Food Safety and HACCP

K N Rao
What is HACCP ?

 Hazard Analysis Critical Control Point

 Food Safety Management System
- preventative
- systematic
- structured
 Safety through Hazard Identification & Control
How does HACCP work?

 Define how the process works

 Identify what can go wrong-the hazards
 Identify control points critical to product safety
 Manage these points effectively
 Verify
General Principles of Food
Hygiene
 primary production
 design and facilities
 control of operation
 maintenance and sanitation
 personal Hygiene
 transportation
 product information and consumer
awareness
 training
The Codex Principles

1.Identify hazards and preventative measures

2.Identify Critical Control Points (CCP’s)
3.Establish Critical Limit
4.Establish a CCP monitoring system
5.Establish corrective action procedures
6.Establish verification procedures
7.Establish documentation and records
Why use HACCP
 Management of product safety
 Prevention of product safety incidents
 Limitations of traditional quality control
 External pressures
 Many benefits
 Effective product management
Benefits of HACCP

 Preventative system
 Systematic
 Increases confidence
 Cost effective control system
 Effective use of resources
Benefits of HACCP

 Internationally accepted
 Strengthens quality management systems
 Facilitates regulatory inspection / external
audit
 Demonstrates management commitment
 Helps demonstrate “due diligence”
PREREQUISITE PROGRAMMES

 Required prior to HACCP development

 Universal steps
 Simplifies HACCP plans
 Also referred to as GAP’S, GMP’S, SSOP’S
Prerequisite Programs

T
Q
M
HACCP
GAP’S / GMP’S /
SSOP’S
Good Agricultural Practices (GAP’S)

 Water
 Organic and inorganic fertilizers
 Animal exclusion
 Pest control
 Worker health and safety
 Harvesting
Premises

 Outside property
 Building
 Sanitary facilities
 Water / steam / ice quality program
2. Transportation and storage

 Food carriers
 Temperature control
 Storage of incoming materials, non-food
chemicals and finished product
3. Equipment

 General equipment design

 Equipment installation
 Equipment maintenance and calibration
4.Personnel

 Training
 Hygiene and health requirements
5.Sanitation and pest control

 Sanitation program
 Pest control program
6.Recalls

 Traceability
 Recall procedures
 Distribution records
HOW TO DO A HACCP STUDY
ASSEMBLE A HACCP TEAM

DEFINE THE TERMS OF REFERENCE

DESCRIBE THE PRODUCT AND INTENDED USE

CONSTRUCT A PROCESS FLOW DIAGRAM

VALIDATE A PROCESS FLOW DIAGRAM

IDENTIFY HAZARDS & PREVENTATATIVE MEASURES

HACCP STUDY (CONT.)
IDENTIFY CRITICAL CONTROL POINTS

IDENTIFY CRITICAL LIMITS (TARGET LEVELS)

IDENTIFY MONITORING PROCEDURES

ESTABLISH CORRECTIVE ACTIONS

ESTABLISH VERIFICATION PROCEDURES

ESTABLISH RECORDS AND DOCUMENTATION

 1.Assemble a HACCP Team
Form 1
Product: Facility:
Date:
HACCP Team Leader
HACCP Team Members
 2.Define the terms of reference
Form 2
Starting Point

End Point

Hazards to be covered
 3.Product description and intended use
Form 3
1. Product name(s)
2. Important product characteristics
3. How it is to be used
4. Type of packaging
5. Shelf life
6. Where it is to be sold
7. Labeling instructions
8. Distribution
9. Consumer target groups
 4.Construct a process flow diagram
Form 4
Product:
5.Validate the process flow diagram

 Checked for accuracy and completeness

 On-site inspection
 6.Identify hazards and preventative measures
Form 5
(1) (2) (3) (4) (5) (6)
Incoming Potential hazard Significance Justify decision Preventative measures Is this step
material of the in column 3 a critical
hazard control
point
 Identify hazards and preventative measures
Form 5
(1) (2) (3) (4) (5) (6)
Process Potential hazard Significance Justify decision Preventative measures Is this step
Step of the in column 3 a critical
hazard control
point
Definition of a hazard

 A biological, chemical or physical

property which may cause a food to be
unsafe for consumption
Biological Hazards
 Bacteria
 Moulds
 Viruses
 Parasites
Chemical Hazards
 Raw materials
 Pesticides

 antibiotics

 Process contaminants
 Cleaning agents

 lubricants

 Packaging
 Ink

 adhesives
Physical Hazards

 Sharp items causing injury

 Hard items causing dental damage
 Items causing air blockages / choking
Identification of Critical Control
Points : HACCP Principle 2

 What is a Critical Control Point?

 How do we find them?
What is a CCP?

 A point, step or procedure where control

can be applied and a hazard can be
prevented, eliminated or reduced to
acceptable levels
 Essential for safety
 Kept to a minimum to ensure correct
focus
How are CCPs identified

 Team expertise and judgment

 CCP decision trees
 Software
CCP Decision Tree

 Incoming material and process steps

 Category and identified hazard
 Determine if fully controlled by prerequisite
programs.
 If yes, indicate the prerequisite program and
proceed to next identified hazard
 If no, proceed to Question 1
CCP Decision Tree (cont.)

 Q1. Do preventative measures exist for the

identified hazard
 If no, not a CCP and proceed to next identified
hazard
 If yes, describe and proceed to next question
CCP Decision Tree (cont.)

 Q2. Is the process step specifically designed

to eliminate/reduce the likely occurrence of
the identified hazard to an acceptable level?
 If no, proceed to next question
 If yes, CCP and proceed to last column
CCP Decision Tree (cont.)

 Q3. Could contamination with the identified

hazard occur in excess of acceptable levels
or could these increase to unacceptable
levels
 If no, not a CCP and proceed to the next
identified hazard
 If yes, proceed to next question
CCP Decision Tree (cont.)

 Q4. Will a subsequent step eliminte the

identified hazard or reduce the likely
occurrence to acceptable level?
 If no, CCP and proceed to the last column
 If yes, not a CCP, identify the subsequent step and
proceed to the next identified hazard
 CCP number
Controlling CCPs :
HACCP Principles 3, 4 and 5

 Establish critical limits and target levels

 Establish monitoring procedures
 Establish corrective action procedures
HACCP Control Chart

 Used to build up the day to day control

requirements for each CCP identified
 Documents information relating to
identified CCPs only
Critical limits or Target Levels:
HACCP Principle 3

 Definition: A value which separates

acceptable from unacceptable
 Must be measurable
 Criteria must be met for each preventative
measure at a CCP
 A target level is control criteria which is
more stringent than Critical Limits
Establish monitoring procedures:
HACCP Principle 4

 Monitoring is the measurement or

observation at a CCP that the process is
operating within the critical limits (or
target levels)
 It must be able to detect loss of control
Establish corrective action
procedures : HACCP Principle 5
 Corrective action is taken when monitoring
indicates that there is a deviation from a
critical limit
 Correction following deviation
 Adjust the process

 Destroy non-complying product

 Re-work
Completing the HACCP Control
Chart : HACCP Principle 6 and 7
 Establish verification procedures
 To verify that the system is working

 To determine compliance with the HACCP

Plan
 Establish records and documentation
procedures
 Objective evidence of all actions and

results