Prerequisite Requirements

of HACCP HACCP IS NOT A

STAND-
STAND-ALONE SYSTEM
B.K.Kolita Kamal Jinadasa,
Research officer, HACCP
Post harvest technology division, is one part of larger
NARA, Colombo-15, QUALITY
Sri Lanka MANAGEMENT/ASSURANCE
SYSTEM

Quality management system Prerequisite programs

• Product/ Food Safety • Not described in the original US National

– HACCP system Advisory Committee on Microbiological
• Product Quality criteria for Foods (NACMCF) or Codex
– Quality control system. HACCP guidelines.
• i.e. meeting buyer specifications, including legal
requirements
• Concept originated in 1993 Agriculture and
• Environmental/Operating condition Agri-Food Canada’s (AAFC) Food Safety
– Prerequisite requirements for HACCP Enhancement Program (ESEF).

Prerequisite Programs
5 6

AAFC/FSEP Definition: HACCP

• Universal steps or procedures PREREQUISITE PROGRAMS

• that control the operational conditions within a
food processing establishment
• allowing for environmental conditions that are
favorable to the production of safe food.
• Basically GMP and hygiene/ sanitation control Æ
basic requirements for all food industry
FOUNDATION OF AN
EFFECTIVE HACCP SYSTEM
• simpler yet more effective HACCP plans – easier to maintain and
manage
• Control potential hazards to becoming significant hazards
• reduce no. of CCPs - kept to true critical points
 Prerequisite Programs Prerequisite Programs
7 8

• Basically applications of GMP & hygiene/sanitation • Cross product line.

Control.

• Not part of the formal HACCP plan.

• Premises and facilities, equipment, sanitation and
hygiene.
• Managed separately rather than include
their performance and control as part of
• Others- personnel training, supplier control,
product traceability and recall, consumer the HACCP plan.
complaints, specification.

Prerequisite Programs
9

Prerequisite program HACCP Plan

• Simpler yet more effective – Deals indirectly with food safety Deals directly with food safety issues
issues – environmental/operating
– HACCP plans- easier to maintain and manage. conditions

More general and may be Product and line specific

• Control potential hazards from becoming applicable throughout the plant
crossing multiple product lines
significant hazards.
Deviations from prerequisite Deviations from a HACCP Plan critical
requirement will not result in a limit will result in a food safety
• Reduce no. of CCPs- food safety hazard or concern – hazard and action against the product
non-critical
– Kept to true critical points.
In other word:
• Ensuring that food is safe and wholesome
• But may not be enough to control business-specific food safety
hazard

Prerequisite programs should be:

Equipments

Premises Personnel • Documented with written SOPs.

training
Prerequisite program • Monitored with proper record to ensure
should cover: effectiveness

Recall Sanitation • Reviewed and revised

– periodically to ensure relevance
Receiving/
storage/
transport
 Premises Premises
• Plant location, construction and layout.
• Construction & layout
• To protect food from unsanitary – Separation of operations.
conditions and cross contamination. – Product flow patterns.
– Adequate working space.
• Location – Lighting.
– Adequate plot size. – Ventilation
– Easy access. – Building materials.
– Pollution risk form surrounding
• Smoke, dust, odors, airborne microbes

Facilities
Premises =
Structural Operating Environment
• Adequate supply of energy/power.
Poorly designed, constructed and maintained food • Adequate supply of potable cold water, hot
premises will
water and steam must be available for
increase the chance of food becoming contaminated cleaning & sanitation when necessary.
Cover:
• Proper plant layout (hygienic design) • A suitable water treatment system where
• Building material, wall and water covering appropriate (chlorination plant, waste
• Water quality
water treatment)
• Sanitary facilities

Facilities Equipment & Utensils

• Adequate sewage & waste disposal.

‰Design-
• Adequate facilities for washing and
disinfecting equipment. ‰Prevent contamination of product.
• Adequate staff amenities (hand washing ‰ prevent accumulation of food residues during
production.
facilities, toilets, staff rooms).
‰For accessibility and cleanability.
• Adequate sanitary plumbing (no cross ‰Durability.
concentration between portable & non ‰Easy maintain.
portable water lines) ‰Performance.
 Equipments & Utensils Personnel training
‰ Construction-
ƒ Staff must be trained to do their jobs competently
‰Food-safe materials e.g. processing skills, HACCP monitoring.
‰Non toxic.
‰Non absorbent ƒ Includes training in those prerequisite
‰Resistant to the product, cleaning and requirements for which they are responsible such
disinfecting agents. as personal hygiene, hygienic handling practices,
cleaning and sanitation.
‰Stainless steel and plastic.
‰ Maintenance- ƒ Training-
‰Schedule for servicing, replacement and ƒ Written training program and schedules.
calibration. ƒ Re-training.
ƒ Training records of personnel.
ƒ Competency testing.

Sanitation & Hygiene Cleaning and Sanitation

9Proper cleaning and sanitation will:
9Decrease the likelihood of food becoming
contaminated; and
9Discourage pests from the premises, vehicle
and/or vessels.
Remember: A dirty surface can not be sanitized!
‰Cleaning:
Removing waste, dirt and grease from
equipment, premise, vehicles and vessels
‰Sanitation:
Reducing the number of microorganisms to a
level that keep a food safe. Food contact
surfaces, equipment and utensils should be
sanitized.

Cleaning and Sanitation Cleaning and Sanitation

• Develop a written program or Sanitation • Cleaning and sanitation procedure and
Standard Operating Procedures (SSOP) schedule should be written and followed.

• FDA seafood HACCP Rule mandates 8 • A master sanitation schedule should be

sanitation area that must be monitored developed and rigorously applied to assure
and documented good housekeeping and minimize product
exposure to contaminants.
 Cleaning and Sanitation
• Written guidance should be developed for
personnel hygiene standards for plant
workers- include proper attire, hair, hand
washing and personnel health expectations.
• An environment sampling program may be
used to confirm the effectiveness of the
cleaning and sanitation program.
FDA 8 Keys sanitation areas
1. Safety of water- that comes into contact
with food or food contact surface, or is
used in the manufacture of ice.
2. Condition & cleanliness of food-contact
surfaces, include utensils, gloves and outer
garments.
3. Prevention of cross-contamination from
unsanitary object to food, food packaging
materials and other food contact surfaces,
including utensils, gloves and outer
garments, and from raw to cooked product.
FDA 8 Keys Sanitation areas
6. Proper labeling, storage and use of
toxic compound.
7.Control of employee health conditions
that could result in the microbiological
contamination of food, food packaging
material and food contact surface.
8. Exclusion of pests from the food plant
Sanitation standard operating
procedure (SSOP)
• Describe a particular set of objectives
associated with sanitary handling of food
and the cleanliness of the plant
environment and the activities conducted
to meat them.
• FDA seafood HACCP rule mandates 8
areas of sanitation that must be
monitored and documented.
FDA 8 Keys Sanitation areas
4. Maintenance of hand-washing, hand-
sanitizing and toilet facilities
5. Protection food, food packaging
materials and food contact surface from
adulteration with lubricant, fuel,
pesticides, cleaning compounds,
sanitizing agents, condensate and other
chemical, physical and biological
contaminants.
Pest control
• Pests such as rodents, birds, insects,
animals e.g. cats and dogs.
• Carriers of human disease agents.
 Pest control program
• Based on 3 principles;
Receiving/ storage/ transport
– Exclusion or preventing access-
• Windows screens, self-closing doors
– Restriction by avoiding to create an All raw materials and products should be stored
environment conducive to pests- under sanitary conditions and proper
• Elimination of harborage and attractant areas environmental conditions (temperature and
(rapid removal of waste).
humidity) to assure their safety and
– Destruction and eradication- wholesomeness
• Usually done by specialist company.

Other program
Recall Program
¾ An action plan which gives the company ability to recover or
retrieve product it has left the control of the company. • Food transport vehicle.
¾ Recall team, coordinator. • Fishing vessels.
• Supplier approval.
¾ Written recall/recover procedures.
• Food packaging.
¾ Minimize bad publicity, consumer complaints, criminal law • Product identification and labeling.
suit and damage to the company reputation

¾ Involves product identification and traceability (raw

materials, ingredients and finished products, distribution
records)
THANK YOU!!!