HACCP in temperature conrolled transport - Assignment Example

? HACCP IN TEMPERATURE CONROLLED TRANSPORT Department Introduction Hazard Analysis Critical Control Point (HACCP) is a preventive measure in food supply chain that Identify potential biological, chemical and physical hazards in the food production and distribution process and goes further to design preventive measures to eliminate or reduce these hazards to acceptable levels. In this regard, HACCP is a preventive measure rather than a corrective measure. Production and distribution of food involves a number of processes that are required to eliminate or prevent reintroduction of food hazards through post contamination. Activities during transportation are even critical because most food products leave the factories when several analyses have been done and food that meet the quality and safety parameters are released to the market. It is therefore important for food transporters to ensure no potential hazards are reintroduced in foods during transport. This principle forms the basis for implementation of HACCP system in a temperature controlled transport. Multidisciplinary approach is the key to successful implementation of HACCP system for temperature controlled transport. This approach should appropriately include: production, chemistry, food technology, engineering, microbiology, agronomy and public health expertise. Hazard Analysis Critical Control Point (HACCP) System is a food safety management system thus should allow transporters whether small or large to identify and manage all hazards that would pose danger to food during transportation. In this respect, it must identify what could go wrong, plan in prior to prevent it and implement the plans by doing what had been planned. In order to achieve this effectively, HACCP system applies seven principles in identification and controlling hazards during refrigerated food transport systems. The efficacy of this system is however dependent on the top management commitment and employees training and involvement on HACCP implementation. This paper focuses on HACCP for refrigerated food transportation. Application of HACCP Principles in Temperature Controlled Transport The application of Hazard Analysis critical Control Point (HACCP) in Temperature controlled transport involves the following activities. It is important to note that these are the key activities involved with regard to logical sequence of HACCP principles. HACCP Team Formation The development and maintenance of an effective HACCP system depends mainly on the management team. Assemblage of the HACCP team is the first stage in implementation. The team should consist of people and individuals with appropriate multidisciplinary expertise. HACCP team for temperature controlled transport must consists of expertise from engineering, food technology, production, logistics and transport, food microbiology, food chemistry, food packaging and storage, food toxicology and food quality assurance (Surak & Wilson 2007 p.8). The composition of HACCP team is very critical in identification of all potential hazards and putting the right control measures. However, if for example a transport company is not able to avail expertise from these disciplines, it is recommended that the company seeks for advice from independent experts. The HACCP team also plays a key role in identification of the scope which for this case is transport and storage of food thus hazards covered here would be within the scope. Product Description and the Intended Use The HACCP team should then describe the products in full and must include all relevant information about safety including physical, chemical and microbiological properties, composition, chemical structure such as water activity and pH, storage conditions and the expiry dates. A full description should also include any form of treatments such as brining, freezing, thermal treatment, smoking and the methods of storage and distribution. However, when the controlled temperature transport system caters for different products, this description can be made simpler by grouping different food products with similar characteristics. This is very common in temperature controlled transport for food products in catering operations. Full description of the product is important since it forms the basis for monitoring and maintaining the rightful characteristics of food during transport. The intended use of the product should clearly be identified by the HACCP team and should be based on the expected uses of the product. As stated by Surak & Wilson (2007 p.11), it may be necessary in certain specific cases to include the vulnerable groups such as feeding institutions or big populations of children. Flow Diagram HACCP team after describing the product being transported must the construct a flow diagram that covers all the steps and activities involved in the cold temperature transport for each specific product being transported. However, just like in the product description, the same flow diagram may be used for the products that are transported using the same steps and parameters. This is important because the application of HACCP depend greatly on the steps preceding specified operation (Gustafsson et al 2008, p. 55). Table 1: Process description Process Step Process description Step 1: Primary/ Secondary Food transport equipment selection and Preparation (CCP 1) Prepare primary, secondary food transport equipment and carriers by washing, rinsing, sanitizing the interior surfaces and ensure food carrier is designed to keep temperatures at 410 F. Ensure a calibrated thermometer is placed at the warmest part of the carrier and ensure the carrier is able to maintain the temperatures set. Record and maintain certificate of cleaning Step 2: Food Collection from factories or Primary stores Ensure food is packed in containers that are suitable for transportation and thus are closed tightly to maintain proper food temperatures. Ensure the packaging is easier to clean and there are no porous packages to avoid leakages. Load packed food into transporting carrier according to the standard operating procedures Step 3: Primary Food Transportation (CCP 2) Food can be transported directly to delivery carriers or can be transported to secondary transportation system used mainly for bulk transportation Step 4: Transfer to Secondary transport equipment All primary transportations are transferred to a larger transport equipment Step 5: Food delivery to consumers or secondary storage facilities (CCP 3) Food in secondary transporting equipment is delivered to consumers or secondary storage locations under temperature controlled at 410 F Chart 1: Process Flow Chart Conduct Hazard Analysis HACCP team should list all the potential hazards that may be associated with each step in temperature controlled transportation. This would depend on the scope covered under HACCP system and include transportation of food up to the point of consumption. Hazard analysis is processes that involve the identification of potential hazards that their reduction to acceptable levels is critical to the delivery of safe food to consumers (Martel et al 2005, p.TUE6). In the process of hazard analysis, it is always important to follow the following guidelines. The likelihood of occurrence of a hazard and how severe adverse health impacts of such occurrence The ability to quantitatively and qualitatively evaluate for the presence of a hazards in each step or process The ability of the microorganism concerned to multiply in the process Conditions necessary for the above activities to occur In conducting hazard analysis for temperature controlled food transport, it is also important to note the control measures that may be necessary to prevent the occurrence of hazard. A control measure can be applied to control several hazards such as ensuring temperature kept below 40C in the transporting equipment. This temperature would be critical in controlling hazards associated with microbial multiplication well as those associated with enzymatic processes. According to Paster (2006 p. 43), microbial and enzymatic actions can lead to food deterioration by production of toxins thus making food unsafe. It is therefore important to keep temperatures at acceptable limits to ensure food safety during transportation in temperature controlled transports. Determination of Critical Control Points Critical control point refers to a step or processes in which a control can be exercised to eliminate or reduce hazards to acceptable levels. The determination of a critical control point (CCP) can be done with reference to a logic reasoning approach known as “decision tree diagram” (Paster 2006 p.43). The application of this logical approach is flexible to any operations in the food chain thus can be applied easily to identify critical control points in a temperature controlled transport. However, before applying the decision tree diagram, it is important to train and create awareness with employees and HACCP system team. Chart 2: Identification of CCP using decision Diagram Kirmeyer et al (2006, p.108 Table 2: Hazard Analysis Step Potential Hazards Introduced or Controlled Is the potential Hazard Significant? Justification Preventive Measures of the Significant Hazards Step 1: Primary and secondary food transport equipment selection and Preparation (CCP 1) Microbial accumulation Residues of cleaning detergents and sanitizing chemicals Yes Leakages, malfunction refrigeration and cleaning system may result into cross contamination by chemicals and microorganisms Conduct thorough inspection and ensure carriers are sanitized and the fitted refrigeration system is functioning well. Record Step 2: Food Collection from factories or primary stores Chemical, microbiological contaminations No Not reasonably likely to occur because the procedures and prerequisite programs has catered for this None Step 3: Primary Food Transportation 40C (CCP 2) Growth of micro-organisms (Bacteria, molds and yeasts mycotoxins Yes High temperatures promote rapid growth of microorganisms Monitoring internal carrier temperatures and must be maintained below 40C Record Step 4. Transfer to secondary transport Equipment Chemical, microbiological contaminations No Not reasonably likely to occur because the procedures and prerequisite programs has catered for this None Step 5. Food Delivery/Transportation to consumers 40C (CCP 3) Growth of micro-organisms (Bacteria, molds and yeasts) Mycotoxins Yes High temperatures promote rapid growth of microorganisms Monitoring internal carrier temperatures and must be maintained below 40C Record As indicated in the decision tree diagram chart 2, when control measures are necessary at a particular step for identified hazard yet there is no control measure at that step, product or process, then that particular step, product, or process must be modified or the earlier steps must be modified to include a control measure for that particular hazard. Establish The Critical Limits For Each CCP Identified. Critical limits are the maximum or minimum value at which the chemical, physical and biological parameters must be maintained in order to minimize or reduce the occurrence of a potential food safety Hazards. As stated by Akkerman et al (2013, p.870), critical limits must not only be identified but must also be validated for each Identified critical control point and may include measuring of water activity, pH, temperature, moisture or time. In temperature controlled transport, temperature is a key parameter that must be maintained within specific limits depending on the nature of food and whether it is frozen or not. Table 3: Critical Limits for Each CCP Identified Critical Control points Critical Limits CCP 1 Internal surface microbial count < 10000 The equipment must be able to achieve and maintain internal chilling of (20C – 30C) CCP 2 Internal carrier temperature range (40C – 50C) CCP 3 Internal carrier temperature range (40C – 50C) Monitoring system for Each Identified CCP Monitoring refers to scheduled observation or measurement of the Identified CCP with respect to critical limits. The most important thing in monitoring of a CCP is that a particular monitoring system must be able to detect whether the CCP being monitored is under control or not. In temperature controlled transport system, we will be monitoring temperatures for each of the two CCPs identified earlier to ensure that they fall within limits outlined above (40C – 60C). It is also important to ensure that temperature controlled equipment is adjustable such that when the system is out of control, i.e. not within the critical limits, it can easily be adjusted. However, the most important thing is to ensure the monitoring systems provide accurate information about the critical limits. This information must also be analyzed by qualified personnel with the skills necessary to initiate a corrective action if the temperature is going beyond the limits within the food transport equipment such as engineering technician (Weightman & Bourlakis 2004, P.193). The frequency of monitoring CCPs would also be very critical in ensuring that the temperatures do not go beyond the established critical limits. In many transporting equipment, there are digital thermometers that monitors the temperatures continuously thus present know worry as to the frequency of monitoring. However, if the transport equipment does not have a fixed digital thermometer to continuously monitor temperatures, the frequency of taking temperature measurement of the transport container must be specified and must be sufficient to ensure the identified CCP is under control. Critical Control Point Monitoring System CCP 1: Primary and Secondary Food transport equipment Selection and Preparation Conduct daily inspection for each equipment including dampness and cleanliness. Ensure temperature monitors are fitted and carriers’ internal temperature controls are working efficiently and are calibrated to achieve and maintain 40C Conduct routine Total plate count and must be 40C for more than 4 hours Audit temperature logs Review corrective action forms CCP 3: Food Delivery/ Transportation to consumers and secondary storage Growth of micro-organisms (Bacteria, molds and yeasts mycotoxins Monitoring internal carrier temperatures and must be maintained below 40C Record Internal carrier temperature range (40C – 50C) Temperature Use digital thermometer Continuous/online QC Officer or driver who has been trained on HACCP Temperature Logs Conduct rapid chilling immediately and Discard food held at >40C for more than 4 hours Review temperature logs Review Calibration certificates Training Effective implementation of a HACCP system in a temperature controlled food transport is most effective when employees and managers are well trained on the principles of HACCP and its applications (Kaml et al 2013, p. 40). It is also important to increase awareness not only to the consumers of transported foods, but also to the suppliers of transport carriers and chilling equipment. Specific training focusing mainly on work instructions and procedures for monitoring temperatures within the carriers is important. Such procedures and working instructions must be available at the point of use and at every critical control point. This would make work easier since it guides the operating staff on what to do in step by step manner thus reduces error. Training and creating awareness with producers, suppliers, manufactures and consumers also increases level of cooperation. Joint training between authorities and all the other stakeholders is also important because efficacy of this system depends on involvement of the people throughout the food supply chain. References Akkerman, R, Farahani, P, & Grunow, M 2010, 'Quality, safety and sustainability in food distribution: a review of quantitative operations management approaches and challenges', OR Spectrum, 32, 4, pp. 863-904. Gustafsson, K, Jonson, G, Smith, D, Sparks, L 2008, Retailing logistics & fresh food Packaging: managing change in the supply chain, Philadelphia PA: Kogan Publishers. Kaml, C, Fogarty, K, Wojtala, G, Dardick, W, Bateson, A, Bradsher, J, & Weiss, C 2013, 'The Development of a Standards-Based National Curriculum Framework for Regulatory Food Safety Training in the United States', Journal Of Environmental Health, 76, 2, pp. 38-42. Kirmeyer, G, Hanson, A, Stevens, L & Mullenger, J 2006, Application of HACCP for Distribution Sysytem Protection, New York NY: Awwa research Foundation. Martel, K, Stevens, M, Deere, D, & McCarthy, N 2005, 'Application of HACCP for Distribution System Protection', Awwa Water Quality Technology Conference -Cd-Rom Edition-, pp. TUE6-TUE1 Paster, T 2006, The HACCP Food Safety Employee Manual, Hoboken, N.J.: John Wiley & Sons Rodrigues, K, Silva, J, & Aleixo, J 2012, 'Effect of the implementation of the Hazard Analysis Critical Control Point (HACCP) prerequisite program in an institutional foodservice unit in Southern Brazil', Food Science And Technology (Campinas), SciELO, EBSCOhost, viewed 12 December 2013. Surak, J, & Wilson, S 2007, The Certified HACCP Auditor Handbook: ASQ Food, Drug, And Cosmetic Division, Wisconsin: American Society for Quality Press. Varzakas, T, & Arvanitoyannis, I 2008, 'Application of ISO22000 and comparison to HACCP for processing of ready to eat vegetables: Part I', International Journal Of Food Science & Technology, 43, 10, pp. 1729-1741, Academic Search Premier, EBSCOhost, viewed 12 December 2013. Wang, L, Ting, J, & Ip, W 2013, 'Design of Supply-chain Pedigree Interactive Dynamic Explore (SPIDER) for food safety and implementation of Hazard Analysis and Critical Control Points (HACCPs)', Computers And Electronics In Agriculture, p. 14. Weightman, P, & Bourlakis, M 2004, Food Supply Chain Management, Oxford, UK: Blackwell Pub Read More