Trying to make a HACCP plan, stuck on Hazard Analysis
We are trying to establish a HACCP plan for fruits and vegetables of all types. I was tasked to guide the team on documentation and testing. Can any help me with a sample and guide to develop our own? I know that the principles of HACCP are the same irrespective of whatever one produce. Go through the steps and come out with own control points, but I’m still confused though.
Do we need to get a sample for each fruit and vegetable and identify the physical, chemical, biological hazards, or 1 fruit and one vegetable will suffice?
I received a helpful answer from Dr Ajay Shah. He said,
If I understand it correctly he was addressing the pesticide reside or chemical hazards.For all produce that you source you have to ensure that you get an MRL (Maximum Residue Limit) which is a certificate that a grower has to provide that they meet the requirements of your country and also that they have a HACCP or SQF 1000 programme in plece etc,.
You must write specifications for each product though.
I hope this helps you.
My additional questions -
How about the physical and biological hazards?
Do we need to get a sample of apple, banana, papaya, melon, broccoli, onion etc.
I am stuck at hazard analysis stage.
Thanks in advance.
I attached a HACCP Analysis of Receival for you. Hope this will help.
Attached Files
For ideas look at recalls and past quality incidents and look around at the plant. Ask the operators for ideas of what could go wrong.
Thank you very much for shedding light on my question, Sir.
Hopefully I could explain to the rest of the organization members how to develop a HACCP plan in lay mans term so they will not have a difficulty on what to do and where to start.
I will surely need help in tackling of some difficulties I will be encountering. I will toss some questions later on.
Again, thank you GMO.. and looking for more from you.
You omitted to mention whether you are interested in the preharvesting or postharvesting stages (or both).?
An example of the latter is (hazard) analysed in the context of ISO22000 here -
http://www.ifsqn.com...dpost__p__34610
Some of the linked references in subsequent posts hv details on both process stages.
As far as ideas for likely raw material hazards are concerned, there are various well-known books (available as Google Books)which summarise this, eg Microorganisms in food vol.6 (= microbial ecology, for memory) which is a minor masterpiece. (Obviously recent events hv not got into the books yet.)
Rgds / Charles.C
1. What will be the Maximum Residue Limit for fresh fruits and vegetables? What is the acceptable level of pesticide for each product?
Background, we have a lot of suppliers. We could require some suppliers especially the big ones of Residue COA, but may be not for small farmers/suppliers especially those who supplied us small quantity.
2. Do we need to do a laboratory test for Pesticides for small suppliers or not?
Question on washing-
If pesticides might be present in the raw materials received and washing is only being done for potatoes, can we justify that we cannot wash the rest of the fruits and vegetables because doing so is tedious considering that we have plenty of them?
Follow up question on Hazard Analysis-
From previous replies, I’ve learned that there is no need for us to do a microbiological laboratory test for each fruit and vegetable because the volume is too many. How do we identify the severity and likelihood of microbiological hazards (if any) and conclude as reasonable likely to occur without doing a laboratory test? Please enlighten me.
Can anyone help with this? My appreciation in advance.
Favorite Charles C.Dear MOM,
You omitted to mention whether you are interested in the preharvesting or postharvesting stages (or both).?
An example of the latter is (hazard) analysed in the context of ISO22000 here -
http://www.ifsqn.com...dpost__p__34610
Some of the linked references in subsequent posts hv details on both process stages.
As far as ideas for likely raw material hazards are concerned, there are various well-known books (available as Google Books)which summarise this, eg Microorganisms in food vol.6 (= microbial ecology, for memory) which is a minor masterpiece. (Obviously recent events hv not got into the books yet.)
Rgds / Charles.C
Thanks for the link. I’m not sure if pre-harvesting or post-harvesting stages should be included. This company (subsidiary) is engage in the purely distribution of fresh fruits and vegetables to key retail accounts in the country, as well as in the wholesale trading and distribution of commercial crops through trade channels like public wet markets etc. We have another company (subsidiary) engage in farming activities, but not this one.
ADDED - Just noticed that this thread is almost a duplicate of another recent thread (??
http://www.ifsqn.com...dpost__p__45370
(my second attachment here is also given in that thread
The document/information you seek will be defined by yr flow chart, ie what process you want to (haccp-wise) describe. Until you do this, you cannot go anywhere.
The Canadians hv done a lot of work on issuing haccp advice in this product area, can try the documents below which attempt to give (clearly stated
Generic Food Safety Standard ( Repacking, Wholesale) Fresh Fruits and Veg..pdf 439.77KB 186 downloads
Generic HACCP Model Workbook( Repacking, Wholesale) Fresh Fruits and Veg..pdf 315.84KB 195 downloads
(But see note at top of this post)
Rgds / Charles.C
Thanks for the links. If and when I am able to I'll look them over.
One quick question. If there is no need for us to do a laboratory analysis on microbiological hazards on fruits and vege, can I simply state in the HACCP plan (Hazard to be controlled column) all the microbes common in fruits and vegetables e.g. E. Coli or not?
Dear MOM,
ADDED - Just noticed that this thread is almost a duplicate of another recent thread (??) -
http://www.ifsqn.com...dpost__p__45370
(my second attachment here is also given in that thread)(sorry folks!)
The document/information you seek will be defined by yr flow chart, ie what process you want to (haccp-wise) describe. Until you do this, you cannot go anywhere.
The Canadians hv done a lot of work on issuing haccp advice in this product area, can try the documents below which attempt to give (clearly stated) generic haccp templates in a detailed, step-by-step form for this product area (typical input data is not given except for the prerequisites). The parent (but member-oriented) website which is linked in the document carries a lot more info. on different process segments. Some, more risk-oriented/hazard analysis/data-based aspects, of this work is linked in the document in my previous post (the source there is not member-oriented .)
Generic Food Safety Standard ( Repacking, Wholesale) Fresh Fruits and Veg..pdf 439.77KB 186 downloads
Generic HACCP Model Workbook( Repacking, Wholesale) Fresh Fruits and Veg..pdf 315.84KB 195 downloads
(But see note at top of this post)
Rgds / Charles.C
The information posted from the Canadian govt site is very useful and I have consulted this in the past and got some good information from it.
Thanks Charles C.
Favorite Charles C,
Thanks for the links. If and when I am able to I'll look them over.
One quick question. If there is no need for us to do a laboratory analysis on microbiological hazards on fruits and vege, can I simply state in the HACCP plan (Hazard to be controlled column) all the microbes common in fruits and vegetables e.g. E. Coli or not?
Hi Mind over Matter,
Firstly I must correct you in that I am a HE (Male)!!! and not a SHE (female)
It is important to conduct random sampling microbiological tests for E.coli, Slamonella spp and Listeria monocytogenes for post harvest produce.
High risk products (Those that can eaten uncooked, grown in or close to ground or have a large uneven surface) e.g. strawberry, spinach, mushroom etc.
Meduim risk will be thiose that are generally eaten cooked e.g. potato, beetroot asparagus etc
Low risk are crops grown over one metre above ground with edible skin e.g. apple , apricot, pear etc.
Low risk crops grown over one metre above ground, skin not eaten such as banana, avocado etc
i hope this helps.
cheers
and thisI assume you're producing a generic HACCP plan or at least one for fruit, one for vegetables? If so, you don't need samples IMO.
confused me even more.It is important to conduct random sampling microbiological tests for E.coli, Slamonella spp and Listeria monocytogenes for post harvest produce.
But hopefully someone can enlighten me???
The intended idea of published generic examples is to indicate a procedural pattern which the authors (and/or perhaps their sources) have found useful for them.
The problem is that without doing some testing, you will not know if it equally applies to your own situation.
This is why HACCP is described as an (ultimately) process specific methodology.
If you can find time to look at the (Canadian) material I previously referred, you will see that certain fruits and vegetables were found to be able to be grouped in a reasonably standard (risk) format whereas others could not. AS's previous post illustrated some possible reasons for such eventualities.
I suppose you might consider re-locating to Canada to avoid microbiological examination?
Rgds / Charles.C
I agree with this. Using common sense Food Safety is not that hard to understand. If pesticides might be present in the incoming raw materials and washing is being done for potatoes alone because tedious to the gigantic supplies of hundreds of types of vegetables, therefore we cannot justify NOT doing chemical and microbiological examinations.Dear MOM,
The intended idea of published generic examples is to indicate a procedural pattern which the authors (and/or perhaps their sources) have found useful for them.
The problem is that without doing some testing, you will not know if it equally applies to your own situation.
I will not argue because I know that food safety is non-negotiable, although different countries have different levels of requirements. But problem is how to say to top management that they must go for training first.This is why HACCP is described as an (ultimately) process specific methodology.
How I wish to be relocated in Canada. Going back to microbiological test, I’m not trying to avoid it. It’s just that this particular subsidiary is purely distribution of fresh fruits and vegetables, thus they don’t have their own laboratory. If microbiological test is a requirement to ensure food safety, then 2 things: they could either use other subsidiary’s laboratory or install their own laboratory.If you can find time to look at the (Canadian) material I previously referred, you will see that certain fruits and vegetables were found to be able to be grouped in a reasonably standard (risk) format whereas others could not. AS's previous post illustrated some possible reasons for such eventualities.
I suppose you might consider re-locating to Canada to avoid microbiological examination?
Rgds / Charles.C
You see? The materials you previously referred are VERY GOOD but have a common knowledge drawback: they COST. That’s the reason why I mentioned earlier the top management food safety trainings.
You see? The materials you previously referred are VERY GOOD but have a common knowledge drawback: they COST. That’s the reason why I mentioned earlier the top management food safety trainings.
?? The documents I was referring to initially are FREE.
See this post –
http://www.ifsqn.com...dpost__p__36566
and attachment DOC1a, one main link in it is –
http://www.omafra.go..._assessment.htm
Rgds / Charles.C
Favorite Charles,Dear Mom,
?? The documents I was referring to initially are FREE.
See this post –
http://www.ifsqn.com...dpost__p__36566
and attachment DOC1a, one main link in it is –
http://www.omafra.go..._assessment.htm
Rgds / Charles.C
You've misunderstood the point of my post, which had to do with management commitment, accountability and provision of resource. It involves financial considerations.
Sorry my statements were not clear.
I agree Strait.Why go crazy? Hire a good Consultant and be done with it. The 21st Century is all about specialization and outsourcing. (NOT AN ADVERTISEMENT).
Regards,
Simon
Some questions on receiving of raw materials -
1. What will be the Maximum Residue Limit for fresh fruits and vegetables? What is the acceptable level of pesticide for each product?
Background, we have a lot of suppliers. We could require some suppliers especially the big ones of Residue COA, but may be not for small farmers/suppliers especially those who supplied us small quantity.
2. Do we need to do a laboratory test for Pesticides for small suppliers or not?
Hello there,
I just would like to share my insight for your concern... Hope I could help...
>for question number 1 - if you consider receiving as a CCP in your HACCP system then you must put up controls to eliminate or reduce risk to an acceptable level.
Just would like to ask, what products are you going to produce from these items? are they going to be sold directly to the end users or will there be further steps after receiving?
>for question number 2 - You must have an approved supplier program and in there you must justify why a specific supplier was picked up to supply goods to you. Suppliers must be compliant with your current local regulations / policies before they are chosen to supply goods / raw materials to you. You should also put up an ongoing ingredients verification where you send samples of raw materials you receive for microbiological analysis on an agreed frequency.
Just would like to ask, did you have further complaints / issues regarding pesticide presence in your finished products lately?
Question on washing-
If pesticides might be present in the raw materials received and washing is only being done for potatoes, can we justify that we cannot wash the rest of the fruits and vegetables because doing so is tedious considering that we have plenty of them?
>If you say washing is the control measure to eliminate risk of potential chemical hazards, you must stick to it. In my experience, we usually do produce disinfection step after washing because washing alone may or may not remove chemical hazards but never a microbiological hazard.
Follow up question on Hazard Analysis-
From previous replies, I’ve learned that there is no need for us to do a microbiological laboratory test for each fruit and vegetable because the volume is too many. How do we identify the severity and likelihood of microbiological hazards (if any) and conclude as reasonable likely to occur without doing a laboratory test? Please enlighten me.
>Are you doing laboratory testing before for every batch your receive before?
Can anyone help with this? My appreciation in advance.