1. Module 4.6
List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

2. Objectives and contents
To emphasize the importance of hazard identification and analysis steps in food safety management
To enable trainees to identify potential hazards in a process and to find appropriate control measures
Contents
Examples of hazards
Carrying out a hazard analysis
Control measures
Hazard assessment
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

3. Importance of hazard analysis
An accurate analysis of hazards is necessary for an effective HACCP plan
Involves technical and scientific expertise in various domains
Hazard analysis must be reviewed when there is any change in
Raw materials
Formulation
Processing procedures
Packaging
Distribution
Use
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

4. Potential hazards
The first step in the development of a HACCP plan is the identification of all potential hazards
Biological, chemical and physical
At all stages from raw material to consumption
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

5. Biological hazards include
Bacteria and mould (spore-forming)
Bacteria (non-spore forming)
Viruses
Protozoa and parasites
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

6. Biological hazards
Commonly associated with humans and with raw products entering the food process
Most have the potential to increase spontaneously if control measures are inadequate
Usually killed or inactivated by heat processing
Fungi include moulds and yeasts
Some fungi are beneficial
Others produce toxic substances (mycotoxins)
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

7. Chemical hazards include:
Naturally occurring chemicals
Added chemicals (intentional and unintentional)
Chemical contaminants may occur at levels that cause
Acute illness
Chronic illness
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

8. Hard or sharp foreign objects can cause injury
Physical hazards
Examples include
Glass, wood, stones, metal, plastic, etc
Hard or sharp foreign objects can cause injury
Poor practices at many points along the food chain can lead to the introduction of physical hazards
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

9. Sources of information for hazard analysis include
Reference texts
Company complaints file
Scientific research and review papers
Epidemiological data
Web pages dealing with food safety issues
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

10. Hazard analysis Objective Overview of approach
To determine which hazards need to be addressed under an effective HACCP plan
Overview of approach
Review incoming material
Evaluate processing operations
Observe actual operating practices
Take and analyse measurements
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

11. Review incoming material
Review product description form (Form 1) for information that could influence the analysis of hazards
Is it ready-to-eat or is further processing envisaged?
Is it intended for a vulnerable group?
For each incoming material (Form 2) write ‘B, C or P’ directly on the form to indicate the nature of all potential hazards
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

12. Review of incoming raw material
There is wide variation in practices (on-farm and throughout the marketing chain) that can influence the analysis of hazards in incoming raw material
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

13. Review incoming material
Potential hazards identified on Form 2 should be fully described on Forms 5, 6 and 7
Raw material
Packaging material
Coffee fruit (cherry) (B, C, P)
60kg sisal stitched printed sacks or lined / unlined containers (B, C, P)
Date:
Approved By:
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

14. Incoming material – biological hazards (Form 5)
Identified biological hazards
Controlled at
Ingredients / Materials
Coffee fruit (cherry)
Could contain ochratoxin or aflatoxin-producing fungi
Jute bags
Could contain spores of toxigenic fungi that might lead to cross-contamination of product
Could contain pathogenic bacteria
(For discussion only)
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

15. Incoming material – chemical hazards (Form 6)
Identified chemical hazards
Controlled at
Ingredients / Materials
Coffee fruit (cherry)
Could contain residues of agricultural chemicals (pesticides, fungicides, etc.)
Could contain OTA or aflatoxin
Could contain heavy metals or other environmental contaminants
Jute bags
Could contain hydrocarbons from batching oils
Could be contaminated by agricultural chemicals depending on previous use
(For discussion only)
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

16. Incoming material – physical hazards (Form 7)
Identified physical hazards
Controlled at
Ingredients / Materials
Coffee fruit (cherry)
Could contain harmful extraneous materials (stones, metal, glass, wood)
Jute bags
Could contain harmful extraneous material, pieces of plastic etc.
(For discussion only)
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

17. Hazards in incoming materials
Sample questions that guide the identification of potential hazards
Could pathogenic organisms, toxins, chemicals or physical objects possibly be present on this material
Are preservatives or additives used in the formulation to kill or inhibit growth of organisms
Are any ingredients hazardous if used excessively or in adequate amounts
Do moisture content and Aw in final product or ingredients affect microbial growth?
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

18. Evaluating process operations
Objective
Identify all realistic potential hazards related to each processing operation, the product flow and employee traffic patterns
Review process flow diagram (Form 3) and plant schematic (Form 4)
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

19. Hazards associated with process steps
Assign a number to each processing step on Form 3
Examine each step and identify potential hazards (B, C, P)
Use plant schematic to assist in identification of potential hazards
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

20. Analysing process steps – guiding questions
Could contaminants reach the product during this operation?
Could micro-organisms of concern multiply to the point where they constitute a hazard?
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

21. Process steps – Form 5: biological hazards
Should be repeated for chemical and physical hazards
Identified biological hazards
Controlled at
Ingredients / Materials
Process steps
1. Harvesting
OTA-producers introduced from environmental sources
Pathogens introduced from environmental sources, workers
3. Gathering / transporting to beneficio
Undue delay in processing after harvest could lead to the proliferation of OTA-producing fungi
4. Storing sacks
OTA-producers introduced from cross contamination of by-products
Pathogens introduced from pests
5. Floatation separation
Inadequate separation of boia from wetter coffee could cause re-wetting of the partially dried boia and proliferation of OTA-producers
Introduction of water-borne pathogens by contaminated water
Cross contamination by OTA-producers if water is overly re-circulated
(For discussion only)
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

22. Observe actual operating practices
HACCP team must be familiar with every detail of each operation
Observe operation long enough to be confident of usual practices
Observe employees
Be attentive of the possibility of cross contamination after a kill step
Identified hazards must be recorded on appropriate form
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

23. Take measurements
Confirm actual processing conditions by taking measurements of important process parameters
Physical properties of the product as Aw, temperature, pH, moisture content
Residence time in processing steps
Dimensions, volumes
Storage conditions
Be sure of accuracy of measuring devices
Collect samples for microbial challenge studies if necessary
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

24. Analyse measurements
Qualified individual must analyse and interpret data to determine impact or processing conditions on identified hazards
For example, plot Aw / moisture content / temperature against time as indicated by the circumstances
Compare Aw or pH values with ranges known to support microbial growth
Estimate and evaluate cooling or thawing rates and determine influence on bacterial growth
Evaluate shelf stability of the product
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

25. Control measures
Control measures are any actions and activities that can be used to prevent or eliminate a food safety hazard or reduce it to an acceptable level
More than one measure may be required to control a specific hazard and
More than one hazard may be controlled by a specified measure
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

26. Controlling biological hazards
Minimize contamination
Prevent or minimize growth and toxin production using heating/cooling, low Aw, low Eh, high acidity, biological processes (e.g. fermentation), preservatives, etc.
Pathogens risk is based on concentration, not just presence / absence
Beware of possible concerted activity of more than one organism together
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

27. Controlling chemical hazards
Source control involving raw material specifications and vendor certification
Proper segregation of non-food chemicals during storage and handling
Control of incidental contamination from chemicals
Formulation control and proper use of additives
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

28. Controlling physical hazards
Source control – raw material specifications and vendor certification
Processing control – use of magnets, winnowers, screens, etc
Good maintenance of facilities and equipment
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

29. Use information from hazard analysis to determine
Hazard assessment
Use information from hazard analysis to determine
Severity of the hazard(s):
Magnitude of consequences that result when a hazard exists (high, moderate, low, negligible)
Risk of hazard(s):
Probability of an adverse effect (high, moderate, low, negligible)
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

30. Use information from hazard analysis to determine
Hazard assessment
Use information from hazard analysis to determine
Which hazards should be addressed under HACCP plan
Hazards of a low probability of occurrence and a low severity should not be addressed in HACCP plan but through GMPs
The points or steps at which control could be applied to prevent eliminate or reduce hazards to an acceptable level (CCPs)
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

31. Health risk assessment modelSa Mi Ma Cr
Low
Medium
High
Negligible
Likelihood of Occurrence
Severity of Consequences
Key
Cr – critical
Ma - major
Mi – minor
Sa - satisfactory
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

32. OTA contamination of coffee
A mycotoxin, Ochratoxin A (OTA), produced by different species of Aspergillus and Penicillium
Aspergillus niger
Aspergillus carbonarius
Aspergillus ochraceus
Penicillium verrucosum
Control of mould growth from primary production to shipping in order to reduce the risk of OTA contamination
All steps in the process flow chart must be analysed to determine points where control should be exercised to eliminate hazards or control them within acceptable limits
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

33. Scientific support for HACCP plan development
Comprehensive identification of potential hazards and sound evaluation of control measures requires availability of good data
‘Scientific support’ for HACCP-based safety management covers:
Mycology – ID of OTA-producers; investigation of conditions of mould growth and OTA- production
Evaluation of processing and handling technologies / equipment; moisture measurement devices
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)

34. Summary What are biological, chemical and physical hazards
Systematically identifying hazards
Control measures
Deciding which hazards are to be addressed under the HACCP plan
Next step: Determining the
critical control points in a process
Module 4.6 – List Potential Hazards; Conduct Hazard Analysis; Consider Control Measures (Task 6 / Principle 1)