www.aqua-syn.eu
con il patrocinio di
Regione Siciliana
Assessorato Regionale dell’Istruzione e Formazione Professionale Dipartimento Regionale dell’Istruzione e Formazione Professionale
UNIVERSITÀ degli STUDI di CATANIA Dipartimento di Scienze Mediche, Chirurgiche e Tecnologie Avanzate
"F. G. Ingrassia"
Ordine dei Tecnologi Alimentari di Sicilia e Sardegna
Catania (Italy), 19 March 2015
WORKSHOP
LA QUALITÀ DELLE ACQUE MINERALI NATURALI THE QUALITY OF NATURAL MINERAL WATER
The HACCP method in mineral water bottling
L'applicazione del metodo HACCP nella fase di imbottigliamento delle acque minerali
Dott.ssa C. Copat e Dott.ssa C. Ledda - LIAA- University of Catania
di Sicilia e Sardegna
What is HACCP?
System of food safety management
Internationally recognized and recommended
Hazard Analysis and Critical Control Point
Internationally recognized and recommended
Identifies where hazards might occur in the production of bottled water Puts into place control measures to prevent the hazards from occurring.
Strictly monitoring and controlling each step of the process, there is less chance for hazards to occur
How to perform a HACCP Study?
Assemble a HACCP Team
HACCP studies involves a logical sequence of tasks and requires the full commitment and involvement of management and the staff
- By involving a team of people, a greater diversity of skills and knowledge appropriate to the system will be available
- It is counselled to create a team with some external people
- Where the necessary expertise is not available on site, expert advice should be obtained from other sources
Define the Terms of Reference
- Identify the process (e.g. the production and supply of water) - Identify the limits of the study
- All hazards (microbiological, chemical and physical) must be considered as - All hazards (microbiological, chemical and physical) must be considered as a whole, or will each type of hazard be considered individually?
- Each process stage is studied individually (e.g. ozonation, filling, capping...)
Describe the Product and Identify the Intended Use
Draw up a full description of the production system, including information on water composition and the method of distribution as well as the materials used in the production
• Raw materials: water, CO2 and added minerals
• Authorised water treatments
• Materials in contact with the product (filling line and containers: bottles, cans ...)
• Storage conditions and methods of distribution
• Storage conditions and methods of distribution
• Theoretical/legal expiry date
Identify the consumer/s target group/s for the product
The intended use shall be based on the composition and expected uses of the product
In specific cases, vulnerable groups of population (e.g. infants, special diets) should be considered
Topics to be considered Characteristics Product name and qualification
(based on the existing norms)
Common Name (Trade Mark?) Natural Mineral Water
Spring Water
Processed / Prepared Water
Sales / Marketing description Mountain Spring Water
Well Water
Carbonated / Natural Sparkling Water Other
Use Drinking as such
Drinking after carbonation
End users General population
Infants
Vulnerable or specific groups
Product specifications Chemical and physico-chemical water parameters Allowed water treatments applied
Carbon Dioxide level: origin Added Minerals
Topics to be considered Characteristics
Packaging Size and volume of packaging
Type of primary container (e.g. glass, plastic, metal, paper, bulk) Type of closure (e.g. plastic, aluminium, other)
Type of secondary packaging (e.g. crates, boxes, packs) Type of tertiary packaging (e.g. pallets, wrapping)
Labelling Type of labels (e.g. paper, polypropylene) and glue specifications Regulatory requirements
Product shelf life Shelf life duration / expiry date Coding description
Coding description
Type of coding (e.g. ink, laser) Storage and Distribution Conditions Internal storage
External storage Distribution ways
Range of temperature storage Retail conditions and constraints
Flow Diagram
Draw a flow diagram of all aspects of the factory considering:
• Source and its protection
• Water operation
• Raw materials
• Processing
• Packing (all steps)
• Storage
• Distribution
• Retailer
Details of each step of the operation must be addressed
It is especially important that this diagram provide an accurate representation of the process, as it is the main basis for the HACCP study
1. Step – process identified in the flow diagram; Hazard - potential source of harm or adverse health effect/s on a person or persons; Risk - the likelihood that a person may be harmed or suffer adverse health effects if exposed to a hazard; Control Measures (CM) harmed or suffer adverse health effects if exposed to a hazard; Control Measures (CM) 2. Critical Control Point Yes/Not (CCP Y/N)
3. Control Limits (verification) (C Limits) 4. Monitoring:
5. Corrective Actions (CA) 6. Verification
7. Documentation
The HACCP team shall list all hazards reasonably expected to occur at each step according to:
- Scope from primary production, processing, manufacture and distribution until the point of consumption
- Each process step identified in the flow diagram shall be assessed for the introduction or presence PRINCIPLE 1
List All Hazards Associated With Each Step And Consider Any Control Measures To Control The Hazard
- Each process step identified in the flow diagram shall be assessed for the introduction or presence of a hazard
The HACCP team shall next conduct a hazard analysis to identify which hazards are of such a nature that their elimination or reduction to acceptable levels is essential to the production of safe bottled / packaged water
Microbiological Hazards
• Pathogenic Bacteria - presence, contamination, survival, growth
• Parasites and Protozoa
• Viruses
• Moulds
Apart from it, it should be considered that many mineral waters have a natural content of microbiological flora which is accepted as natural
Chemical hazards
• Xenobiotics and natural compounds, e.g. - pesticides, microbial toxins, algal toxins, allergens ...
• Packaging-derived materials, e.g. - plasticizers, ink/adhesive
• Packaging-derived materials, e.g. - plasticizers, ink/adhesive
• Added during the process, e.g. - cleaning agents, lubricants, hydrocarbons, pesticides, allergens, fumes/dust, microbial toxins
Physical Hazards
• People’s origin, e.g. - buttons, teeth, hair, jewellery, paper clips, matchsticks...
• Natural origin, e.g. -, nutshells, seeds, fruit stones
• Factory’s environment, e.g. - glass, wood, metals, chips from tiles, gaskets
• Equipment – nuts, bolts, screw, rusting metal flakes, plastic
In conducting the hazard analysis, the following shall be included wherever possible:
1. The likely occurrence of hazards and severity of their adverse effects in view of the risk evaluation 2. The qualitative and/or quantitative evaluation of the hazard
3. The possible presence or multiplication of any microorganism of concern 4. Production or persistence in water of toxics, chemical or physical agents 5. Conditions leading to the above
Consideration shall be given to what control measures, if any exist, can be applied to each hazard Describe the real control measures applied to control these hazards
It is to consider that more than one control measure may be required to control a specific hazard
How to calculate the significance of the hazard (example)
The HACCP team could decide that the hazards with a low risk number, e.g., lower than 2, are not significant and do not need specific control measures (CM)
This needs an application to the bottled water specificities
The identification of a Critical Control Point (CCP) in the HACCP system is facilitated by the application of a Decision Tree. Application of the Decision Tree determines if the step is a
"critical" control point for the identified hazard PRINCIPLE 2
Identify the Critical Control Points
If a hazard has been identified at a step where control is necessary for safety and no control measure exists at that step, or at any other step, then the product or process must be modified at that step, or an earlier or later stage, to include a control measure
Critical limits shall be specified and validated for each CCP. Details of the establishment of critical limits shall be recorded
These critical limits shall be measurable
Criteria often used include: measurements of time, temperature, concentration of disinfecting agent, PRINCIPLE 3
Establish Critical Limits for each CCP
Criteria often used include: measurements of time, temperature, concentration of disinfecting agent, pH, absence of metals, microbiological limits, sensory parameters e.g. visual appearance and texture, etc.
In some cases more than one critical limit will be elaborated at a particular step
Monitoring is a planned sequence of observations or measurements of a CCP target level and tolerance Monitoring must be able to provide confidence in the established controls, be able to detect any loss of control and enable timely corrective actions
Typical monitoring methods include visual evaluations, physical measurements. E.g. temperature, chemical analysis, and microbiological assessment
PRINCIPLE 4
Establish a Monitoring System for each CCP
Records and documents associated with monitoring CCPs must be signed by the person(s) doing the monitoring and by a responsible reviewing official of the company
If monitoring is not continuous, then the amount of frequency of monitoring must be sufficient to guarantee the CCP is under control
Specific corrective actions must be developed for each CCP in order to deal with any deviations. The action must ensure the CCP is brought under control and include details of what to do with affected product
PRINCIPLE 5
Establish Corrective Action
PRINCIPLE 6
Validate the HACCP System
Monitoring and auditing should be carried out to determine if the system is working correctly.
Examples include a review of the HACCP system and its records, review of deviations, checks to ensure CCPs are under control, validation of established critical limits, etc.
Validation helps to maintain confidence in the system, identifies areas for improvement and provides documentary evidence of due diligence in managing food/bottled water safety
Validate the HACCP System
Verification should be carried out by someone other than the person who is responsible for
performing the monitoring and corrective actions. Where certain verification activities
cannot be performed in house, verification should be performed on behalf of the business by external experts or qualified third parties
Examples of verification activities include:
• review of the HACCP plan and its records
• review of finished products’ microbiological data
• review of deviations and product dispositions
• confirmation that CCPs are kept under control
In order to be efficient and effective, the keeping of records is essential.
Such records help to illustrate compliance with these Guidelines and are important in establishing a due diligence defence.
Each process step as documented in the flow diagram must be detailed in the HACCP chart and the PRINCIPLE 7
Establish Record Keeping and Documentation
Each process step as documented in the flow diagram must be detailed in the HACCP chart and the controls, monitoring, corrective actions, etc. determined accordingly. This will ensure that the hazards at each process step are duly considered and controlled
These records must be reviewed periodically e.g. annually or when there is a significant change in operation
SAMPLE HACCP CHART
Therefore, the HACCP process can be summarized as follows:
