THE APPLICATION OF HACCP SYSTEM IN MEAT PRODUCTS FOR CATERING INDUSTRY A PRACTICAL GUIDE FOR PORK LOIN CHOP

Headnote

ABSTRACT

The HACCP system is based on an assumption that the virtual hazard and irregularities in food processing may be detected before or during technological processes, so that their risk is minimalised. Preventing health hazards is a major objective of the HACCP system, which is currently considered as one of the most efficient tools available in this respect.

The aim of the present study is to elaborate selected sections of the HACCP system for meat products, to adapt and verify it in the production chain. The study involved a description of selected representative meat product - Pork Loin Chops, the production design, designation of critical control points (CCP) in the process, the hazard and the development of a hazard identification analysis sheet. A monitoring system, prevention and correction measures were also planned. The HACCP system was practically verified by testing its introduction and implementation during the production process.

- Key words: catering, critical control point, HACCP, food safety, meat products, pork loin chops -

PRACTICAL APPLICATIONS

Present investigations aimed at the minimization of contamination risk as the HACCP system are based on hazard identification during all stages of the food chain process. The system's main goal is the prevention of problems, facilitating the elimination of hazards originating from raw materials, equipment, human resources and accessories. Presented results are guidelines for modern catering industry, which may not work properly without quality control systems. The preparation of the presented HACCP system included a representative meal, starting with raw material acceptance and ending with consumption by consumers. Biological, physical and chemical hazards had been formulated and located. Quality control systems in catering business turned out to be beneficial on the condition that all actions are systematically controlled.

INTRODUCTION

Today's consumers' confidence in food safety is ensured by applied quality control systems. The Hazard Analysis Critical Control Point (HACCP) system is based on the control focused on operation points critical for food safety (CODEX ALIMENTARIUS, 2003). The other standards widely used include the Danish Standard (2002) or the new ISO 22000 Standard (2005). The main system's advantages are monitoring, preventiveness and easiness (HENSON et a?., 1999). Another positive aspect of the HACCP system is managing the resources, food hygiene, improved productivity and profitability and reduced production costs (WORSFOLD, 2001; WORSFOLD and GRIFFITH, 2003). On the other hand, also negative reasons why HACCP system incorrectly implemented would fail (MITCHELL, 1998). The most important of these are: no business and customers' demand, constraints on financial and human resources, and the absence of legal requirements (ENGEL, 1998; WORLD HEALTH ORGANIZATION, 1999). The first step in the implementation of food safety and quality systems along the entire food production chain is the GHP and GMP practice (CHARISIS, 2004; USDA, 2005; FDA, 2008). Good Hygiene Practice (GHP) refers to procedures that must be undertaken and hygiene conditions that must be fulfilled and monitored at all stages of production or trade in order to guarantee food safety, while Good Manufacturing Practice (GMP) is focused on actions, conditions that must be fulfilled and materials admissible for contact with food, that are properly executed, guarantying food safety for human consumption.

The accession of Poland to the European Union was a milestone for the development of food and catering industry. According to the Council Regulation (EC) No 852/2004, since 1st of January 2006 the implementation of the HACCP system is obligatory for all sectors of food business that participate in food production and distribution processes. The HACCP system was introduced and extended by the government aiming at enhancing food safety (WORLD HEALTH ORGANIZATION, 2003.). Free trade exchange within the European Union requires the unification of food legislation and quality standards within the EU. The HACCP system was primarily recommended to food exporters, then it became a required system for all food industry units as a food safety assurance tool (HEALTH & CONSUMER PROTECTION D.G., 2005.). As the living standards in Poland are improving and more foreigners visit our country every year, it has become very important to increase food product safety and thus welfare of the domestic consumer.

Catering and restaurant meals have been mainly implicated in foodborne disease outbreaks (TAYLOR, 2008; COMMUNITY SUMMARY REPORT, 2009; WIENEKE et al, 1993). Main contributors to general outbreaks are Clostridium perfringens, Salmonella, Staphylococcus aureus, Listeria monocytogenes and Bacillus cereus (DeROEVER, 1999; SORIANO et a?,. 2002). Research showed that the introduction of a HACCP system facilitated an improvement of microbiological quality of meals (BRYAN, 1990; MARTINEZ-TOME et ah, 2000; LITTLE et a?., 2002; WALKER and JONES, 2002). The application of the HACCP system also makes it possible for producers to take correct and safe actions in case of governmental inspection. The benefits of quality control systems would be manifested on the condition that all food chain actions are systematically controlled. Hazard analysis and critical control points system is applied both in basic production and at all stages of the food chain, starting with farms and finishing with consumer safety (SUN and OCKERMAN, 2005; BAS etat, 2006; KNAFLEWSKA and POSPIECH, 2007).

Practically no research has been conducted in this field, especially on practical guidelines and examples of implementation of the HACCP system in Poland. Although current literature shows many aspects of HACCP and advantages and disadvantages of its implementation, there is still a limited body of literature showing the manner of applying the quality assurance system particularly in food production, e.g. grocery products (GRAMZA-MICHALOWSKA and KORCZAK, 2008; VARZAKAS and ARVANITOYANNIS, 2008).

The objective of this study is to elaborate selected aspects of the HACCP system based on a representative meat product, i.e. pork loin. Research involved a description of the selected meat product, production design, designation of critical control points (CCP) in the processes, the hazard and the identification analysis sheet. On the basis of received data selected chapters of the HACCP manual for catering meat products were created. Research also showed the complexity and precision that is required for the HACCP system for its correct adoption and satisfactory operation.

MATERIALS AND METHODS

The subject of the study is the implementation of the HACCP system in food production at a restaurant. The menu of the restaurant was checked and corrected following the actual technological process, all the HACCP system procedures were presented and adapted. Pork loin was selected as a representative of meat products, and then technological processing and its production now diagram were elaborated, corrected and verified according to its daily application. Afterwards hazard identification, its controlling procedures and critical control points identification were evaluated. Identification of CCP was carried out using the HACCP decisive tree (CODEX ALIMENTARIUS, 2003). Subsequently parameters and inspection characteristics for critical limit assessment, CCP monitoring and controlling methods and corrective measures have been elaborated. The last step of HACCP implementation in practice was to conduct the documentation and HACCP system verification processes.

RESULTS AND DISCUSSION

The implementation of basic sanitary and HACCP system requirements allows food producers to evaluate a complete HACCP manual. The most important step is product specification, so not the sensory value, but consumer safety should be the most important aspect (Table 1). A conventional product description should include: materials, recipe, basic storage conditions (label), and expiration date or instruction for use. It is also very important to foresee all possible uses and evaluate a potential negative effect on consumers' health, including other preparation methods or a possible presence of allergens.

The next step is the elaboration of technological process design (Fig. 1). The technological process flow diagram should be drawn by technologists or cooks that know best the specific production steps. All production flow diagrams need to be verified in practice, otherwise they will never be adequate for a correct operation of HACCP systems. The verification process makes it possible to find potentially forgotten side processes and procedures that play an essential role in integral food production. This step is not concerned with any hazard analysis, but it includes only specific processes.

The most common mistakes in the evaluation of hazard analysis include confusing causes and effects, or even ignoring other hazards that might occur during the production chain. A standard procedure for the hazard analysis sheet is to create a table consisting of process stages, hazard identification, description, category (biological, physical and chemical), prevention procedures and corrective measures (Table 2). The next step is to evaluate the importance of control points with the use of a decisive tree. A series of different questions and answers leads to the determination of critical control points. According to the HACCP system regulations, the CCP is a part of procedure or step which should be controlled and where food safety hazard can be prevented, eliminated or reduced to acceptable levels. The most common critical control points in catering production are shown to be: the acceptance of materials and products, storage, heat processing or cooling, and washing of consumers' utensils. An average CCP list consists of too many points determined. Usually it is done by thinking forward (commonly called "just in case"), which is surely not a good manner of HACCP implementation. The number of marked CCPs is clearly reversely proportional to the modernity of a given catering institution and employees' knowledge. The next step of HACCP implementation is the designation of parameters for critical CCP values (Table 3). Critical values should be described as easy to measure, especially since the catering process is very fast and it could be a problem to conduct microbiological analysis of products. The monitoring system should be defined as a specific and detailed information source, concerning who and how should monitor CCPs. The possibility of losing control over a CCP (exceeding critical limits) should be easy to identify, while produced food needs to be condemned, specifically labeled, protected and separated from other food products. Such an inadequate food product should be marked and considered as an incompatible product. The verification process should be continuous with the use of audit or laboratory evaluations (e.g. levels of pathogens or chemicals), especially when the food process is modernized. The HACCP system verification is mainly based on the correct critical control point monitoring and efficient sanitary procedures. Apart from actual practical evaluations, the correctness of HACCP system documentation should also be continuously checked. When a food safety assurance system is regularly working the Quality Manual is introduced to the auditor for the system documentation approval.

CONCLUSIONS AND IMPLICATIONS

Consumer protection as the last step of the food chain is the most essential step during the HACCP quality control system evaluation. The application of the HACCP system facilitates a faster and simpler execution of adequate control measures and as a result the elimination of hazards. It promotes consumer confidence in food safety and quality.

Restaurants or catering business with the applied HACCP system proved its correct and safe operation in case of governmental inspection. Quality control systems may turn out to be beneficial on the condition that all actions are systematically controlled. The catering industry should first work on the basis of GHP and GMP systems, creating an accurate and safe environment for the correct realization of the production process. The preparation of the presented FlACCP system included pork loin chop production, starting with raw material acceptance and ending with consumption by clients. The present study formulated and located biological (e.g. pathogens), physical (e.g. bones), and chemical hazards (e.g. cleaning liquid residues). For meat products two critical control points were identified. The most important is the control of storage conditions, but heat processing is crucial for meat product safety and quality. Aiming at the minimization of contamination risk the FIACCP system is based on hazard identification in the technological process, during all stages of the food chain process. The system's main goal is the prevention of problems, facilitating the elimination of hazards originating from raw materials, equipment, human resources and accessories. Modern catering industry may not work properly without quality control systems following government and European Union regulations and directives. Moreover, today's conscious consumers demand high quality food products provided with meal safety assurance.

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Paper received March 16, 2010 Accepted July 20, 2010