HACCP - Hazard Analysis Critical Control Point

1. TOPIC : HACCP

2. HAZARD - FOOD CONTAMINATION /
SPOILAGE.
ANALYSIS - FINDING OUT THE SOURCE.
CRITICAL - THE LEVEL OF DANGER.
CONTROL - THE REMEDIAL ACTION.
POINT - THE STAGE FOR CORRECTIVE
ACTION.
HACCP
HACCP – THE FOOD SAFETY TOOL

3. DEFINITION
HACCP is a systematic approach to
identify, evaluate and control food
safety hazards that are caused by
Biological, Chemical or Physical
agents.
These agents can cause illness if not
controlled.
HACCP

4. … Its History
•The HACCP system of food safety was
pioneered in the 1960’s by the pillsbury Co.
•Pillsbury and National aeronautics and space
administration(NASA) jointly developed
HACCP in their collaborative development of
foods for the space programme.
•Their aim was to prevent aeronauts from food
poisoning and to produce 100% safe food .
HACCP

5. …Its OBJECTIVES
• To ensure that the food served to the consumer is
SAFE for human consumption.
• Awareness to Food handling techniques.
• Understanding the faults and taking Corrective
actions.
• Better knowledge to food handlers for longer Shelf
life of cooked and raw food.
• To monitor the quality of food from FARM to FORK.
HACCP

6. …The 7 principles
1. Conduct a hazard analysis - Identify hazards.
2. Establish critical limits - Maximum or minimum
value to reduce hazards to an acceptable level.
3. Determine the critical control point [CCP’s]-
The step or procedure at which control can be
applied.
4. Establish a system to monitor the control of
the CCP’s – Visual check, temperature recording
,etc.
HACCP

7. 5) Establish corrective actions to be taken when
monitoring – Any deviation should be rectified.
6) Ensuring the procedures – Periodical checks to
ensure that the system is working as intended.
7) Establish procedures for verifications to
confirm that the HACCP system is working
effectively – Record keeping and
documentation.
…The 7 principles
HACCP

8. HACCP
The Critical Limits

9. HACCP
Prerequisite Programs (PRPS):-
 PRP’s are the foundation for the HACCP system.
 They are the “ procedures” including good
manufacturing practices, that address
operational conditions.
 These are general control measures aimed at
maintaining the safe and hygienic environment.
EXAMPLE:-
 Cleaning and Sanitation.
 Personal hygiene
 Training

10. HACCP
Operational Prerequisite Programs (OPRP’s):-
 They are nothing but the PRE and POST checks that are
need to be done to ensure that the food is having a safer
processing.
 This means that these are also essential for the smooth
functioning of the food processing.
 They are also control measures aimed at maintaining a
safe and hygienic environment.
EXAMPLE:-
 Checking the magnetic strength before and after.
 Checking on sieve condition before the process and at
end of process to ensure food safety.

11. HACCP
Critical Control Points(CCP’s):-
 According to FDA a 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”.
 They are based on the ideas of critical limits,
which are thresholds used to determine safe and
unsafe conditions.
 They are considered to have absolute control
over the hazard.
EXAMPLE:-
 A specific heat process, like pasteurization.

12. HACCP
[1] Conduct a hazard analysis
HACCP is always conducted by cross functional team in a Food Industry.
1. QA Team.
2. Production Team.
3. RM/ PM Ware Housing and Stores.
4. Procurement Team.
5. Accounts Team.
6. Product Dispatch Team.
Rules the Team to follow:
1. No discrimination of points laid down by any team member.
2. Focus on possible Hazard in a particular step of production process.
3. Team to discuss on all possible Hazard End to End.
4. Team to collectively discuss control measure.
Formation of HACCP Team.

13. [2] Establish critical limits
HACCP
Step 1 : Will be at elimination at Hazard at source.
Step 2 : Will be at elimination of Hazard during processing stage if not able to do at
Step 1.
First and Foremost thing we need to start HACCP.
A Detailed Process Flow Chart
Raw material receipt Raw material Storage. RM inward to process section. RM Tipping section.
RM segregation section.
RM Mixing section.
RM Processing section.
Finished Product Processing section.
Finished Product Packing section. Finished Product Storage section. Finished Product Dispatch section.
All Departments to be covered during HACCP

14. [3] Determine the Hazard control
points
Critical limits can be further classified as.
(a) PRP’s: Prerequisite Programs [ Example: GMP / Zoning / Hygiene etc…]
(b) OPRP : Operational Pre-requisites point. [ Example: Checking of sieve /Checking
of Magnet strength]
(c) CCP : Critical Control point. [ Example: Pasteurization temperature/Storage
temperature etc…]
HACCP
Severity of health effect
Can cause fatality A
Can lead to serious
illness
B
Can cause illness C
Can cause inconvenience D
Almost of no significance E
1 2 3 4 5
Unlikely Rare Could occur Likely Frequent
(<1or 2 / years) (1 / year) (1/6 month) (1 / month) (1 / week)
Likelihood of occurrence of Hazard
The Hazard Criticality is done by analyzing the source of the Hazard and the
intensity of the Hazard it can Cause to Human Safety.
GUIDANCE TABLE

15. [4] Establish a system to monitor control &
CCP’s
HACCP
1. Visual Checks and recording in log sheet. [CP]
2. Control checks [ OPRP]
3. Thermographs with Alarm and Auto diversion [CCP]
4. High speed cameras with Auto rejection [CCP]
5. Metal detectors with Auto rejection [CCP]
HACCP DOCUMENTATION
Work sheet 1 : TEAM FORMATION SHEET.
Work sheet 3 : PRODUCT DESCRIPTIONS sheet
Work sheet 2 : MEETING ACTIVITY LOG
Work sheet 4 : Process Flow chart
Work sheet 5 : Hazard Identification and Description
Work sheet 6 : Hazard and consequence Guidance Table.
Work sheet 7 : CONTROL MEASURE SELECTION and CATEGORIZATION.
Work sheet 8 : HACCP plan for CP /CCPs / OPRPs / MODIFICATIONS.
Work sheet 9 : VERIFICATION PLAN.
Work sheet 10 : VALIDATION OF CONTROL MEASURES.
Work sheet 11 : LIST OF HAZARDS.
Work sheet 12 : LIST OF SUPPORTING DOCUMENTS.

16. HACCP
5. Establish corrective actions to be taken when
monitoring.
1. Timely check and monitoring in log sheet.
2. Action in case of deviation.
3. Pre-checks before start [ OPRP].
4. Traceability
5. QA Representative sampling and checks.
FORMATION of QMS [ Quality Monitoring Scheme].

17. 6. Ensuring the procedures
HACCP
Daily Shift wise Check and Internal Audits
Check : Process Log sheets.
Check : Process Installation Calibration log sheet.
Check : QA Checks.
Check : Verification file Action in case of Deviation.

18. 7. Establish procedures for verifications to confirm that the HACCP
system is working effectively
HACCP
Verification Plan.
QMS Audit.
FSMS Audit.
Traceability Audit.

19. HACCP