FEDIAF Code of Practicefor the Manufacture of Safe Pet Food

TRAINING PACKAGEModule III

Hazard Analysis and Critical Control Points

Food Safety Management System

CI

Reviewmeasure

HACCP

Food safety management Prerequisites (GMP)

Food Safety Management System

Food safety management system consists of a prerequisite programme and a HACCP system

Components of the system:

Senior management commitment

Implemented within the quality management system

HACCP team leader and personnel trained and skilled

Specific to the application, practical and effective

Reviewed regularly and validated

CCPs identified, controlled, monitored and recorded

3. HACCP

Hazard Analysis and Critical Control Points is a technique that identifies, evaluates and controls hazards significant for food safety

What is HACCP?

A biological, chemical or physical agent in, orcondition of, food or feed with the potential to

cause an adverse health effect

What is a hazard?

Assurance that, when eaten according to its intended use, the pet food will not harm the animal

What is pet food safety?

Examples of food borne hazards

Bacteria:Aeromonas, Clostridium perfrigens,

Clostridium botulinum, Campyloabcter, pathogenic E.coli, Listeria monocytogenes,

Salmonella, Staphylococcus aureus…

Viruses:Hepatitis A, Rotavirus, Norwalk-like viruses…

Parasites:Trichinella spiralis, Taenia,

Fasciola hepatica…Chemicals:PCBs, Dioxins, Heavy metals,Pesticides, Veterinary Drugs,

Mycotoxins, Toxins…

Physical:Metal, Glass…

HACCP principles

Step 0 Implement Pre-requisite Programmes

Principle 1

Conduct a hazard analysis Assemble HACCP TeamDescribe productIdentify intended useConstruct Flow diagramConfirm flow diagram on siteList all potential hazardsConduct a hazard analysisConsider control measures

Principle 2Determine the Critical Control Points (CCPs)

Use decision tree to determine CCPs

Principle 3 Establish critical limits Establish action and critical limits for each CCP

Principle 4Establish CCP monitoring procedures

Establish monitoring systems for each CCP

Principle 5Establish corrective action plans

Establish the corrective action to be taken when monitoring indicates that a particular CCP is not under control

Principle 6Establish verification procedures

Establish procedures for verification to confirm that the HACCP system is working effectively

Principle 7Establish documentation and recordkeeping systems

Establish documentation concerning all procedures and records appropriate to these principles and their application

HACCP study

Risk assessment to identify hazards:

Occurrence/severity of hazards and adverse effects

Qualify/quantify hazards

Micro-organisms growth

Toxins, chemicals or physical agents

Conditions leading to the above

Probability of causing an adverse health effect caused by the occurrence and severity of a hazard in food

What is a risk?

Clostridium botulinum

Ex.: decision tree to identify CCPs

Preventative control measures exist?

Modify steps in process

Is control necessary?

Not a CCP

Is the step designed to eliminate or reduce the likely occurrence of a hazard to an acceptable level?

Stop*

Contamination occurs with identified hazard(s) in excess of acceptable

level(s)?

Not a CCP

Elimination of identified hazard(s) or reduction to acceptable levels?

Critical Control Point

Stop*

Not a CCP

Yes

Q1

Yes

No

No

Yes

No

No

Yes

Yes No

Stop*

Q4

Q3

Q2

Point, step or procedure at which control can be applied and is essential to prevent or eliminate hazards or reduce it to an acceptable level

HACCP examples: wet pet food

Critical Control Point Hazard to be controlled Typical Control Method

Receiving raw materialsconform spec.

Incorrect or contaminated raw materials Supplier Assurance + inspection

Metal detection Metal contamination (e.g. fish hooks) Permanent magnets, electric metal

Seaming / Sealing Re-contamination by pathogens Seam / seal control

Sterilisation Microbial growth due to under-sterilisation(Fc0 < 3)

Monitoring Time and Temperature

Cooling Re-contamination of pathogens due tocontaminated cooling water

Monitoring free and active Chlorine incooling water

HACCP examples: semi-moist

Critical Control Point Hazard to be controlled Typical Control Method

Receiving raw materials conform spec.

Incorrect or contaminated raw materials Supplier Assurance + inspection

Addition of preservatives Pathogen growth Monitoring / inspection

Processing Pathogen or mould growth (due to high Aw)

Aw Monitoring, monitoring of the right recipe

Filling Microbial growth due to condensation (high filling temp.) + risk moulding

Monitoring / inspection filling temp. and external temp.

Metal detection Metal contamination Electric metal detection device

HACCP examples: dry pet food

Critical Control Point Hazard to be controlled Typical Control Method

Receiving raw materials conform spec.

Incorrect or contaminated raw materials Supplier Assurance + inspection

Extrusion/ press Pathogen growth Control of temp/time or Monitoring density as a indicator of the cooking step

Processing Pathogen or mould growth (high Aw) Monitoring Aw, moisture,

Filling Microbial growth due to condensation Monitoring / inspection filling temp. and ambient temperature

Metal detection Metal contamination Permanent magnets (only Ferrous), electric metal detection device

Storage of product Pathogen or mould growth Warehouse assurance program

HACCP examples: chews

Critical Control Point Hazard to be controlled Typical Control Method

Receiving raw materials conform spec.

Incorrect or contaminated raw materials Supplier Assurance + inspection

Storage of raw Materials conform spec.

Deteriorated raw materials Stocking silo assurance programme and inspections

Dosing and mixing of ingredients

Incorrect proportion of ingredients and additives

Calibration and capability assessment of dosing and mixing

Processing Growth of Pathogenic bacteria in process (e.g. Salmonella due to Aw, time and temp., cross contamination)

Monitoring / inspection, shelf-life control

Bag Filling Condensation (high filling temp.) Monitoring / inspection filling temp.

Metal detection Metal contamination Permanent magnets, electric metal detection device

HACCP examples: frozen

Critical Control Point Hazard to be controlled Control Method

Receiving raw materials conform spec.

Incorrect or contaminated raw materials Supplier assurance + inspection

Processing Growth of pathogenic bacteria (Salmonella due to AW, time and temp., cross contamination)

Monitoring / inspection,

Metal detection Metal contamination Permanent magnets (only Ferrous, electric metal detection device

Cooling / Freezing Microbiological ingress during cooling Monitor airflow/temperature

Storage, transport, including point of sales

Contamination or deterioration Warehouse assurance and inspection, temp. monitoring

HACCP examples: fresh / chilled

Critical Control Point Hazard to be controlled Control Method

Receiving raw materials conform spec.

Incorrect or contaminated raw materials Supplier Assurance + inspection

Processing Growth of pathogenic bacteria in process (Salmonella due to AW ,time and temp., cross contamination)

Monitoring / inspection,

Metal detection Metal contamination Permanent magnets (only Ferrous), electric metal detection device

Cooling / Chilling Microbiological ingress during cooling Monitor airflow/temperature

Storage, transport, including point of sales

Contamination or deterioration Warehouse assurance and inspection, temp. monitoring , shelf life control