Food Safety for the 21st Century

Sara .E. Mortimore, Vice President Quality and Regulatory Affairs, Land O'Lakes, Saint Paul, Minnesota, USA Carol A. Wallace, University of Central Lancashire, UK William H. Sperber, Cargill, USA

Preface xiii Acknowledgements xv Disclaimer xv How to use this book xvi The authors xviii Glossary of terms and acronyms xx PART ONE FOOD SAFETY CHALLENGES IN THE 21ST CENTURY 1 1 Origin and evolution of the modern system of food safety management: HACCP and prerequisite programmes 3 1.1 Historical perspectives 3 1.2 Origin and evolution of HACCP 5 1.3 The necessity of prerequisite programmes 10 1.4 The future of HACCP 10 2 Lessons learned from food safety successes and failures 12 2.1 Introduction 12 2.2 Benefits of using HACCP - lessons learned from successful implementation 12 2.3 Misconceptions or 'failure to understand HACCP' 14 2.4 Barriers to effective HACCP use 20 2.5 Reasons for failure 21 2.6 Difficulties with applying HACCP through the entire food supply chain 24 2.7 Roles and responsibilities - lessons learned 26 2.8 Conclusions 28 3 Food safety challenges in the global supply chain 30 3.1 Introduction 30 3.2 Increased complexity of the global supply chain 32 3.3 Food safety issues in global trade 37 3.4 Strategic-level responses 41 3.5 Tactical level responses 43 3.6 Conclusions 46 4 The future of food safety and HACCP in a changing world 48 4.1 Introduction 48 4.2 Food safety issues 49 4.3 Technology advancements 50 4.4 Food safety management 51 4.5 Changes in thinking/policy making 59 4.6 Conclusions 61 PART TWO FOODBORNE HAZARDS AND THEIR CONTROL 63 5 Recognising food safety hazards 65 5.1 Introduction 65 5.2 Biological hazards 66 5.3 Chemical hazards 78 5.4 Physical hazards 85 5.5 Conclusions 86 6 Designing safety into a food product 87 6.1 Introduction 87 6.2 Formulation intrinsic control factors 87 6.3 Use of experimental design and analysis 97 6.4 Ingredient considerations 102 6.5 Conclusions 104 7 Designing a safe food process 105 7.1 Introduction 105 7.2 Process control of microbiological hazards 106 7.3 Process control of chemical hazards 117 7.4 Process control of physical hazards 119 7.5 Conclusion 122 PART THREE SYSTEMATIC FOOD SAFETY MANAGEMENT 123 8 Overview of a world-class food safety programme 125 8.1 Introduction 125 8.2 Preliminary concepts and definitions 126 8.3 World-class food safety programmes in the global food supply chain 130 8.4 Continuous improvement of the world-class food safety programme 131 8.5 Conclusions 132 9 Building the foundations of a world-class food safety management programme: essential steps and practices 133 9.1 Introduction 133 9.2 Essential management practices 135 9.3 Preparation activities for food safety programmes 143 9.4 Prioritisation of corrective actions 150 9.5 Conclusions 152 10 Formalised prerequisite programmes in practice 154 10.1 Introduction 154 10.2 Prerequisite definitions and standards 154 10.3 Prerequisite programmes - the essentials 155 10.4 Prerequisite programmes and operational prerequisites 173 10.5 Validation and verification of prerequisite programmes 175 10.6 Conclusions 175 11 Conducting a product safety assessment 176 11.1 Introduction 176 11.2 Training for research and development personnel 179 11.3 Example of a product safety assessment 179 11.4 Conclusions 184 12 Developing a HACCP plan 185 12.1 Introduction 185 12.2 Preliminary concepts 186 12.3 Applying the codex logic sequence to develop a HACCP plan 189 12.4 Conclusions 215 13 Implementing a HACCP system 216 13.1 Introduction 216 13.2 Activities for implementation of a HACCP plan 217 13.3 Considerations for implementing updates and changes to an existing HACCP system 223 13.4 Conclusions 223 14 Maintaining a food safety programme 224 14.1 Introduction 224 14.2 What is food safety programme maintenance? 224 14.3 Responsibility for food safety programme maintenance 225 14.4 Maintenance of prerequisite programme elements 226 14.5 Maintenance of HACCP system elements 226 14.6 Use of audit for successful food safety system maintenance 228 14.7 Incident Management 233 14.8 Conclusions 233 References 235 PART FOUR APPENDICES 245 Appendix 1 HACCP case studies 247 Introduction 247 Case study 1: Shell eggs - food safety case study 249 Case study 2: Manufacturing - prepared meals 271 Case study 3: Food service - Lapland UK food service operation 293 Case study 4: Food safety in the home: a review and case study 303 Appendix 2 Global food safety resources 311 Index 315