HACCP in the food industry

You can't buy trust, yet making a purchase does call for a certain amount of trust – and that's exactly why the HACCP concept was developed. Safety – and therefore also cleanliness and reliable cleaning processes – play a major role in the food industry; high standards should ensure that consumers can enjoy products without any concerns. In light of this, the HACCP concept is an important tool for self-monitoring, which can be used to help identify and analyse potential hazards and bring these under control.

More diligence, less uncertainty: HACCP as an authority in food safety

The responsibility shouldered by food companies is immense. Diligence and responsible actions are paramount not only for manufacturers, but also for companies involved in logistics and wholesale when it comes to the fundamental principle of product safety. Minimising risks and preventing contamination are always a top priority; this is the only way to avoid product defects – and the associated costly recalls and downtime.

HACCP-assisted measures are an important element in achieving this requirement. But what exactly does the HACCP concept involve and how exactly is it realised in operations? Food companies need to take a close look at this matter and also consider the role that hygiene plays in this regard.
It should not be forgotten that the scope of impact for HACCP-assisted measures is not limited to production or processing alone. Warehousing, packaging, onward transport, etc. are also important links in any chain that supplies consumers with end products – products that are intended to be safe to consume and should pose no risk to human health.

Grafik HACCP – Hazard Analysis and Critical Control Points

HACCP unpacked

The acronym HACCP stands for Hazard Analysis and Critical Control Points. As such, the model is made up of two main poles: the hazard analysis on the one hand and the critical control points (CCPs) on the other. Overall, HACCP represents a systematic and science-based system that identifies hazards and corresponding control mechanisms to ensure the safety of food.

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Originally developed by NASA, the HACCP concept is now an indispensable part of the food industry. In the Codex Alimentarius published by the FAO (Food and Agriculture Organisation of the United Nations) and the WHO (World Health Organisation), the HACCP system is incorporated as an overarching concept that affects the entire food value chain. Potential risks are identified and addressed throughout this entire chain, rather than looking solely at the end product as such. This is done by means of so-called critical control points or CCPs – defined as "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"1. Individually set, they therefore serve as helpful and indispensable tools for risk and fault prevention, as well as controls for a safe operating state.

In many countries, corresponding procedures are prescribed; within the EU, the legal basis for implementing such a system is Regulation (EC) no. 852/2004. It should be noted that the HACCP system is not rigid and does not have to be implemented in the same way for all food businesses. The regulations within the EU, for example, therefore allow a certain degree of flexibility in their application, meaning the procedure can be adapted to the business in question. Whether or not a company can utilise a flexible regulation and therefore a simplified HACCP procedure depends on the size and type of company. The latter refers to the question of whether the company processes and packs food or only works with pre-packaged food, for instance.

Hygiene as a critical factor

Regardless of the type and size of the business, hygiene always plays a critical role. So-called prerequisite programs (PRPs) are the foundation for hygiene in a business – and at the same time the prerequisite for the successful implementation of HACCP principles.

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The basic hygiene measures, which include procedures such as good hygiene practices (GHP) and good manufacturing practices (GMP), define the basic hygiene requirements and relate to elementary areas such as personal hygiene, room hygiene, temperature control and humidity regulations in store rooms, etc.

PRPs are therefore not to be regarded as hazard-specific and are suitable for eliminating minor and general hazards. This places them in direct contrast with oPRPs and CCPs: oPRPs are "operational prerequisite programs", i.e. PRPs that are linked to the production process. They are suitable for managing moderate risks. CCPs, on the other hand, are used to control major risks. Altogether, however, all of these tools are essential for a safe end product. This becomes all the clearer when looking at the aspect of control measures: these play a fundamental role in the context of HACCP and are defined as "those actions and activities that can be used to prevent hazards, eliminate them or reduce their impact or likelihood of occurrence to acceptable levels"2 – they are therefore the response to an identified hazard. These are not limited to those control measures specifically linked to a production process: many preventative control measures also make up the PRPs.

So if you look at how an HACCP system works with the overarching goal of food safety, preventative measures are part of the equation.

Counteracting hazards through cleaning

The HACCP concept aims to eliminate food safety hazards or prevent them from arising. In this regard, a hazard is defined as a "biological, chemical or physical agent in, or condition of, food or feed with the potential to cause an adverse health effect"3. A distinction is therefore made between biological or microbiological, chemical and physical hazards.

Physical hazards, such as nutshells and pieces of plastic or metal, are often the result of a lack of maintenance or contamination of the processed goods. Chemical hazards, such as dioxins and allergens, and biological hazards, such as bacteria or parasites, are far more likely to be countered by efficient cleaning processes, both in production-related environments and in the production process itself. This is often achieved by means of preventative measures or oPRPs.

It is beneficial if the contamination can be removed at the point where it occurs, to prevent any carryover. Fast and flexible industrial vacuums are particularly well suited for removing residues and dusts. Although these are generally more suitable for small-scale dirt removal, they have the added advantage that they can also be used three-dimensionally, for example to clean tubes or extract dust when bagged goods are transferred into the production process. Scrubber dryers are a different matter: these are a good option for larger areas, such as tiled and hard floors, however these only operate in a two-dimensional space.

When it comes to cleaning the production machines themselves, specialist cleaning solutions are often available that are adapted specifically to the conditions – for example, specialist wet and dry vacuum cleaners that have been developed specifically for bakeries and can be used to vacuum out the ovens, even while they are still hot.

Cleaning in bakeries

Strict standards of cleanliness and hygiene apply to the processing and sale of food – including in bakeries and their shop fronts. Professional and efficient cleaning not only ensures consumer safety, but also creates a positive overall impression, preserving value and giving confidence in the company. However, there are some specific tasks that require the right technique and approach.

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A commercial kitchen with various foods and cooking utensils

Cleaning kitchens

Wherever food is cooked, there will be stubborn stains. Grease and food residues must be systematically removed in accordance with the HACCP guidelines in order to eliminate breeding grounds for microorganisms. What can high pressure cleaners, surface cleaners, steam cleaners, scrubbers or scrubber dryers do? What specifics need to be considered when using them? And what should disinfection look like? Here is an overview.

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A person operates a scrubber-dryer in a cold storage room

Hygiene in the cold store

Low temperatures, high relevance: cold stores can be found in numerous companies – and where they are found, they are generally integral to operational processes. In hotels and restaurants, in industrial production plants or in supermarkets, cold stores provide the correct conditions for storing perishable and temperature-sensitive goods. For the cold store to function perfectly, it requires specialist professional cleaning that reflects the special conditions.

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Cleaning production facilities

Clean production facilities and surrounding areas are fundamental to smooth processes, safety and product quality. Consequently, keeping production plants clean is a key to success for any company, whether it is in the automotive, food industry, metal or chemical industry. Each and every industry struggles with specific types of dirt that require custom cleaning solutions. Soiling occurs either as a by-product of the production process or as a result of unforeseen incidents, such as leaks. The various types and origins of dirt give rise to different ways of efficiently integrating cleaning tasks into everyday production.

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In situations where water cannot be used for cleaning and/or where the main aim is to avoid having to stop production or disassemble machinery for cleaning, dry ice offers a suitable cleaning solution, especially for extruder screws used in the production of ice cream or baby food, for instance.

If cleaning cannot be carried out with water or dry ice alone, detergents may be a consideration. In companies that work with raw materials such as meat, for example, the entire production facility usually has to be wet-cleaned after each production shift – using high or medium pressure and detergents to ensure a high level of biosecurity. However, it should be noted that residues of either the detergent or the dirt dissolved may potentially cause subsequent contamination. Thorough cleaning therefore always includes the extensive removal of all residues of detergent and dirt to ensure no new hazards are created.

A person gently cleans surfaces with the dry ice blasting machine

A man vacuums the floor with the industrial vacuum cleaner

A person cleans the production facility with the high-pressure cleaner

Tip – working with detergents:

A degree of variation in the detergents used can help to avoid unwanted consequences: in a biologically and chemically highly dynamic environment, a strategically varied approach to detergent use can help to keep resistance in germs and pathogens to a minimum.

In addition to production itself, adjacent areas such as delivery, storage and onward transport must also be taken into account. In potato production, for example, the large crates for the potatoes are sterilised with hot steam from the high-pressure cleaner or almost boiling hot water to prevent the transfer of pests and plant diseases to stored potatoes.

The spaces intended for employees also need to be organised accordingly: in large butcher facilities, for instance, the social areas for employees are often efficiently separated according to the black and white principle, with everyday clothing being worn in the black area and clothing for production worn in the white area. This is coupled with regular floor cleaning using a scrubber dryer or high-pressure cleaner combined with suitable detergents in each case.

This procedure is coupled with a hygiene lock where staff clean their shoes and hands. When changing clothes, all personal items are left in the black area to avoid accidental or deliberate contamination of the products.

Hygiene in meat processing

In food processing companies such as butcher's shops, extra care and attention should be given to cleaning and disinfection tasks. This applies to work surfaces, tools and machines, as well as floors in production and storage areas and cold storage rooms – because any spread of germs would have harmful consequences. For added convenience, high-pressure cleaners in particular can be used to complete numerous tasks efficiently.

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Cleaning floor coverings

Whether carpeting in a hotel corridor, cement screed in a production hall or wooden flooring in a school building, there are countless floor coverings that are suitable for different loads and ensure safety through properties such as anti-slip design or studs. Cleaning floor coverings is important in some areas to ensure hygiene, while in other areas the focus is on appearance. In either case, well-maintained floor coverings have a longer service life, meaning that they need to be replaced less frequently. With regular maintenance cleaning, you can even postpone the need for a time-consuming deep clean.

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The HACCP principles

A look at real-life situations reveals a wide range of hazards in the most diverse areas. Each of the seven steps on which the HACCP procedure is based is designed to counter these hazards effectively and comprehensively. In addition to identifying the hazards and determining the critical control points (CCPs), the steps also set limits for these CCPs and establish procedures for monitoring them. Further to this, corrective measures are defined – in the event that a CCP is no longer under control – as well as verification procedures that serve to check the HACCP plan. The seventh and final principle is the documentation of the measures.

Hazard analysis

Identifying hazards that must be avoided, eliminated or reduced to an acceptable level.

HACCP Concept Step 2: Identification of control points

Identifying control points

Establishing the critical control points (CCPs) at the process stage(s) where control is necessary to prevent or eliminate all hazards or reduce these to an acceptable level.

Setting limits

Establishing limit values for these CCPs to distinguish between acceptable and unacceptable levels with a view to preventing, eliminating or reducing identified hazards.

Establishing monitoring measures

Establishing and implementing effective procedures for monitoring critical control points.

Defining corrective measures

Establishing corrective measures in the event that monitoring indicates that a critical control point is not under control.

Determining verification procedures

Establishing regular verification procedures to determine whether the requirements of principles 1 to 5 have been fulfilled.

Documenting

Preparing documents and records appropriate to the type and size of the food business in order to demonstrate compliance with the requirements of principles 1 to 6.

Well prepared. Well positioned.

Preparation is key in the implementation of these seven principles. This includes forming an interdisciplinary HACCP team, as well as describing the product and the company's typical manufacturing process in detail. The normal or expected use of the product must also be taken into account.

The description of the manufacturing process, which also takes place within this framework, is provided in the form of a flow chart that considers all stages of the process in chronological order. This flowchart should take into account all processes, from receipt of the raw material to placing the end product on the market.

In the hazard analysis that follows, all hazards must initially be identified and named. In addition, the probability of occurrence of each hazard and the severity of its adverse health effects must be determined. Possible control measures for the identified hazards must also be considered, as these are highly relevant for the subsequent process of establishing the CCPs – at this point, it must be determined which of the available control measures can be applied within the framework of a CCP.

Control is better

A CCP is only set up where a high risk exists according to the hazard analysis. It must be able to eliminate or avoid the identified hazard or reduce it to an acceptable level by means of the corresponding control measure.

It should be noted that there may be multiple CCPs to control one hazard; conversely, multiple hazards may be controlled by one CCP – for example, various microbial pathogens can be eliminated by means of pasteurisation. Important: if no suitable control measure exists for a significant hazard, the production process itself must be adapted.

Validated limit values must be in place for each control measure defined in this process. These can be used to determine whether the corresponding CCP is being effectively managed, i.e. is under control. To ensure that these limit values are adhered to, a monitoring or measurement process must be carried out at each CCP – such as measuring the temperature in cold rooms or checking the premises for pest infestation. For instance, a swab method can be used to check cleaning processes, whereby the microbiological findings provide information about the hygiene levels of the surface in question.

Depending on the circumstances, monitoring can be carried out continuously or periodically. In the latter case, the frequency must be high enough to ensure seamless monitoring and enable corrective measures to be taken in good time.

The frequency of monitoring varies according to the level of risk, i.e. depending on factors such as the likelihood of a hazard occurring and the number of employees handling the product.

Rapid intervention if the worst comes to the worst

Any corrective measures to be taken must be clearly defined in advance, so that they can be applied immediately as soon as a deviation from the limit value is identified. Not only must the instruments and measures for correcting the deviation be defined, but also, for example, the measures to be taken in relation to those products that were produced during the deviation. Lastly, the established measures must be validated and verified. Validation describes the process of proving – before starting or adapting a process – that the control measures are effective, provided they are applied correctly. Verification, on the other hand, describes the regularly repeated testing of whether the control measures are effective – for example by means of sampling the food.

Finally, step seven of the HACCP procedure relates to the creation of documentation and records. The documentation includes not only work instructions and test methods, but also monitoring results, verification results, etc. For cleaning processes, the minimum requirements include documenting the date and time of cleaning and recording the person carrying out the cleaning.

Sources

1 2016/C 278/01 Commission Notice on the implementation of food safety management systems covering prerequisite programs (PRPs) and procedures based on the HACCP principles, including the facilitation/flexibility of the implementation in certain food businesses, Annex 1

2 2016/C 278/01 Commission Notice on the implementation of food safety management systems covering PRPs and procedures based on the HACCP principles, including the facilitation/flexibility of the implementation in certain food businesses, Annex 2, Section 4.2

3 Regulation (EC) no. 178/2002, Article 3(14)