haccp and hygiene in honey production ©2005 by qsi argentina, oct./nov. 2005honey - haccp1 haccp...
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©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 1
HACCP and hygiene in honey production
HACCP & Hygiene in HACCP & Hygiene in honey productionhoney production
Buenos Aires, Concepción del Uruguay, Mendoza
October / November 2005
©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 2
HACCP and hygiene in honey production
Content of the seminar
1. General requirements of hygiene in honey production
2. HACCP: A brief introduction
3. “Good beekeeping practice”
4. HACCP in honey processing
5. Establishing self-checking mechanisms in honey production according to HACCP principles
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HACCP and hygiene in honey production
1.
General requirements of hygiene
in honey production
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HACCP and hygiene in honey production
Hygiene in honey production is protection
against
dirt and diseases spoiled food complaints financial losses
1.
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HACCP and hygiene in honey production
Hygiene in honey production is necessary because
• legislations (EC Regulations 852/853/854)• consumer protection• product liability• prerequisite program for HACCP under the aspect of food safety (EC-
Regulation 178/02) demand it.
1.
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HACCP and hygiene in honey production
European Community Legislation
• Council Regulations law in every member state
• EC Directivesshall be adopted in member statesno legal force until promulgated by national parliament
• Horizontal legislation refers to all food stuffs e.g. for contaminants, additives, labelling Regulation EEC 2377/90 drugs )Directive 96/23/EC (monitoring)
Vertical legislation refers to specific products e.g. Honey Directive 2001/110/EC
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HACCP and hygiene in honey production
EC Hygiene Regulations
852/2004 general food hygiene
853/2004 specific requirements for food of animal origin
854/2004 specific procedures for the official control of food of animal origin
replacing 16 different Directives
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HACCP and hygiene in honey production
What is new ?
• primary production is included • all food producing companies must be
registered • principle of equivalence for imported food
from third countries• HACCP mandatory as well as documentation
as self control
.
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HACCP and hygiene in honey production
852/04 (9)
Community rules should not apply either to primary production for private domestic use, or to the domestic preparation, storage or handling of food for private domestic consumption. ..........
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HACCP and hygiene in honey production
HACCP for smaller enterprises
852/04 Article 5
The HACCP requirements .........They should provide sufficient flexibility to be applicable in all situations including small businesses. In particular it is necessary to recognize that in certain businesses it is not possible to identify critical control points and that in some cases a good hygienic practice can replace the monitoring of critical control points. ..........
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HACCP and hygiene in honey production
Basic Regulation Food Safety 178/02
e.g.
Consumer protectionTraceabilityRapid Alert System
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HACCP and hygiene in honey production
Prerequisite for HACCP
Cleaning and sanitationsPest controlSupplier approvalEmployee trainingPersonal hygieneWater controlMaintenanceProduct specifications Product storage control
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HACCP and hygiene in honey production
Hygiene only works for teams, if everyone uses the same set of rules.
validity for everyone regular reminder standard information reliable inspection mutual confidence
1.
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HACCP and hygiene in honey production
Cleaning and sanitation applies to
• the working area • the equipment and • the people coming into contact with or close
to the product is
ESSENTIAL!
1.
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HACCP and hygiene in honey production
Washing facilities must be available:
- Working rooms must be equipped with:
- wash-basin (warm and cold water)
- paper towels, liquid soap dispenser
- Toilets:
- with wash-basin
- separate toilet entrance with anteroom
1.
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HACCP and hygiene in honey production
Also necessary:
- Sufficient air ventilation to prevent condensed water and foreign odors
- Adequate temperatures
- Artificial lighting with splinter protection
- Dressing-rooms with wardrobe for clean working clothes (separated from street clothes)
- No pets
- Exclusion of any people suffering from infectious
diseases
1.
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HACCP and hygiene in honey production
Further prerequisites for working rooms and equipment:
Floors:
- must be cleaned regularly
- made of non-toxic materials
- water-proof and hydrophobic
Ceilings:
- prevent condensed water
- no moulds
- no removable fragments (loose paint particles e.g.)
1.
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HACCP and hygiene in honey production
Windows:
-supplied with gauze or fine mesh (exclusion of pests and insects)
Doors:
- with plane, hydrophobic and easy-to-clean surface
Surfaces, tools and appliances, walls:
- made of plane, cleanable and non-toxic materials.
- desinfection possible
Further prerequisites..., contd.
1.
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HACCP and hygiene in honey production
Equipment:
- free of corrosion
- containers made of food-safe, cleanable and smooth material
- can be disinfected easily
Suitable cleaning devices
- must be easy-to-clean
- corrosion-proof
- must be kept clean best using a dishwasher
Further prerequisites..., contd.
1.
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HACCP and hygiene in honey production
2.
HACCP: A brief introduction
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HACCP and hygiene in honey production
Definition of HACCP
Hazard
Analysis
Critical
Control
Point system
2.
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HACCP and hygiene in honey production
• HACCP is a preventive safety system that
ensures the production of harmless foods
• most powerful method to repel and eliminate possible hazards regarding foods
• enables applying science-based controls
• from raw material to finished products
2.
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HACCP and hygiene in honey production
A biological, chemical or physical agent that is reasonably likely to cause illness or injury in the absence of control.
• Biological (e.g. bacteria, virus)• Chemical (e.g. drug residues, cleaning
compounds, heavy metals, mycotoxins)• Physical (e.g. wood, metal, stones, glass, hair,
jewelry, plastic)
The hazards
2.
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HACCP and hygiene in honey production
HACCP is not a stand-alone system. It works hand in hand with
• Standard Operating Procedures (SOPs)
• Definite responsibility
• Documentation
2.
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HACCP and hygiene in honey production
Prerequisites to HACCP
• Good Processing Practices (GPP)• Good Hygiene Practices (GHP)• Good Manufacturing Practices (GMP)
• Appropriate QM systems like ISO series
2.
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HACCP and hygiene in honey production
HACCP
SOP
GPP
GMP
GHP
2.
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HACCP and hygiene in honey production
1. Realization of a hazard analysis 2. Identifying and setting Critical Control Points (CCPs)3. Setting Critical Limit(s) and standards4. Monitoring of each relevant CCP in honey production 5. Establishing corrective actions6. Verification of the system7. Documentation procedures
The seven principles of HACCP
2.
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HACCP and hygiene in honey production
3. Good Beekeeping Practice
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HACCP and hygiene in honey production
Application of good beekeeping practice is required for
1. working at the beehives
2. harvesting and transporting honey
3. extracting honey from supers
4. storing honey
5. bottling honey
3.
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HACCP and hygiene in honey production
Contaminants from beekeeping
Environment
- Pesticides- Heavy metals - Bacteria-Genetically modified organism (GMO)- Radioactivity
Beekeeping
- Acridicides for Varroa control- Antibiotics against diseases e.g. AFB, EFB - Pesticides for wax moth control- Repellents at honey harvest- Other contaminants
Contamination
of honey
Plants, Air, Water
3.
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HACCP and hygiene in honey production
CONTAMINANT SOURCE OF CONTAMINATION
CONTROL MEASURE
1. Antibiotics in honey Control of bacterial diseases with antibiotics (AFB, EFB, Nosema)
Alternative control without the use of antibiotics
2. Synthetic acaricides in bees Wax, propolis and honey
Varroa control with synthetic acaricides
Alternative Varroa control without synthetic acaricides
3. Pesticides in honey and beeswax
Control of wax moth with pesticides; Chemical control of the Small Hive Beetle
Wax moth control by alternative measures. Alternative control of the SHB
4. Repellants for honey harvest
Use of synthetic repellents at the honey harvest
Use of smoker with natural material, “mechanic systems”
5. Toxic metals or organic substances
container, drum Use material which do not diffuse contaminants into honey
6. Wood protectants, Painting Pesticides in wood protectants Use of wood protectants containing no pesticides
Contaminants from beekeeping and control measures
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HACCP and hygiene in honey production
Contamination:
Today major factor for quality of honey
Incorrect apicultural practice
including hygiene e.g. as prevention of diseasesinstead of using „medicine“
3.
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HACCP and hygiene in honey production
Selected examples for important sources for hazards corresponding to “good beekeeping practice”
Example Defect
Control Measures:
1 Jars and lids before filling
Contamination dirt, foreign,l odour, remaining water Hazard of quick deterioration of the content! SEM ! as residue of sealing compound lids Azodicarbonamide
Visual and sensory check
Another cleaning or destroying of the damaged jars/lidsreplace with other material
2 Liquefying honey , heat treatment
D: Reduction of the enzyme activity; if HMF > 40 mg Complaints accord. to honey directives C: Temperature, time, quick cooling
Tempera-ture, time measuring
Use as industrial honey
3.
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HACCP and hygiene in honey production
Example Defect
Control Measures:
3 Straining honey foam
In the scum there might be wax particles that possibly contain harmful residues or other contaminants
Visual control
Removal of remaining honey scum by other methods
4 Addition of nuts or dried fruits to cream honey
Contamination of nuts / dried fruits with mould or pests Honey product is deteriorated
Looking for mould, cocoons etc.
Visual control
Dispose of the nuts / dried fruits
3.
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HACCP and hygiene in honey production
Example Defect Control Measures
5 Cleaning pollen (blowing out, sorting by hand)
Organic contamination, foreign substances (dust), impurities, etc.
Insect bodies or parts of them
Visual control
Another cleaning
6 Insufficient drying of Pollen
storage
Deterioration possible (water content) Storage temperature max. 6 °C (freezer: -18 °C)
Continuos tempera-ture control
Adjustment of temperature
3.
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HACCP and hygiene in honey production
Example Defect Control Measures
7 Storage of Royal jelly- cooled- frozen
Quick deterioration possible Storage temperature max. 4°C (freezer: -18 °C)
Continuos tempera-ture control
Adjustment of temperature; thawed pollen mustn’t be freeze again
3.
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HACCP and hygiene in honey production
4.HACCP in honey processing
- Realization of a hazard analysis - Identifying preventive measures - Identifying and setting critical control points (CCP) - Setting critical limits and standards - Monitoring of each relevant CCP in honey production - Establishing corrective actions - Documentation procedures
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HACCP and hygiene in honey production
HACCP Implementation
1. Must have Management Commitment
2. most Food Safety Failures are Management Failures
3. Must follow the 7 principles to develop HACCP at each Production Plant
.
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HACCP and hygiene in honey production
I. Assembling the HACCP team
Multidisciplinarye.g. beekeepers, co-workers of the collecting stations, analysts, representatives of quality control, engineers4-6 peopleTeam must be able to evaluate risks and make food safety judgements
HACCP Plan Development
.
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HACCP and hygiene in honey production
II. Describing the food and its distribution
• Types of raw material e.g. liquid honey, creamed honey, comb honey, bulk honey, wax, pollen, propolis
• Intrinsic control factors (moisture, colour)
• Process control factors (heating, drying)
4.
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HACCP and hygiene in honey production
III. Describing intended use and consumers
e.g. pharmaceutical industry, food industry, cosmetic industryConsumer all groups of the population
4.
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HACCP and hygiene in honey production
IV. Developing a flow diagram
• Including all process steps e.g. uncapping, extracting, straining, filtering, homogenising, stirring, packing, storage
• Including all inputs e.g. raw material, package material, water, air
4.
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HACCP and hygiene in honey production
V. On-site confirmation of the flow diagram
1.all steps of the operation
2.all times of production
3.modify flow diagram as necessary
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HACCP and hygiene in honey production
VI. List all potential hazards associated with each step, conduct a hazard analysis and consider any measures to control identified hazards.
• likely occurrence of the hazards
• expected severity of the hazards
4.
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HACCP and hygiene in honey production
Physical Hazards (P)
• Insect fragments• Soil• Plant material• Packaging• Glass• Equipment
Hazards in honey processing
4.
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HACCP and hygiene in honey production
Chemical Hazards (C)
• Pesticides and herbicides • Bee medicines, antibiotics• Bee repellents • Coating / varnish of drums
4.
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HACCP and hygiene in honey production
Biological Hazards (B)
• Pathogens e.g. Clostridium botulinum
4.
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HACCP and hygiene in honey production
Hazards may occur as a result of:
• an input (object, material)
• the process itself
• direct or indirect contamination from „other sources“
4.
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HACCP and hygiene in honey production
Inputs & associated hazards
Bee Hive material
Wax
Bee hive sites
Drums
Glass jars
4.
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HACCP and hygiene in honey production
Hazards at different process steps
1. Removing the honey combs out off the hives
2. Holding in hot room
3. Uncapping
4. Extracting
5. Liquefying
.
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HACCP and hygiene in honey production
Form for evaluation of hazards and possibilities for control (Agroscope Liebefeld-Posieux,Schweizerisches Zentrum für Bienenforschung, 2004)
4.
1.1 HAZARD: CONTAMINATION
Hive a) Contamination by the environment: (agriculture, industry) by heavy metals, pesticides etc.
medium Identification and contamination source place the hives to a another site
b) Bees are intoxicated by pesticides small Identification and contamination source and its avoidance
©2005 by QSI Argentina, Oct./Nov. 2005 Honey - HACCP 52
HACCP and hygiene in honey production
Form for evaluation of hazards and possibilities for control (Agroscope Liebefeld-Posieux,Schweizerisches Zentrum für Bienenforschung, 2004)
1.1 HAZARD: CONTAMINATION
IMPORTANCE CONTROL MEASURES
Hive a) Lack of order and hygiene, endangering quality of bee products
medium Re-installment of order, cleanness and hygiene
Extraction Plant resp. room
b) Lack of order, cleanness and hygiene, bees present, foreign odour
great Re-installment of order, cleanness and hygiene
c) Centrifuge, tanks are improper, rusty
great Re-installment of order, cleanness and hygiene
d) Instrumentation and instruments are cleaned with waste water e.g. pond, river
great Use drinking water
4.
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HACCP and hygiene in honey production
1.2 HAZARD: ADULTERATION, CONTAMINATION
Feeding of bees
a) Sugar syrup is mixed with honey great Correct choice of time and quantity of sugar feeding
b) Use of improper water when preparing sugar feed leads to transfer of contaminants into the hive.
great Use of drinking water
1.3 HAZARD: CONTAMINATION
Bee diseas-es
Treatments of bees contrary to instructions resp. illegal treatment leads to intolerable residues in honey
great Follow instructions of veterinary authorities
4.
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HACCP and hygiene in honey production
1.4 HAZARD: CONTAMINATION
Change and storage of combs
Combs are very dark, there are moths and bee excretions, dirt which might cause bee infections and honey contamination. Use of pesticides for wax moth control
great Regular control of brood and honey combs. Optimise storage of combs. Use alternative control for wax moth control.
1.5 HAZARD: CONTAMINATION, ADULTERATION
Honey harvest
a) Water content of honey >20 % small Harvest honey with less than 20% w.cont.
Packing storage and labelling
b) In honey there are contaminats from wax, bees, dirt, extraneous substances and odours
medium Re-installment of order, cleanness and hygiene
c) Improper conditions of honey storage leads to dcrese of honey quality
medium Store honey at optimal conditions (room, recipients)
d) overheating of honey while packing leads to reaching of too much HMF
medium Liquefy honey at the optimum temperature and time
4.
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HACCP and hygiene in honey production
VII. Identifying preventive measures
4.
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HACCP and hygiene in honey production
Step Risk Measure Application of antibiotics and pesticides
Contamination of bee products caused by the application of anitbiotics/presticides
1. Ban of antibiotics 2. Regulation of pesticides
application by plant sanity 3. Monitoring of chemical
compounds 4. Training
Feeding of bees Quality, application and handling of feedstuff
1. Purchase of suited feedstuff
2. Usage of suited equipment 3. Correct application of
feedstuff Desinfection and cleaning of hives
Transfer of diseases Fufillment of hygenic and health norms
Examples for preventive measures
4.
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HACCP and hygiene in honey production
Identifying and setting Critical Control
Points (CCPs)
The seven principles of HACCP, contd.
4.
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HACCP and hygiene in honey production
CCP =
A step where control can be applied and is essential to prevent, eliminate or reduce a food safety hazard to an acceptable level
CP = means any point, step or procedure in a specific food system at which biological, physical and chemical factors can be controlled
.
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HACCP and hygiene in honey production
Critical control-points show where
processes have to be supervised
Creating a decision tree facilitates finding the CCPs
4.
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HACCP and hygiene in honey production
The decision tree Questions
4.
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HACCP and hygiene in honey production
Q1: Do control measure(s) exist?
No
Is control necessary here? Yes
No
Modify step, process orproduct
Not a CCP Stop
Yes
4.
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HACCP and hygiene in honey production
Q2: Is the step specifically designed to eliminate or reducethe likely occurance of a hazard to an acceptable level?
Yes
CRITICAL CONTROL POINT
4.
No
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HACCP and hygiene in honey production
Q3. Could the identified hazard increase to unacceptable levels?
No
Not a CCP Stop
4.
Yes
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HACCP and hygiene in honey production
Q4. Will a subsequent step eliminate identified hazard(s) or reduce likely occurrence to an acceptable level ?
No
CRITICAL CONTROL POINT
Yes
Not a CCP
Stop
4.
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HACCP and hygiene in honey production
3. Setting Critical Limit(s) and standards
The seven principles of HACCP, contd.
4.
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HACCP and hygiene in honey production
Critical limit =
A criterion that separates
accceptability from unacceptability
4.
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HACCP and hygiene in honey production
A critical limit
- must relate to control measure - must be observable / measurable (time, temp., pH etc.) - must be validated
4.
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HACCP and hygiene in honey production
Examples for critical limits:
• For the application of e.g. antibiotics, bee-repellents, wood preservatives
• Limits in honey for e.g. water content (fermentation), HMF, invertase, diastase, antibiotics, pesticides (regulated by law)
• Contamination by cleaning agents
• Adulteration e.g. by sugar cane, maize (C4-sugars)
4.
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HACCP and hygiene in honey production
Limits are a result of:
- Legislations / guidelines - Directives - Specifications within the own company
if limits exceeded: corrective action
4.
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HACCP and hygiene in honey production
The seven principles of HACCP, contd.
4. Monitoring of each relevant CCP in honey production
4.
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HACCP and hygiene in honey production
Monitoring of each CCP means:
• watch and check CCPs to ensure that instructions and corrective procedures are carried out right
• Determing for each CCP:– Who?– When?– What?
4.
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HACCP and hygiene in honey production
5. Establishing corrective actions
The seven principles of HACCP, contd.
4.
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HACCP and hygiene in honey production
Corrective actions depend on the faults, see examples next pages
4.
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HACCP and hygiene in honey production
Corrective actions have to be introduced as soon as critical limits are exceeded so the CCPs will not get out of control
2nd measure:stop process anddispose products
1st measure: influence products or processes
or
4.
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HACCP and hygiene in honey production
CCPs in the Honey Process
I. The hive and the honey removal
II. Transportation of honey in supers
IV. Filtration
III. Uncapping
VI. Preparation to bottle & bottling
VII. Distribution & display
V. Storage
4.
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HACCP and hygiene in honey production
I. The hive and the honey removal
Inputs
• Honey supers
• Uncapping, sump, pump to tanks
Final Output
• Bulk honey
4.
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HACCP and hygiene in honey production
Hazards
• Physical: soil, wire, wood, varnish particles, rust etc.
• Chemical: - medicines: pest., antibiotics, - plant toxins (e.g. pontic honey, tutin) - paints, preservatives• Biological: - Bacterial spores e.g.
Clostridium
MonitoringCheck:• - No contact with soil /
vegetation • - Chemicals applied for
suitability of use- Regular inspections to detect vermin infestations
- Treatment - Instructions for use• Reliable lab. test, reports
I. The hive and the honey removal4.
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HACCP and hygiene in honey production
Control and corrective action
• Dispose off honey • Use as winter feed (if recognized as safe)
I. The hive and the honey removal4.
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HACCP and hygiene in honey production
II. Transportation of honey supers
Hazard:• Physical and chemical
contamination from:
- Transportation
- Animals
- Rain water
Monitoring:• Inspect vehicles
- Clean and free from petrol, oil, soil, plant & animal material
- Cover super with e.g. polythene sheet
4.
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HACCP and hygiene in honey production
Control and Corrective Action:
• Dispose off honey
II. Transportation of honey supers4.
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HACCP and hygiene in honey production
III. Uncapping and extraction
Hazard• Contamination from
- Equipment (not stainless steel parts)
- room
- people
Monitoring• Inspect all equipment• Clean daily resp.
regularly• Provide suitable
clothing
4.
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HACCP and hygiene in honey production
Control and Corrective Action:
• Complete all checks before processing start• Documentation !!
III. Uncapping and extraction4.
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HACCP and hygiene in honey production
IV. Filtration
Hazard• wax with residues• foreign matter
Monitoring• Check filters before and
after use for damages
4.
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HACCP and hygiene in honey production
Control and Corrective Action:
• Re-filter with good filter if found damaged after use
IV. Filtration 4.
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HACCP and hygiene in honey production
V. Storage
Hazard• Contamination from
- container
- surroundings
- pests• high HMF due to high
temperatures• Moisture increase on
surface
Monitoring• Check containers for
food storage suitability• Prevent moisture
absorption • Use suitable lids• Maintain temp. below
40°C
4.
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HACCP and hygiene in honey production
Control and Corrective Action:
• Make sure conditions have been met before bottling• Organoleptic test• measuring HMF, moisture
Use as industrial honey if the above have failed
V. Storage4.
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HACCP and hygiene in honey production
VI. Preparation to Bottle & Bottling
Hazards• HMF increase • Crystallisation (liquid
honey)
• Foreign matter due to contamination from:
- environment
- glass breakage
Monitoring• Monitor temp. under
50°C• Check area and
surroundings• Check no. of
glass/plastic before & after bottling for breakage
4.
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Control and Corrective Action:
• Downgrade honey if temp. exceeded 50°c• Do not bottle if area is not clean • Dispose honey exposed to broken glass• Re-check unfilled glass jars
VI. Preparation to Bottle & Bottling4.
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VII. Distribution & Display
Hazards• Moisture absorption
due to: - damaged seals- poor handling- poor packaging
HMFCrystallisation (liquid
honey)
Monitoring• Suitable shipping
containers• Temperature ?
4.
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Control and Corrective Action:
• Remove damaged product
VII. Distribution & Display4.
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6. Verification of the system
The seven principles of HACCP, contd.
4.
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Establishing verification procedures
• Procedure to ensure that HACCP is performed correctly and that it is effective
– Is the system suited?– Are the procedures specified (e.g.
monitoring) and the corrective actions applied correctly?
4.
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Verifications can be:
– Verification of HACCP-inspections and the respective data
– Verification of deviations– Audits– Validation of determined limits and
tolerances, e.g. participation in ring trials
4.
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The seven principles of HACCP, contd.
7. Documentation procedures
4.
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Documentation
In terms of a traceable and effective self-control, a minimum of documentation is recommended
4.
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Documentation, contd.
Recommended documentation regarding: - Necessary cleanings - Disinfection measures - Storage temperatures - Pest combat - etc.
• Signatures are obligatory There is no proof without evidence!
4.
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Date:
Cleaning agent:______
Disinfection agent: ______
Dilution:
Work space and adjacent walls in the processing room / etc.
Floors: __________
Walls, doors, windows:
Honey extractor
Other equipment:
Refrigerator:
Responsible / Signature:
Example 1: Documentation of cleaning and disinfection measures
4.
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Example 2: Documentation of pest control and combat
Control date:
Pest detected:
Location / rooms:
Amount:
Measures:
Subsequent control:
Result:
Responsible / Signature:
4.
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5.
Establishing self-checking mechanisms in honey production
acc. to HACCP principles
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Based on the HACCP approach:
Autocontrol system for beekeepers
- Should be as simple as possible
- should contain all the principles that ensure good quality
- Allows successful management of beekeeping units
- is cheap
The system has to ensure that all factors, which influence honey quality are under control and are within the legal limits
This system is applicable for small and medium beekeeping units.
5.
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- The EC demands implementation of an Autocontrol-system
- In some European countries manuals for the production of quality honey based on HACCP have been published
- The implementation of autocontrol-systems in honey production is slow yet, since food control authorities regard honey as a microbiologically safe product
Autocontrol system for beekeepers, contd.
5.
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For example, in Switzerland forms have been created for the self control system, which help to evaluate hazards and document control measures
5.
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europe.eu.intKeyword: eur-lex, number of regulation