HACCP

Awareness
In House Training Course

What is HACCP?

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 HACCP
What is HACCP?
HACCP: Stands for

“Hazard Analysis and Critical Control Point”

Q-01 Is HACCP a Standard? NO
Q-02 Is HACCP a Guideline? NO
Q-03 Is HACCP a FSMS? NO
Q-04 Who can guide me to implement it?
Q-05 Can I call it a QMS? YES
Q-06 Does HACCP Certify a Product? NO
Q-07 Can we go ahead to next slide?  YES
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 HACCP
EVOLUTION OF HACCP
 HACCP concept was pioneered in 1960 by Pillsbury
Company for the production of safe foods for
National Aeronautics and Space Administration
(NASA).

 NASA wanted a zero defect programe to guarantee

the safety of food consumed in space.

 HACCP is a systematic and preventive approach that

addresses biological, chemical and physical hazards
through anticipation and prevention, rather than
through end-product inspection and testing.
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 HACCP
On what basis KDD implemented HACCP?
Primary Base:
“Requirements for a HACCP Based Food Safety System”
Option A: Management System Certification
Compiled by the National Board of Experts – HACCP
The Netherlands
4th Version released in June 2006.

This version of the specification has been accredited by the

“Dutch Accreditation Council (RvA)” since 1997 &
From 2002 this is a “GFSI – Global Food Safety Initiative” recognized standard.

Address:
National Board of Experts – HACCP
P.O. Box 693, 4200 AR Gorrinchem, The Netherlands
Web Site: www.foodsafetymanagement.info
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 HACCP
On what basis KDD implemented HACCP?
Secondary Base (and core of Primary Base):

1. Codex Alimentarius Commission, “General Principles of Food Hygiene, CAC/ RCP

1-1969, Rev. 4 (2003).
2. Codex Alimentarius Commission, Hazard Analysis and Critical Control Point
(HACCP) System and Guidelines for its Application”, Annex to CAC/ RCP 1-1969,
Rev.4 (2003).
3. Some useful management terminologies from ISO 22000:2005 and ISO 9001.

For More details and standards you can always visit:

www.who.int

www.fao.org

www.codexalimentarius.net
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ADVANTAGES
 HACCP is a science based approach to control food safety
hazards.
 It ensures & facilitates systematic analysis of processes.
 Constant monitoring allows rapid response when action
required.
 Process is controlled on the spot by an operator (not by the
laboratory which is remote from operation)
 It is based on prevention and reduces the reliance of end
product inspection and testing.
 Reduces barriers to international trade.
 Helps food companies compete more effectively in the world
market
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 HACCP
Things to be in Place before applying HACCP: -
CODEX advises that minimum hygiene measures should be in place before HACCP is
implemented. In other words “ THE PRE REQUISITE PROGRAMS - PRP”.
GMPs: (Good Manufacturing Practices) - Comprises the basic steps and procedures
prescribing operation conditions for production of safe food.
GMPs are preventive measures to avoid or reduce the probability of contamination
(physical, Chemical, Biological)
GMP can be designated as GAP (Good Agriculture Practices) GDP (Good Distribution
Practice) GLP (Good Laboratory Practice) GWP Good Warehousing Practice) depending
on the sector.
GMPs are Pre Requisite Programes (PRPs)

PRPs are basic conditions that are suitable for the production and handling of safe food
at7 all stages of the food chain. QA-PRP-INST-003
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 HACCP

GMP is the Foundation.

GMPs are a prerequisite or foundation
for HACCP based food safety HACCP- HOUSE
management programme.

General Practices, Everywhere!

Cleaning

Chemicals
Preventive Maintenance
Employees Training
Pest control

Water
Air
Hygiene

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 HACCP
DEFINITIONS
 Hazard: A biological, chemical or physical agent in, or condition of, food with the
potential to cause an adverse health effect.
 HACCP plan: A document prepared in accordance with the principles of HACCP to
ensure control of hazards which are significant for food safety.
 Critical Control Point (CCP): A step at which control can be applied and is essential to
prevent or eliminate a food safety hazard or reduce it to an acceptable level.
 Specific Control Measures: Are control measures related to CCP. Specific Control
Measures are actions or activities often measurable in terms of physical or chemical
parameters such as temperature, time, moisture, pH, and sensory parameters such
as visual appearance and texture.
 General Control Measures: Are actions which are part of PRPs. In general these
measures will achieve control at acceptable levels.
 Critical limit: A criterion which separates acceptability from unacceptability.

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 HACCP
Logic sequence for application of HACCP
Awareness Training, 5 preliminary steps & 7 HACCP Principles
Step – 00 – HACCP Awareness training to target implementers
Step – 01 – Assemble A HACCP Team

12 Steps for HACCP Implementation

5 Preliminary
Step – 02 – Describe the Product

Steps
Step – 03 – Identify Intended Use
Step – 04 – Construct Flow Diagram
Step – 05 – Onsite Confirmation of Flow Diagram

Principle – 01 – Conduct a Hazard Analysis

Principle – 02 – Determine CCPs
Principle – 03 – Establish Critical Limits for each CCP

7 HACCP
Principles
Principle – 04 – Establish Monitoring system for each CCP
Principle – 05 – Establish Corrective Action
Principle – 06 – Establish Verification Procedures
Principle – 07 – Establish documentation and record keeping

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 HACCP
HACCP ANALYSIS : 7 PRINCIPLES
Conduct a hazard analysis
(Principle 1)
Determine the Critical Control
Points [CCPs] (Principle 2)
Establish critical limit[s]
(Principle 3)
Establish a system to monitor
control of the CCP (Principle 4)
11
Establish documentation concerning all
procedures and records appropriate to these
principles and their application (Principle 7)
Establish procedures for verification
to confirm that the HACCP system is
working effectively (Principle 6)
Establish the corrective action
to be taken when monitoring
indicates that a particular CCP
is not under control (Principle 5)
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 HACCP
1. Assemble a HACCP team
Multi disciplinary team of specific knowledge and expertise is formed.
2. Describe the product
A full description of the product should be drawn up, including relevant
safety information such as: composition, packaging, durability and
storage conditions.
3. Identify intended use
The intended use should be based on the expected uses of the product
by the end user or consumer. In specific cases, vulnerable groups of the
population, e.g. institutional feeding, may have to be considered.
4. Construct flow diagram
The flow diagram should be constructed by the HACCP team. The flow
diagram should cover all steps in the operation. When applying HACCP
to a given operation, consideration should be given to steps preceding
and following the specified operation.
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 5. On-site verification of flow diagram:
The HACCP team should confirm the processing operation against the flow
diagram during all stages of operation.
6. Conduct a hazard analysis:
List all potential hazards associated with each step. Conduct a hazard
analysis, and consider any measures to control identified hazards. The HACCP
team should list all hazards that may be reasonably expected to occur at each
step from primary production, processing, manufacture, and distribution until
the point of consumption.
7. Determine Critical Control Points
Decision tree to identify critical control points. If a hazard has been identified
at a step where control is necessary for safety, and no control measure exists
at that step, or any other, then the product or process should be modified at
that step, or at any earlier or later stage, to include a control measure.
8. Establish critical limits for each CCP
Critical limit is a criterion which separates acceptability from unacceptability.
Critical limits must be specified and validated for Critical Control Point
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 HACCP
Types Of Hazards to look for ?
1. Physical – Visual Foreign Body damage or

contamination.

2. Chemical – Accidental spillage or cross contamination

from chemicals.

3. Biological – Mainly microbiological including Bacteria,

Viruses and Fungi.

Back
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 9. Establish a monitoring system for each CCP
Monitoring is the scheduled measurement or observation of a CCP

10. Establish corrective actions

Specific corrective actions must be developed for each CCP in the HACCP
system in order to deal with deviations when they occur.

11. Establish verification procedures

Verification activities include:
 Review of the HACCP system and its records
 Review of deviations and product dispositions
 Confirmation that CCP’s are kept under control.

12. Establish documentation and record keeping

Efficient and accurate record keeping is essential to the application of an
HACCP system.
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 HACCP
How to identify Critical Control Points?

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 HACCP
How to identify Critical Control Points?

EXERCISE 01: Time 15 minutes.

Receiving Milk
1. Do a hard analysis for Milk Pasteurization Process from Farm

2. Identify the critical control points. Milk Chilling

3. Determine the critical limits. Storage in Tank

4. Establish monitoring plan / procedures
Pasteurization
5. Establish corrective actions plan.
Storage in Tank
6. Establish verification plan / procedure
Filling
7. Establish records to prove implementation of first 6 principles.
Chilled storage

Customer Use/ Plate Customer pick up Display in Chillers Transport to Market

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 HACCP
Summary of HACCP Based System
CCP + OPRP + PRP = HACCP

Specific General

O CCP OPRP
P
R
P
P GMP PRP
R
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 HACCP
Structure of KDD HACCP System Documentation
QA Manual PRP/GMPS
Document Control
QMS Quality Manual Internal Audits
Food Safety Policy Validation and Verification Procedure
Cleaning and Sanitation
QMS Definitions
Pest Control
HACCP Manual Utility Control
Building and Maintenance
HACCP Equipment Maintenance & Calibration
HACCP Team Storage and Distribution
Product Descriptions Waste Management
Process Flow Diagrams (Common) Personnel Hygiene
Process Description Supplier Control
Process Flow Diagrams (Detailed) Supplier Audit
Hazard Analysis Product Recall & Mock Recall
HACCP Plan (CCP/ OPRP/ PRP) Training Program
Key Performance Indicator

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 HACCP

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