Hazard Analysis Critical Control Point

S Mohammad Sharif
Foodborne illness
§ Foodborne illness or injury results from the natural, accidental, or malicious
contamination of foods by hazards
• Hazard: Unacceptable contamination of a biological, chemical, or physical nature
• Survival and/or multiplication of microorganisms of concern to safety (or spoilage)
• Unacceptable production of foods, with toxins or any other undesirable products of microbial metabolism
• Biological Hazard: Infectious or toxigenic bacteria, viruses, molds, parasites, mushrooms, fish, etc.
• Chemical Hazards: Pesticides, cleaning compounds, antibiotics, heavy metals, additives (i.e., sulfites, MSG, etc.), &
food allergens
• Physical Hazards: Metal fragments, glass, wood splinters, stones, etc.
• May cut mouth, break teeth, choke, perforate gut, etc.

§ Impacts of foodborne illness may include morbidity and mortality, increased health care
costs, loss of consumer confidence, economic losses, and lost productivity to industry
§ Globalization of our food supply
• Foodborne illness outbreaks associated with widely distributed contaminated foods result in
human illnesses that cross local, Provincial/Territorial and national boundaries
• Annually a total of about 4 million (1 in 8) Canadians are affected by a food-borne illness. Of
these, there are about:
• 11,600 hospitalizations
• 238 deaths
Canada’s foodborne illness response

§ Health Canada, CFIA, PHAC, and smaller public health bodies work together to try to mitigate
the risk of foodborne illness outbreaks, and respond when necessary
• Foodborne Illness Outbreak Response Protocol (FIORP)
• Natural, accidental, or intentional contamination of foods with hazards
• Food crossing provincial/territorial or national borders
• Inspections are carried out by CFIA
• Routinely to prevent/control the incidence of foodborne diseases
• Communicate with international food safety authorities
• Intraprovincial/territorial food sales or trade does not always require any licensing
• Interprovincial/territorial food sales does usually require SFCR licensing (based off HACCP methodologies)
• Commodities in Canada that are federally regulated include dairy products, fish and seafood, fresh fruit or vegetables,
honey, maple products, meat products, poultry and egg products, and processed fruit or vegetable products
• Limitations of inspections include:
• They are not done frequently enough
• They are not done thoroughly enough to provide an acceptable degree of food safety
• They are not conducted at times when high risk foods or critical processes are being done
• Inspections and audits can be subjective (documentation is CRUCIAL)
Microbiological testing
§ Microbiological testing is limited statistically to a limited
number of test samples (recall sampling plans)
§ Tests may take a few days (recall enumeration methods)
• Food may have already been shipped to the provider or
even eaten by the consumer

§ It is simply not feasible to test and guarantee food safety

for every batch of food that is produced or imported into
Canada
§ The focus therefore is on prevention!
Food Safety Enhancement Program (FSEP)

International certifications / agreements

Required for regulated industries

(most industries nowadays adopt some form
of HACCP)

Processor level

§ The Food Safety Enhancement Program (FSEP) is one example of a type of preventive control plan (PCP)
§ FSEP is based on the Hazard Analysis and Critical Control Point (HACCP) principles
§ Implemented by meat, dairy, processed fruits and vegetables, shell eggs, processed eggs, honey and maple food operators as well as
hatcheries
§ The Canadian Food Inspection Agency (CFIA) created this document as guidance to help regulated parties comply with the Safe Food for
Canadians Regulations
Good Manufacturing Practices (GMP)

§ GMPs control hazard related to people and the processing environment

§ GMP standards are firmly rooted in the Codex Alimentarius Commission
• These guidelines for practices are the basis of any effective food safety program
§ GMP program covers hazards associated with:
ü Personnel practices ü Pest control
ü Shipping, receiving, ü Recall
handling, and storage ü Water safety
ü Sanitation ü Processing
ü Equipment environment
ü Standard Operating
Procedures (SOPs)
Hazard Analysis and Critical Control Points
§ HACCP is a systematic approach to food safety
• WWII Standard Operating Procedures in Weapons/Ammunition factories

• In the 1960s, food processors and the US aerospace program (NASA)

collaborated to produce a program to try to standardize food microbiology +
quality control + risk assessment

• Adopted by the Codex Alimentarius in 1969. Since then, more than 150
countries and regulatory bodies have been committed to the HACCP system to
ensure the safety of ingredients and products made in food facilities

• CFIA was created in 1997 to start to implement standards and regulate

compliance
• Since then, Canada’s FSEP (in accordance with HACCP standards) has been
continually evolving

• Not all food facilities require HACCP in Canada (although most adopt to
enhance food safety and product marketability)

• In Canada, federally registered facilities including meat and meat products,

poultry, and seafood need to be HACCP certified (as per the Safe Food for
Canadians Act)
• Most other federally regulated industries (dairy, honey, maple syrup, etc.) as
well as larger food manufacturers implement FSEP anyways to be able to trade
across provincial/territorial borders, or internationally
Pre-requisite programs

CFIA’s FOOD SAFETY ENHANCEMENT PROGRAM

MANUAL

https://inspection.canada.ca/DAM/DAM-food-
aliments/STAGING/text-
texte/food_fsep_man_1343667674768_eng.pdf
HACCP Team
§ Usually led by an appointed Food Safety Team Leader
• Puts together the food safety team- usually involving:
•f

• Responsible for overseeing the development of the company’s PRP(s)

and HACCP plan, and ensuring they are implemented and monitored
• Each manager or team member has the responsibility to enforce and monitor
compliance over their field of competence
Example of a Product Description
The product description
outlines the type of food
manufactured, and includes all
the labelling requirements
Ingredients List

The Ingredients list

describes the product and
outlines all the materials
(food, chemical, water,
etc.) required
Product Diagram

The step-by-step product

manufacturing diagram
helps identify areas where
hazards may occur, and
therefore need CPs or
CCPs
Food Plant Diagram

The plant diagram/schematic will

enable the manufacture to identify
specific areas of preventative control
(i.e., parts of the pre-requisite
programs, or HACCP plan)
Hazard Analysis Critical Control Point

1. Conduct a Hazard Analysis

2. Determine the Critical Control Points
3. Establish Critical Limits
4. Establish Monitoring Procedures
5. Establish Corrective Actions
6. Establish Verification Procedures
7. Establish Record-keeping and Documentation procedures
1. Conduct a Hazard Analysis
§ Identify the hazards that might affect a particular product in a specific
processing facility
• Performed by lab people or consultants
• Takes time (follow-up audits usually are quicker)
• HACCP designers need a thorough understanding of Food Microbiology, Food
technology, and often Toxicology

§ Collecting and evaluating information on the hazards and the conditions

leading to their presence
§ Deciding which hazards are SIGNFICIANT to food safety
• All operations must address these hazards via HACCP plan(s)
§ Hazards vary between establishments even if they produce the same food because:
• Source of ingredients may differ
• Formulations
• Processing equipment & methods
• Duration of processing and storage
• Experience, knowledge, attitude of personnel
• Distribution practices

Types & examples of Hazards:

Biological Chemical Physical
§ Bacteria § Naturally occurring § Metal
§ Clostridium spp. § Mushroom § Plastics
§ Bacillus spp. § Shellfish § Seeds and fruit pits
§ Campylobacter spp. § Food allergens § Bones
§ Pathogenic E. coli § Mycotoxins
§ Glass
§ Listeria monocytogenes § Added § String
§ Salmonella spp. § Polychlorinated biphenyls
§ Shigella dysenteriae (PCBs) § Wood
§ Hepatitis A & E § Agricultural Pesticides § Stone
§ Norwalk virus group § Pest control chemicals § Pest related (ex. Fur, skin,
§ Certain protozoa & parasites § Cleaners and sanitizing agents bodies, teeth, etc.)
§ Paints § Personnel related (ex. Hair,
§ Food dyes nails, jewelry, etc.)
Severity and Risk
§ It is important to be able to assess each identified potential
hazard’s severity and risk
§ Severity: magnitude of hazard/degree of consequences
• 3 classifications:
I. Li= Life threatening illness

II. Si= Severe or chronic illness

III. Mi= Mild or moderate illness
• IMPORTANT TO NOTE: TIME AND PLACE MAY REQUIRE MOVEMENT OF SOME
OF THESE FROM ONE CLASSIFCATION TO ANOTHER

• i.e., Usually, a HIGHER DOSE means shorter incubation time for bacteria and a more
severe outcome
 Examples of Li- Life threatening illness
§ Clostridium botulinum
§ Salmonella typhi
§ Listeria monocytogenes
§ Fetuses, infants, immunocompromised
§ Vibrio cholerae
§ Vibrio vulnificus
§ Halophile, food poison/sepsis/sores
§ Paralytic or amnesic shellfish poisonings

Examples of Si- Severe or chronic illness

§ Brucella § Vibrio parahaemolyticus
§ Campylobacter § Yersinia enterocolitica
§ Pathogenic E.coli § Hepatitis A virus
Biological § Salmonella § Mycotoxins
§ Shigella § Ciguatera toxin
Hazards § Strep type A § Tetramines

Examples of Mi- Mild or moderate illness

§ Bacillus § L. monocytogenes
§ C. perfringens § In healthy adults
§ S. aureus § Histamine like substances
§ Norwalk-like viruses § Heavy metals
§ Most parasites
§ Diarrhetic shellfish poisoning
Risk: An estimate of the probability of occurrence of a hazard
• Or sequential occurrence of several hazards

DEGREE OF RISK

• High H

• Moderate M

• Low L

• Negligible N

• May Vary V

§ Microbiological hazards: Highest risk to the greatest number of people

§ Physical hazards: Usually limited, risk to individuals

 2. Determine Critical Control Points
§ “An operation” (or practice, procedures, process, or location) at which
a preventive or control measure can/should be exercised in order to
eliminate, prevent, or minimize a hazard or several hazards
Ordinary Control Points
§ There are also ordinary control points where preventative/control steps are
taken
• Mandated by GMPs, regulations, product reputation, company policies, etc.
• These do not need to be monitored/verified/or documented as often as CCPs
• Ex. Washing hands before entering the processing floor can be considered a CP
§ To determine whether an area/step where a hazard may occur is a Control Point or Critical
Control Point, a CCP determination table must be used
§ This is a series of questions that will help the HACCP team determine whether the risk of
the hazard needs to be addressed at that step, or if it is controlled for elsewhere
Decision Trees- CCP determination

• Decision trees are used to help identify

CCPs. Recall that it is not feasible or
necessary to control every control
point (CP)

• If identified as a CCP, monitoring and

record keeping is necessary!
Example of a Hazard Analysis table and
CCP determination
Critical Control Point classification
• CCP1: Hazards are eliminated/prevented
• CCP2: Minimized, reduced delayed
• CCPe: Eliminated
– Retorting, pasteurizing steps
• CCPp: Prevented
– Freezing step (hazard may return if thawed)
• CCPr: Reduced (minimized, delayed)
– NOT eliminated or even prevented
– E.g., Handling food with sanitized utensils, rather than your
hands, or putting perishable foods in the fridge
Process diagram for frozen tortellini With CCPs:

Handler contamination

Surfaces

Raw ingredients
3. Establish Critical Limits
§ Critical Limits must be specified for each CCP
• Specified criteria or characteristics
• Target and tolerance limits
• Must be measurable
Microbiological testing
• Physical: time, temperature, etc.
• Chemical: amount of salt, acetic acid, etc.
• Biological: sensorial, microbiological, etc.

Example of a hand-held salinity meter (salt testing) Time & temperature

4. Establish Monitoring Procedures

§ Check that process at each CCP meets the criteria

§ Observing: handling/cleaning practices
§ Measuring:
• Time • Detergent or
• Temperature disinfectant
• pH, acidity concentration
• Aw • Container conditions
(seams, vacuum, etc.)
Example of a monitoring checklist
5. Establish Corrective Actions
§ Are clearly specified
§ Decided upon prior to any trouble
§ Immediate actions could include:
§ Stopping production
§ Quarantining affected product
§ Cleaning the affected area
§ Removing equipment from the area
§ Icing product to stop biological hazards
§ Informing management
Examples of flow diversion valves
§ Follow up actions could include:
§ Rechecking additional batches of
product
§ Retraining or disciplining staff
§ Reviewing procedures
§ Repairing equipment
§ Disposing or downgrading of product
6. Establish Verification Procedures
§ Supplemental tests
§ Review of monitoring records
§ Tells you when part of HACCP system need modification
7. Record Keeping and Documentation
There are 8 forms that make up a good HACCP plan

§ Form 1 is the Product Description, which identifies all products being produced.

§ Form 2 is the Ingredients & Incoming Materials, which identifies all ingredients and incoming materials, including packaging
materials and processing aids that come in contact with the product or are used in processing the product.

§ Form 3 is the Process Flow Diagram, which will be created separately; examples are in the HACCP Advantage Guidebook.

§ Form 4 is the Plant Schematic, which will be created separately; examples are in the HACCP Advantage Guidebook.

§ Form 5 is the Hazard Description and Critical Control Point Determination

• This version of Form 5 is a new format which utilizes the decision tree, and it is saved as a "form"
• Simply type your plan name and types of hazards in the white boxes then click on the boxes beside the "yes/no" answers. You will need a
new page for each hazard
§ Form 6 is the Flow Diagram with Critical Control Points
• You will add the CCPs determined from form 5 onto the flow diagram made in form 3
§ Form 7 is the Uncontrolled Hazards, which are determined by using form 5
§ Form 8 is the HACCP Matrix, documenting the critical limits, monitoring, verification and records for each CCP (A summary
of the HACCP plan)
Global Food Safety Initiative (GFSI)-recognized
food safety and quality standards:
§ Safe Quality Food (SQF)- SQF is one of the world's leading food safety and quality management systems, designed to
meet the needs of retailers and suppliers worldwide. The Program provides independent certification that a supplier's
food safety and quality management system complies with international and domestic food safety regulations.

§ British Retail Consortium (BRC)- BRC Global Standards, the world’s first GFSI-recognized standard, is one of the
choices for retailers worldwide looking for confidence from food suppliers

§ Global Standard for Food Safety- BRC Global Standard for Food Safety is developed by food industry experts from
retailers, manufacturers and food service organizations to ensure it is a rigorous and detailed, yet easy to understand
the BRC Global Standard. It provides a framework to manage product safety, integrity, legality and quality, and the
operational controls for these criteria, in the food and food ingredient manufacturing, processing and packing industry.

§ FSSC 22000 (ISO 22000 & PAS 220)- (Food Safety System Certification standard), is the latest certification scheme for
food manufacturers. The scheme is based on the integration of ISO 22000:2005 Food Safety Management Systems
standard and Publicly Available Specification (PAS) 220. Supported by the Confederation of the Food and Drink
Industries of the European Union (CIAA), FS 22000 has been fully approved by the Global Food Safety Initiative (GFSI)

§ IFS International Food Standard is a quality and food safety standard for retailer (and wholesaler) branded food
products, which is intended to assess suppliers' food safety and quality systems, with a uniform approach that
harmonizes the elements of each.
§ https://laws-lois.justice.gc.ca/eng/regulations/SOR-2018-108/page-
7.html#h-844497
§ https://canadianfoodsafety.com/courses/haccp-certification/
§ https://www.brcgs.com/our-standards/food-safety/
§ https://www.sqfi.com/
§ https://www.fda.gov/food/hazard-analysis-critical-control-point-
haccp/haccp-principles-application-
guidelines#:~:text=The%20Codex%20Alimentarius%20General%20Pri
nciples,are%20specific%20to%20their%20operations.
Takeaway message
§ HACCP essentially simplifies food safety by allowing Industry professionals to focus on a FEW critical operations
and give MEANINGFUL ways to control and monitor them

§ Managers are responsible for understanding and implementing new information continually, BUT it really is the
workers who are responsible for running and having a “working knowledge and practice” of HACCP in order to
protect our food system

• Key points for successful implementation of HACCP are:

• Full management commitment

• Suitable training for all staff (doesn’t necessarily mean a formal course for everyone, verbal on the job
instructions with visual reminders at CCP points may be all that is required)

• Quick handover from HACCP team to all staff once system is established
• Regular reviews of the system