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HAZARD ANALYSIS AND RISK ASSESSMENT (ISO 22000 & PS 3733 Halal Food
Management System)

Method · September 2018

DOI: 10.13140/RG.2.2.27416.85760

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Yousaf Ayub
University of the Punjab
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 FLOUR MILLS (Pvt.) Ltd
STANDARD OPEARTING PROCEDURE (SOP)

HAZARD ANALYSIS AND RISK ASSESSMENT

(ISO 9001, 22000 & PS 3733 Integrated Management System)

Approved by
Name: Signature
SOP-012
Designation:
Date:
Rev: 00
Issue Date: Sep 08, 2018
SOP FOR HALAL AND FOOD HAZARD ANALYSIS & RISK ASSESSMENT

DOC #: SOP-012 REV # : 00 ISSUE DATE: Sep 08, 2018

Amendment History Record

Rev. No. DCR Number Section Amended Text

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 SOP FOR HALAL AND FOOD HAZARD ANALYSIS & RISK ASSESSMENT

DOC #: SOP-012 REV # : 00 ISSUE DATE: Sep 08, 2018

1. Purpose
This procedure provides the guidelines to identify the food hazards and evaluate the risks to
quality & safety of product. Analyze hazards to identify any hazardous biological, chemical,
physical or halal property in raw materials and processing steps, and to assess their likeliness
of occurrence and potential to render food unsafe or haram for consumption.

2. Scope
This procedure is applicable to all processing steps, storage and raw materials of Flour Mill.

3. Responsibility
3.1 Food Safety Team has the overall responsibility to manage and coordinate the
activities related food safety and halal food safety hazards identification and risk
assessment.
3.2 Food Safety Team (FST) is responsible for carrying out all the activities related to
this procedure such as identification of food safety hazards, risk assessment and
determining appropriate controls. Periodically review this procedure and ensure
that it remains appropriate to the activities of Flour Mill.
3.3 All the employees working at Flour Mill are responsible for reporting any Food
Safety hazard to FST identified during routine activities.

4. Procedure
Stepwise activities carried out at Flour Mill for the identification of Halal & Food safety
hazards or food safety risks analysis includes;
 Identification of Hazards
 Assessment of Risks
 Determining Controls
 Implement Controls
 Monitor and Review
4.1 Hazard Identification
4.1.1 A Food Safety Team (FST) headed by Miller identifies the Halal & Food Safety
hazards and conduct hazard risk assessment associated with the operational
activities of Flour Mill
4.1.2 When conducting hazard analysis, FST needs to identify and evaluate the
potential hazards associated with:
a. Raw materials
b. Ingredients and additives
c. Packaging materials
d. All processing steps, including receiving and storage

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DOC #: SOP-012 REV # : 00 ISSUE DATE: Sep 08, 2018

e. Potential cross-contamination points (tools, equipment, machines, etc.)

4.1.3 Hazard description includes the specific hazard (i.e. name of the pathogen,
type of physical hazard) and the conditions that are associated with it (i.e.
presence, survival, growth).
4.1.4 Following are the types of the hazards;
Biological hazard: Occurrence of Microbial or pathogenic contamination
at any stage of the process
Chemical hazard: Allergen contact or contact with sanitizers, cleaners,
solvents, lubricants or additives.
Physical hazard: Entry of physical items which could harm the health of
the consumer
Halal Hazard: These are the items/materials with Haram/Najis nature
which has been forbidden in Islam.
4.2 Risk Assessment
After identification of the hazards next step is the evaluation of the identified hazards.
Hazards are evaluated by the FST, based on the severity and likelihood to determine
which are significant.
Likelihood is categorized into following categories;

Likelihood Description
Certain It is expected to occur at some time in the near future (daily)
Possible Might occur at some time (weekly or monthly)
Rare The event may occur only in exceptional circumstances

Severity is categorized into following categories for food safety, however, severity for
haram/najis will always be at “Severe (03)”;

Severity Description
No effect or minor discomfort on health when consumed without
Minor
hospitalization.
Can cause mild health effects such as vomiting or diarrhoea and
Moderate
medication or hospitalization is required
Severe Can cause severe health effects or even fatality when comes in food
contact

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The risk is evaluated by plotting the likelihood against the consequences in the following
way.

RISK ASSESSMENT MATRIX

SEVERITY
LIKELIHOOD
Minor (1) Moderate (2) Severe (3)
Certain (3) 3 6 9
Likely (2) 2 4 6
Possible (1) 1 2 3
4.3 Significance Determination
Hazards with risk value of 1 to 2, obtained after the risk assessment is considered as Non-
Significant Hazard and the hazards with risk value of 6 to 9, obtained after the risk
assessment is considered as a Significant Hazard and this hazard is further evaluated for
CCP/OPRP determination.

LEGEND
This hazard is required to be controlled through proper monitoring
6-9 Significant and measurement. Activities needs to be stopped and control action
is required immediately.
Activities could be carried out with temporary measures in place and
3-4 Moderate
proper control action is required within 01 week.
Non- Supervisor attention is required. Proper hygienic environment is
1-2
Significant required.

4.4 Justification for Significance

Food Safety Team gives the justification for the decision of declaring a Hazard as
significant or Non-Significant. Justifications are based on severity of the hazard and the
control measures applied to the process.
4.5 Acceptable Levels of Hazard in End Product
Food Safety Team defines the level of hazard which is acceptable in the product
whenever possible. Following things are considered by the Food Safety Team when
defining the acceptable level of hazards;

a. Statutory and regulatory requirements

b. Food safety requirements
c. The intended use by consumer

4.6 Selection and Establishment of Control Measures

a. Food Safety Team determines and establishes appropriate control measures
specifically according to the identified hazard.
b. The control measures established should limit the hazard within acceptable
levels.
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DOC #: SOP-012 REV # : 00 ISSUE DATE: Sep 08, 2018

c. When the risks are evaluated, their cause is found out and then the control
measures are suggested.
d. The control measures are prioritized according to the magnitude of the risk

4.7 OPRP/CCP Determination

Food Safety Team evaluates the each identified significant hazard against the CCP/OPRP
decision tree (Appendix A) to determine whether it is required to be controlled through
Operational Prerequisite Program or Critical Control Points.

4.8 Risk Assessment

For Halal Food Management System, likelihood is categorized into following categories;

HALAL PRODUCT
Likelihood Description Severity
Certain (5) Confirmed non Halal Catastrophic (5)
Likely (3-4) Only claim by supplier no authentic proof Severe (3-4)
Claim / Declaration by manufacturer / supplier
Possible (2) with sufficient document proof but no test Major (2)
report.
Declaration by manufacturer only but no
Unlikely (1) authentic test report. MSDS also prove absence Moderate (1)
of Haram ingredients.
No traces at all confirm through authentic
Rare (0) source, test report of lab. Or manufacturer is Minor (0)
Halal certified.

4.9 Monitoring and Measurement

4.9.1 Results of team findings are documented on identification of halal & food
safety hazards and their risk assessments. If there is any ambiguity in the
results, a member is nominated to resolve the ambiguity.
4.9.2 To keep an update on the food safety hazards and risk assessment, they are
re-evaluated based on their significance at least once in a year by the
implementation team.
4.9.3 All the hazards are monitored by the Food Safety Team on regular basis.
Supervisor/ in-charge is responsible for continuous monitoring of hazards
associated controls like Prerequisite Programs, Pest Control, and Personal
Hygiene.

5. Associated Records
5.1 Food Safety Team
5.2 Product Description Form
5.3 Process Flow Diagram
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DOC #: SOP-012 REV # : 00 ISSUE DATE: Sep 08, 2018

5.4 HACCP Plan

5.5 Test Plan
5.6 Verification Plan
5.7 Hazard Identification & Risk Assessment Form

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DOC #: SOP-012 REV # : 00 ISSUE DATE: Sep 08, 2018

Appendix A – OPRP/CCP Decision Tree

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 SOP FOR HALAL AND FOOD HAZARD ANALYSIS & RISK ASSESSMENT

DOC #: SOP-012 REV # : 00 ISSUE DATE: Sep 08, 2018

Process Flow Diagram of Flour Mill in Native Language

2 B1 S1
1 1

B2 S2
( )
1
1 3 B3 2 S3

1
B4 1R
( ) ( )
3
4R 2R
4

1 1 5R 3R

2 B5
( )

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