Fish Microbiology and Quality Assurance (2+2)

Unit 9 - Assurance and management quality of fish

9.2.5. Hazard Analysis and Critical Control Points (HACCP)
The foods preserved for human consumption should be free from infectious organisms. Application of good manufacturing practices often fails to ensure zero tolerance required for many pathogenic microorganisms. The classical approach to microbiological quality control has relied heavily on determination of microbiological parameter of both raw material and product. This requires too long time for getting results, offers no control over the process and often foods fail to meet quality standards. Thus, there is a need for fool proof approaches to ensure production of safe products. The newer approach for ensuring product quality is through the adoption of HACCP concept as a method of choice for ensuring the safety of foods from farm to table.

What is HACCP?
HACCP is a statement of prevention system of controls based on hazard analysis and critical control point. HACCP involves application of more systematic rule based approach for ensuring production of microbiologically safe food.

Hazard analysis
Hazard analysis involves identification of ingredients and products which might have pronounced effect on food safety. Hazards include any biological, chemical and physical property that might cause unacceptable consumer health risk due to contaminants, toxins, microorganisms etc.

HACCP was originally developed by Pillsbury Company to produce zero defect food for astronauts of NASA in USA. Since 1973, it has been adopted in food industry to produce quality food by identifying stages of hazards and applying control points to reduce /eliminate hazards. HACCP has been recommended by Codex Alimentarius and has become international reference system for food safety assurance.

Critical control point (CCP)
Any point or procedure in a food processing system where control can be exercised and hazard can be minimized or prevented. Therefore, loss of control over processing parameters would result in unacceptable risk to consumers.

Principles of HACCP
HACCP as a natural and systematic approach to food safety is based on seven basic principles. These include,

• Conducting hazard analysis.
• Determining critical control points.
• Establishing critical limit.
• Establishing monitoring procedures.
• Establishing corrective actions.
• Establishing verification procedures.
• Establishing record keeping and documentation procedures.

Conducting hazard analysis
This involves assessing hazards and risks associated with growing, harvesting, raw material, ingredients, processing, distribution, marketing, preparation and consumption of food in question. It helps to determine hazard which could pose threat to the safety of those consuming the product. Hence, hazards must be controlled by production process.

Determining critical control points
CCPs are identified after hazards are analyzed. This involves identifying potential hazards and their occurrence in process line (where they occur), and measures to control them. CCP is defined as a location, step or procedure at which some degree of control can be exercised over a microbial hazard threby the hazard can be prevented, eliminated or reduced to acceptable levels. Loss of control at CCP would result in an unacceptable risk to the consumer or product.
Ex: Raw material as CCP – if it contains microbial hazard, subsequent processing will not guarantee its control. Procedures like cooking, chilling, freezing, cleaning, disinfection etc could be CCPs.

Establishing critical limits
A critical limit is one or more prescribed tolerances that must be met to ensure that a CCP effectively controls a microbiological hazard. The critical limits (with tolerance limits where appropriate) established should include parameters such as,
Physical parameters such as temperature, humidity, quantity of material in a package, can seam dimensions etc.
Chemical parameters such as pH in acidified foods, aw of IMF, salt concentration, available chlorine in cooling water for cans, level of preservatives etc.
Sensory information such as appearance, texture, odour etc.
Management factors such as correct labeling of product, instruction of handling and use etc.

Establishing monitoring procedures
Monitoring of CCPs involve the scheduled testing or observation of a CCP and its limits. This helps to confirm and record that the control is maintained on CCPs. But, only such parameters which are easy and quick to measure and results can be obtained immediately should be considered to monitor CCPs. Example: physical and chemical parameters such as temperature, time, pH, aw etc.
Microbiological parameters are not generally suitable as long time is required to obtain results. Proper records should be kept on the performance of CCPs. This will help in process verification, analyse trends which could lead to loss of process control and to take easy remedial measures.

Establishing corrective actions
This involves establishing corrective actions whenever deviations occur in CCP monitoring. Actions taken must eliminate hazard created by deviation in plan/process. If product produced is unsafe due to deviation in process, such products should be removed. The actions taken variws widely depending on the product being processed, and action taken must bring the CCPs under control.

Establishing procedures for verification
This involves establishing procedures for verification that the HACCP system is working correctly. Verification consists of methods, procedures and tests used to determine that the system is in compliance with the plan. Verification confirms hazards in HACCP system whenever occurs. Verification measures include compliance with set established microbiological criteria. Verification activates generally include establishment of verification inspection schedule, review of HACCP plan, CCP records and deviations, random sample collection and analysis etc.

Establishing effective record keeping system
Establishing effective record keeping system is necessary to document the HACCP plan. The HACCP plan must be on file at the food establishment and made available to official inspectors. For recording and documentation, standard forms may be used with necessary modification. Record keeping should provide documentation for all raw material, ingredients, processing steps, packaging, storage and distribution.