A REVIEW PAPER

ON

HAZARD ANALYSIS CRITICAL CONTROL POINTS –

BY

NWIYI, I.U.

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SUMMARY

HACCP is a system that enables the production of safe food products through the thorough

analysis of production processes, identification of all hazards that are likely to occur in the

production establishment, the identification of critical points in the process at which these

hazards may be introduced into product and therefore should be controlled, the establishment

of critical limits for control at those points, the verification of these prescribed steps, and the

methods by which the processing establishment and the regulatory authority can monitor how

well process control through the HACCP plan is working. HACCP can be applied throughout

the food chain from primary production to final consumption and its implementation should

be guided by scientific evidence of risks to human health. As well as enhancing food safety,

implementation of HACCP can provide other significant benefits. In addition, the application

of HACCP systems can aid inspection by regulatory authorities and promote international

trade by increasing confidence in food safety. The system does not mean the absolute

elimination of pathogens, but that it did mean preventing and reducing contamination with

pathogenic microorganisms to a degree that very substantially reduces and minimizes the risk

of foodborne illness. The history of the development of HACCP is briefly reviewed, and an

example of practical application of HACCP is briefly described.

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1.0 INTRODUCTION

Hazard Analysis and Critical Control Point (HACCP) is a systematic preventive approach to

food safety from biological, chemical, and physical hazards in production processes that can

cause the finished product to be unsafe, and designs measurements to reduce these risks to a

safe level. In this manner, HACCP is referred as the prevention of hazards rather than

finished product inspection. The HACCP system can be used at all stages of a food chain,

from food production and preparation processes including packaging, distribution, etc.

(Sperber, and Stier, 2009; FDA, 2014).

The HACCP system is a food safety management tool developed in the early 1970s by the

food industry. Since it enhances the safety of food, it is of considerable public interest and,

thus some 20years ago the World Health Organization (WHO) recognized HACCP as an

important concept to prevent foodborne disease (FAO, 1999). HACCP is an effective and

rational means of assuring food safety from harvest to consumption (FSIS, 2014). The system

provides assurances and documentation that processes used in manufacturing meat and

poultry products are under control and are producing safe, wholesome, and unadulterated

products (Hulebak, and Schlosser, 2009).

HACCP can be applied throughout the food chain from primary production to final

consumption and its implementation should be guided by scientific evidence of risks to

human health. As well as enhancing food safety, implementation of HACCP can provide

other significant benefits. In addition, the application of HACCP systems can aid inspection

by regulatory authorities and promote international trade by increasing confidence in food

safety (Codex Alimentarius 2003). The system does not mean the absolute elimination of

pathogens, but that it did mean preventing and reducing contamination with pathogenic

microorganisms to a degree that very substantially reduces and minimizes the risk of

foodborne illness (Hulebak, and Schlosser, 2009).

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The successful application of HACCP requires the full commitment and involvement of

management and the work force. It also requires a multidisciplinary approach; this

multidisciplinary approach should include, when appropriate, expertise in agronomy,

veterinary health, production, microbiology, medicine, public health, food technology,

environmental health, chemistry and engineering, according to the particular study. The

application of HACCP is compatible with the implementation of quality management

systems, such as the ISO 9000 series, and is the system of choice in the management of food

safety within such systems (Codex Alimentarius 2003).

1.1 BRIEF HISTORY OF HACCP

HACCP was first developed by the Pillsbury Company as a means of assuring the safety of

food produced for the U.S. space program. The National Aeronautics and Space

Administration (NASA) in the early 1960s wanted a “zero defect” program to guarantee

safety in the foods astronauts would consume in space. Using the traditional end product

testing method, it was soon realized that almost all of the food manufactured was being used

on testing and very little was left for actual use. It was realized that a new approach was

needed (Sperber, and Stier 2009; Hulebak and Schlosser, 2009).

HACCP, they recognized after surveying available control options, was the system that could

provide the greatest assurance of safety while reducing dependence on finished product

sampling and testing. HACCP, by virtue of identifying the hazards inherent in the product

and process, and devising preventive measures that could be monitored, would control the

process. Since Pillsbury presented the HACCP system at the 1971 U.S. National Conference

of Food Protection, it has become gradually recognized as a valuable approach (Hulebak, and

Schlosser, 2009).

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The United States Food and Drug Administration (FDA) asked Pillsbury to organize and

conduct a training program on the inspection of canned foods for FDA inspectors. This 21

day program was first held in September 1972 with 11 days of classroom lecture and 10 days

of canning plant evaluations (Sperber, and Stier 2009). Thus began the adoption and

implementation of HACCP as a world class food management system.

1.2 HAZARD ANALYSIS AND CRITICAL CONTROL POINT (HACCP):

that can be validated as effective in eliminating, preventing, or reducing to an acceptable

level the food safety hazards that are reasonably likely to occur in an official establishment’s

particular production processes. Under the HACCP regulatory system, establishments assume

full responsibility for producing products that are safe for consumers (FSIS, 2014). The

central goal of the HACCP system is to stimulate improvement in food safety practices by

setting public health-oriented targets or standards that all food production/packaging

establishments must meet. A key feature of this concept is that by establishing targets or

standards, innovation and changes will be stimulated to reduce the risk from all sources of

foodborne hazards – biological, chemical, and physical – while simultaneously providing a

tool for holding establishments accountable for achieving acceptable levels of food safety

performance (Codex Alimentarius 2003, Hulebak, and Schlosser, 2009).

HACCP process consists broadly of a two part process. The first part involves identifying

potential food safety hazards (Hazard analysis) and the second part is to design a system that

prevents or eliminates the hazards (FSI, 2009).

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According to the Codex Alimentarius, 2003 the seven principles of HACCP, which
encompass a systematic approach to the identification, prevention, and control of food safety
hazards include:

1. Conduct a Hazard Analysis

2. Determine Critical Control Points

3. Establish Critical Limits

4. Establish Monitoring Procedures

5. Establish Corrective Actions

6. Establish Recordkeeping and Documentation Procedures

7. Establish Verification Procedures

1.2.1 PRINCIPLE 1: CONDUCT A HAZARD ANALYSIS

Foods (NACMCF) as a biological, chemical or physical agent that is reasonably likely to

occur, and will cause illness or injury in the absence of its control. A thorough hazard

analysis is the key to preparing an effectively designed HACCP plan (FSIS, 2014). It is the

first step in establishing a HACCP system. All hazards such as – biological, physical, or

chemical - that can be associated with the product. The hazard must be such that its

prevention, elimination, or reduction to acceptable levels is essential to the production of a

safe food. It is important to be able to identify all the possible microbiological, chemical and

physical hazards (Hulebak and Schlosser, 2009).

It is important to consider in the hazard analysis the ingredients and raw materials, each step

in the process, product storage and distribution, and final preparation and use by the

consumer. When conducting a hazard analysis, safety concerns must be differentiated from

quality concerns. Establishments must consider all three types of hazards – biological,

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chemical, and physical – at each step of the production process. A "step" is a point or activity

in an operation within the production process that is essential to the proper production of the

finished product. A food safety hazard that is reasonably likely to occur is one for which a

prudent establishment would establish controls because the hazard has historically occurred

in the product/process or because there is a reasonable probability that the hazard would

occur in the absence of these controls (FAO, 1999 and FSIS, 2014).

The hazard analysis and identification of associated control measures accomplish three
objectives:

1. Hazards and associated control measures are identified,

The hazard analysis is the foundation of the food safety system. A thorough hazard analysis is

the key to preparing an effectively designed HACCP plan. Food industries/establishments

must conduct hazard analyses for each process. During the development and design of the

hazard analysis, establishments must consider all three types of hazards – biological,

chemical, and physical – at each step they identify in the production process. Once the

establishment has identified potential hazards, these hazards are evaluated to determine if

each one is reasonably likely to occur (RLTO), or not reasonably likely to occur

(NRLTO). If the establishment determines that the hazard is reasonably likely to occur, a

preventive measure must be identified and a critical control point must be developed to

address the hazard, either at that step or later in the process. If the establishment determines

the hazard is not reasonably likely to occur, they must provide justification for this decision.

Establishments may use scientific or technical support, or they may have a variety of

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supporting programs as the basis for the decision that a hazard is not likely to occur (FSIS,

2014).

Microbiological Hazards: Any bacterium, virus, or protozoan that is capable of causing

illness and that grows or may be carried on food. Well-known examples of bacteria are

Campylobacter, Listeria and Salmonella. The most likely food-borne viruses are the Norwalk

type viruses. Giardia is an example of a protozoan that may be food borne. It is important to

have some understanding of the risks associated with different types of microbiological

hazards (NZFSA, 2003).

Chemical Hazards: Examples include excessive or toxic amounts of heavy metals,

chemicals, pesticides, herbicides, insecticides, vitamins, minerals, preservatives,

disinfectants, detergents and cleaning compounds. Some hazards may be naturally present

such as in green potatoes or taro and rhubarb leaves (NZFSA, 2003).

Physical Hazards: Objects that get into food, or are already present in food, may cause

illness, injury or distress to the person eating it. Some examples are glass, metal fragments

etc. Other contaminants such as hair or insects may be offensive but not necessarily a danger

to health. They should nonetheless be considered and controlled. That can occur at every

stage of the food business – from growth, processing, manufacture, storage and distribution,

until the point where it is sold to the customer and eaten. As far as possible you should

consider how the customer might handle it too (NZFSA, 2003).

1.2.2 PRINCIPLE 2: DETERMINE CRITICAL CONTROL POINTS

A critical control point (CCP) is defined as a point, step, or procedure in a food process at

which control can be applied, and, as a result, a food safety hazard can be prevented,

eliminated, or reduced to acceptable levels. Critical control points are locations in a process at

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which some aspect of control can be applied to control food safety hazards that have been

determined reasonably likely to occur (FSIS, 2014). Decision should be made on which of the

control points are critical. This means identifying whether it is the essential step at which to

control an identified hazard. It should be kept in mind that different types of hazard may have

critical controls at different steps in the process (NZFSA, 2003 and FSIS, 2014).

Examples of CCPs include product temperature, certification of incoming product,

microbiological testing, testing for foreign objects such as metal contamination, the chemical

concentration of a carcass rinse or spray, and other such parameters.

The step of the process at which the critical control point is located does not necessarily have

to be at the point where the hazard is introduced. They may be placed at any location deemed

adequate to prevent, eliminate, or effectively control the hazard in the product produced. The

control point for a hazard may be later in the process than the point at which the hazard

occurs. For example, the cooking step is a common control for biological hazards that have

been introduced into the product at previous steps.

Control may actually be achieved as a cumulative effect, also known as multiple hurdles.

There may be several steps in the process that together attain sufficient control, but

individually do so only partially. For example, an official establishment that slaughters cattle

may have a pre-evisceration organic acid rinse, a post evisceration organic acid rinse, and a

wash step followed by steam pasteurization.

For each hazard that is determined to be reasonably likely to occur, the establishment must

identify critical control points and corresponding critical limits that are measurable or

observable. Establishments must have documentation supporting all of these decisions, and

they must be able to demonstrate that their plan designs are valid and effective in operation

(FSIS, 2014 and FDA, 2014).

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1.2.3 PRINCIPLE 3: ESTABLISH CRITICAL LIMITS

Establishing Critical limits (CL) for each critical control point is the next step in the

development of HACCP plan. Critical limits (CL) are the parameters that indicate whether

the control measure at the CCP is in or out of control. The National Advisory Committee on

Microbiological Criteria for Foods (NACMCF) states that a CL is a maximum or minimum

value to which a biological, chemical, or physical parameter must be controlled at a CCP to

prevent, eliminate, or reduce to an acceptable level the occurrence of a food safety hazard.

The establishment must consider the food safety standard that must be met at each CCP.

Critical limits are designed to ensure applicable targets or performance standards pertaining

to the specific process or product. Critical limit design should be based on applicable FSIS

regulations or compliance guidelines, FDA tolerances, scientific and technical literature,

experimental studies, or the recommendations of recognized experts in the industry,

academia, or processing authorities. Critical limits should not be confused with operational

limits which are established for reasons other than food safety (FSIS, 2014 and FDA, 2014).

Critical limits are most often based on process parameters such as temperature, time, physical

dimensions, or presence of target pathogens. Critical limits must be actual values that can be

measured or quantified. Regardless of the parameter used, the critical limit must be sufficient

to prevent, eliminate, or reduce to an acceptable level the occurrence of the food safety

hazard it is designed to control. The establishment must be able to provide the basis for their

decision documents regarding the selection and development of the critical limits. The CLs

must also be designed to work effectively given the capabilities and limitations of the

establishment’s processes (NZFSA 2003, FSIS 2014 and FDA, 2014).

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1.2.4 PRINCIPLE 4: ESTABLISH A MONITORING SYSTEM

Once critical limits are set for each CCP during the HACCP plan development, procedures

must be established to monitor the CCPs to determine whether the critical limits are being

met. Monitoring is a planned sequence of observations or measurements to assess whether a

CCP is under control and to produce an accurate record for future use in verification (FSIS,

2014). Monitoring according to the New Zealand Food Safety Authority (NZFSA), is the

regular measurement or observation of a critical control point to ensure it is not beyond its

critical limits. The monitoring system must ensure any loss of control at the critical control

point can be discovered in time to take corrective action before the product is rejected.

Every CCP that is in the HACCP plan must be monitored to ensure that the critical limits are

consistently met and that the process is producing safe product. Establishments are

responsible for determining the procedure used to monitor each CCP. Monitoring procedures

usually involve either a measurement or an observation. If the critical limit is a numerical

value, then monitoring usually involves a measurement. If the critical limit is defined as the

presence or absence of an attribute, then the monitoring procedure may involve observation.

Monitoring procedures should be designed to determine when deviations from the critical

limit occur so that appropriate corrective actions can be initiated (FSIS, 2014). To be sure

that the critical limits are always effective, it is important to set up a system to monitor and

record control at the critical control point (NZFSA, 2003).

Information obtained from monitoring must be assessed by someone who has the knowledge

and authority to carry out corrective actions when needed. Quick on-line chemical and

physical measurements and observations are better than microbiological tests that take time to

analyse. Usually simple time and temperature records are sufficient. Often all that is needed

is a system to record observations. All records and documents must be signed by the person

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doing the monitoring and by a responsible reviewing official of the food business (NZFSA,

2003).

Establishments must determine how often they need to monitor CCPs. Ideally; the monitoring

frequency would be continuous whenever possible. An example is the continual recording of

cooking temperatures on temperature recording charts. The advantage of continuous

monitoring is that it allows an establishment to see what is occurring at a CCP throughout the

production process at any given time. When it is not possible to monitor a CCP on a

continuous basis then it is monitored intermittently and the frequency must be determined.

The frequency selected should be adequate to determine that the CCP is under control.

Statistically designed data collection systems are used to establish the frequency when

monitoring is not on a continuous basis. Establishments can select any employee to conduct

monitoring activities. Assigning monitoring responsibilities is an important consideration for

establishment management. HACCP monitors are often production employees or quality

control personnel. Employees selected to be HACCP monitors should be adequately trained

and should understand the purpose of monitoring. They should also be trained to immediately

report unusual occurrences to the individual responsible for initiating corrective actions. The

HACCP plan does not have to specify who will do the monitoring (FSIS, 2014 and FDA,

2015).

FSIS, in their 2014 HACCP publication itemized the following as monitoring objectives:

o To track control of the process: Monitoring the process allows the establishment

to identify situations in which a trend is developing that may lead to loss of process

control. If monitoring detects such a trend, establishments can take appropriate

measures to restore process control before a deviation occurs.

o To determine when there is a loss of control and a deviation occurs: Monitoring

serves to determine when the process has deviated from the critical limit. This

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 information lets the establishment know appropriate corrective actions must be taken

to restore process control and to effectively address all affected product.

o To provide a written document to be used in verification: Monitoring results must

be recorded on official HACCP records, and such records serve as the basis for

verification activities.

1.2.5 PRINCIPLE 5: ESTABLISH CORRECTIVE ACTION

The corrective actions must be determined for each CCP in cases where the CL is not met.

The specific corrective actions depend upon the process used and type of food produced.

When there is a deviation from the critical limit, corrective actions are required to prevent

potentially hazardous foods from reaching consumers. The HACCP plan must include

corrective actions to be taken when a deviation from the critical limit occurs at a critical

control point. The corrective actions consist of:

o Identifying and eliminating the cause of the deviation,

o Ensuring that the CCP is under control after the corrective action is taken,

o Ensuring that measures are established to prevent recurrence, and

o Ensuring that no product affected by the deviation is shipped.

HACCP plans should specify what is to take place when a deviation occurs, who is

responsible for implementing corrective actions, and that corrective actions will be

documented as part of the HACCP records. When designing their HACCP plans,

establishments can either specify particular corrective actions they will take when a deviation

occurs, or can simply state that they will address the regulatory requirements. Experts may be

consulted to review the information available and to assist in determining disposition of non-

compliant product (NZFSA, 2003 and FSIS, 2014).

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1.2.6 PRINCIPLE 6: ESTABLISH RECORD KEEPING AND DOCUMENTATION

REQUIREMENTS

While developing the HACCP plan, the establishment must ensure that the HACCP system

has an effective recordkeeping system. Records are written evidence documenting the

operation of the HACCP system. All measurements taken at a CCP, and any corrective

actions taken, should be documented and kept on file. These records can be used to trace the

production history of a finished product. If any questions arise about the product, a review of

records may be the only way to determine whether the product was produced in a safe

manner according to the HACCP plan (FSIS, 2014). The level of documentation required will

depend upon the needs and the complexity of the food business. In a small business, a simple

log book or diary may be all that is needed (NZFSA, 2003).

More detailed or formal documentation will be necessary for larger/complex business outfit.

The National Advisory Committee on Microbiological Criteria for Foods (NACMCF)

recommends that the establishment maintain four types of records.

o Summary of the hazard analysis including the rationale

o HACCP plan

o Support documentation such as validation records

o Daily operational records generated during the operation of the HACCP plan

The summary of the hazard analysis covers the basis and justification for an

establishment’s HACCP plan. This includes information about decisions the establishment

made during the hazard analysis process. It contains all the information about the hazard

analysis, including justification for CCPs and critical limits.

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The HACCP plan outlines the formal procedures the establishment will follow to meet the

seven principles. The NACMCF recommends that HACCP plan records should contain the

following.

o List of the HACCP team and assigned responsibilities.

o Description of the food, its distribution, intended use, and consumer.

o Verified flow chart for the entire manufacturing process

o HACCP Plan Summary Table that lists the following for each hazard of concern—the

CCP, critical limit, the monitoring procedures and frequencies, the corrective actions,

the verification procedures and frequencies, and the recordkeeping system.

The supporting documentation includes the rationale used to establish CCPs, critical limits,

monitoring procedures and frequencies, corrective action procedures, and verification

procedures and frequencies. This includes all scientific references, regulatory resources, and

materials from other sources (for example, extension services, academic experts, consultants)

that have been used in the development of the HACCP plan.

The daily operational records are what most of us think of when we think of HACCP

records. These include the actual records from the implementation of the HACCP plan

(monitoring, corrective actions, and verification). Record keeping and documentation systems

must meet the needs of the business and be adequate to show that the food safety programme

is working (NZFSA, 2003; FSIS, 2014; and FDA, 2014).

The HACCP records should:

o Contain the date and time of the activity reflected on the record.

o Contain the signature or initials of the employee making the entry.

o Have the information entered on the record at the time it is being observed.

o Contain actual observations or data values obtained.

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1.2.7 PRINCIPLE 7: ESTABLISH VERIFICATION PROCEDURES

Verification procedures are tests and programmes that ensure the HACCP system is working

properly. This must be done systematically. In the NACMCF explanation of the verification

principle, four processes are involved in the verification of the establishment's HACCP

system (NZFSA, 2003; FSIS, 2014). The establishment is responsible for the first three; FSIS

is responsible for the fourth.

o The first is the scientific and technical process, known as validation for determining

that the CCP and associated critical limits are adequate and sufficient to control likely

hazards.

o The second process is to ensure, initially and on an ongoing basis, that the entire

HACCP system functions properly.

o The third process consists of documented, periodic, reassessment of the HACCP

plan.

o The fourth process defines FSIS's responsibility for certain actions (government

verification) to ensure that the establishment's HACCP system is functioning

adequately.

Examples of verification include: reviewing the HACCP system and its records to ensure that

controls are effective reviewing corrective action reports to ensure that the corrective actions

were undertaken occasional testing to demonstrate that control has been maintained (NZFSA,

2003; Manafi, 2011). Verification confirms the accurate monitoring of the critical control

points. The verification procedures demonstrate that the HACCP system is adequately

controlling food safety hazards. After initial validation the system must be verified

periodically. Periodic verification involves the use of methods, procedures, or tests in

addition to those used for monitoring, to determine whether the HACCP system is in

compliance with the HACCP plan, or whether the HACCP plan needs modification and

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revalidation to achieve its food safety objective. Establishments must also be able to provide

supporting documentation for the verification procedures and frequencies specified in the

HACCP plan. Ongoing verification activities consist at a minimum of calibration procedures

(if there are instruments that require calibration), direct observations of monitoring and

corrective actions, and records review. They should be described in the HACCP plan (FSIS,

2014; FDA, 2014).

The goal of calibration procedures is to ensure that all measurements taken with process-

monitoring equipment are accurate. If the findings from the procedures show that the

measuring device is incorrect, then the device must be recalibrated or replaced. The direct

observation procedures and frequency for involve observing the monitor to determine that

monitoring is being done correctly. The purpose of records review is to ensure that the

records were prepared correctly, that all activities were performed as required by the HACCP

plan, that no activity was missed, and that all results were within the critical limits (FSAN,

2013).

Not all CCPs require the calibration of process-monitoring equipment. Establishments are not

limited to only these three types of verification activities. Other types of verification

procedures that establishments may use include independent checks or measurements to

verify the accuracy of monitoring and microbiological testing (Codex Alimentarius, 2003;

FSIS, 2014 and FDA, 2014)

1.3 IMPORTANCE OF HACCP

The Joint FAO/WHO Expert Committee on Food Safety reported in 1983 that illness due to

contaminated food is perhaps the most widespread health problem in the contemporary world

and an important cause of reduced economic productivity. The incidence reports indicated

that the foodborne diseases were not only widespread but, despite the efforts made by the

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public health authorities, they are on the increase, at least in some countries. This trend

indicated that efforts of public health authorities over the past two decades have not been

effective in preventing foodborne disease (Motarjemi, et al., 1999).

HACCP provides businesses with a cost effective system for control and food safety, from

ingredients right through to production, storage and distribution to sale and service of the

final consumer. The preventive approach of HACCP not only improves food safety

management but also complements other quality management systems (Manafi, 2011; FSAI,

2009; and FSI, 2009). Main benefits of HACCP with the acronym- SAFE FOOD;

1.) Saves the business owner money in the long term: Reduced product loss and decreased

likelihood of food recalls.

2.) Avoids incidences of poisoning of customers: Reduces risk of foodborne illness.

3.) Food Safety standards increase: focuses employees on food safety precautions and

improves their understanding of food safety hazards.

4.) Ensures compliance with government regulations: Helps to meet the large retailer’s

prerequisite supplier standards.

5.) Foods quality standards increase: Helps to open the door to international trade markets.

6.) Organises the processes of business owner to produce safe food.

7.) Organises the staff promoting teamwork and efficiency among them.

8.) Due diligence defence in court: Protection of business reputation and reduced liability
risk.

1.4 BUSINESS BENEFITS OF APPLYING HACCP PRINCIPLES

Centre for Food Safety and Applied Nutrition- FSAN, 2013 published the following as
accruable benefits to business for applying HACCP Principles;
o The step by step approach helps ensure that all food safety issues are identified

considered and dealt with, not ignored or forgotten until an incident occurs.

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 o The focus on planning means that problems are anticipated so that they can be

avoided and, if they occur, they can be handled quickly and the costs minimised. Any

food that may have become unsafe can be dealt with properly and quickly.

o Attention is focussed on the most important steps in the production process to help

achieve food safety efficiently and economically with best use of staff.

o Effective implementation of HACCP-based procedures demonstrates operator and

employee responsibility and company commitment to food safety i.e. ‘due diligence’.

o Accurate and timely records provide evidence of effective food safety management.

o A HACCP-based system can accommodate change or technological developments,

such as advances in equipment design, new processing procedures.

o Food handlers can be motivated when the importance of their efforts to maintain food

safety are recognized.

o As an internationally accepted tool for food safety management, customers regard the

implementation of HACCP-based procedures as a basic requirement for trade.

1.5 HACCP APPLICATION IN THE FOOD INDUSTRY: BEEF SLAUGHTER:

AN ILLUSTRATION

The goal of HACCP for slaughter operations is to prevent, eliminate, or reduce the incidence

and levels of microorganisms pathogenic to humans. While beef slaughter operations do not

include a treatment lethal to pathogens (such as cooking) that ensures the elimination of

pathogenic microorganisms, a number of the processing steps can be controlled to minimize

microbiological hazards.

Hazard Analysis; A beef slaughter establishment’s hazard analysis may identify several

hazards, particularly enteric pathogens, such as Salmonella. CCPs where Salmonella

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contamination might occur can be identified and then controlled by establishing critical

limits, monitoring those limits at an appropriate frequency, and taking corrective actions

when deviations occur. Record keeping and verification procedures would also be identified

for these CCPs in the establishment’s HACCP plan.

For example, Critical Control Points include; the intestinal tracts of animals which can

harbour large populations of enteric pathogens, such as Salmonella, even though the animals

themselves are not sick. As the slaughtered animals are eviscerated, there is potential for

spreading the Salmonella from the intestinal tract to the carcass, operator, or equipment, if the

intestines are accidentally cut. Therefore, evisceration would be considered a CCP in a

HACCP plan for beef slaughter.

Critical limits for the evisceration CCP might be zero percent occurrences of the following

defects for a single carcass: faecal material, ingesta, urine, or abscesses. The establishment

employees working at evisceration would monitor by observing carcasses for contamination

defects and would take corrective actions if the critical limits were exceeded.

Corrective actions might include: immediate trimming of defects from carcasses, addition of

more establishment employees to the slaughter line, a reduction in line speed, sanitation of

evisceration tools in 180°F water, etc.

Records resulting from this CCP might include a random post-evisceration carcass

examination log. Verification might consist of supervisory review of records and operations,

and random examination of carcasses after evisceration using a sampling plan sufficient to

assure process control.

Removing the hide from cattle is a major source of microbial contamination during the

slaughter process. Cattle entering the slaughter establishment carry with them microbial

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populations that reflect what occurred during pre-slaughter care and handling. Salmonella and

other bacteria can be spread during the skinning process through contact with hide, hands,

and various pieces of equipment. Therefore, skinning would be a CCP in a beef slaughter

HACCP plan. Methods for control of contamination at skinning might include adequate

training of the person doing the skinning to minimize contamination, including pulling the

hide down and out from the carcass as opposed to upward and away, and proper cleaning and

sanitation of equipment and carcass contact surfaces. Monitoring at this CCP might include

observation of the effectiveness of the skinning process for each carcass, with a possible

critical limits set so that 20 percent of carcasses or less have dressing defects. If this critical

limit is exceeded, required corrective actions could include immediate trimming of defects on

carcasses, additional establishment employees added to the slaughter line, and a reduction in

line speed. Records from this CCP might include a random post-skinning carcass

examination log. Verification might consist of a supervisory review of records, examination

of random carcasses after skinning is complete using a sampling plan sufficient to assure

process control, and reviewing control charts to confirm that sampling frequency is sufficient

to detect 20 percent defect criteria (Hulebak and Schlosser, 2009).

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CONCLUSION

Consumers have the right to expect the food they eat to be safe and suitable for consumption.

Foodborne illness and foodborne injury are at best unpleasant; at worst, they can be fatal. But

there are also other consequences. Outbreaks of foodborne illness can damage trade and

tourism, and lead to loss of earnings, unemployment and litigation. Food spoilage is wasteful,

costly and can adversely affect trade and consumer confidence. International food trade, and

foreign travel, are increasing, bringing important social and economic benefits. But this also

makes the spread of illness around the world easier. Eating habits too, have undergone major

change in many countries over the last two decades and new food production, preparation and

distribution techniques have developed to reflect this. Effective hygiene control, therefore, is

vital to avoid the adverse human health and economic consequences of foodborne illness,

foodborne injury, and food spoilage. Everyone, including farmers and growers,

manufacturers and processors, food handlers and consumers, has a responsibility to assure

that food is safe and suitable for consumption (Codex Alimentarius 2003).

FDA endorses the voluntary implementation of food safety management systems in retail and

food service establishments. Combined with good basic sanitation, a solid employee training

program, and other prerequisite programs, HACCP can provide you and your employees a

complete food safety management system (FSAN, 2013).

The HACCP Principles lay a firm foundation for ensuring food hygiene and should be used.

The principles described in the HACCP system are internationally recognized as essential to

ensure the safety and suitability of food for consumption. The General Principles are

commended to Governments, industry (including individual primary producers,

manufacturers, processors, food service operators and retailers) and consumers alike.

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REFERENCES
Centre for Food Safety and Applied Nutrition- FSAN (2013) Managing Food Safety: A
Manual for the Voluntary Use of HACCP Principles for Operators of Food Service and
Retail Establishments. Retrieved from
www.food.gov.uk/sites/default/files/multmedia/pdfs/migpartthree.pdf 03/02/2015

Codex Alimentarius (2003). General Principles of Food Hygiene, CAC/RCP 1-1969 Rev. 4-
2003 - Annex. Retrieved from www.codexalimentarius.org 02/02/2015

Food and Drug Agency, US - FDA (2014). Hazard Analysis & Critical Control Points
(HACCP) Publication. Retrieved from
www.fda.gov/Food/GuidanceRegulation/HACCP/ 02/02/2015

Food Safety Authority of Ireland - FSAI (2009). Benefits of HACCP. Retrieved from
www.fsai.ie/food_businesses/haccp/benefits_of_haccp.html 03/02/2015

Food Safety India - FSI (2009). HACCP – The Basics and benefits. Retrieved from
www.foodsafetyindia.com/2009/11/haccp-basics-and-benefits.html 03/02/2015

Food Safety and Inspection Service – FSIS (2014). HACCP Seven Principles. Inspection
Methods. Retrieved from www.fsis.usda.gov/wps/wcm/connect/9bef6a34-d7ef-441e-
8478-f431aee441cf/16_IM_HACCP_Principles.pdf?MOD=AJPERES02/02/2015

Hulebak, K.L., and Schlosser, W., (2009). HACCP History and conceptual overview. U.S.
Dept. of Agriculture Food Safety and Inspection Service Office of Public Health and
Science. Retrieved from www.ce.ncsu.edu/risk/pdf/hulebak.pdf 02/02/2015

Manafi, M., (2011) HACCP in food production, Presented at Medical University of Vienna.
Retrieved from www.univie.ac.at/hygiene-aktuell 02/02/2015

Motarjemi, Y., Schothorst, M., Jongeneel, S., (1999) HACCP: Principles and Practice.WHO
and Industry Council for Development publication. Retrieved from
www.whqlibdoc.who.int/hq/1999/WHO_SDE_PHE_FOS_99.3_Intro_Module1.pdf
02/02/2015

New Zealand Food Safety Authority – NZFSA (2003). An Introduction to HACCP Food
Safety Information for New Zealand Businesses. Publication of NZFSA. Retrieved
from www.nzfsa.govt.nz 02/02/2015

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Sperber, W.H., and Stier., R.F. (2009). “Happy 50th Birthday to HACCP: Retrospective and
Prospective”. Food Safety magazine. pp. 42–46. Retrieved 11/01/2015.

The Basic Principles of HACCP. http://www.efsic.com/Downloads/studies/Haccp.pdf

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