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WHAT IS HACCP?
Codex Definition:
HACCP is a system which identifies , evaluates, and controls hazards which are significant for food safety
THE HACCP SYSTEM
Is systematic Guided by scientific evidence of risks to human
health Identifies specific hazards and measures for their
control Focuses on prevention (rather than relying mainly
on end-product testing) Is capable of accommodating change and new
technological developments.
THE HACCP SYSTEM
Can be applied throughout the food chain (“from farm to fork”)
Increases confidence in food safety Requires full commitment and involvement of
management and workforce Requires a multidisciplinary approach Is compatible with the implementation of Quality
Management Systems Is the system of choice for Food Safety Management
THE HISTORY OF HACCP
1959 NASA requested Pillsbury create food for astronauts
End points check only Preventative approach to food processing Adopting , with significant modifications , by US Army
Natic Research , Development , and Engineering Centre
as a preventative approach for medical supplies . 1971 HACCP presented to public
THE HISTORY OF HACCP
1974 Application of HACCP to low Acid Canned Foods (USFDA)- further proliferation by the USDA’s NMFS .
1985 National Academy of Science recommended HACCP for control of microbial hazards .
1993 Codex Committee developed guidelines . 1995 SQF 2000 Quality Code Released . 1995/97 CODEX Guidelines reviewed and revised
HACCP
HACCP is not a guarantee of food safety and is not a zero-risk system .
It is designed to minimize the risk of food safety hazards .
WHY HACCP ?
Globally there has been an increasing demand for HACCP to reduce food borne incidents caused by contaminated products that have implications for human health , and increased costs to the supplier and to the community .
THE MAJOR CAUSES OF FOOD BORNE INCIDENTS ARE :
Contaminated raw materials Mishandling raw materials Change in product formulation Change in the product process Cross- contamination Inadequate cleaning Inadequate maintenance Addition of incorrect ingredients
FOOD SAFETY INCIDENTS AND OUTCOMES
Mexican – style cheese , USA Listeriosis from cheese contaminated with raw milk 142 confirmed cases , 47 deaths – Cost ? , Executives to jail Salmonella in dried baby food , UK Contamination through cracks in drier 76 ill , 1 death-Cost : >$30 million , one factory
closed Frozen French Fries Wire bristle contamination Destruction of 18 million pounds of product Cost:
$4million World – wide recall of bottled water Benzene contamination Filtration system not changed in 18 months Cost : $ 40 million in US and lost market share
THE BENEFITS OF HACCP …
Applied throughout the food chain Reduces food poisoning incidents Meets food quality and regulatory
requirements Reduces regulatory involvement Reduces inspection efforts
THE BENEFITS OF HACCP …
Meets commercial requirements Helps to improve business ( productivity) Forms the basis for a food quality system Helps demonstrate due diligence
HAZARDS ( FOOD SAFETY )
A biological , chemical or physical agent in , or condition of, food with the potential to cause an adverse health effect
( CODEX definition )
FOOD SAFETY HAZARDS
1. Biological 2. Chemical 3. Physical
HAZARDS ( QUALITY )
A quality hazard is a factor that has the potential to cause an adverse affect on product or process quality and hence profitability
Quality hazards can cause food products to fail to meet agreed finished product specifications, but do not cause illness
QUALITY HAZARDS
1. Product quality hazards2. Environmental hazards3. Animal welfare hazards4. Production hazards5. Occupational health and safety hazards6. Regulatory hazards
BIOLOGICAL HAZARDS
Macrobiological and microbiological
The 5 types of biological hazards Bacteria – (Clostridium spp.,Salmonella
spp.,Listeria monocytogenes) Viruses- (Hepatitis, Rotavirus) Fungi – (Aspergillus spp., Fusarium spp. ) Parasites – (Fasciola hepatica, Giardia lamblia, ) Algae –(dinoflagellates, blue-green algae, golden-
brown algae )
FACTORS AFFECTING THE GROWTH OF BIOLOGICAL HAZARDS
Intrinsic factors
pH Moisture content Nutrients Anti-microbial constituents Biological structures
Extrinsic factors
Temperature
Humidity
Gases
CHEMICAL HAZARDS
Chemical compounds are used frequently in the food supply chain and can present food safety risks if their use is not managed :
Cleaning chemicals Pesticides Allergens Toxic Metals Nitrites , Nitrates & N-nitroso compounds Polychlorinated Biphenyls (PCB ‘ s)
CHEMICAL HAZARDS …
Plasticizers and Packaging Migration Veterinary Drug Residues Chemical Additives Seafood toxins Zootoxins Phyllotoxins
ALLERGENS
Naturally occurring proteins Minute amounts can cause allergic
reaction - Only 5-10 ppm can trigger reaction - Symptoms occur within minutes and death
within hours . Some reactions are fatal - Nut and seafood allergies - 1-2 % of population have food allergies
PHYSICAL HAZARDS
Physical hazards are objects not normally found in food that may cause illness or injury to the consumer:
Glass Wood Metal stones, twigs, leaves Jewellery Pests Plastic
HACCP STEP 1ASSEMBLE THE HACCP TEAM
Step 1 a Codex Guidelines Step 1 (a)
Define the Scope and Purpose
of the HACCP Plan
HACCP STEP 1ASSEMBLE THE HACCP TEAM
Scope
The Scope of the HACCP plan defines the product, the start and
the finish of the process under
HACCP study
HACCP STEP 1ASSEMBLE THE HACCP TEAM
Purpose
The Purpose of the HACCP plan defines the reasons why you are implementing HACCP
HACCP STEP 1ASSEMBLE THE HACCP TEAM
Step 1 b
Codex Guidelines Step 1 (b)
Assemble the HACCP Team
HACCP STEP 1ASSEMBLE THE HACCP TEAM
Management Commitment Provide resources Approve and drive the HACCP or food safety policy Approve the business issues and ensure the project continues to move forward and remains valid Appoint a Project Manager and HACCP team Ensures adequate resources are made available Establishes a progressive reporting procedure Ensures that the project plan is realistic and achievable
HACCP STEP 1ASSEMBLE THE HACCP TEAM
The HACCP Team Develops & drives the HACCP or food safety policy Ensures the HACCP project continues to move forward and remains valid Elects a HACCP team leader Reports on progress regularly Ensures a correct balance of technical/industrial
experience Asses the need for specialized expert knowledge and engages this resource as required
HACCP STEP 1ASSEMBLE THE HACCP TEAM
Team requirements Specialist knowledge may be required of: 1. Raw materials and ingredients 2. Finished product 3. Processing equipment 4. Processing procedures 5. Pre-requisite programs 6. The production environment ( premises and surroundings)
HACCP STEP 1ASSEMBLE THE HACCP TEAM
Team requirements Specialists will need full knowledge of: Hazards associated with the raw material, the
product and the process The likelihood and probability of these hazards
occurring A knowledge of regulatory requirements and
applicable to the food Be trained in and have a thorough technical
knowledge of HACCP
HACCP STEP 2DESCRIBE THE PRODUCT
Codex guidelines Step 2. Describe the Product
Step 2: Describe the product providing details of its composition, physical/chemical structure, packaging, safety information, processing treatments, storage and method of distribution
HACCP STEP 2DESCRIBE THE PRODUCT
Codex guidelines A full description of the product should be drawn up,
including relevant safety information such as:o Compositiono Physical/chemical structure (e.g. pH, a w, etc.)o Mode of preservation (e.g. chilling, freezing, heat
treatment, smoking, etc.)o Packaging and shelf lifeo Storage conditionso Method of distribution
HACCP STEP 3IDENTIFY THE INTENDED USE
Codex guidelines Step 3.
Identify the intended use of the product and its target consumers
with reference to sensitive sectors
of the population
HACCP STEP 3IDENTIFY THE INTENDED USE
Codex guidelines Step 3.
The intended use should be based on the expected normal use of the product by the end user or consumer
In specific cases, vulnerable groups of the population: e.g., the old, the very young,
the sick or hospitalized have to be considered
HACCP STEP 4CONSTRUCT THE PROCESS FLOW DIAGRAM
Codex guidelines Step 4.
Construct a Process Flow Diagram covering the full scope of the HACCP study
HACCP STEP 4 CONSTRUCT THE PROCESS FLOW DIAGRAM
Codex guidelines Step 4 The flow diagram should be constructed by the HACCP team, with the help of
people working in the immediate areas The flow diagram should cover all steps in the operation When applying HACCP to a given
operation, consideration should be given to steps preceeding and following the
specified operation
HACCP STEP 4 CONSTRUCT THE PROCESS FLOW DIAGRAM
The process flow diagram should depict: Details of all process activities including tasks, inspections, transportation, storage, etc. Inputs into the process in terms of raw
materials, packaging, water, and chemicals Outputs from the process e.g. finished
product, waste product-in-progress, re-work and
rejected products
HACCP STEP 5VERIFY THE PROCESS FLOW DIAGRAM
Codex guidelines Step 5. The HACCP team should confirm the
process against the flow diagram during hours of operation and amend the flow diagram where appropriate
It should be done by all members of the HACCP team during all stages and hours
of operation
Golden rule: MISS A STEP – MISS A HAZARD
HACCP STEP 5VERIFY THE PROCESS FLOW DIAGRAM
Verify the Process Flow Diagram
A HACCP team responsibilityObserve process flowSample activitiesConduct interviewsCover all routine/non routine operations
HACCP STEP 6PRINCIPLE 1 HAZARD ANALYSIS
Codex Guidelines Step 6. HACCP Principle 1
List all potential hazards associated with each step
Conduct a hazard analysis; and determine the significance of each hazard
Consider any measure to control identified hazards
HACCP STEP 6PRINCIPLE 1 HAZARD ANALYSIS
A- Hazard Identification List all potential hazards Sources of potential hazards: Raw materials Plant and equipment design Intrinsic factors in the product or raw materials Process design (Procedures) Personnel (Staff/Visitors) Storage and distribution
HACCP STEP 6PRINCIPLE 1 HAZARD ANALYSIS
Examples of raw materials are: Live animals Food ingredients (chilled, frozen meat, etc.) Water (used in formulation or to wash or rinse
product) Cleaning chemicals Packaging Pesticides, insecticides
HACCP STEP 6PRINCIPLE 1 HAZARD ANALYSIS
B- Hazard Evaluation
Conduct hazard analysis and determine the significance of the identified hazards * Determine likelihood of occurrence * Determine severity * Influence of pre-requisite programs * Determine significance
HACCP STEP 6PRINCIPLE 1 HAZARD ANALYSIS
A significant hazard has the potential to cause serious illness or injury when the food-stuff is consumed
HACCP STEP 6PRINCIPLE 1 HAZARD ANALYSIS
Assessment of Hazard Significance – Method 1
The significance of the hazard can be determined by considering the likelihood of hazard occurrence and its severity.
Likelihood of hazard occurrence may be rated as high (H) or low (L)
Severity is also rated as (H) or (L) If likelihood and severity are both high (H),
then the significance is (H) or critical (CCP) when planning control measures and
critical limits
HACCP STEP 6PRINCIPLE 1 HAZARD ANALYSIS
Assessment of Hazard Significance – Method 2 Matrix Method for Food Safety:
Severity (consequence) Likelihood (frequency)
1.Fatality A. Common repeating2.Serious sickness B. Known to occur3.Product recall C. Could occur4.Customer complaint D. Not expected to
occur5.Not significant E. Practically impossible
HACCP STEP 6PRINCIPLE 1 HAZARD ANALYSIS
Hazard Significance Matrix for Food Safety FREQUENCY A B C D E
CONSEQUENCE
1 1 2 4 7 11
2 3 5 8 12 16
3 6 9 13 17 20
4 10 14 18 21 23
5 15 19 22 24 25
HACCP STEP 6PRINCIPLE 1 HAZARD ANALYSIS
C- Identify Control Measures
Control measures are any factors, actions and activities that can be used to control
an identified food safety or quality hazard
Control measures must eliminate, control or reduce the effect of a hazard to an acceptable level
HACCP STEP 6PRINCIPLE 1 HAZARD ANALYSIS
Control Measures For Biological Hazards:Pasteurization – application of
time/temperatureFermentationAcidification – pH controlPickling – addition of saltDrying – Aw reductionFreezing/chillingTraining to prevent cross contamination
HACCP STEP 6PRINCIPLE 1 HAZARD ANALYSIS
Control Measures For Chemical Hazards:Supplier quality Assurance ProgramsCertificate of Analysis – signed & meet
specificat.Sanitation Program – approved food
grade chemicals, visual inspectionPest Management Program – approved
pesticidesAntibiotic TestingCorrect Labels – for products containing
allergens
HACCP STEP 6PRINCIPLE 1 HAZARD ANALYSIS
Control Measures For Physical Hazards:SievesScreensMagnetsFiltersMetal detectorsGlass control policyGMP’s – personal hygiene proceduresUse of plastic (not wooden) pallets
HACCP STEP 7PRINCIPLE 2 CRITICAL CONTROL POINTS
Codex Guidelines Step 7. HACCP Principle 2:Determine the Critical Control Points (CCP’s)
A Critical Control Points (CCP) is a step at which control can be applied and is essential to
prevent or eliminate a food safety hazard or reduce it to
an acceptable level A Control Points (CP) is a step in the process
where control may be lost without presenting a food safety hazard
HACCP STEP 7PRINCIPLE 2 CRITICAL CONTROL POINTS
Critical Control Points
For every significant hazard identified during hazard analysis there must be one or more Critical Control Points (CCP’s) where the hazard is controlled
A CCP can be used to control more than one hazard. Likewise, more than one CCP may be needed to control one hazard
HACCP STEP 7PRINCIPLE 2 CRITICAL CONTROL POINTS
CCP Decision Tree
A logical sequence of questions that is applied to each hazard in order to aid in the determination
of CCP’s and CP’s
The HACCP team should ask an additional question when using the decision tree at question 1. Is this hazard controlled by existing pre-requisite program. If yes then the step is a
CP not CCP
Is there a significant hazard at this process step ? - What is it ?
Do preventative measures exist for the identified hazards ?
Is the step specifically designed to eliminate or reduce the likely occurrence of the hazard to an
acceptable level ?
Could contamination occur at or increase to unacceptable levels ?
Will a subsequent step or action eliminate or reduce the hazards to an
acceptable level ?
Yes
Yes
no
Yes
no
Modify step , process, or product
Not a CCP
Is control necessary at this step for
safety ?
Yes
no
no
Not a CCP
Not a CCP
no
no
Not a CCP Yes
Yes
HACCP STEP 8PRINCIPLE 3 CRITICAL LIMITS
Codex Guidelines Step 8. HACCP Principle 3: Establish Critical Limits
What is a critical limit? Critical limits are criteria which separate
acceptable from unacceptable, safe from unsafe
They are the tolerance parameters for safety or
product acceptance, the boundaries for control
HACCP STEP 8PRINCIPLE 3 CRITICAL LIMITS
Codex Guidelines
Critical limits must be specified and validated for
each critical control point In some cases more than one critical limit will
be elaborated at a particular step Criteria often used include measurements of
temp., time, etc.
HACCP STEP 8PRINCIPLE 3 CRITICAL LIMITS
Critical Limits
Must be applied to All CCP’sMust be validatedMust be measurable
HACCP STEP 8PRINCIPLE 3 CRITICAL LIMITS
Source of information on Critical Limits: Published data Expert advice Experimental data Regulatory guidelines Mathematical modelling Best practices If the information needed to define the critical limit is not available, a conservative value
can be used
HACCP STEP 8PRINCIPLE 3 CRITICAL LIMITS
Types of Critical Limits: Physical limits (temp., time, size, color, etc.) Chemical limits (pH, a w, salt conc., etc.) Microbiological limits Microbiological limits are not often used as critical
limits because of the lengthy time needed to obtain results. One exception to this is the rapid testing (e.g. ATP Bioluminescence) for hygiene assessment of cleanliness of equipment and effectiveness of cleaning procedures
HACCP STEP 8PRINCIPLE 3 CRITICAL LIMITS
Validation of Critical Limits
Validation of Critical Limits is proving the critical limit will in fact, control the hazard
Example 1: Microbiological analysis of meat before and after chilling to ensure that the critical limit of 1°C to 4°C, does control the growth of pathogens
HACCP STEP 8PRINCIPLE 3 CRITICAL LIMITS
Validation of Critical Limits:
Example 2: Sampling chicken meat for chemical
residues to ensure that the withholding period of medication is appropriate
HACCP STEP 9PRINCIPLE 4 MONITORING
Codex Guidelines Step 9. HACCP Principle 4: Establish a monitoring procedure for each CCP
Monitoring is the act of conducting a planned sequence of observations or measurements of control parameters to assess whether a critical control point is under control
HACCP STEP 9PRINCIPLE 4 MONITORING
The 5 Aspects of Monitoring:
1. Why monitoring is important 2. Who monitors 3. How to monitor 4. When to monitor 5. Frequency of monitoring
HACCP STEP 9PRINCIPLE 4 MONITORING
Why monitoring is important Know when CCP’s are out of control Identify problems before they occur Pinpoint the cause of problems Part of verification Proves due diligence
“ If it isn’t written down, it didn’t happen”
HACCP STEP 9PRINCIPLE 4 MONITORING
Monitoring involves: Asking the right questions Analyzing data to get the right information Knowing where to collect Being unbiased Training of data collectors/operators/monitors Auditing the collection process
HACCP STEP 9PRINCIPLE 4 MONITORING
Who, How and When to monitor WHO HOW WHEN*Trained *Observation *On-line*Unbiased *Sight *Continuous *Smell
*Discontinuous *Taste Measurement Off-line *Weight *Discontinuous *Time *Temperature
HACCP STEP 10PRINCIPLE 5 CORRECTIVE ACTION
HACCP Principle 5
Establish the corrective action to be taken when monitoring indicates that a particular critical control point (CCP) is not under control
HACCP STEP 10PRINCIPLE 5 CORRECTIVE ACTION
Codex Guidelines Step 10. HACCP Principle 5:
Specific corrective actions must be delivered for each critical control point (CCP) in the HACCP system in order to deal with deviations when
they occur
HACCP STEP 10PRINCIPLE 5 CORRECTIVE ACTION
Codex Guidelines The actions must ensure that the critical control point
(CCP) has been brought under control Actions taken must also include proper disposition of
the affected product Deviation and product disposition procedures must be
documented in the HACCP records
HACCP STEP 10PRINCIPLE 5 CORRECTIVE ACTION
Corrective Action
Any action to be taken when the results of monitoring at a critical control point, or process control point indicate a loss of control
HACCP STEP 10PRINCIPLE 5 CORRECTIVE ACTION
The Two Levels of Corrective Action Immediate Action – (short term control) Adjust the process to regain control Deal with the suspect product Preventive Action – (long term control) Determine root cause Assign responsibility to complete preventive action Record details of actions taken and update HACCP as required Record details of the corrective actions taken
HACCP STEP 11PRINCIPLE 6 VERIFICATION
Codex Guidelines Step 11. HACCP Principle 6:
Establish procedures for verification to confirm that the HACCP system is working effectively
HACCP STEP 11PRINCIPLE 6 VERIFICATION
Verification is “Doing it Right”
Verification is the application of methods, procedures, tests and other evaluations, in
addition to monitoring to determine compliance with the HACCP Plan
HACCP STEP 11PRINCIPLE 6 VERIFICATION
Codex Guidelines – Verification
Establish procedures for verification. To determine if the HACCP system is working correctly, verification that includes auditing methods, review procedures , tests, random sampling and analysis can be used. The frequency of verification should be sufficient to confirm that the HACCP system is working effectively
HACCP STEP 11PRINCIPLE 6 VERIFICATION
Codex Guidelines – Verification
Verification activities determine compliance with the HACCP Plan
Examples of verification activities include:I. Review of the HACCP system and its recordsII.Review of deviations and product dispositionIII.Confirmation that the Control Points are under control
HACCP STEP 11PRINCIPLE 6 VERIFICATION
Verification consists of (5) five types of activities:
1.Review of Monitoring results2.Validation3.Auditing4.HACCP System Review5.Product Testing
HACCP STEP 11PRINCIPLE 6 VERIFICATION
Validation – “Are you Doing the Right Thing?”
Validation is a formal process that must be carried out before implementation of the HACCP Plan Validation records should include: List of skills used in preparation the HACCP plan List hazards and supporting data Critical limits for all CCP’s and supporting data Evidence that monitoring system control the hazards Evidence that Corrective Actions prevent shipment of defective produce
HACCP STEP 11PRINCIPLE 6 VERIFICATION
Validation and Verification – Working Together
The processes of verification and validation work
together and can be seen as a means of continuous improvement of the HACCP plan
Verification may indentify changes needed to the
HACCP plan . These changes will need to be validated , the HACCP plan updated and implemented .
HACCP STEP 11PRINCIPLE 6 VERIFICATION
An Audit …
Is a systematic and independent examination to determine whether activities and related results comply with planned arrangements. To determine whether these arrangements are
implemented effectively and are suitable to achieve objectives .
HACCP STEP 11PRINCIPLE 6 VERIFICATION
Verification of the HACCP plan provides :
1. Assurance that the system will result in the production of safe , quality food 2. Assurance that the HACCP plan in being
applied 3. Information that can be used to improve the HACCP plan 4. Assurance that the HACCP plan as originally designed is still relevant to the process .
HACCP STEP 11PRINCIPLE 6 VERIFICATION
Verification Benefits Include : Increase awareness and understanding of the system by all staffProvides documented evidence Independent and objective review Maintains confidence in the HACCP plan Identifies opportunities for improvements Ensures obsolete documents have been
removed Ensures continuous improvement through the ongoing audit cycle .
HACCP STEP 11PRINCIPLE 6 VERIFICATION
Verification of Industry of Government Responsibilities :
1.Validation of critical limits
2.Validation within HACCP plans .
3.Revalidation
4.Government verification
HACCP STEP 12PRINCIPLE 7 RECORD KEEPING
Codex Guidelines Step 12. HACCP Principle 7:
Establish Documentation and Record Keeping
HACCP STEP 12PRINCIPLE 7 RECORD KEEPING
Codex Guidelines: Efficient and accurate record keeping HACCP procedures should be documented Documentation and record keeping should be appropriate to the nature and size of the
operation
HACCP STEP 12PRINCIPLE 7 RECORD KEEPING
Records
Records are written evidence that an act has taken place
A form is the template on which the results of acts are recorded
A completed form becomes a record
HACCP STEP 12PRINCIPLE 7 RECORD KEEPING
The type of HACCP records that should be kept
as part of a HACCP system are: HACCP Plan and Support Documents Monitoring Records Corrective Action Records Verification Records