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FDE101 INTRODUCTION TO FOOD ENGINEERING
FoodSafetyDr.IlgınYıkıcı
Food safety
Defined as: “the assurance that food will not cause harm to the consumer when it is prepared and eaten according to its intended use”
It is a fundamental requirement of any food process that the product should be safe for human consumption.
Food quality
“the combination of attributes or characteristics of a product that have significance in determining the degree of acceptability of the product to a user”
Scope of food quality
and food safety
The term “food” covers any unprocessed, semi-processed, or processed item that is intended to be used as food or drink.
• Any ingredient incorporated into a food or drink
• Any substance that comes into direct contact with a food during processing, preparation, or treatment
Scope of food quality and food safety
Food quality and food safety principles &
practices
Farm produce
Contact surfaces
Packaging materials
Processingaids
Ingredients
Raw materials
Processedfood products
Livestock
Responsibility for food quality and food safety
Shared by all segments of the food system
Food industry
ConsumersGovernment
Both legal and moral responsibility to provide foods that meet all established quality and safety requirements
•Food laws and regulations
•Regulatory agencies
•Need to be careful in their assessment of foodsfor safety and quality•Must pay attention tothe instructions forhandling, storage,preparation, and use offoods
Distinctionbetween
food quality and food
safety
Food quality: the extent to which all the establishedrequirements relating to the characteristics of a food are met
Food safety: the extent towhich those requirementsrelating specifically to characteristics or propertiesthat have the potential to beharmful to health or to cause illness or injury are met
Distinctionbetween
food quality and food
safety
A food that does not conform tothe food safety requirementsautomatically does not conformto the food qualityrequirements.
On the other hand, a food can conform to the food safety requirements, but not conformto the other food quality requirements.
quality
safety
Food safety The assurance that a food will not cause harm, injury, or illness is determined by:
• whether all harmful substances present in the food have been eliminated, reduced to an established acceptable level, or prevented from exceeding the acceptable level
• whether the food has been prepared, handled, and stored under controlled and sanitary conditions.
Food safety Key elements to ensure that food safety is achieved in food manufacture:
• safe design of the process, recipe and packaging format
• prerequisite programs or good manufacturing practice to control the manufacturing environment
• use of the Hazard Analysis and Critical Control Points (HACCP)system of food safety management
Total food safety
Safe product design HACCPPrerequisite programmes
•Understanding hazards•Intrinsic factors•Process and packaging knowledge
•HACCP study•HACCP plan•HACCP team
•Facility design•Operational hygiene control•Maintenance and sanitation•Personal hygiene•Transportation•Training•Product information/Consumer awareness
Safe product design
Effective HACCP systems and prerequisite programs will manage and control food safety, but they cannot make safe a fundamentallyunsafe product.
Criteriainvolved in
designingand
manufacturing a safe
product
• Understanding the food safety hazards that may be presentedthrough the ingredients,processing and handling methods
• Intrinsic factors involved in developing a safe recipe
• Knowledge of the chosen food processing and packaging technologies
• Manufacturing in a facility operating with prerequisite good manufacturing practice systems
Food safety hazards
Definition: any substance that is reasonably likely to causeharm, injury or illness, when present above anestablished acceptable level
• Biological hazards
• Chemical hazards
• Physical hazards
• Allergens
Possible Hazards in
Foods
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Food safety hazards
The origin of these hazards in foods can be:
• naturally occurring substances or agents in foods
• deterioration or decomposition of foods
• contamination of foods at various stages of their harvesting, storing, processing, and distribution
Biological hazards in
foods• Pathogenic bacteria
• Viruses
• Parasites
Biological hazards in
foods
Pathogenic bacteria
More than 40 different pathogenicbacteria are
known.
– Salmonella spp.
– Eschericha coli 0157:H7
– Lysteria monocytogenes
– Clostridium perfringens
– Clostridium botulinum
– Staphylococcus aureus
– Campylobacter jejeuni
Biological hazards in
foods
Viruses
• HepatitisA and E viruses
• The Norwalk group viruses
• Rotavirus
Parasites
• Parasitic protozoan species
• Parasitic worms (taenia, trichinella)
Biological hazards in
foods
Foods that are commonly involved in food
poisoning incidents:
• Meat and poultry and their products
• Seafood and seafood products
• Egg and egg products
• Milk and dairy products
• Fruits and vegetables and their products
• Low-acid canned foods
• Water
Biological hazards in
foods
• Numerous severe and fatal illnessesoccur as a result of food poisoning from pathogenic bacteria.
• Infants and the elderly are particularly vulnerable.
Chemical hazards in
foods
• Permitted food additives
• Naturally occurring harmful compounds
• Unavoidable contaminants
• Agricultural residues
• Industrial contaminants
• Chemical residues
• Food allergens
Chemical hazards in
foods
Permitted food additives
• Specified maximum levels
• Although food additives are permitted by government regulations, many can be harmful if they are present in thefood at levels above the maximum established.
Chemical hazards in
foods
• A permitted food additive presentbelow the maximum allowable level in a food can be a health hazard for specific segments of the population.
– Sodium bisulfite for asthma patients
– Must be clearly labeled
Chemical hazards in
foods
Naturally occurring harmful compounds
• Naturally occurring substances that can be harmful when present in excess of certain levels
– Toxins in mushrooms and in shellfish
Unavoidable contaminants
• Cannot be removed through processing or manufacturing practices
– Aflatoxins from molds in peanuts and in some cereals
Chemical hazards in
foods
Agricultural residues
• Pesticides
• Herbicides
• Fungicides
• Drugs
• Hormones
• Antibiotics
Chemical hazards in
foods
Industrial contaminants
• Harmful chemicals that enter theenvironment as a result of industrialactivity
– heavy metals à lead, mercury, arsenic
– organo-chlorinated compounds àpolychlorinated biphenyls (PCBs)
Chemical hazards in
foods
Chemical residues
• Non-permitted chemicals used in food processing operations
– chemical compounds used for cleaning and sanitizing food contact surfaces
Food allergens
• inherent components that cause seriousallergic responses in a relatively small proportion of consumers
– peanut, soybean, milk, egg, fish, crustacea, tree nuts, wheat
Physical hazards in foods
• Broken glass
• Pieces of hard or soft plastic materials
• Stones
• Pieces of metal
• Pieces of wood
• Personal articles
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Understanding hazards
• No food is completely risk-free. The acceptability of each risk will depend on a number of factors, including the alternatives available, cost, benefit, and size of the actual risk.
• It is the job of government and industry to ensure that these risks are minimal and acceptable.
• Risks from processed foods can be reduced through use of good manufacturing practices and careful analysis of the most important steps in processing. à “ hazard analysis on critical control points” or HACCP.
Understanding hazards
At the product design stage, it is important to understand the possible hazards to identify the best ways to control these hazards.
• Preventing their entry to the process,
• destroying them, or
• reducing the contamination to an acceptable level
Understanding hazards
Consideration of the possible hazards at the product design stage can help to keep these hazards out of the product.
• careful choice and sourcing of ingredients
– Salmonella from eggs à pasteurized eggs
• identification of appropriate processing technologies and/or equipment
– Physical hazards due to open vessels àredesign the equipment to use closed vessels
Controlling intrinsic
factors affecting
safety
Intrinsic factors: The formulation
criteria that control the ability of microorganisms to survive and grow in foods
• water activity
• pH
• organic acids
• preservatives
Food processing
technologies for safety
It is important for food safety that the chosen food process is thoroughly understood so that any potential food safety hazards can be effectively controlled.
• to control microbiological hazards
– pasteurization, UHT sterilization, salt/sugar preservation, irradiation
• to remove physical hazards
– cleaning, filtration
Food packaging
considerationsfor safety
Food packaging systems prevent contamination and ensure achievement of desired shelf life;
however, there may be hazard considerations if
the packaging system is inappropriate to the type
of food or proposed storage conditions.
– Cans à hygienic container, but degradation and leaching of metal into the product must be prevented.
– Glass à hygienic container, but breakage must be prevented.
Effects of food processing on food safety hazards
Processing operation
Intended effecton food safety hazards
Example food types
Dry cleaning Removal of foreign material and dust
Grain crops
Wet cleaning Reduction in level of microorganismsand foreign material
Raw foods, e.g. vegetables,fruit, dried fruit
Pasteurization/Cooking
Destroys vegetative pathogens,e.g. Salmonella spp, Listeria monocytogenes
Milk products, meat, fish,ready meals
Effects of food processing on food safety hazards
Processing operation
Intended effecton food safety hazards
Example food types
UHT/asepticsterilization
Destroys pathogens and prevents recontamination in packaging system
UHT milk, fruit juices
Canning Destroys pathogens Canned meats, soups, petfood, etc.
Drying Halts growth of pathogenic bacteria at aw 0.84, allmicroorganisms at aw 0.60
Various foodstuffs, e.g. dried fruit, milk powder, cake mixes,etc.
Effects of food processing on food safety hazards
Processing operation
Intended effecton food safety hazards
Example food types
Salt preserving
Halts growth of pathogenic bacteria at aw 0.84, all microorganisms at aw 0.60; growth of many microorganisms halted at ca. 10% salt
Fish, meats, vegetables
Sugar preserving
Halts growth of pathogenicbacteria at aw 0.84, all microorganismsat aw 0.60
Jam, fruits, syrups, jellies,confectionery
Effects of food processing on food safety hazards
Processing operation
Intended effecton food safety hazards
Example food types
Chilling (< 5 oC)
Slows or prevents growth ofmost pathogens
Cooked meats, dairy products,fruit juices
Freezing (at least – 10 oC)
Prevents growth of all microorganisms.Destroys some parasites.
Many foodstuffs, e.g. fruit, vegetables, meat, fish, ice cream, etc.
Safe product design -Summary
• Consideration of food hazards
• Improvement of safety through manipulation of intrinsic factors
• Improvement of safety through proper food processing technologies
• Consideration of packaging
Prerequisite programs
Definition: practices and conditions needed prior to and during the implementation of HACCP and which are essential to food safety
HACCP is only one component of a food safety program. Without working conditions free from microbiological, chemical, and physical contamination, a HACCP plan cannot be effective.
Prerequisite programs
• Facilities and grounds
• Supplier control
• Specifications
• Production equipment
• Cleaning and sanitation
• Personal hygiene
• Training
• Chemical control
• Receiving, storage and shipping
• Traceability and recall
• Pest control
HACCP –Hazard
Analysis and
Critical Control
Point
• In the early 1960s, the Pillsbury Company was working with NASA to provide food for the American manned-space program.
• Until then, most food safety control systems had been based on end product testing, which would not give enough assurance of food safety for such an important mission.
à a system that looks at what can go wrong at each step in the process and provides a control to prevent the problem from occurring
HACCP principles
1. Conduct a hazard analysis. Hazard Analysis: the process of collecting and evaluating information on hazards and conditions leading to their presence, in order to decide which are significant for food safety
2. Determine the critical control points (CCPs). Critical control point (CCP): 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.
3. Establish critical limit(s). Critical limit: a criterion that separates acceptability from unacceptability.
4. Establish a system to monitor control of the CCP.
HACCP principles
5. Establish the corrective action to be taken when monitoring indicates that a particular CCP is not under control.Corrective action: any action to be taken when the results of monitoring at the CCP indicate a loss of control
6. Establish procedures for verification to confirm that the HACCP system is working effectively.
7. Establish documentation concerning all procedures.
Example of hazard analysis processProcess step Hazard and
source/causeSignificanthazard?(yes or no)
Control measure
Incomingraw milk
Presence of vegetativepathogens, e.g. Salmonella,due to contaminationfrom animal
Yes Control by pasteurisationstep in process
Pasteurisation Survival of vegetativepathogens, e.g. Salmonella,due to incorrect heat process
Yes Effective heat process(correct time/temperaturecombination)
CCP
decision
tree
