lautnusantara.com Foodborne diseases pose a serious threat to public health. Cross-contamination, improper storage, and unhygienic food processing are some of the main causes of these illnesses. According to Ministry of Health data from 2023, there were 4,792 cases of food poisoning as of October 16, an increase of 1,000 cases from the previous year. This figure highlights the importance of strict food safety oversight at every stage of production and distribution.

Risk of Hazardous Exposure

In the food industry, strict operational standards, including the use of masks and gloves by food handlers, are initial steps to ensure cleanliness and prevent contamination. However, the risk of contamination doesn't just come from harmful microorganisms, but also from heavy metals such as Arsenic (As), Lead (Pb), Cadmium (Cd), Mercury (Hg), and Tin (Sn). These heavy metals can accumulate in food products and pose serious health risks to consumers. Therefore, a comprehensive prevention strategy is needed to avoid the entry of harmful substances into the body through the consumption of food products.

Understanding HACCP

HACCP (Hazard Analysis and Critical Control Point) is a scientific, systematic method that identifies specific hazard risks and their control measures to ensure the safety of manufactured food products. By focusing on contamination prevention, HACCP can help plan work processes in the food industry, including designing equipment and processing procedures. Here are the 7 principles of HACCP:

Principle 1: Conduct a Hazard Analysis

The first step in the HACCP system is to conduct a hazard analysis. This involves identifying and evaluating biological, chemical, and physical risks that may occur at each stage of food production. This allows the HACCP team to determine effective control measures. For example, in chicken processing, the risk of microbiological contamination in raw materials can be controlled by ensuring proper storage temperatures.

Principle 2: Determine Critical Control Points (CCPs)

Identifying Critical Control Points, or CCPs, as the second principle, is where control is necessary to eliminate or reduce risks to an acceptable level. The application of a CCP decision tree aids in this identification process, emphasizing the importance of a tailored approach based on the unique characteristics of each production facility. An example of a CCP in chicken processing is the storage temperature of raw materials to prevent microbiological contamination in processed chicken.

Principle 3: Establish Critical Limits

Establishing critical limits is the third principle. Critical limits define the operational parameters considered safe. It's crucial to clearly establish and communicate these critical limits to all relevant parties to ensure the safety of manufactured food products. An example of a critical limit is a storage temperature of below -18°C to prevent microbial growth.

Principle 4: Establish Monitoring Procedures

Monitoring ensures that production processes run according to established standards. Effective monitoring requires accurate equipment and trained personnel, allowing for early detection and prevention of deviations from critical limits. For example, storage temperature monitoring is performed every 4 hours (at the beginning, middle, and end of the shift) to detect deviations from the established critical limits.

Principle 5: Establish Corrective Actions

Effective corrective actions ensure that every work process is handled appropriately and the HACCP system operates according to the established plan. This involves systematic evaluation of the HACCP plan and process validation to ensure its effectiveness in controlling hazards. For example, if the storage temperature is found to be above -18°C, the freezer needs to be inspected, and raw materials must be immediately moved or processed.

Principle 6: Establish Verification Procedures

Verification procedures by individuals with relevant technical expertise ensure the integrity and effectiveness of the HACCP system. For example, the QC team conducts periodic temperature measurements to verify the effectiveness of temperature control.

Principle 7: Establish Record-Keeping and Documentation Procedures

Finally, comprehensive record-keeping and documentation, as the seventh principle, ensure that all aspects of the HACCP system are well-documented, from hazard analysis to implemented control measures. This allows for tracing and verifying the system's effectiveness in maintaining food safety. For example, recording freezer temperatures on a temperature measurement form with a signature facilitates tracing and verification.

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Examples of Important Steps in Ensuring Food Safety

Identifying Microbiological Hazards in Raw Chicken

Microbiological hazards, such as Salmonella and E. coli bacteria, are often found in raw chicken. This risk can increase if raw materials are not stored at the correct temperature. Therefore, it's important to conduct a hazard analysis as the first step in the HACCP system.

Determining Critical Control Points (CCPs)

The CCP for processed chicken is the storage temperature of raw materials. Maintaining the correct storage temperature is essential to prevent the growth of harmful microorganisms.

Establishing Critical Limits

The critical limit for raw chicken storage temperature is set below -18°C. This temperature is chosen based on food safety guidelines indicating that temperatures below -18°C can inhibit microbial growth.

Monitoring Procedures

Storage temperature monitoring is performed every 4 hours, including measurements at the beginning, middle, and end of the shift. This monitoring ensures that the temperature always remains within the established critical limits.

Corrective Actions

If the storage temperature is found to be above -18°C, the first step is to check the freezer's function. If the freezer is not functioning properly, the raw materials must be immediately moved to another freezer with the correct temperature or promptly processed to prevent the risk of contamination.

Verification Procedures

The QC team or storage team must conduct periodic temperature measurements as part of the verification procedure. This verification ensures that all control measures have been implemented correctly and effectively.

Record-Keeping and Documentation Procedures

Recording freezer temperatures on a temperature measurement form with a signature is an important part of HACCP documentation. This documentation allows for tracing and auditing the storage process, as well as ensuring compliance with food safety standards.

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