www.aqua-syn.eu

con il patrocinio di

Regione SicilianaAssessorato Regionale dell’Istruzione e Formazione ProfessionaleDipartimento Regionale dell’Istruzione e Formazione Professionale

UNIVERSITÀ degli STUDI di CATANIADipartimento di Scienze Mediche, Chirurgiche e Tecnologie Avanzate"F. G. Ingrassia"

Ordine dei Tecnologi Alimentari

di Sicilia e Sardegna

Catania (Italy), 19 March 2015

WORKSHOPLA QUALITÀ DELLE ACQUE MINERALI NATURALI

THE QUALITY OF NATURAL MINERAL WATER

The HACCP method in mineral water bottlingL'applicazione del metodo HACCP nella fase di imbot tigliamento delle

acque mineraliDott.ssa C. Copat e Dott.ssa C. Ledda - LIAA- Universi ty of Catania

di Sicilia e Sardegna

What is HACCP?

System of food safety management

Internationally recognized and recommended

Hazard Analysis and Critical Control Point

Internationally recognized and recommended

Identifies where hazards might occur in the production of bottled water

Puts into place control measures to prevent the hazards from occurring.

Strictly monitoring and controlling each step of the process, there is less chance for hazards to

occur

How to perform a HACCP Study?

Assemble a HACCP Team

HACCP studies involves a logical sequence of tasks and requires the full commitment and

involvement of management and the staff

- By involving a team of people, a greater diversity of skills and knowledge appropriate to the

system will be available

- It is counselled to create a team with some external people

- Where the necessary expertise is not available on site, expert advice should be obtained from

other sources

Define the Terms of Reference

- Identify the process (e.g. the production and supply of water)

- Identify the limits of the study

- All hazards (microbiological, chemical and physical) must be considered as - All hazards (microbiological, chemical and physical) must be considered as

a whole, or will each type of hazard be considered individually?

- Each process stage is studied individually (e.g. ozonation, filling, capping...)

Describe the Product and Identify the Intended Use

Draw up a full description of the production system, including information on water composition and

the method of distribution as well as the materials used in the production

• Raw materials: water, CO2 and added minerals

• Authorised water treatments

• Materials in contact with the product (filling line and containers: bottles, cans ...)

• Storage conditions and methods of distribution• Storage conditions and methods of distribution

• Theoretical/legal expiry date

Identify the consumer/s target group/s for the product

The intended use shall be based on the composition and expected uses of the product

In specific cases, vulnerable groups of population (e.g. infants, special diets) should be considered

Topics to be considered Characteristics

Product name and qualification

(based on the existing norms)

Common Name (Trade Mark?)

Natural Mineral Water

Spring Water

Processed / Prepared Water

Sales / Marketing description Mountain Spring Water

Well Water

Carbonated / Natural Sparkling Water

Other

Use Drinking as such

Drinking after carbonation

End users General population

Infants

Vulnerable or specific groups

Product specifications Chemical and physico-chemical water parameters

Allowed water treatments applied

Carbon Dioxide level: origin

Added Minerals

Topics to be considered Characteristics

Packaging Size and volume of packaging

Type of primary container (e.g. glass, plastic, metal, paper, bulk)

Type of closure (e.g. plastic, aluminium, other)

Type of secondary packaging (e.g. crates, boxes, packs)

Type of tertiary packaging (e.g. pallets, wrapping)

Labelling Type of labels (e.g. paper, polypropylene) and glue specifications

Regulatory requirements

Product shelf life Shelf life duration / expiry date

Coding descriptionCoding description

Type of coding (e.g. ink, laser)

Storage and Distribution Conditions Internal storage

External storage

Distribution ways

Range of temperature storage

Retail conditions and constraints

Flow Diagram

Draw a flow diagram of all aspects of the factory considering:

• Source and its protection

• Water operation

• Raw materials

• Processing

• Packing (all steps)

• Storage

• Distribution

• Retailer

Details of each step of the operation must be addressed

It is especially important that this diagram provide an accurate representation of the process, as it is the

main basis for the HACCP study

1. Step – process identified in the flow diagram; Hazard - potential source of harm or

adverse health effect/s on a person or persons; Risk - the likelihood that a person may be

harmed or suffer adverse health effects if exposed to a hazard; Control Measures (CM)harmed or suffer adverse health effects if exposed to a hazard; Control Measures (CM)

2. Critical Control Point Yes/Not (CCP Y/N)

3. Control Limits (verification) (C Limits)

4. Monitoring:

5. Corrective Actions (CA)

6. Verification

7. Documentation

The HACCP team shall list all hazards reasonably expected to occur at each step according to:

- Scope from primary production, processing, manufacture and distribution until the point of

consumption

- Each process step identified in the flow diagram shall be assessed for the introduction or presence

PRINCIPLE 1

List All Hazards Associated With Each Step And Consider Any Control Measures To Control The Hazard

- Each process step identified in the flow diagram shall be assessed for the introduction or presence

of a hazard

The HACCP team shall next conduct a hazard analysis to identify which hazards are of such a nature that

their elimination or reduction to acceptable levels is essential to the production of safe bottled /

packaged water

Microbiological Hazards

• Pathogenic Bacteria - presence, contamination, survival, growth• Parasites and Protozoa• Viruses• MouldsApart from it, it should be considered that many mineral waters have a natural content of microbiological florawhich is accepted as natural

Chemical hazards

• Xenobiotics and natural compounds, e.g. - pesticides, microbial toxins, algal toxins, allergens ...• Packaging-derived materials, e.g. - plasticizers, ink/adhesive• Packaging-derived materials, e.g. - plasticizers, ink/adhesive• Added during the process, e.g. - cleaning agents, lubricants, hydrocarbons, pesticides, allergens,

fumes/dust, microbial toxins

Physical Hazards

• People’s origin, e.g. - buttons, teeth, hair, jewellery, paper clips, matchsticks...• Natural origin, e.g. -, nutshells, seeds, fruit stones• Factory’s environment, e.g. - glass, wood, metals, chips from tiles, gaskets• Equipment – nuts, bolts, screw, rusting metal flakes, plastic

In conducting the hazard analysis, the following shall be included wherever possible:

1. The likely occurrence of hazards and severity of their adverse effects in view of the risk evaluation

2. The qualitative and/or quantitative evaluation of the hazard

3. The possible presence or multiplication of any microorganism of concern

4. Production or persistence in water of toxics, chemical or physical agents

5. Conditions leading to the above

Consideration shall be given to what control measures, if any exist, can be applied to each hazard

Describe the real control measures applied to control these hazards

It is to consider that more than one control measure may be required to control a specific hazard

How to calculate the significance of the hazard (example)

The HACCP team could decide that the hazards with a low risk number, e.g., lower than 2, are notsignificant and do not need specific control measures (CM)This needs an application to the bottled water specificities

The identification of a Critical Control Point (CCP) in the HACCP system is facilitated by the

application of a Decision Tree. Application of the Decision Tree determines if the step is a

"critical" control point for the identified hazard

PRINCIPLE 2

Identify the Critical Control Points

If a hazard has been identified at a step where control is necessary for safety and no control measure

exists at that step, or at any other step, then the product or process must be modified at that

step, or an earlier or later stage, to include a control measure

Critical limits shall be specified and validated for each CCP. Details of the establishment of critical

limits shall be recorded

These critical limits shall be measurable

Criteria often used include: measurements of time, temperature, concentration of disinfecting agent,

PRINCIPLE 3

Establish Critical Limits for each CCP

Criteria often used include: measurements of time, temperature, concentration of disinfecting agent,

pH, absence of metals, microbiological limits, sensory parameters e.g. visual appearance and

texture, etc.

In some cases more than one critical limit will be elaborated at a particular step

Monitoring is a planned sequence of observations or measurements of a CCP target level and tolerance

Monitoring must be able to provide confidence in the established controls, be able to detect any loss

of control and enable timely corrective actions

Typical monitoring methods include visual evaluations, physical measurements. E.g. temperature,

chemical analysis, and microbiological assessment

PRINCIPLE 4

Establish a Monitoring System for each CCP

Records and documents associated with monitoring CCPs must be signed by the person(s) doing the

monitoring and by a responsible reviewing official of the company

If monitoring is not continuous, then the amount of frequency of monitoring must be sufficient to

guarantee the CCP is under control

Specific corrective actions must be developed for each CCP in order to deal with any deviations. The

action must ensure the CCP is brought under control and include details of what to do with

affected product

PRINCIPLE 5

Establish Corrective Action

PRINCIPLE 6

Validate the HACCP System

Monitoring and auditing should be carried out to determine if the system is working correctly.

Examples include a review of the HACCP system and its records, review of deviations, checks to

ensure CCPs are under control, validation of established critical limits, etc.

Validation helps to maintain confidence in the system, identifies areas for improvement and provides

documentary evidence of due diligence in managing food/bottled water safety

Validate the HACCP System

Verification should be carried out by someone other than the person who is responsible for

performing the monitoring and corrective actions. Where certain verification activities

cannot be performed in house, verification should be performed on behalf of the business by

external experts or qualified third parties

Examples of verification activities include:

• review of the HACCP plan and its records

• review of finished products’ microbiological data

• review of deviations and product dispositions

• confirmation that CCPs are kept under control

In order to be efficient and effective, the keeping of records is essential.

Such records help to illustrate compliance with these Guidelines and are important in establishing a due

diligence defence.

Each process step as documented in the flow diagram must be detailed in the HACCP chart and the

PRINCIPLE 7

Establish Record Keeping and Documentation

Each process step as documented in the flow diagram must be detailed in the HACCP chart and the

controls, monitoring, corrective actions, etc. determined accordingly. This will ensure that the

hazards at each process step are duly considered and controlled

These records must be reviewed periodically e.g. annually or when there is a significant change in

operation

SAMPLE HACCP CHART

Therefore, the HACCP process can be summarized as follows:

Grazie per l’attenzione