Introduction to HACCP for the Agri Feed/ Food Supply chain

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1 April 2016

2 Contents 1 What is HACCP? HACCP History HACCP in the Agri Feed/ Food Supply Chain today HACCP Principles The Steps in the HACCP Process How HACCP can help Agri Feed/ Food businesses?... 5 AIC 2016 All rights reserved. No part of this publication may be reproduced or transmitted in any material form or by any means, mechanical, electronic, photocopying, recording or otherwise, or stored in any retrieval system of any nature, without the written permission of the copyright owner except in accordance with the provisions of the Copyright, Designs and Patents Act WARNING: The doing of an unauthorised act in relation to copyright may result in both a civil claim for damages and a criminal prosecution. AIC and its officers, employees, agents and subcontractors accept no liability whether in contract, tort (including negligence), breach of statutory duty or otherwise for any loss (including indirect or consequential losses) by a participant or other third party arising under or in connection with the scheme and its administration. Page 1 AIC April 2016 Edition 1

3 1 What is HACCP? Hazard Analysis and Critical Control Points (HACCP) is a system that was devised to identify, evaluate and control hazards that are significant for food safety. The aim of this introduction is to help companies to understand and implement effective HACCP in the Agri Feed/ Food supply chain. Additional AIC Guidance documents will cover in more detail key aspects of the HACCP process. 1.1 HACCP History Hazard Analysis and Critical Control Points (HACCP) is a methodology jointly developed during the 1960s by the Pillsbury Company, the United States Army Laboratories and the National Aeronautics and Space Administration (NASA) to ensure that foods provided to astronauts would not cause illness. Product testing alone was not a practical solution as this would be destructive and so not necessarily represent the food taken into space. It was clear to those involved that the focus needed to be on identification of what could go wrong (Hazards in HACCP-speak) and what needed to be done to manage them (Control Measures). Today HACCP is used globally to assess potential food safety hazards and is the recommended food safety methodology of the World Health Organisation. Whilst it is a requirement of food and feed regulations and certification standards in Europe and throughout the world many food and feed companies have found that HACCP can deliver real benefits, both financial and otherwise, to their businesses. In particular, the management of commercial risk is a significant benefit of an effective HACCP system. 1.2 HACCP in the Agri Feed/ Food Supply Chain today In its original form, HACCP was concerned solely with food safety and only with food intended for human consumption. The thought processes behind HACCP can be applied to a much wider range of hazards. In Europe most feed businesses are required by the Feed Hygiene Regulation (EC) No. 183/2005 to put in place, implement and maintain, a permanent written procedure or procedures based on the HACCP principle. AIC HACCP Guidance is intended to help companies use HACCP principles to develop practical and beneficial systems to manage risks to the business, and as such consider wider issues that may not strictly be hazardous, but are of critical interest to the industry. Consequently references in this Guide to HACCP should be interpreted as meaning HACCP principles as described in Codex Alimentarius 1 and HACCP methodology rather than pure HACCP. 1 The Codex Alimentarius Commission is a joint FAO/ WHO body which drafts guidance documents related to food safety. Page 2 AIC April 2016 Edition 1

4 1.3 HACCP Principles The Codex seven principles of HACCP (CAC/RCP , rev ) are reproduced below, with the wording from Feed Hygiene Regulation (EC) No. 183/2005 in brackets where it differs and offers additional explanation: Conduct a hazard analysis. (identify any hazards that must be prevented, eliminated or reduced to acceptable levels); Determine the Critical Control Points (CCPs). (identify the critical control points at the step or steps at which control is essential to prevent or eliminate a hazard or reduce it to acceptable levels); Establish critical limit(s). (establish critical limits at critical control points which separate acceptability from unacceptability, for the prevention, elimination or reduction of identified hazards); Establish a system to monitor control of the CCP. (establish and implement effective monitoring procedures at critical control points); Establish the corrective action to be taken when monitoring indicates that a particular CCP is not under control; Establish procedures for verification to confirm that the HACCP system is working effectively. (establish procedures to verify that the measures outlined in points [above] are complete and working effectively. Verification procedures shall be carried out regularly); Establish documentation concerning all procedures and records appropriate to these principles and their application. (establish documents and records commensurate with the nature and size of the feed businesses to demonstrate the effective application of the measures set out in points [above]) Page 3 AIC April 2016 Edition 1

5 1.4 The Steps in the HACCP Process Most HACCP guides then go on to extend the Codex principles into a number of steps or stages which need to be followed. Codex identifies 12 steps, but others identify more, notably Campden BRI in their Guideline 42 HACCP: a practical guide identify 14 stages, with some of those being broken down into sub-steps. AIC will use an adapted version of the Campden BRI stages, which will be expanded upon in further guidance documents in this series. Stage 1 Senior Management Responsibility Stage 2 Define the scope of the study and terms of reference Stage 3 Select the HACCP team Stage 4 Describe the product and process Stage 15: Establish documentation and record keeping Stage 5 Stage 6 Stage 7 Stage 8.1 Stage 8.2 Stage 8.3 Stage 9 Stage 10 Stage 11 Stage 12 Identify the intended use of the product Construct a process flow diagram On-site confirmation of the process flow diagram List all potential hazards associated with each process step Conduct a hazard analysis Consider appropriate measures to control the identified hazards Determine the CCPs (if any) Establish critical limits for the control measures at each CCP Establish a monitoring system at each CCP Establish a corrective action plan for each CCP Stage 14.1: Perform validation activities Stage 13 Communication of HACCP requirements Stage 14.2 Perform verification activities Stage 14.3 Perform review activities Key: Preparatory Stages HACCP Study Implementation, Review and Maintenance Page 4 AIC April 2016 Edition 1

6 2 How HACCP can help Agri Feed/ Food businesses? Very few existing HACCP guides and courses address how HACCP can be applied to Agri Feed/ Food businesses. This is often due to the syllabus of formal examinations focussing on higher risk food activities such as producing ready to eat cooked foods and catering. The Agri Feed/ Food supply chain, in many ways, can be seen as a lower risk industry, but the nature of the hazards encountered can be more diverse and complex than those in food processing. For example, the Agri Feed/ Food business needs to consider hazards in relation to a more diverse group of consumers. The business must consider: Hazards which affect the safety of food produced by/ from the livestock Hazards which directly affect the health of the livestock This second situation is complicated further because: A hazard may vary in its effect on different animal species The distinction between safety and quality in the feed context is not as clear as with food. A quality issue such as rancid oil leading to palatability issues can rapidly progress to an animal performance problem, and then on to animal welfare and ultimately animal health concerns, due to the lack of an alternative food source for the livestock. By having a clearly defined process for identifying hazards and to which consumers they represent a risk an Agri Feed/ Food business can ensure that resources can be focused where they are most needed and maximise food and feed safety. Page 5 AIC April 2016 Edition 1

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