HAC
CP
HACCP is an acronym for Hazard Analysis and
Critical Control Point
Food safety program
Developed in 1960s for NASA
To ensure the safety of food products that were to
be used by the astronauts in the space program.
HAC
CP
A systematic process control system designed to
determine potential hazards and implement control
measures to reduce or eliminate the likelihood of
their occurrence
Focus is on hazard prevention, rather than hazard
detection
HAC
CP
Basically:
Determining the step or steps that the really
serious problems occur or could occur in your
production process
Monitoring these steps so you know there are
problems
Fixing any problems that arise
How to make HACCP
work?
Must make the commitment
Must let everyone get involved
Must be able to document all production
steps
Must be able to monitor … simple / validate
Prerequisite
Programs
Applicable to the overall manufacturing environment
Includes Good Manufacturing Practices
Foundation for an effective HACCP program
Prerequisite
Programs
Prerequisite programs to have in place before starting
HACCP
Procedures, including GMPs, that address operational
conditions providing the foundation for the HACCP
system
Examples of Common Prerequisite
Programs
Facilities
Production equipment
Standard operating procedures
Supplier controls
Production specification
Personnel policies
Traceability and recalls
Eight Key Sanitation
Conditions and
Safety of water
Practices:
Condition and cleanliness of food-
contact surfaces
Prevention of cross-contamination
Maintenance of hand-washing, hand-
sanitizing and toilet facilities
Protection from adulterants
Labeling, storage and use of toxic compounds
Employee health conditions
Exclusion of pests
HACCP
process 1
Preliminary Steps:
Task 1 - Establish a HACCP team
Task 2 - Describe the product
Task 3 - Identify the product's intended use
Task 4 - Draw up the commodity flow diagram
Task 5 - On site confirmation of flow diagram
Basic Flow Diagram
Example
Incoming materials
Processing
Packaging
Storage
Distribution
HACCP
Task 6 - Identifyprocess 2
and analyse hazard(s) - (Principle 1)
Task 7 - Determine the critical control points (ccps) -
(Principle 2).
Task 8 - Establish critical limits for each ccp -
(Principle 3)
Task 9 - Establish a monitoring procedure -
(Principle 4)
Task 10 - Establish corrective action - (Principle 5)
Task 11 - Verify the HACCP plan - (Principle 6)
Task 12 - Keep record - (Principle 7)
1. Conduct a Hazard
Analysis
Hazard identification
Hazard evaluation
Likelihood of occurrence
Severity
Safety concerns must be differentiated from
quality concerns.
Hazard
Identification
List potential hazards at each operational step in
the process from receipt of raw materials
through release of the finished product
All potentially significant hazards must be
considered
Hazards
List
Biological Hazards
Pathogenic microorganisms (e.g., bacteria, viruses)
Parasites
Chemical Hazards
Natural toxins
Chemicals
Pesticides
Drug residues
Unapproved food and color additives
Decomposition (safety only, e.g., histamine)
Physical Hazards
Metal, glass, etc.
Hazard
Analysis
A hazard must be controlled if it is:
Reasonably likely to occur, and
Likely to result in an unacceptable risk
to consumers
e.g., Listeria monocytogenes in ready-
to-eat food
Control
Measures
Actions and activities that can be used to prevent
or eliminate a food safety hazard or reduce it to
an acceptable level
Bacterial Hazards
Time/temperature control
Heating and cooking processes
Cooling and freezing
Fermentation and/or pH control
Addition of salt or other preservatives
Drying
Source control
2. Determine the Critical
Control Points
A point, step or procedure at which control can
be applied and is essential to prevent or
eliminate a food-safety hazard or reduce it to an
acceptable level
Control
Point
Any point, step or procedure at which
biological, physical or chemical factors can be
controlled
CCPs vs. Control
ControlPoints
Points
Points where quality factors can be
controlled
Points where non-HACCP regulatory
requirements can be controlled
CCPs
Points where food-safety hazards can be
controlled
CCPs are product- and process
specific
They may change with differences
in:
Plant layout
Formulation
Process flow
Equipment
Ingredient selection
Sanitation and support programs
CCP Decision
Tree
Q1: Does a control measure(s) exist at this step or
subsequent steps in the process flow for the
identified hazard?
Q2: Does this step eliminate or reduce the likely
occurrence
of a significant hazard to an acceptable level?
Q3: Could contamination with an identified hazard or
hazards occur in excess of acceptable levels, or could
these increase to unacceptable levels?
Q4: Will a subsequent step eliminate the identified
hazard(s) or reduce the likely occurrence to an
acceptable level?
3. Establish Critical
Limits
Critical Limit
A maximum and/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
Options for Controlling
Hazards
Often a variety of options exist for controlling
a particular hazard
The selection of the best control option and critical
limit is often driven by practicality and experience
4. Critical Control Point
Monitoring
To conduct 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
Purpose of
Monitoring
To track the operation of the process and enable
the identification of trends toward a critical
limit that may trigger process adjustments
To identify when there is loss of control
(a deviation occurs at a CCP), and
To provide written documentation of the
process control system
Monitori
ng
What: Usually a measurement or observation to
assess if the CCP is operating within the critical
limit
How: Usually physical or chemical measurements
(for quantitative critical limits) or observations (for
qualitative critical limits). Needs to be real-time and
accurate.
When (frequency): Can be continuous or
intermittent
Who: Someone trained to perform the
specific monitoring activity
What will be
Monitored?
Measuring a characteristic of a product or
process to determine compliance with a
critical limit
Cold-storage temperature
pH of an acidifying ingredient
Line speed
Monitori
ng
Must provide rapid results
Microbiological testing is seldom effective
Physical and chemical measurements
are preferred monitoring methods
Time and temperature
Water activity
Acidity (pH)
Sensory examination
Monitori
ng
Examples of monitoring equipment
Thermometers
Clocks
pH meters
Water activity meters
Monitoring
Frequency
Continuous monitoring is preferred:
Continuous monitoring procedures:
Temperature recording chart
Metal detector
Dud detector
Continuous records need to be observed
periodically
Monitoring
Frequency
Non-continuous Monitoring :
Non-continuous monitoring must be used when
continuous monitoring is not possible
Frequency of non-continuous monitoring
How much does the process normally vary?
How close are normal values to the critical limit?
How much product is the processor prepared to risk if
the critical limit is exceeded?
Who will
Monitor?
Those responsible for monitoring should:
Be trained in CCP monitoring techniques
Fully understand the importance of
CCP monitoring
Have ready access to the monitoring
activity
Accurately report each monitoring
activity
Immediately report critical limit infractions so
that immediate corrective actions can be
taken
5. Establish Corrective
Actions
Procedures to be followed when a
deviation occurs
Options Include:
Isolating and holding product for
safety evaluation
Diverting the affected product or ingredients
to another line where deviation would not be
considered critical
Reprocessing
Destroying product
Corrective Action
ToComponents
correct and eliminate the cause of
the deviation and restore process
control
Bring CCP back under control
Determine cause of deviation to prevent
future recurrence
To identify the product that was produced
during the process deviation and
determine its disposition
6. Establish Verification
Procedures
Those activities, other than monitoring, that
determine the validity of the HACCP plan and
that verify the system is operating according to
the plan
“Only marked is
done”
Verification provides a level of confidence that the
HACCP plan:
is based on solid scientific principles,
is adequate to control the hazards associated with
the
product and process, and
is being followed
Elements of
Verification
Validation
CCP verification activities
Calibration of monitoring devices
Calibration record review
Targeted sampling and testing
CCP record review
HACCP system verification
Observations and reviews
Microbiological end-product testing
Regulatory agencies
Validati
on focused on collecting and
The element of verification
evaluating scientific and technical information to
determine if the HACCP plan, when properly
implemented, will effectively control the hazards
Who validates the HACCP plan?
HACCP team
Individual qualified by training or experience
What does validation involve?
A scientific and technical review of the rationale
behind each part of the HACCP plan from hazard
analysis through each CCP verification strategy
Validation
Initially Frequency
When factors warrant, e.g.,
Changes in raw materials
Changes in product or process
Adverse review findings
Recurring deviations
New information on hazards or control
measures
On-line observations
New distribution or consumer handling
practices
Verification of
CCPs
Calibration
Calibration record review
Targeted sampling and testing
CCP record review
HACCP System
Verification
Determines if the HACCP plan is being followed
Annually
Occurrence of a system failure or significant change
in product or process
Verification Activities of the
HACCP
System
Check the accuracy of the product description
and flow chart
Check that CCPs are monitored as required by
the HACCP plan
Check that processes are operating
within established critical limits
Check that records are completed accurately and
at the time intervals required
Verification Procedures by an
Agency Include:
Review of the HACCP plan and any
modification
Review of CCP monitoring records
Review of corrective action records
Review of verification records
Visual inspection of operations to determine
if the HACCP plan is followed and records
are properly maintained
Random sample collection and analysis
7. Establish record-
keeping and
documentation
Four Kinds of HACCP Records:
procedures
[Link] plan and support documentation used
in developing the plan
2. Records of CCP monitoring
3. Records of corrective action
4. Records of verification activities
CCP Monitoring
Records
Kept to demonstrate control at CCPs
Used to determine if critical limits have been violated
Verification
Records
Modifications of the HACCP Plan
Audits of supplier compliance with guarantees
or certifications
Calibration records
Microbiological tests
In-house, on-site inspections
Equipment evaluation tests
Record Monitoring
Information
Monitoring information should be recorded at the
time the observation is made
Computerized records: Include controls to ensure that
records are authentic, accurate and protected from
unauthorized changes
Review: All monitoring records of critical control
points shall occur within 1 week of the day the
records are made
Advantages of
HACCP
Focus on identifying and preventing hazards from
contaminating food
Based on sound science
Permits more effective and efficient government
oversight
Places responsibility for ensuring food safety on
the processor or distributor
Helps companies compete more effectively in the
marketplace
Benefits of
HACCP
The main benefits of HACCP are:
S aves your business money in the long run
A voids you poisoning your customers
F ood safety standards increase
E nsures you are compliant with the law
F ood quality standards increase
O rganises your process to produce safe food
O rganises your staff promoting teamwork and
efficiency
D ue diligence defence in court.
Some
links
[Link]
id/118/[Link]
[Link]
HACCP - Making Food Products Safe, Part 1
[Link]
HACCP -Making Food Products Safe, Part 2
[Link]
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