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This information can be used to develop food safety and quality programs that meet the requirements of modern Regulatory, Customer and Industry Standards:
When considering the development, documentation, and implementation of HACCP: Chemical Hazards Management within food safety and quality management systems, the following information should be considered to ensure effective outcomes:
When considering the hazards associated with the process steps in the HACCP plans, the three traditional groupings of hazards to consider include biological, chemical, and physical hazards. As HACCP plans evolve and customer standards and regulatory requirements become more stringent, allergens, regulatory hazards, quality hazards, and engineering hazards are also commonly considered in HACCP Plans.
Chemical hazards are quite often viewed by the consumer as posing a significant food safety risk, whereas, in reality, they more often pose a very low immediate health risk at levels likely to be found in food. Some chemicals are harmful to health and others simply affect the quality of food as judged by consumers. Chemical contamination of foodstuffs can occur at any stage of their production, from the growing and cultivation of raw materials to the consumption of the finished product. The effect of chemical contamination on the consumer can be long term chronic effects that are extremely damaging to the body, such as for carcinogenic or accumulative chemicals including heavy metals, which can build up for many years, or it can be short term acute, such as the effect of allergenic foods. Improper use, storage, location, display, and labeling of poisonous and toxic materials, first aid supplies, medicines, and cosmetics presents public health risks due to food and food contact surface contamination.
Examples of accidental chemical food contamination situations could include:
Any of the above situations could potentially result in disastrous consequences.
Naturally occurring chemical hazards that may present within foods may include:
Reactions due to allergens of naturally occurring chemical hazards can range from mild to extremely serious, depending on the dose and the individual’s sensitivity to the nominated component. Product analysis and related labeling form the front line in assessing a product’s potential to cause harm. Labeling must be specific in noting ingredients of concern, particularly in nomination. For example, species of fish, and types of nuts should be shown, as certain individuals may be specifically allergic to only certain types of ingredients. The potential for cross-contamination within the processing environment is a major concern within this area, forming a loop through which ingredient nomination becomes invalid if cross-contamination does occur.
Chemicals are usually in solution and cannot be seen unless they are a recognized color. Food accounts for a high percentage of the total human exposure to most chemicals from environmental sources. Fish poisoning, for example, by Ciguatoxin and Scombrotoxin accounts for a large portion of the reported outbreaks. Scombroid poisoning is most often a result of histamine production in fish that have been improperly refrigerated. Heavy metal poisoning occurs frequently when acid foods such as lemonade and carbonated beverages come in contact with such heavy metals as copper, zinc, antimony, and cadmium.
The following form the general basis of concern regarding chemical contamination:
Cleaning chemicals are prevalent in any food-related operation, and therefore form one of the most significant chemical hazards. Cleaning or sanitizing chemical residues may remain on utensils, in pipes, or on food contact surfaces and equipment, making a transfer to food a very real possibility. Cleaning chemicals may also contact food through splashing during cleaning if the proper precautions are not taken. Taking these factors into account, the use of cleaning chemicals, as it is necessary to support other aspects of the food safety system, should be ratified within the food safety system itself, to reduce the risk of potential contamination. Potential hazards can be significantly reduced through separation by the time of cleaning activities and production activities, the use of non-toxic chemicals, correct dosing/dilution ratios, and through the design, application, and management of appropriate cleaning procedures. This will include adequate training of staff and may involve post-cleaning inspections.
This class of chemicals involves any toxic or non-toxic substance that is applied to control or kill pests.
Pesticides may include the following variants:
Pesticides are present in varying applications throughout many different industries around the world. The use of most concern in food safety is in agriculture, but contamination from all sources must be considered. Agricultural industries use chemicals as protection, in storage and to improve crop yields. Not all pesticides are safe for use in food production, and even those that are used may leave residues that can be harmful in high concentrations. Most countries have stringent controls over the use of pesticides, including which chemicals can be used in specific applications, and the residual limits that are acceptable. A food safety viewpoint dictates that all information regarding pesticides in relation to raw materials being used, be available for some stage of processing. Permitted pesticides and their accompanying residual limits must be understood in each case, to assert control over such chemicals in the production of foodstuffs. In addition to the raw materials that have possibly been exposed to pesticides during the primary levels of their production, there is always the very real threat of contamination with pesticides at any stage of its further processing. This could occur in the form of contact with pesticides on your site. As pesticides are an intrinsic part of any food safety system, it is important to understand and control their role within the system itself.
As with other chemicals, pesticides must be stored and handled in a manner that facilitates safe practice. This generally includes storing these types of chemicals in locked, stable, and well-ventilated storage areas. Procedures for the storage, handling, and use of such chemicals should be documented, which include specific nominations regarding skills and training requirements for personnel and contractors involved in providing technical advice and/or applying chemicals.
Metals can enter the food chain through many sources and can be a major risk to human health in high quantities. Toxic metals are also commonly known as Heavy Metals.
The most prevalent forms of toxic metal risks into the food chain are:
Toxic Metals of particular concern include:
As for other chemical hazards, it is important to assess and understand the particular risks of toxic metals to your products, in raw materials, metal equipment, processing, and packaging.
Nitrates occur naturally in the environment and are present in some fruit and vegetables. They are a constituent of many fertilizers, which have increased levels in agricultural soils and associated effluent runoffs. Nitrites and Nitrates have historically been added to many food products to aid in their preservation. The process of deliberately adding nitrates and nitrites to foods is strictly governed by legislation as high levels of these substances in foods can produce a variety of toxic effects in humans. Specific examples include carcinogenic effects and infantile blood-related disorders. N-nitroso compounds can be formed in food as a result of reactions between nitrites and/or nitrates and other compounds. They can also be formed within the human body when large amounts of nitrites and nitrates are present in the diet. Nitrates can cause significant problems in canned products where it can cause the breakdown of internal lacquer linings, allowing the tin to enter the food product via leaching. The food safety management system must include nominations for safe usage that do not exceed legal limits where such substances are being added to a product, or run the risk of post contamination from these substances giving an increased overall level.
Polychlorinated Biphenyls or PCB’s are part of a group of organic compounds that are used in several different industrial applications. These are highly toxic compounds, and their use is limited to closed systems. Their production has been banned in many countries. The most significant source of PCB’s in foods is through absorption from the environment into fish. The compounds then accumulate through the food chain and become concentrated in larger fish with tissues that contain high-fat levels. This issue becomes a concern when raw marine products are being used in processing.
Certain plasticizers and other plastics additives can be cause for concern if they can migrate into food. The transfer of such substances into foodstuffs depends on the constituents present, and also the type of food, noting that fatty foods promote migration more readily than some other foods. The constituents of plastics that are used in food contact are generally governed by strict legislation regarding the availability of possible transfer of substances into foodstuffs. Plastic utensils should also be considered in this area, as they may also permit chemical migration.
Growth hormones, regulators, and antibiotics used in animal treatments can be passed into foods. Hormones and growth regulators have been banned from use in food-related animals in some countries, and the use of antibiotics and other medicines is strictly controlled. Antibiotic carry-over in animals for food can cause serious allergic responses in susceptible individuals, and similarly, hormones and growth regulators can cause serious toxic responses when consumed in quantities. The input of quality raw materials from sufficiently registered suppliers usually guarantees that the certified product is accepted.
Chemical additives are not only used to create safe and hygienic products, but also to assist processing, and to enhance or beautify otherwise bland, though nutritious products. They may also be of substantial nutritional benefit, as in the case of vitamins and/or minerals. The use of specified chemical additives is governed by strict legislation, which not only classifies additives as to their purpose but also as to their limitations of use across various categories of foodstuffs. Chemical additives also include natural non-synthetic substances, for example, plant extracts that may be acutely toxic. It is therefore advantageous in controlling all such additives to be fully aware of correct applications in dosing, and cross-contamination issues.
Chemical additives may include:
All first aid supplies, medicines, and cosmetics must be stored and displayed in such a manner to prevent contamination and special consideration needs to be given to the following:
The use of chemicals within any food business must include elements that not only promote food safety but which also promote the general safe use, handling, and storage of all cleaning, sanitation, pest control, maintenance, and other chemicals. This can generally be facilitated by ensuring documented procedures for chemical control are documented and available to everyone using chemicals.
Chemical usage procedures may include:
Chemicals used within food businesses must be properly stored and located with insecticides and rodenticides stored separately from cleaning compounds and other chemicals. All chemicals and pesticides must be stored separately from food, food contact surfaces, and single-use and single-service articles. In this context, the term separate does not include storage of toxic chemicals above food, food contact surfaces, single-use, and single-service articles.
The storage of chemicals must also meet local regulatory and environmental protection requirements.
Where necessary, adequate facilities for the storage and handling of food, ingredients, and non-food chemicals including cleaning chemicals, pest control chemicals, lubricants, and other maintenance chemicals must be provided.
Where appropriate, food storage and handling facilities should be designed and constructed to:
The type of facilities required will depend on the nature of the food items being stored and handled by a food business. Where necessary, segregated and secure storage facilities should be provided for cleaning chemicals, pest control chemicals, lubricants, and other maintenance chemicals. Storage facilities for ingredients, packaging, and other materials should also be appropriately secured and adequately ventilated.
Specific Chemical Training is a standard requirement for persons involved with the use of chemicals within food businesses. It is important that chemical training is tailored to the specific requirements of the chemicals being used, to ensure that foods do not become contaminated by such usage.
It is important that the application of chemical handling and usage training is completed before persons are left unsupervised to use chemicals within a food business. Competency against chemical handling and usage training requirements should also be verified before un-supervised interactions.
It is important to consider that specific chemical handling and usage training should be developed, scheduled, conducted, and recorded to display compliance for functional chemicals used as food additives or processing aids. The use of such chemicals should be well controlled; it is common for chemicals such as nitrites and sulfites to be stored in secure areas, and only accessible to authorized persons to ensure any accidental or intentional misuse is unlikely to occur.
If your food business supplies foodstuffs manufactured to a customer’s specifications, it is important to consider any specific HACCP: Chemical Hazards Management Development requirements in relation to their items.
Document: A document provides guidance and/or direction for performing work, making decisions, or rendering judgments that affect the safety or quality of the products or services that customers receive.
Documented policies, procedures, work instructions, and schedules form the basis of any food safety and quality management system. The following documentation formats may be considered to ensure ongoing compliance with specified requirements for HACCP: Chemical Hazards Management:
If your food business supplies foodstuffs manufactured to a customer’s specifications, it is important to consider any specific HACCP: Chemical Hazards Management Documentation requirements in relation to their items.
You may wish to visit the HACCP: Chemical Hazards Management Templates section of haccp.com for examples of HACCP: Chemical Hazards Management documentation, record and resource formats commonly applied within food safety and quality systems.
Implementation: Implementation is the application of documented food safety and quality system elements into the actual business operation.
The implementation of HACCP: Chemical Hazards Management within any food business requires genuine commitment from senior management, staff, and visitors to ensure the nominated goals of implementation are achievable on an ongoing basis. It is a step that requires significant planning and consideration of general and specific food business circumstances to ensure the outcomes of HACCP: Chemical Hazards Management do not negatively impact the safety and quality of the food items dispatched from the business.
Implementation of HACCP: Chemical Hazards Management must include a clear definition of responsibilities and authorities for all levels of participation by senior management, staff, and visitors to the site.
When implementing HACCP: Chemical Hazards Management within food safety and quality system, you may wish to consider the following requirements before completion:
If your food business supplies foodstuffs manufactured to a customer’s specifications, it is important to consider any specific HACCP: Chemical Hazards Management Implementation requirements in relation to their items.
Monitoring: Monitoring is the act of reviewing and confirming measurable parameters of a defined process or product status.
Monitoring requirements within food industry sectors are generally identified against limits of acceptability defined within HACCP plans, implementation procedures, and work instructions. Monitoring usually includes some element of record-keeping, which may be maintained manually or through digital systems. It is important to consider that advancements in technology have spawned many systems and processes which are self-monitored and or self-adjusted when variances are identified. Regardless of the system used; The goal of any monitoring activity is to provide sufficient evidence that any limit of acceptability has been met.
Traditional HACCP: Chemical Hazards Management monitoring requirements include manual recording and the application of corrective actions when the results of monitoring are found to be outside acceptable limits. Corrective Actions should also generally be strongly linked to the monitoring process where applied to ensure full traceability of the applied actions.
Common monitoring activities and record formats may apply to HACCP: Chemical Hazards Management:
If your food business supplies foodstuffs manufactured to a customer’s specifications, it is important to consider any specific HACCP: Chemical Hazards Management Monitoring requirements in relation to their items.
You may wish to visit the HACCP: Chemical Hazards Management Templates section of haccp.com for examples of HACCP: Chemical Hazards Management documentation, record and resource formats commonly applied within food safety and quality systems.
Corrective Action: Corrective action is mandatory action to be taken when a deviation to the Quality System occurs, particularly to a Critical Control Point.
Preventative Action: At any step in the process where a hazard has been identified, preventative action must be put into place to prevent re-occurrence.
Corrective Action and Preventative Action are implemented to ensure that any identified non-conformance issues are documented, investigated, and rectified within appropriate time frames. Corrective action is any action applied to regain control over a product, process, policy, or procedure that has been identified as being non-conforming or outside nominated limits of acceptability. Preventative action is any action applied to prevent any identified non-conformance from reoccurring.
The outcomes of corrective and preventative actions should result in regained process control after effective application. Specified corrective actions are commonly linked to the HACCP Plans and the food business certification process.
Below are Corrective Action and Preventative Action examples which may be associated with HACCP: Chemical Hazards Management related non-conformance:
If your food business supplies foodstuffs manufactured to a customer’s specifications, it is important to consider any specific HACCP: Chemical Hazards Management Corrective Action requirements in relation to their items.
You may wish to visit the Corrective Action and Preventative Action section of haccp.com for examples of best practice applications for this food safety and quality system element.
Verification: The act of reviewing, inspecting, testing, checking, auditing, or otherwise establishing and documenting whether items, processes, services, or documents conform to specified requirements.
Verification is the detailed review of all food safety and quality system elements to confirm that they are effectively developed, documented, implemented, monitored, and reviewed. All food safety and quality system elements, including documented policies, procedures, training, HACCP plans and their operational applications must be verified on an ongoing scheduled basis. The verification process commonly includes a defined schedule for which verification activities are required, how often they are conducted, who is responsible, and detailed documented procedures for each nominated verification activity.
The general goal of an established verification process is to ensure any systemic non-conformance issues are identified and rectified within an appropriate time frame. When non-conformance issues are identified through the verification process, Corrective Actions and Preventative Actions should be implemented to ensure they do not impact the effectiveness of the food safety and quality system.
The following examples of verification activities may apply to HACCP: Chemical Hazards Management:
If your food business supplies foodstuffs manufactured to a customer’s specifications, it is important to consider any specific HACCP: Chemical Hazards Management Verification requirements in relation to their items.
You may wish to visit the Verification Activities section of haccp.com for examples of best practice applications for this food safety and quality system element.
Validation: The process of gathering evidence to provide a scientific basis for the documented act of demonstrating that a procedure, process, and activity will consistently lead to the expected results. It often includes the qualification of systems and equipment.
Validation is the provision of evidence to support the limits of control or acceptability for food safety or quality parameters nominated within systemic elements. Limits of control or acceptability are commonly included within documented food safety and quality systems elements such as procedures, HACCP plans, and specifications.
Common sources of validation include regulatory and legislative standards, finished product specifications and customer requirements, industry codes of practice and guidelines, verified and validated research, historical product, and process control outcomes, and analytical testing.
The general goal of an established validation process is to ensure any systemic non-conformance issues are identified and rectified within an appropriate time frame. When non-conformance issues are identified through the verification process, Corrective Actions and Preventative Actions should be implemented to ensure they do not impact the effectiveness of the food safety and quality system. Validation activities are commonly defined within the verification schedules and procedures of established food safety and quality management systems.
The following examples may apply to validation of the limits of control or acceptability for HACCP: Chemical Hazards Management:
Skills and Knowledge: Skills and knowledge are attributes of human interactions commonly linked to competency within any specified job-related task.
Training and competency requirements for HACCP: Chemical Hazards Management must be ongoing, including regularly scheduled reviews to ensure the effectiveness of training and competency outcomes.
Team members who have defined responsibilities regarding HACCP: Chemical Hazards Management should have a knowledge including:
Team members who have defined responsibilities regarding HACCP: Chemical Hazards Management should have skills including:
Team members who have defined responsibilities regarding HACCP: Chemical Hazards Management should have access to resources including:
If your food business supplies foodstuffs manufactured to a customer’s specifications, it is important to consider any specific HACCP: Chemical Hazards Management Training, Competency, and Resources requirements in relation to their items.
You may wish to visit the Training, Competency, and Resources section of haccp.com for examples of best practice applications for this food safety and quality system element.
haccp.com was created to support food businesses and food industry professionals in achieving and maintaining the stringent requirements of food industry compliance.