Use statistical techniques when developing HACCP plans for fresh-cut fruit and vegetables.

New challenges to the food supply have prompted the FDA to consider adopting a HACCP-based food safety system on a wider basis. One of the most important challenges facing processors is the increasing number of new food pathogens. For example, between 1973 and 1988, bacteria not previously recognized as important causes of foodborne illness, such as E. coli O157:H7 and S. enteritidis, became more widespread. While HACCP is not yet mandatory for the fresh-cut produce industry, the International Fresh-Cut Produce Association has been encouraging its members to voluntarily implement HACCP programs in their facilities.

This minimal processing industry, unlike most other processors, faces the daunting task of ensuring product safety with no true kill step in processing operations. The processors primarily achieve preservation and safety by using hurdle technology, which includes the application of modified atmospheric packaging and refrigeration. In addition, the association is offering educational materials--food safety guidelines, HACCP models and training programs, yearly technical seminars, basic technology training and an accredited HACCP workshop--to its members.

Due to the vulnerable nature of fresh-cut produce, it is imperative that the best process control techniques be utilized to promote safety. The majority of fresh-cut processors have already implemented HACCP programs, but these typically focus on qualitative issues rather than quantitative data.

A HACCP program's effectiveness and reliability as a safety tool can be greatly enhanced by using statistical techniques, specifically statistical process control (SPC). SPC offers an objective, quantitative and scientifically valid means for determining process capability and for predicting the ability to control critical control points (CCPs) during the monitoring and verification activities of a HACCP plan.

SPC uses control chart graphs to illustrate the kinds of variation occurring within the CCP and can provide early warning of a safety problem within the process. For example, the chlorine content in flume wash water, a designated CCP in fresh-cut processing, may operate in statistical control, yet the variation in the chlorine level is such that it does not ensure safety control in the water. Ideally, processors should strive to have their CCPs in statistical control as well as within safety limits.

The U.S. National Academy of Sciences recently recommended SPC as a way for processors to achieve performance safety standards. The academy also recommended that such principles be incorporated into food safety regulations, thereby providing regulatory agencies with a tool to monitor the compliance of these performance standards in the food industry.

Further information. Dr. William Hurst, Department of Food Science, University of Georgia, 240-C Food Science Building, Athens, GA 30602-7610; phone: [phone]; fax: [phone]; email: [e-mail].