In-line Pathogen Detection at Critical Control Points (CCPs)
Ever wonder how that juicy burger or crisp salad arrives on your plate safe for you to eat? It's not just magic. The food and beverage industry relies on a system called Hazard Analysis and Critical Control Points (HACCP), an internationally recognized method for preventing foodborne illnesses. This proactive approach pinpoints stages in the food production process where interventions can be applied to ensure the elimination of pathogens and other contaminants. Combined with in-line pathogen detection, these systems work together to keep your food safe and delicious.
What are Critical Control Points (CCPs) in a Supply Chain?
A critical control point (CCP) is a specific step in a supply chain where controlling a hazard is essential to ensure food safety. Imagine it as a checkpoint where you must intervene to prevent a potential hazard, such as the growth of harmful bacteria. If something goes wrong at this step, there's a high risk that the hazard will occur and contaminate the food. CCPs are often the final point where you can effectively control the hazard before the food reaches the consumer, making them especially crucial for maintaining food safety and public health [1].
How Do You Determine Critical Control Points?
1. Conduct a Thorough Hazard Analysis
The first step to identifying CCPs is to evaluate potential biological, chemical, or physical hazards that could occur at each stage of the food production process. The goal is to understand where hazards might enter the process, assess the likelihood and severity of the hazards, and determine preventive measures to control these hazards.
When conducting a hazard analysis, safety concerns must be differentiated from quality concerns. A hazard is defined as a biological, chemical, or physical agent that is reasonably likely to cause illness or injury in the absence of its control, whereas quality concerns may include the appearance, taste, or smell of a product.
For example, in poultry processing, biological hazards might include Salmonella and Campylobacter, chemical hazards could include cleaning agents, and physical hazards might include metal fragments [1].
2. Map Out the Production Process
Once the hazards have been identified, the next step is to examine each step in the production process to determine where controls can be applied to manage these hazards. This involves mapping out the entire production process from raw material acquisition to the final product, then listing the process steps for which you identified a significant hazard(s) [1].
3. Use a CCP Decision Tree
Once every hazard at every step of the process has been identified, they can be assessed with a CCP Decision Tree. The decision tree typically involves asking a series of questions about each step where a hazard can be controlled to determine which points can be considered CCPs.
For example, below is a decision tree developed by Codex [1].
Source: https://inspection.canada.ca/en/preventive-controls/preventive-control-plans/critical-control-points
Establishing Critical Limits for a CCP
Critical limits are the maximum or minimum values to which biological, chemical, or physical parameters must be controlled at a CCP to prevent, eliminate, or reduce the occurrence of a food safety hazard. Critical limits should be specific and measurable: they should produce an immediate result to ensure a quick decision on whether the identified hazard is controlled to an acceptable level.
The first step to establishing a critical limit is identifying the specific parameter that needs to be controlled to ensure food safety for each CCP. Note that each CCP will have one or more control measures, and each of these control measures has one or more associated critical limits. Critical limits may be based upon measurable factors such as temperature, time, humidity, moisture level, water activity (aw), pH, salt concentration, preservatives, or sensory information such as aroma and visual appearance. These critical limits must be based on scientific evidence, regulatory standards, or expert guidance to ensure it is sufficient to control the hazard [1].
Common CCPs and Critical Limits in Food Production
While CCPs can vary depending on the specific food production process, some common examples include [1]:
Cooking: Reaching a specific internal temperature for a set time is crucial to kill bacteria and other pathogens.
Parameter: Internal temperature.
Critical Limit: Minimum 165°F (74°C) for poultry.
Cooling: Chilling or freezing cooked foods prevents bacterial and parasitic growth.
Parameter: Time and temperature.
Critical Limit: Cool from 140°F to 70°F within 2 hours, and from 70°F to 41°F within an additional 4 hours.
Formulation: Controlling concentration of additives or preservatives to prevent spoilage or contamination.
Parameters: Concentration (ppm), pH
Critical Limit: pH must be below 4.6 to prevent the growth of Clostridium botulinum in acidified foods.
Dehydration: Reducing water activity to prevent bacterial growth.
Parameters: Water activity (Aw)
Critical Limit: An Aw below 0.9 prevents the growth of most spoilage bacteria.
Chlorination: Disinfecting water to eliminate pathogens.
Parameters: Concentration, volume
Critical Limit: A chlorine concentration between 0.04 to 2.0 mg/L is effective for disinfection without the compromising taste or safety of drinking water.
Filtration: Removing physical contaminants or microorganisms based on size.
Parameters: Filter pore size
Critical Limit: The filter pore size should be small enough to remove the target contaminant or microorganism. For example, a 0.45-micron filter might be used to remove bacteria, while a larger pore size might be used to remove larger particles like protozoa.
The 7 Principles of HACCP
Conducting a hazard analysis, identifying CCPs, and establishing critical limits are just three of the seven principles of HACCP. The remaining principles focus on following through with the identified CCPs to establish monitoring procedures and corrective action to neutralize the effect of food safety hazards.
1. Conduct a Hazard Analysis
2. Determine Critical Control Points (CCPs)
3. Establish Critical Limits
4. Establish Monitoring Procedures
After CCPs and critical limits are defined, monitoring procedures must be established to check that CCPs remain within the critical limits. Monitoring involves a planned sequence of observations or measurements to determine whether a CCP is under control, creating an accurate record for future verification. If monitoring reveals a trend toward loss of control, corrective actions can be taken before a critical limit deviation occurs. Continuous monitoring is always preferred when feasible, as improperly controlled processes and deviations can result in unsafe food. For example, continuous pathogen monitoring can detect microbial contamination within a batch of food before it is processed and/or released on the market [2].
5. Establish Corrective Actions
The next step is to establish corrective actions to be taken when monitoring indicates that a CCP is not within the critical limits. Corrective actions should identify and rectify the cause of non-compliance, determine the disposal of non-compliant products, and record the corrective actions taken. For example, if the cooking temperature of beef is below the critical limit, corrective actions may include extending the cooking time until the correct temperature is reached and discarding any potentially unsafe product [2].
6. Establish Verification Procedures
Verification involves activities that confirm the validity of the HACCP plan and ensure the system operates according to it. One key aspect of verification is assessing whether the facility's HACCP system is functioning as intended. An effective HACCP system minimizes the need for end-product testing by integrating validated safeguards early in the process. Therefore, firms should prioritize frequent reviews of their HACCP plans, ensure proper implementation, and regularly review CCP monitoring and corrective action records.
Another crucial element is the initial validation of the HACCP plan to ensure it is scientifically and technically sound. Validation often requires expert advice, scientific studies, and in-plant observations. For instance, validating the cooking process for beef patties should include scientific justification for the required heating times and temperatures to eliminate pathogenic microorganisms and studies to confirm these conditions are met during cooking.
Ongoing validations are documented by a HACCP team or independent experts, especially after system failures, significant changes in products, processes, or packaging, or the recognition of new hazards [2].
7. Establish Record-Keeping and Documentation Procedures
Finally, maintaining detailed records is important to successfully implement and maintain the HACCP plan. These records should include hazard analysis, CCP determination, critical limits, monitoring activities, corrective actions, verification procedures, and any modifications to the plan, and should be easily accessible for review by auditors or regulatory agencies [2].
The Importance of In-line Pathogen Detection
Traditionally, pathogen detection has relied on periodic sampling and laboratory analysis. This involves collecting samples of food or water at regular intervals and then sending these samples to a laboratory for testing. While effective, this method has significant limitations, including time delays and intermittent rather than continuous monitoring. These limitations can be costly when monitoring CCPs, as they may lead to delays in corrective actions or contaminated products going undetected.
In-line pathogen detection addresses these limitations by integrating detection systems directly into the production or treatment lines. These systems offer continuous monitoring, producing consistent maintenance of food safety protocols by ensuring intermittent contamination events are not missed.
Furthermore, in-line pathogen detection systems offer immediate results, allowing for swift action to be taken when contamination is detected. This rapid response capability is essential for preventing contaminated products from reaching consumers, thus reducing the risk of foodborne illnesses.
Finally, in-line detection technology can produce long-term savings from reduced product recalls, lower labour costs, and decreased waste. Early detection and intervention help prevent large-scale contamination events, ultimately saving money and protecting brand reputation.
Overall, in-line pathogen detection enhances the ability to maintain control over CCPs, ensuring that food safety hazards are effectively managed throughout the production process. Companies like Kraken Sense are leading the way in developing advanced in-line detection systems that integrate seamlessly into existing production lines. These systems leverage real-time qPCR technology to provide quantifiable microbial and chemical detection.
Conclusion
In-line pathogen detection at critical control points (CCPs) is a game-changer for the food safety and water treatment industries. By providing real-time, accurate monitoring, these systems enhance public health and safety and improve operational efficiency within the food and beverage industry. As technology continues to evolve, the future of pathogen detection is looking bright.
About Kraken Sense
Kraken Sense develops all-in-one pathogen detection solutions to accelerate time to results by replacing lab testing with a single field-deployable device. Our proprietary device, the KRAKEN, has the ability to detect bacteria and viruses down to 1 copy. It has already been applied for epidemiology detection in wastewater and microbial contamination testing in food processing, among many other applications. Our team of highly-skilled Microbiologists and Engineers tailor the system to fit individual project needs. To stay updated with our latest articles and product launches, follow us on LinkedIn, Twitter, and Instagram, or sign up for our email newsletter. Discover the potential of continuous, autonomous pathogen testing by speaking to our team.