Introduction To HACCP

Prepared by:

Jared L. Espeleta
Tarek al mourad
HACCP Team Coordinator
 What is HACCP?
Hazard analysis critical control points is a preventive approach to
Food Safety from Biological, Chemical , and physical hazards in the
whole life cycle of the product, starting production till it reach the
customer level. These processes might cause harm to the finished
product, making it unsafe for human consumption. HACCP serve as
measurements to reduce these risks to a safe level.
 Food Poisoning
Mishandling the product might cause damage to it. Food
poisoning might result in such situations.

Common symptoms:
– stomach aches
– vomiting
– diarrhea
– fever
Can result in long-term diseases and death.
Often caused by food that looks, smells and tastes normal.
 Types of Hazards in
Food
Food can be contaminated by:

– Chemical hazard

– Physical hazard

– Micro-Biological hazard
Chemical Hazards
 Chemical Hazards
Chemicals in the home include those used:
– to clean surfaces and equipment
– as pesticides.

Chemicals can be very harmful if they are:

– spilt on or near food
– mistaken for food or drink.
Chemical Hazards: Natural
Toxins
Toxins are poisonous substances produced by some micro-organisms,
plants and animals.
Most toxins that cause food poisoning are tasteless and remain toxic
even after cooking.

In warehouse:
It is essential to make sure cleaning chemicals , oil or any type of
chemical material will not be kept in direct contact with the product.
During both storing and distribution

For this cleaning chemical must stored and labeled in specified area.
Physical Hazards
 Physical Hazards
Foreign matter can:

– physically injure people

– introduce harmful bacteria into food.

Examples of foreign matter include:

– Dead insects

– Hair

– Jewelry

– Glass

– Pieces of metal.

The above mentioned hazard mostly happens during production , but still precaution must
be taken and proper preservation of the product is needed during storing and distribution
Microbiological Hazards
 Microbiological Hazards
This hazard comes from microorganisms that can make us sick
such as :

– Viruses (rotavirus, norwalk virus..)

– Bacteria (Salmonella, E. coli, Listeria…)
– Parasites (Toxoplasma gondii, Trichinella spiralis..)
– Mould (Aspergillus flavus..)

Viruses and bacteria are the most common causes of food

poisoning.

Most foodborne disease is preventable with proper food handling

.Temperature monitoring during storage and distribution is an OPRP
.

Temperature should be ≤ 5 for fresh

And ≤ 25 for UHT and Processed jar cheese
Pre-requisite Programs
Pre-Requisite Programs
Supplier Approval Management
Pest Control Systems
Hygiene Regulations and Training
Cleaning & Disinfection Systems
Waste Management
Pre-Planned Maintenance
Hygienic Premises Design
Effective Temperature and Storage Controls
Supplier Approval
Management
•We need to be sure that we use reputable suppliers so
that food we produce is made from ingredients that are
known to be safe in the first place.

–In practice this means that we:

• Carry out supplier audits and/or
• Request a supplier questionnaire each year
• Maintain records on supplier issues and corrective actions taken
Pest Control System
We need to be sure that we have good
pest control and detection systems in
place so that we minimize the risks of
infestations.
In practice this means that we:
Appoint a pest control Company ( Nadec
have signed a contract with SAMES as
national contract)

Have good Pest Prevention & detection

measures in place

Maintain records on pest issues and

corrective actions taken. It is mandatory
to implement .
Hygiene Regulations &
Trainings
We need to be sure that all Food
handling staff are trained in hygiene
and are aware of the rules and
regulations
◦ In practice this means that we:
◦ Train all staff in food hygiene
practices
◦ Enforce a hygiene Policy
◦ Provide good clean protective
clothing
◦ Maintain records on training and
staff illness.
Cleaning and Disinfection
Systems
We need to be sure that all processing
equipment and Food rooms cleaned on
regular basis and that we can monitor
levels of cleanliness
◦ In practice this means that we:
◦ Require a cleaning schedule
◦ Require professional cleaning
equipment and chemicals
◦ Keep records of cleaning and micro
results
◦ Maintain records on all corrective
actions
Waste Management
We need to be sure that waste is stored
and processed properly and it does not
encourage pests or cause cross
contamination
◦ In practices this means that:
◦ Wastes are stored in professional
waste bins
◦ Regular removal of waste
◦ Wastes are stored in areas away from
food processing
◦ Records of waste and its removal
from site
Pre-Planned
Maintenance
We need to ensure that crucial
equipment such as coolers
pasteurizers, filling machines etc. are
well maintained and do not breakdown
or malfunction.
◦ In practice this means:
◦ Regular service of equipment
◦ A maintenance schedule
◦ Engineers trained in hygiene
practices
◦ Records of maintenance carried
out
Hygienic Premises
Design
We need to ensure that the premises that
we store and manufacture food has been
designed and is kept in a hygienic
manner.
◦ In practice this means:
◦ Smooth, non-porous surfaces
◦ Easy to clean equipment
◦ Modern wall cladding
◦ Adequate drainage
Effective Temperature
and Storage Conditions
We need to ensure that (Coolers, chillers
for stores etc. are adequate for the job
and work effectively on an on-going basis
◦ In practice this means:
◦ Coolers, chillers are properly size for
the job
◦ On-going maintenance records.
◦ Adequate storage capacity
◦ Contingency plan for coolers, chillers
failure
Preparation & HACCP
Team
Before you start to HACCP plan you need a
HACCP team capable of working together to
build your HACCP system.
The HACCP Team should consist of a range
of skills from the business and ideally have
the following knowledge or experience.
• Product knowledge
• Senior Managers of the business
operations
• Knowledge of bacteria/advanced food
Hygiene
• Trained in HACCP principles
Preparation & HACCP
Team
•Clear roles need to be decided in the
HACCP team so that it functions effectively.

•The HACCP team should appoint the

following roles and responsibilities,
– Chairperson
– Meeting documenter
– Policy and procedure coordinator
– HACCP documenter
– System Implementation and training
– System supervisor

One person may take one or more than one role in the HACCP
team but they should not do all roles.
 The Seven Principles of
HACCP
1. Conduct a hazard analysis
2. Determine critical Control Points
3. Establish Critical Limits
4. Establish Monitoring Procedures
5. Establish Corrective Actions
6. Establish Verification Procedures
7. Document the System
The Seven Principles the
logical way….
• If you decide a Hazard is critical to
food safety then it needs Limits that
are monitored.
• Monitoring rings the Alarm Bell
when it finds bad results.
• Corrective action is required to
bring things under control once
more.
• Everything needs to be
documented so we can prove food
is safe for human consumption.
7 HACCP Principles
The 14 Stages of HACCP
1.Define the terms of reference
2.Select the HACCP Team
3.Describe the product
4.Define the intended use

5.Draw up the flow diagram

6.Verifiy the flow diagram
7.Identify and analyze hazards
8.Determine the CCP’s
9.Establish Critical Limits
10.Establish Monitoring
procedures
11.Establish corrective actions
The 14 Stages of HACCP
12.Verify the HACCP plan
13.Document the HACCP plan
14.Review the HACCP Plan
Phase 1 – Terms of Reference, HACCP
Team, Product Intended Use
This phase of HACCP planning involves planning the foundation of the
HACCP by outlining in a document called “Terms of Reference”.

In this phase we need to:

Document the terms of reference

•Products, Process, Activities to be Analyzed.

•What types of Hazards are being considered, usually
microbiological, chemical, physical and sometimes, Allergenic
hazards.
•Decide if pre-requisite program hazards are to be included.
•Describe the product/process in words from start to finish.
•Describe the intended use of finished product.
•Record the HACCP Team details, roles and responsibilities.
It is important to determine the scope of
HACCP , Study the process and analyze
what are the Hazard that might happen to
the product
Nadec List of Products
Product Description and Intended Use
Product Product Product Finished Label Product Product Shelf-Life Storage Intended
Name type: e.g. Characte product Meets contains contains of Instructio use of the
cooked, ristics: and requirem restricted allergens product n (e.g. product;
raw (e.g. pH, recipe ents of ingredien as per Keep include
processe Aw, meets of Consume ts as per Health fresh, special
d, ready salinity, Food and r Food and Guideline Keep delivery
to eat state, Drug Act Packagin Drug Act s (Y/N)? If Frozen, instructio
other (Y/N) g and (Y/N)? If yes, list Humidity n, special
qualities) Labeling yes, list allergens. control, consumer
Act and restricted ready to s group
Regulatio ingredien cook) (e.g.
ns ts elderly ,
immuno-
comprom
ised
 Product Description The National Agricultural Development Company Form No.: HM-003
Rev. No.: 03
Depot HACCP Manual - Product Description and Intended Use
Issue Date: 12.12.15
Fresh Juice and Cavita Page No.: 1 of 23

Product Name: Fresh Juices

Apple Juice - Golden coloured apple juice, smooth light texture, sweet.
Full details of Fresh juice are
Berry Cocktail Juice – Dark Violet coloured Berry Cocktail juice, smooth light texture, sweet.

Mango Juice - Orange colour mango juice, smooth thick texture, sweet mentioned in product
Strawberry Juice - Strawberry fruits with seeds crushed and dissolved in a syrup solution, with
added colour and flavour. Sweet , Thick product with rich mouth feel. No smooth texture due to
crushed strawberry seeds.
description. Information such as
Mixed Fruit - Red coloured cocktail juice, smooth light texture, sweet. color of the product,
specifications and packaging
Product Description: Lemon Mint Juice – cloudy colorless lemont juice, smooth light texture, sweet

Kiwi Lime Juice – lime green Kiwi and Lime juice, smooth light texture, sweet

Pomegranate Juice – Dark red pomegranate juice, smooth light texture, sweet

Pineapple Juice – Cloudy yellow pineapple juice, smoth light texture, sweet
material are highlighted.
Mango Cherry Juice – Brick Red mango cherry juice. Smooth thick product with rich mouth feel.
Sweet

Mango Lychee Juice – Dark Orange juice. Smooth thick product with rich mouth feel. Sweet

Characteristics:
Chemical: Please refer to finished product specifications sheet (Ref.SP-016/6.1) Information's stated on the label
Microbiological:

Ingredients:
Please refer to finished product specifications sheet (Ref.SP-016/6.1)

Fruit Concentrates, pulps, natural flavours, vitamin C, stabilizers, colours. Sugar

must follow SASO and GSO
Important Preservation
Characteristics:
Keep closed and refrigerated after opening
regulatory standards.
Shelf Life: 30 Days
Packaging:
Please refer to Raw and Packaging Materials Specifications
Primary Packaging:
PET, HDPE and LDPE bottles and Caps, Aluminum Foil Seal for 1.0 L, 1.75 L, 3.0 Liter
Pack in HDPE Crates or corrugated box.
Secondary Packaging:
Hijira Calendar , Gregorian and English text on Print Code

Labeling Instruction: Refrigerate after opening

Where the product is Sold: Wholesaler and Retailer

Special Distribution
Avoidance from any bottles or caps damage. Keep at temperature <5OC
Control:

Product Use: For direct consumption as Fresh Juices

Identification of
Product Suitable for general population
Consumer Suitability:
Phase 2 – Flow Diagram and Hazard
Analysis
This phase of HACCP planning involves sketching out the process flow
diagram and listing all possible hazards and their control measures.

In this phase we need to:

•Draw and verify a process flow diagram.

•List all possible hazards for the process or product.
•Identify Pre-requisite program hazards.
•Carry out a risk assessment for each hazards
•Record and discard hazards of very low significance
•Agree the control measure for each hazard
Flow Diagram
<5◦ c

Warehouse
Warehouse <5◦ c Warehouse
Warehouse <5◦ c Warehouse

Customer
<5◦ c
Process Flow Diagram

It is required to maintain proper record for temperature monitoring in addition to taking

corrective and preventive action.
Decide whether to show or not to show the
PRP’s in the HACCP Plan

Decide before proceeding to the risk assessment.

Document your decision in the terms of reference document.

There are benefits in including them, such as:

•Ease of staff training

•One overall, integrated management system
•A “ones stop shop” for all food safety information.
Risk Assessment
The risk assessment can be carried out by asking two simple questions about each hazard as follows:

Q1. What are the consequence of this hazard

Q2. What is the likelihood that this hazard will occur

The National Agricultural Development Company Form No.: HM-015
Rev. No.: 01
HACCP Manual Issue Date: 01.04.15
Risk Assessment Page No.: 1 of 1

Likelihood
Risk Assessment Matrix
A B C D E
Likelihood Description
1 1 2 4 7 11 A - Daily

2 3 5 8 12 16 - Once a Week
Severity

B
3 6 9 13 17 20 C - Once a Month

4 10 14 18 21 23 D - Once a Year

5 15 19 22 24 25 E - Once Every Five Years

Note: Severity Description

1 - 10 considered as significant hazards 1 Fatality with long term sequels

2 Serious Sickness with long term sequels

3 Sickness without long term sequel

4 moderate sickness (fast recovery)

5 Not significant

“ If we assess these two questions together in a grid we can easily arrive to a decision of overall significance and set a
threshold above which we deem the hazard as a “Not significant” and therefore not to be included in the HACCP Plan
 Hazard Analysis

The National Agricultural Development Company Document No.: HMD-004

DEPOT HACCP Manual Rev. No.: 00
Issue Date: 01.08.15
Hazard Analysis Page No.: 3 of 4
Does this step need a high level of
Does this step eliminate, reduce monitoring/regular monitoring all Final CCP/OPRP
Step No. Hazard Cause Likelihood Severity Significance Q1 Q2 Q3 Q4 Control Measures
hazards to acceptable levels? day long in order to prevent all Significance /PRP
proliferation cases?
Microbiological growth due to insufficient cooling or Vehicle Inspection during receiving.SOP, GWP, Training in
Biological Microbiological Growth C 2 8 No No No - - - - PRP
high temperature at trailer. place
Bad handling practices. Microbiological growth on
Biological Microbiological Growth E 2 16 - - - - - - - - -
damaged product due to improper handling.
Bad Practices - Staff handling products without
washing their hands. Staff may observe some loosed
Biological Microbiological Growth E 2 16 - - - - - - - - -
cap and tighten it by their bare hands, eventually the
product will be sent to market.
Receiving of
Insects/pest Contamination of pest/insects migrating through
finished Physical D 2 12 - - - - - - - PRP Pest Control in Place, SOP,GWP, Training
contamination damaged packs.
products Wood pieces due to the use of broken or damaged
Physical Wood pieces from pallets E 2 16 - - - - - - - - -
pallets.
Physical Broken glass pieces Broken glass pieces from lights inside the trailers E 2 16 - - - - - - - - -
Cross contamination of hazardous
Hazardous chemicals/cleaning chemicals from trailers
Chemical chemicals/cleaning previously used to transport chemicals. Trailer E 3 20 - - - - - - - - -
chemicals previously cleaned using cleaning chemicals but not
properly rinsed.

“Any hazard that you identify as not significant should not appear in you main HACCP plans but instead it should be
documented why you arrived at this decisions in terms of its significance”
Phase 3 – Determine CCP’s, Critical Limits,
Monitoring Corrective Action
Some key tips when using the decision tree
questions

Q1. Are control measures in place to control the hazard?

Tip: Because we have already identified the possible control measure during Phase 1
the answer to this question is always yes.

Q2. Is the process step designed to eliminate the hazard to an acceptable level?

Tip: Substitute the process step and the hazard name into the question and read it back
to answer this question e.g.

Is UHT Processing designed to eliminate pathogens or reduce to acceptable level?

Q3. Could the hazard increase to an unacceptable level?

Tip: You need to consider what changes might occur that could cause the hazard to
occur more frequently. Things like changes in staff, Management, The process step,
ingredients, suppliers, even the seasons can affect the answer to this question.

Q4. Does a later process step control this hazard/

Tip: Make a list of the later process steps “downstream” of the current process step and
decide if any of those process steps will control the hazard
Best Practices
Best Practices
Product must be highlighted and specified displaying
Production Date for better tracking of FEFO and FIFO
Best Practices
Best Practices
Best Practices
Best Practices
Best Practices
Thank you