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CU Process Training
Introduction to HACCP
22/06/2010

CU Process Training – Introduction to HACCP

1
Agenda
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1. Introduction to HACCP
2. Why use HACCP?
3. Preparing for HACCP
4. Hazards in foods
5. Designing safety into products and processes
PAUSE
6. How to do a HACCP study?

CU Process Training – Introduction to HACCP 2

1. Introduction to HACCP
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 HACCP = Hazard Analysis and Critical Control

Points
= a common sense approach to food safety management,
formalized in a number of procedures
= a systematic and preventive approach to assure safety
of foods

CU Process Training – Introduction to HACCP 3

1. Introduction to HACCP
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 Systematic
– Well defined procedures consisting of several steps
– Documentation of all steps required
– In-built verification mechanismes
 Preventive
– Intend to prevent problems of food safety, not to
remediate
 Safety
– Intended to prevent adverse health effects, not to
improve quality

CU Process Training – Introduction to HACCP 4

1. Introduction to HACCP
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 Guidelines and international commissions

– Codex alimentarius: authorative guidelines elaborated
by a subgroup of UN-FAO. These guidelines are often
adopted in national legislation
– NACMCF = National Advisory Committee on
Microbiological Criteria for foods, US

CU Process Training – Introduction to HACCP 5

1. Introduction to HACCP
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 The seven universal principles of HACCP:

1. Conduct Hazard Analysis
2. Identify Critical Control Points (CCP’s)
3. Establish Critical limits
4. Establish monitoring requirements
5. Establish corrective actions
6. Establish record-keeping procedures
7. Establish verification procedures

CU Process Training – Introduction to HACCP 6

2. Why use HACCP?
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 Management of food safety:

– Food safety = top priority, not negotiable
– HACCP can be very cost-effective

 External pressure: by legislation, customers,

media, …

CU Process Training – Introduction to HACCP 7

3. Preparing for HACCP
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 Who should be involved?

– People from various disciplines: QA, production,
engineering, R&D, others …
– People from top to bottom: from management to the
floor
• Safety is everyone’s responsibility
• HACCP can only succeed with cooperation of everyone
 Training!
– Succes of HACCP depends on competence of people
involved: appropriate training needed

CU Process Training – Introduction to HACCP 8

4. Hazards in food
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 Hazard = a physical, chemical or

(micro)biological property of a food that:
– May cause it to be unsafe for consumption
– Is reasonably likely to cause illness or injury in the
absence of its control

CU Process Training – Introduction to HACCP 9

4. Hazards in food
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 Biological:
– Macrobiological: e.g. poisonous insect
– Microbiological:
• Bacteria:
– High Infective Dose: e.g. S. aureus, C. botulinum
– Low Infective Dose: e.g. Salmonella
• Viruses: e.g. Hepatitis A
• Protozoa: e.g. Toxoplasma
• Mycotoxins: secondary metabolites of some fungi
• Parasites: e.g. flatworms, nematodes

CU Process Training – Introduction to HACCP 10

4. Hazards in food
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 Chemical
– Cleaning/disinfection chemicals
– Pesticides
– Allergens (alergy vs. intolerance)
– Toxic or heavy metals
– Nitrite and related compounds
– PCB’s/dioxines
– Compound from packaging materials
– Veterinary residues: e.g. hormones, antibiotics
– Additives

CU Process Training – Introduction to HACCP 11

4. Hazards in food
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 Physical
– Foreign objects
• Can cause injury if they are hard or sharp
• Can cause choking
– Examples
• Glass
• Metal
• Plastic
• Stones
• Wood
• Pests (insects, mice, …)
– Indirect impact: foreign objects can potentially carry a
microbiological hazard

CU Process Training – Introduction to HACCP 12

Control points
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 Control point
= point, step or procedure where control can be applied
and a hazard can be prevented, eliminated, or reduced
to an acceptable level

 CRITICAL control point (CCP)

= Control point where control is essential for the safety of
the product

CU Process Training – Introduction to HACCP 13

5. Designing safety into
products and processes Group
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1. Product formulation (intrinsic factors)

2. Raw material safety
3. Safe production
4. Safe and achievable shelf life

CU Process Training – Introduction to HACCP 14

5.1 Product formulation
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 Product formulation (intrinsic factors)

– pH and organic acids
– Preservatives
– Water activity aw

CU Process Training – Introduction to HACCP 15

5.2 Raw material safety
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 A safe raw material supply

– Raw materials should
• Contain NO hazards
• OR, contain only controllable hazards
– Raw materials decision tree

CU Process Training – Introduction to HACCP 16

5.2 Raw materials safety
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Is there a hazard associated with this raw material?

YES NO
Proceed

Are you or the customer going to process this hazard out of the product?

YES NO
High level of control required
CCP

Is there a cross-contamination risk to finished products that will not be

controlled?

YES NO
High level of control required Proceed
CCP

CU Process Training – Introduction to HACCP 17

5.2 Raw materials safety
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 Exercise: Mixed salad

 Production process:
Lettuce - Feta Cheese - Vinega r

Rinse

Mix
 Consider the Lettuce  is this Raw Material safe?

CU Process Training – Introduction to HACCP 18

5.2 Raw materials safety
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 SQA = Supplier quality assurance

– Product specifications
– Auditing of supplier
– Certificates of analysis
– Require HACCP approach from suppliers

CU Process Training – Introduction to HACCP 19

5.3 Safe production
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 Processes
– Thermal process
• During production
• By consumer
– Fermentation
– Drying
– Freezing
– Packaging
• E.g. modified atmosphere

CU Process Training – Introduction to HACCP 20

5.3 Safe production
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 Manufacturing environment
– Factory lay-out: product flows, hygiene facilities
– Building materials: easy to clean, non-porous
– Equipment: corrosion-proof, cleanable, no dead spaces
– People: training, clothing
– Cleaning
– Chemicals
– Raw materials: proper storage and use
– Storage
• Segregation
• T-control
• Humidity control
• FIFO
CU Process Training – Introduction to HACCP 21
5.4 Safe and achievable shelf
life Group
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 Shelf life determination

– Predictive models
– Challenge testing

CU Process Training – Introduction to HACCP 22

 6. How to do a HACCP study
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• Define terms of reference

• Describe product and its intended use
Preparatory
• Construct process flow diagram
steps
• Validate process flow diagram
1. Identify hazards and preventative measures
2. Identify CCP’s
3. Establish Critical limits Universal
4. Identify monitoring procedures principles
5. Establish corrective action procedures
6. Establish record-keeping procedures
7. Establish verification procedures

CU Process Training – Introduction to HACCP 23

 6. Preparatory steps
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 Define terms of reference

– Define precise scope of the study
• Which types of hazards (P, C, B)
• Which products/product groups
• Which process steps
• Only production, or also distribution, consumer handling, …

 Describe the product and its intended use

– List of ingredients
– Description of preparation
– Profile of consumers

CU Process Training – Introduction to HACCP 24

6. Preparatory steps
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 Construct process flow diagram

– Serves as basis for hazard analysis
– Contains all relevant information, but not too much
detail
• Raw materials: storage conditions, chemical data,
physical data, …
• T, t-profiles for all steps
• Delay between process steps
• Product recycling loops
• Floor plan with indication of high-low hygiene areas, …

 Validate process flow diagram on the spot!!

CU Process Training – Introduction to HACCP 25

6.1 Identify hazards and
preventative measures Group
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 Hazard identification
– Objective: make complete list of all hazards for each
process step
– Requires multidisciplinary expertise
• Understanding processes, technical knowledge of
equipment, …
• Food science in general, food microbiology and
toxicology
• History of reported cases

 Identification of preventative measures

– Factors which can be used to control an identified
health hazard

CU Process Training – Introduction to HACCP 26

6.2 Identification of CCP’s
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 CCP
= a point in the process where control can be applied and
a hazard can be prevented, eliminated or reduced to
acceptable levels
– Important to
• Not miss CCP’s  unsafe food
• Not identify more CCP’s than really necessary!
 CCP decision tree
– To be applied for each hazard
– ! Separate processes from raw materials

CU Process Training – Introduction to HACCP 27

 Q1: Is there a hazard at this process step?

YES NO  no CCP

Q2: Do preventative measures exist?

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or product

YES NO

Is control necessary for safety?

NO  no CCP YES
Q3: Is this step specifically designed
to eliminate or reduce the occurrence
of the hazard to an acceptable level?

NO YES

Q4: Could contamination occur at or increase to

unacceptable levels?

YES NO  no CCP CCP

Q5: Will a subsequent step or action eliminate

or reduce the hazard to an acceptable level?

YES  no CCP NO

CU Process Training – Introduction to HACCP 28

6.2 Identification of CCP’s
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 Example:
 Chocolate chip cookies
 Raw milk powder
 Chocolate chips

CU Process Training – Introduction to HACCP 29

6.3 Establish critical limits
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 Critical Limit
= criteria for a preventative measure at a CCP, which
specifies the absolute tolerance for safety
- Boundary between a safe and an unsafe product
- Definition of criteria requires expert knowledge
- Literature
- Experts
- Experimental data
- Predictive models

CU Process Training – Introduction to HACCP 30

6.3 Establish critical limits
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 Criteria
- Measurable:
- Chemical limits: aw, pH, level of residues, …
- Physical limits: T/t, particle size, …
- Microbiological limits: to be avoided!
- Target levels:
- More stringent than critical limits
- Allow to take action and correct deviation before a health
hazard is produced

CU Process Training – Introduction to HACCP 31

6.4 Identify corrective actions
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 Corrective actions
- Preventative actions: before exceding CL
- Corrective actions: after exceding CL
- Act quickly, before releasing the food
- Adjust process to bring it under control
- Deal with hazardous product
- Keep records of all stages

CU Process Training – Introduction to HACCP 32