8. 8
It is a standardized, scientific and systematic method to:
assess all potential food safety risks
put in place monitoring control for identified high risks,
to remove or minimize these risks.
HACCP is now recognized as the global standard
for food safety.
9. 9
HACCP
Hazard
◦ Any potential risk to the safety of food to be consumed and/or sold.
◦ Main risks fall into three categories
Physical
Chemical
Microbiological
Analysis
◦ Assessment of the likelihood and severity of all potential risk
Critical Control Point
◦ Focus food safety management at the highest risks
10. 10
HACCP Principles
Codex Alimentarius sets out 7 principles and 12 steps for
establishing a HACCP based program to identify potential risks
and to control/prevent these food safety risks.
It involves documented detail of the people and processes
involved in the food production process.
11. 11
Preliminary Steps
These may include:
◦ Documented Procedures
◦ Good Manufacturing Practices
◦ Staff Training
◦ Cleaning & Hygiene
◦ Pest Control
◦ Approved Suppliers
12. 12
The 7 Principles of HACCP
1. Conduct a hazard analysis
2. Determine the Critical Control Points (CCP)
3. Establish critical limits for each CCP
4. Establish the monitoring of each CCP
5. Establish corrective actions for each CCP
6. Establish verification of the HACCP Plan
7. Establish documentation and records
13. 13
The 12 Steps of HACCP
1. Assemble and train the HACCP Team
2. Describe the product
3. Identify its intended use
4. Construct a process flow diagram
5. Verify the flow diagram
6. Apply the 7 Principles of HACCP (Steps 6-12)
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Step 1 -Assemble the HACCP team
The HACCP Team should consist of people
who have the following skills:
A knowledge of HACCP
- This person will also act as the Team Leader
A knowledge of the process and disciplines
A knowledge of the product and its intended use
A member of senior management
- to show the commitment of
senior management to the HACCP Plan
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The Product
Step 2 Describe the product
◦ Product name, ingredients, how it is processed, shelf life,
storage and handling, packaging, labelling and
any particular characteristics
Step 3 Identify its intended use
◦ Identify the consumer
◦ Are there high risk consumers (children, elderly, infirmed)
◦ How will product be used by consumer?
◦ Consumed as is, re-heated or further processed
◦ Instructions for correct use
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Process Flow Diagram
Step 4 Construct a flow diagram
◦ Determine the scope of the process flow
◦ Draft a flow diagram or chart that shows each step of the process
Step 5 Verify the flow diagram
◦ The verified flow diagram must be documented
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Step 6 - Conduct Hazard Analysis
Using the verified flow diagram assess the
potential food safety hazards and risks at each step
At each step identify the following hazards
◦ Physical
◦ Chemical
◦ Microbiological
Determine the risk associated with each of the identified
hazards
◦ Likelihood
◦ Severity
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Identify Hazards
Physical
Sticks, stones, metal, glass, etc.
Chemical
-Naturally occurring toxins – allergens, tannins, anti-nutrients
(gossypol, glucosinulates)
-Naturally produced toxins - mycotoxins
-Man-made toxins
-Insecticides and other agricultural chemicals,
Detergents and sanitizers, Fuels and lubricants
Microbiological
◦ Bacterial - Salmonella, Listeria, E.coli, etc.
◦ Molds and fungi.
◦ Pathogens, viruses, parasites.
19. 19
Assess the Risk
Severity
◦ If the hazard did occur what would be the severity or the outcome?
◦ Fatal, illness, harm, discomfort or no effect
Likelihood
◦ What is the likelihood, probability or frequency
of the hazard actually occurring
◦ All the time, once a month, once a year, never
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SEVERITY
SCORE
SEVERITY
SCORE
Negligible feed
safety risk
1
Minor feed safety
risk
2
Major feed safety
risk
3
Critical feed
safety risk
4
PROBABLE
FREQUENCY
SCORE
Remotely possible 1
Known to have
occurred in the past
2
Strong possibility of
occurring
3
Has occurred
previously
4
Hazard is present
all the time
5
21. 21
Step 7 – Determine CCPS
Critical Control Points
◦ A critical control point (CCP) is a point, step, or procedure in a
food manufacturing process at which control can be applied and,
as a result, a food safety hazard can be prevented, eliminated, or
reduced to an acceptable level.
◦ It must be the last point of control for the identified hazard to be
controlled
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Step 8 – Critical Limits
A critical limit is the maximum or minimum value to which a physical, biological, or chemical
hazard must be controlled at a critical control point to prevent, eliminate, or reduce to an
acceptable level.
Some critical limits can be regulated by Government
Typical critical limits may include:
◦ Temperature, time, pH, moisture, water activity, allowable level of contamination
Critical limits are generally referred to as:
◦ Upper or maximum level (UCL)
◦ Lower or minimum level (LCL)
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Step 9 - Monitoring
Monitoring method should be rapid so as to
allow operators to make a quick decision as to
whether the limit has been breached or not.
Visual monitoring is the most effective and rapid method.
This may include checking temperature
and assessing moisture content.
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Step 10 – Corrective Action
The HACCP plan must identify the corrective actions
to be taken if a critical limit is not met.
Corrective actions are intended to ensure that no product
is injurious to health or otherwise adulterated.
Corrective actions must bring the process and/or the product back into
control.
Corrective actions may include isolation, rework and disposal.
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Step 11 - Verification
Verification ensures the HACCP plan is adequate
and is working as intended.
Verification procedures may include such activities
as review of HACCP plans, CCP records, critical limits and
microbial sampling and analysis.
Verification can include:
◦ Internal audits
◦ Alternative and/or external test analysis
◦ Visual observation of CCP procedures
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Verification also includes 'validation’
– the process of finding evidence for the accuracy
of the HACCP system.
Validation evidence may include:
◦ Scientific evidence for critical limitations
◦ Scientific evidence for potential hazards
◦ Government regulations such as Maximum Residue Limits
◦ Industry Code of Practice
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Step 12 - Documentation
HACCP requires that all plants maintain certain documents,
including its hazard analysis and written HACCP plan, and
records documenting the monitoring of critical control points,
critical limits, verification activities, and the handling of
processing deviations.
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The 12 Steps of HACCP
1. Assemble and train the HACCP Team
2. Describe the product
3. Identify its intended use
4. Construct a process flow diagram
5. Verify the flow diagram
6. Apply the 7 Principles of HACCP (Steps 6-12)
31. 31
The 7 Principles of HACCP
1. Conduct a hazard analysis
2. Determine the Critical Control Points (CCP)
3. Establish critical limits for each CCP
4. Establish the monitoring of each CCP
5. Establish corrective actions for each CCP
6. Establish verification of the HACCP Plan
7. Establish documentation and records
◦ Time consuming (food has decomposed before test results have been finalized)
◦ Expensive (Too many hazards to test for
◦ Not practical (most of the food has been used for the testing)
The concept of HACCP was developed as a tool for NASA to ensure food safety for astronauts.
The Codex Alimentarius is generally regarded HACCP as the best method to use to achieve FOOD SAFETY. The Codex Alimentarius Commission is a body founded by the Food and Agriculture Organisation (FAO) of the UN and the World Health Organisation (WHO). It is recognized by the World Trade Organisation as an international trade reference point.
It requires an analysis of potential food safety hazards and the risks associated.
It includes detailed monitoring and recording of the control of the risks.
It identifies what will be done when a risk becomes out of control.
Before implementing the HACCP Plan a number of preliminary or prerequisite procedures need to be established and implemented.
These are
When making a HACCP PLAN, we must follow these 12 steps
The HACCP team must be trained in the 7 Principles and 12 Steps. The HACCP Team meetings must be recorded.
This will provide the HACCP team with correct information to identify the hazards.
Step 4 --◦ Where does the company take control of raw materials?
◦ Where does the company hand-over control to the consumer? Step 5 --◦ On site walk through of the flow chart to verify that the chart does actually represent the true process
◦ “Walking the line” ensures that all information, processes and controls have been accounted for
what could go wrong Identify the hazards that affects the process Identify the steps that hazards likely to occur Decide which hazards are significant Determine the measures necessary to control the hazards
Hazards are anything that could make a food unsafe for consumption and are generally categorized as:
The risk assessment rates the identified hazards according to the severity and likelihood of the hazard occurring.
The HACCP Team determines which hazards are critical and it is these that move onto Step 7. Most important points / steps where the control measure must be used to prevent, eliminate or reduce the hazards to an acceptable level
◦ It must be the last point of control for the identified hazard to be controlled.
◦ In the following slide the hazards identified as Red and Orange would be CCPs that must be monitored
and controlled.
◦ Those identified as Yellow would require monitoring as the minimum level of control.
Establish critical limits for each critical control point that has been identified Safety limits which separate the acceptable from unacceptable Eg: Cooking Temperature: Storing Temperatures: Food Temperatures:
Establish critical control point monitoring requirements Monitoring activities are necessary to ensure that the process is under control at each critical control point. Setup checks for control measures at CCP to confirm that the process is under control and critical limits are not exceeded Codex Alimentarius requires that each monitoring procedure and its frequency be listed in the HACCP plan.
Establish corrective actions. These are actions to be taken when monitoring indicates a deviation from an established critical limit.
Establish procedures for ensuring the HACCP system is working as intended Validation ensures that the procedures have been followed and did what they were designed to do; that is, they were successful in ensuring the production of a safe product. Prove that HACCP plan is working
Establish record keeping procedures
When making a HACCP PLAN, we must follow these 12 steps
