazards
▪ Inorganic chemicals: arsenic, cadmium, lead, mercury, selenium, sulphites (used in shrimp processing)
▪ Organic compounds: polychlorinated biphenyls, dioxins, insecticides (chlorinated hydrocarbons). Thisis a very diverse group with a wide range of industrialusers. Unfortunately the chemical stability allow themto accumulate and persist in the environment
▪ Processing related compounds: nitrosamines and contaminants related to aquaculture (antibiotics, hormones).
Physical Hazards
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
▪ Physical hazards include any potentially harmful extraneous matter not normally found in food. The extraneous matter found in fish products can be divided or classified as:
▪ Non-food safety hazards (e.g. filth)▪ Food safety hazards (e.g. glass, metal, wood,
bones, stones, hard plastic).
▪ The Codex guidelines define a critical control point (CCP) as "a step at which control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level".
▪ The determination of a CCP in the HACCP system can be facilitated by the application of a decision tree such as that included in the Codex Hazard Analysis and Critical Control Point (HACCP) sys-tem and guidelines for its application which indicates a logical reasoning approach.
▪ The application of the decision tree should be flexible according to the type of operation (production, slaughter, processing, storage, distribution or other).
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Step 7: Determine Critical Control Points-Principle 2
Decision Tree
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Step 8: Establish Critical Limits For Each CCP Principle 3
▪Critical Limit is a criterion which separates acceptability from unacceptability.
▪Critical limits are criteria, which must be met if control is to be achieved. These are based on experience, regulations, literature searches, microbiological data, etc.
▪Targets set at each critical control point which guarantees to eliminate or reduce the hazard to a safe level
▪Critical limits can be values of : pH, temperature, time, Maximum residue limits, Maximum levels (of contaminants), Limits in microbiological criteria, Level of cleanliness, Levels of chlorine, overpressure etc.
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Step 9 : Establish a Monitoring System For Each CCPPrinciple 4
▪The Codex Hazard Analysis and Critical Control Point (HACCP) system and guidelines for its application defines monitoring as "the act of conducting a planned sequence of observations or measurements of control parameters to assess whether a CCP is under control".
▪To measure the performance level of the system's operation at the CCP (trend analysis)
▪To determine when the performance level of the system results in a loss of control at the CCP, e.g. when there is deviation from a critical limit
▪To establish records that reflect the performance level of the system's operation at the CCP to comply with the HACCP plan
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Monitoring Document Example
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Critical Control Point
Monitoring Step Monitoring Frequency
Critical Limits Action on Deviation
Storage Temperature Verify required storage temperature is met. Prior to production start and in afternoon
Maintain products between 0 0C and 3 0C
When internal temperature exceeds 3 0C,product is culled by a supervisor for decomposition
Multiple Use of Storage Area
Confirm Processed and raw fish are separated by a divider.Confirm that no chemicals or cleaners are in storage unit.
Daily No mixing processed and raw fish products.No chemicals or cleaners in storage unit.
Confirm if stored product is contaminated and cull as required.Remove chemical/cleaners. Check product for contamination.
Product Inspection Inspect each lot for decomposition and required identification.Confirm proper icing of unprocessed fish.
Each Monday and Thursday
Each lot to be adequately identified (receipt date or production date and source).All unprocessed fish to be layered and covered with ice.
Assign lot identity.Re-ice products when required.
Rotation of Stock All product is checked determine length or storage.Confirm stock (raw and finished) is rotated on a first –in first- out basic.
Weekly Use dressed fish for production within 5 days.Ship finished product within 3 days.Rotation system is adhered to.
Ensure passed product is immediately processed or shipped.Modify rotation system.
Notify supplier for all noted deviations.All corrective actions to be recorded and signed by supervisor.
Step: Product and Refrigerated Storage FRESH FISH
Step 10 : Establish Corrective Actions- Principle 5▪The Codex Hazard Analysis and Critical Control Point (HACCP) system and guidelines for its application defines corrective action as "any action to be taken when the results of monitoring at the CCP indicate a loss of control".
▪For each CCP, corrective actions have to be planned in advance by the HACCP team, so that they can be taken without hesitation when monitoring indicates a deviation from the critical limit.
▪Corrective actions should ensure that only safe products reach the consumer
▪Actions to be taken when the results of monitoring at the CCP indicate a loss of control
▪Corrective action procedure include; deviation, identification deviation, isolated of affected products, evaluation of affected products and all procedure records.
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Step 11 : Establish Verification Procedure –Principle 6
▪Verification procedures are intended to check the effectiveness of the HACCP system
▪The HACCP team should specify the methods and procedures to be used for determining if the HACCP is working correctly.
▪Methods for verification may include in particular:▪ random sampling and analysis
▪ reinforced analysis or tests at selected critical points
▪ intensified analysis of intermediate or final products
▪ surveys on actual condition during storage, distribution and sale and on actual use of the product
▪Verification procedures include;▪ HACCP plan validation
▪ HACCP system audits
▪ Equipment calibration
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Example Verification Procedures
Verification Procedures Minimum Frequency
Verification schedule Annually
Prerequisite program verification In the beginning and annually thereafter
Validation of critical limits and HACCP system Before and during HACCP system implementation
Revalidation of HACCP plan Annually or upon significant change
Observation and interview of CCP monitor Quarterly/monitor/CCP
CCP monitoring record review Daily
Equipment calibration According to HACCP plan
Others records review Monthly
HACCP system verification Annually
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Step 12: Establish Documentation and Record Keeping – Principle 7
▪Four types of records should be kept as part of the HACCP programme:▪ Support documentation for developing the HACCP plan
▪ Records generated by the HACCP system
▪ Documentation of methods and procedures used
▪ Records of employee training programmes
▪HACCP system records are kept to demonstrate adherence of the HACCP system with the HACCP plan. These records are used to demonstrate control at CCPs in the food process. The records generated by the HACCP system include all activities and documentation required by the plan, as follows.▪ Monitoring records for all CCPs
▪ Deviation and corrective action records
▪ Verification/validation records
▪ Training records
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Step 12: Establish Documentation and Record Keeping – Principle 7
▪ Efficient and accurate record keeping is essential to the application of a 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: ▪ Parasite Control Form
▪ Packaging Control Form
▪ Metal Dedector Control Form
▪ Record examples are: ▪ CCP monitoring activities;
▪ Deviations and associated corrective actions;
▪ Modifications to the HACCP system
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Prerequisite ProgramsPrerequisite Program: A programme that is required prior to the application of the HACCP system to ensure that a fish and shellfish processing facility is operating according to the Codex Principles of Food Hygiene, the appropriate Code of Practice and appropriate food safety legislation.
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
Prerequisite Programs▪The application of HACCP does not stand alone in a food processing facility. The plan must be built on other food safety programs.
▪Sanitation standard operating procedures (SSOPs)▪ Good Manufacturing Practices (GMP)
▪ Sanitation
▪ Personal hygiene
▪ Employee training
▪ Recall procedure
▪ Supplier Control
▪ Chemical Control
▪ Receiving, Storage and Shipping
▪ Pest control
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY
REGIONAL WORKSHOP ON “POST-HARVEST MARKET MEASURES, RULES AND STANDARDS FOR SAFE AND QUALITY FISH AND FISH PRODUCTS” 12-13 NOVEMBER 2019 ISTANBUL-TURKEY