Benefits of an Accredited HACCP

System
• Increases consumer confidence in food safety.
• Demonstrates an actively maintained and
continuously improving food safety system.
• Meets customer (e.g. co-packer, retailer)
requirements.
• Displays product quality and productivity.
• Increases criteria of internal auditing, rather than
relying on government inspection.
What is HACCP?
 Hazard
 Analysis
 Critical
 Control
 Point
5 Preliminary Steps in HACCP
Preliminary Step 1 – Assemble HACCP Team

To ensure that all likely hazards and critical control points (CCPs) are identified, a
multidisciplinary team of people must be assembled to develop, implement and maintain
the HACCP system.

The HACCP Team needs to be formed with people who have operational experience,
product specific knowledge and a good understanding of the production process. The
HACCP Team should include the following types of employees: Quality Control (QC),
technical staff, production managers / supervisors, laboratory personnel, engineering staff
and sanitation staff.

A HACCP Team Leader needs to be designated to oversee the development,

implementation and maintenance of the HACCP system. The HACCP Team Leader must
have a good understanding of HACCP and a working knowledge of the product and its
production process.
5 Preliminary Steps in HACCP
Preliminary Step 2 – Describe Product

A full description of the product needs to be prepared to

provide a profile of the product and to help determine
the food safety hazards associated with its production.

Product Descriptions must describe relevant food

safety information, such as:

· Available water pH;

· End product characteristics e.g. shape, size, colour,
texture, odour etc.
· Method of preservation
· Packaging
· Storage conditions
· Shelf life
· Special labelling information
· Customer preparation
· Method of distribution.
5 Preliminary Steps in HACCP
Preliminary Step 3 – Identify Intended Use

It is important to identify the expected use of a product by the end user or

consumer (e.g. cooked before consumption or ready to eat without
cooking) because the intended use of a product will affect hazard
analysis decisions.

Intended use information also needs to identify whether the end user will
be the general public or a specific consumer group, particularly
vulnerable groups of the population such as infants, the elderly, pregnant
women, ill people, immuno-compromised persons or cancer patients.
5 Preliminary Steps in HACCP
Preliminary Step 4 – Construct Flow Diagram

The HACCP Team needs to create a flow

diagram that provides a clear, simple outline of
all inputs, steps and outputs in the food
production process. The main steps in the
process must be set out, including any rework or
recycling of materials.

The flow diagram will provide the basis for

carrying out a systematic hazard analysis.
5 Preliminary Steps in HACCP
Preliminary Step 5 – On-site Confirmation of Flow Diagram

An on-site review of the flow diagram must be carried out to check that the
flow diagram accurately reflects the production process for the product. The
HACCP Team should follow the production process on-site and check that
the flow diagram includes all steps that are carried out.

When verifying the accuracy of the flow diagram consideration needs to be

given to different shifts and hours of operation, different batch sizes, optional
ingredients and non-routine steps such as maintenance of equipment.

After the five preliminary steps to developing a HACCP plan have been
completed, a solid foundation is in place to successfully apply to the seven
principles of HACCP.
HACCP 7 Principles
 (PRINCIPLE 1)  (PRINCIPLE 4)
 Identify hazards associated with  Establish Monitoring Procedure(s)
each step
 (PRINCIPLE 5)
 (PRINCIPLE 2)  Establish Deviation Procedure
 Apply HACCP decision tree to
determine CCP’s  (PRINCIPLE 6)
 Establish Verification Procedure
 (PRINCIPLE 3)
 Establish Critical Limit(s)
 (PRINCIPLE 7)
 Establish record/documentation
system
Hazard Identification Procedures
a) Review Incoming goods and materials
b) Evaluate Operations Material for Hazards
c) Observe Actual
d) Take Measurements Operating Practices
e) Analyze Measurements
Philosophy Behind HACCP:

 Systematic approach
to ensure food safety
with prevention being
the key element
Principle One: Hazard Analysis

What is a “hazard?”

• A hazard is an agent that is reasonably likely to cause illness or

injury in the absence of a control

• A hazard is an unacceptable contamination that causes the

consumer a health problem or an injury
Hazards
Unacceptable contamination that may cause a food to be
unsafe for consumption.
A microbiological, chemical or physical property which may
cause a food to be
unsafe for consumption.

Types:
1) Biological
2) Chemical
3) Physical
Hazard Analysis
 Principle 1

• Use plant specific information

• Use information obtained in HACCP Pre-steps 2-5
• List hazards associated with each step
Hazard Analysis Tools
 Flow Charting
 Brainstorming
 Cause Effect Analysis
 Failure Mode Effect Analysis
 Research and data evaluation
How to Carry out Hazard Analysis
For each step in the Process Flow Diagram, considering
the recipe and intrinsic control factors, flow,
equipment, evaluate:

 What can go wrong leading to an unsafe product?

 How can we prevent it going wrong?
 What is the best control approach?
 Is this currently in place?
HAZARD ANALYSIS:
MAKING INFORMED DECISIONS
 Correct balance in the HACCP
Team
 Application of knowledge
 Common sense
 Educated judgement based
on best information available
Risk Assessment: What is the Risk?
Risk is a combination of:

The likelihood of the hazard occurring

and
The severity of the illness or injury

HACCP requires control of any hazard that may be

reasonably expected to occur
Risk Assessment
 Detailed product / process
knowledge

 Historical evidence

 Use information sources

 Research and evaluate the

information
Undertake a Risk Assessment
 This is done by considering the Likely Occurrence of the
Hazard and the Severity of the injury/illness that it may
cause
 The company must document a decision on which level
of concern is significant
 Only those activities which fall into or above this level
are further considered as potential CCPs
 Risk Assessment Scale
RISK TABLE (L) LIKELIHOOD OF OCCURRENCE
RISK SCORE DESCRIPTION

1 Unlikely to ever occur.

2 Occasional – might occur at some time.
3 Frequent – is expected to occur.

RISK TABLE (S) SEVERITY IF HAZARD OCCURS

RISK SCORE DESCRIPTION

1 Insignificant – no injuries, illness, insignificant financial loss

2 Moderate – possible medical treatment required, medium financial loss

3 Significant – medical treatment required, significant financial loss

4 Critical - fatality, huge financial loss

 Risk Score Table: Likelihood x Severity = Risk Level
LIKELIHOOD(L) -Probability
Frequent (3) Occasional(2) Unlikely(1)

12 8 4
Critical (4)

SEVERITY(S) 9 6 3
Significant (3)

6 4 2
Moderate (2)

3 2 1
Insignificant (1)

High Risk 8-12

LEGEND Medium Risk 4-6
Low Risk 1-3
How do we Identify CCP`s?
 Team expertise and judgement
 Tools
 CCP decision trees
 Food Safety Risk Analysis Matrix
is based on Operational Risk
Management (ORM) concept
and is equivalent to the results
you would achieve using the
HACCP decision tree
 Documentation
 DETERMINATION OF CCP’S
 Principle 2

 A point, step or procedure at which

control can be applied and a food
safety hazard can be prevented,
eliminated or reduced to acceptable
levels.

 *Use of the Codex Alimentarius

HACCP decision tree.
HACCP Decision Tree
1. Could a control measure(s) be used by the operator at
any process step?
2. Is it likely that contamination with the identified
hazard could occur in excess of the acceptable level or
could increase to an unacceptable level.
3. Is this process step specifically designed to eliminate
or reduce the likely occurrence of the identified hazard
to an acceptable level?
4. Will a subsequent step eliminate the identified hazard
or reduce its likely occurrence to an acceptable level?
Establish Critical Limits
 Principle 3

 Values which separate acceptability from unacceptability.

 These parameters, if maintained within limits, will confirm

the safety of product.

 More than one critical limit may exist.

 IF WE EXCEED A CRITICAL LIMIT, A POTENTIAL HAZARD

EXISTS!
Monitoring Procedures
 Principle 4
 A planned sequence of
observations or
measurements, to assess
whither a CCP is under
control and to produce an
accurate record.
 Monitoring procedures
determines if critical limits
are out of control.
 Must be done rapidly if
possible.
Deviation Procedures
• Principle 5

• Corrective actions must eliminate potential hazard.

• Specific corrective actions needed for each CCP.
• Pre-determined and documented set of corrective actions
that are implemented when a deviation occurs.
• A deviation is a failure to meet specified critical limits.
Verification Procedures
 Principle 6

 Methods, procedures, or tests

used to determine if the HACCP
system’s in compliance with the
HACCP plan and whether the
HACCP plan needs modification
and revalidation.
Record Keeping/Documentation
 Principle 7

 HACCP records is the in plant record keeping that is

done at each CCP and contains information required to
ensure that HACCP plan is followed.

 Ex. Charts, Graphs, Written, Computer

HACCP Prerequisite Programs
 Prerequisite programs are the
foundations for the establishment of
HACCP plans and of the guidelines
for the production, storage and
distribution of safe food products
HACCP Prerequisite Programs
 SSOPs – Sanitation Standard Operating
Practices
 GMPs – Good Manufacturing Practices
 Food Defense (Security)
 Preventive Maintenance
 Pest Control
 Receiving and Shipping Programs
 Waste Management
 Outside grounds maintenance
HACCP Prerequisite Programs
A. All of these prerequisite programs must be developed,
documented, implemented and verified.

B. All applicable prerequisite programs must be in place before a

HACCP plan can be developed.

C. Observations / activities must be recorded.

D. Corrective actions and preventative actions must be documented

and completed.
Other Prerequisite Programs
• Vendor approval program
• Training Programs: GMPs, SSOPs, Allergens, etc.
• Cleaning and Sanitation Program
• Employee GMP rules (Health, hygiene and practices).
• Ingredient, packaging and product Identification and traceability
program
• Finished product Recall Program
• Crises management program
Other Prerequisite Requirements

 Glass and hard plastics policy

 Quarantine procedures

 Allergen awareness and protection

programs

 Finished product testing programs

 Prevention of cross-contact and

cross-contamination
Other Prerequisite Programs
 Safety of the water

 Condition and cleanliness of the food

contact surfaces

 Environmental swabbing programs

 Prevention of cross-contamination
and cross-contact

 Maintenance of hand washing

/sanitizing and toilet facilities
Personnel training program
Common Mistakes With HACCP
1 . Not reviewing a current HACCP plan already in
place

• HACCP plans must be reviewed

annually

• Helps ensure everyone is up-to-date

on the latest information

• Increases conformances
Common Mistakes With HACCP
2. Management does not commit
• Staff must buy into HACCP
• Starting at the TOP
• Help them realize the value of HACCP

3. Lack of expertise or knowledge

• Do not take the back seat!
• It is essential to know the basics of food hygiene!
Common Mistakes With HACCP
4. Lack of Training
• Staff turnover
• Language barriers
• Lack of time

5. Inadequate Prerequisite Program

• REMEMBER:
• PRPs are part of a HACCP Program
• PRPs address the FS hazards
• Do not let your PRPs lack in strength, #s and actual content
Common Mistakes With HACCP
6. Too Many CCPs
• Can complicate a HACCP
Program
• No longer user-friendly
• Paperwork nightmare
7. Believing all your work
is done after your HACCP
Program is implemented
• Re-evaluate your flow process
• Re-assess your program
Common Mistakes With HACCP
8. Irregular FS meetings
• Schedule regular FS meetings
• Assign responsibilities

9. Not reviewing your HACCP records and non-conformities

• Review daily
• Train other personnel how to review
• Teach them what to look for
• Finding the root cause of the problem
• Preventative Action Plan is crucial
• Learn from past mistakes
Common Mistakes With HACCP
10. Completing Records
• Records are evidence that a task was performed
• Missing signature
• Use of white out or pencil
• Falsification of times or results
• Records can become legal document

11. No Validation for Verification

• Scientific proof
• Objective evidence to verify
Common Mistakes With HACCP
12. No Internal Audit Plan
• Create an internal audit team
• Ongoing training

13. Ineffective Root Cause Analysis

• Pick the method that works best for you
• 5-Why?, 8D, Fishbone
Common Mistakes With HACCP
14. Ineffective Monitoring
• Monitor frequently
• Keep a watchful eye
Questions & Answers
THANK YOU!