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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


Scope

The Scope of the HACCP plan defines the product, the start and

the finish of the process under

HACCP study


Purpose

The Purpose of the HACCP plan defines the reasons why you are implementing HACCP


Step 1 b

Codex Guidelines Step 1 (b)

Assemble 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


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


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)


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


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


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


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


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


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


A significant hazard has the potential to cause serious illness or injury when the food-stuff is consumed


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


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


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


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


Control Measures For Biological Hazards:Pasteurization – application of

time/temperatureFermentationAcidification – pH controlPickling – addition of saltDrying – Aw reductionFreezing/chillingTraining to prevent cross contamination


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


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


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


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


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.


Critical Limits

Must be applied to All CCP’sMust be validatedMust be measurable


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


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


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


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


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


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”


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


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


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


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


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


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


Establish procedures for verification to confirm that the HACCP system is working effectively


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


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


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


Verification consists of (5) five types of activities:

1.Review of Monitoring results2.Validation3.Auditing4.HACCP System Review5.Product Testing


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


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 .


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 .


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 .


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 .


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


Establish Documentation and 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


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


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