HACCP for Grain Storage

Delivering a quality product that is safe for consumers has always been a top priority for grain processors across the globe. Stricter food safety program requirements and government regulation and customer requests require more documentation and certification of proper food safety practices. Hazard Analysis and Critical Control Points (HACCP) programs have long been the standard for product safety requirements in the food industry. This is also the program referenced recommended in CODEX. Many, if not most of the Agricultural Companies apply HACCP standards in their grain storage operations.

The concept of HACCP was created to be a comprehensive program controlling the people, process, materials, environment, packaging and distribution involved in the food production process.

Food safety hazards are properties or contaminants that may cause food to be unsafe for consumption and are defined in three general categories: physical, chemical or biological. One of the most important parts of defining critical control points for a HACCP program is to understand and define non-hazards. Product quality characteristics such as protein content or moisture are not critical control points. Insect damage or the presence of most insects in grain is not a critical control point. These qualities and contaminants are not desirable in a quality product but would not cause illness or harm if consumed.

Physical hazards are defined into two classes: size and unexpected material. Size hazards are restricted to materials larger than 7 millimeters (mm) and smaller than 25 mm. Contaminants smaller than 7 mm are considered too small to be hazardous, while items larger than 25 mm are considered large enough to unlikely be placed into the mouth. In the mill, metal, glass, ceramics, wood, and brittle plastics are contaminants that should be addressed in a comprehensive program.

Chemical hazards can be naturally occurring, or chemicals added either intentionally or unintentionally. Naturally-occurring chemical hazards include mycotoxins that may be produced from molds that occur in the field or during storage, or any naturally occurring toxins from plant material. Non-intentional chemical contaminants range from cleaning chemicals used in the employee lunchroom to pesticides and herbicides potentially used in the production of the grain.

The third category, biological hazards, has been the focus for much of the new attention of regulations. Biological — specifically microbiological — contaminants come in several forms. Many are naturally occurring molds, yeasts and bacteria in the grain field. In the field, before the grain is harvested, the grain is exposed to insects, birds and other pests that can potentially leave behind bacteria. This is not a new development but one that has to be included in a food safety program.

There are seven principles of HACCP that must be followed when evaluating the grain storage process and creating a HACCP program. These principles include:

• Conducting a hazard analysis of the process;
• Identifying critical control points;
• Establishing critical limits;
• Establishing monitoring requirements;
• Establishing a corrective action plan for deviations from the HACCP plan;
• Establishing procedures for verification of the HACCP system; and
• Having a recordkeeping system to document the HACCP system.

In summary

In South Africa, Grain Storage is regulated by South African Law. SA, however, has signed up to CODEX, which is the international standard for Food Safety. As such we are obliged to comply with the standards and international best practice guidelines as constituted in CODEX.