HACCP PRESENTATION

Prepared by: Bhaskar TRIPATHI

Qualification: [Link] DAIRY

Experience : 08 Years

Company Name: SAFE BITE AUDIT SOLUTIONS ( Director)

 HACCP SYSTEM

7
HACCP is a management system in which food safety is Principle
addressed through the analysis and control of biological, s&5
Points
chemical, and physical hazards from raw material
production, procurement and handling, to manufacturing,
distribution and consumption of the finished product.
Totally
Points are
required to
develop a
HACCP
system
 WHAT IS HACCP
HACCP IS THE ACRONYM The HACCP system is a
FOR “HAZARD systematic approach,
ANALYSIS CRITICAL which leads to the
CONTROL POINT”. detection, the description
IT IS A PREVENTIVE and the control of
SYSTEM WHICH hazards.
SAFEGUARDS AGAINST
FOODBORNE ILLNESS The HACCP system
TO ENSURE THAT ALL eliminates food hazards
FOODSTUFF REACHING by prevention rather than
THE CONSUMER ARE by end-product
SAFE FOR inspection.
CONSUMPTION.
 7 PRINCIPLES OF HACCP
Principle 1: Hazard analysis
Principle 2: Identify critical control points
Principle 3: Develop critical limits for
preventive measures
Principle 4: Establish procedures to monitor
critical control points
Principle 5: Develop a corrective action
plan

Principle 6: Establish procedures to verify

that the HACCP system is working

Principle 7: Establish effective record

keeping system that documents the
HACCP system
 SEQUENCE OF APPLICATION OF HACCP
( FOOD SAFETY SYSTEM)

[Link] the Food safety Team

2. Describe Product

3. Identify intended Use

4. Construct Flow Diagram.

5. On-site Verification of Flow diagram

6. Analyze hazards
 SEQUENCE OF APPLICATION OF HACCP
( FOOD SAFETY SYSTEM)

7. Determine the CCPs

[Link] critical limits for each CCP

9. Establish a monitoring system for each CCP

10. Establish corrective action for deviation that occur

11. Establish verification procedures

12. Establish record keeping and Documentation

 [Link] A FOOD SAFETY TEAM

The FOOD SAFETY team usually comprise

candidates who are most familiar with
the establishment's overall food
production, service systems, and food
safety hazards.

Each team member's responsibility

should be clearly defined and written
out in a HACCP plan as part of
system's documentation
 [Link] A FOOD SAFETY TEAM

• PRODUCTION
• QUALITY ASSURANCE
• RESEARCH & DEVELOPMENT
• ENGINEERING
• MAINTENANCE
• SANITATION
• PROCUREMENT
• DISTRIBUTION
• MARKETING/SALES
• APPROPRIATE EXPERTS IN HAZARD
ANALYSIS
 [Link] PRODUCT & CHARATERISTICS

1. RAW MATERIALS, INGREDIENTS, AND PRODUCT –

CONTACT MATERIAL
E.G: BIOLOGICAL, PHYSICAL, CHEMICAL (B P C)
CHARACTERISTICS, ORIGIN,
METHOD PREPARATION, STORAGE CONDITIONS ETC.
2. CHARACTERISTICS OF THE END PRODUCTS.
E.G: PRODUCT NAME, COMPOSITION, (B PC) CHARACTERISTICS,
INTENDED SHELF LIFE, PACKAGING.
 [Link] PRODUCT & CHARATERISTICS

Describe the food and its distribution:

What is the product?
What is the nature of the product?
e.g. fresh, canned, dried, vacuum-packaged.
What type of storage and distribution is required?
What is the shelf life of the product.
Are there any other special considerations that need
to be addressed?
How is the product produced/processed?
 3. IDENTIFY INTENDED USE

• THE INTENDED USE OF THE PRODUCT BY THE

CUSTOMER OR CONSUMER AND THE CONSUMER
TARGET GROUPS SHOULD BE DEFINED TO
ENCOMPASS ANY SPECIAL CONSIDERATIONS
• E.G HIGH SUGAR, LOW SUGAR, HIGH PROTEIN ,
LOW PROTEIN ETC
 3. IDENTIFY INTENDED USE

• DESCRIBE THE INTENDED USE AND CONSUMERS OF THE

FOOD.
• WHAT IS THE INTENDED USE? (RETAIL, FOODSERVICE, FURTHER
MANUFACTURING)
• WHAT IS THE POTENTIAL FOR MISHANDLING?
• WHAT PREPARATION PROCEDURES ARE REQUIRED BY THE
CONSUMER/CUSTOMER?
• IS THE PRODUCT INTENDED FOR USE BY IMMUNE-COMPROMISED
INDIVIDUALS?
 4. PROCESS FLOW DIAGRAM

PURPOSE

• A CLEAR DESCRIPTION OF THE

PROCESS STEPS

• HELPS FOOD SAFETY TEAM

UNDERSTAND PROCESS

• HELP REGULATORS AND

CUSTOMERS UNDERSTAND THE
PROCESS FOR VERIFICATION
PROCEDURES

• HELPS IDENTIFY CRITICAL POINTS

AND DEVELOPMENT OF CCPS
 4. PROCESS FLOW DIAGRAM
• Include all ingredients, processes, storage
and packaging steps.
– Show process from raw goods receiving
to shipping dock.
– Identify all steps that affect the product
in any way.
– Show movement of ingredients and
product through the production and
storage processes
• Separate diagrams, if needed, for different
product streams
• Keep it easy to understand
– Engineering drawings are not required
 [Link] OF PROCESS FLOW DIAGRAM

ON-SITE OBSERVATION OF THE PROCESS BY

THE FOOD SAFETY TEAM:
VERIFY ACCURACY AND COMPLETENESS
OF THE DIAGRAM
MODIFICATION OF THE PROCESS FLOW
DIAGRAM TO REFLECT THE ACTUAL
CONDITIONS, AS OBSERVED BY THE FOOD
SAFETY TEAM
FLOW DIAGRAM IS A DYNAMIC DOCUMENT:
MUST BE MODIFIED AND UPDATED TO
REFLECT THE CURRENT PROCESS
 [Link] ANALYSIS

• PURPOSE

TO DEVELOP A LIST OF HAZARDS THAT ARE

OF SUCH SIGNIFICANCE THAT THEY ARE
REASONABLY LIKELY TO CAUSE INJURY OR
ILLNESS IF NOT EFFECTIVELY CONTROLLED.
• CONSISTS OF AN EVALUATION OF ALL
PROCEDURES CONCERNED WITH THE
PRODUCTION, DISTRIBUTION, AND USE OF
RAW MATERIALS AND FOOD PRODUCTS.
 [Link] ANALYSIS

• IDENTIFY POTENTIALLY HAZARDOUS RAW

MATERIALS AND FOODS
• IDENTIFY POTENTIAL SOURCES OF
CONTAMINATION
• DETERMINE THE POTENTIAL OF
MICROORGANISMS TO SURVIVE OR
MULTIPLY DURING PRODUCTION,
DISTRIBUTION, STORAGE OR USE.
• ASSESS THE RISKS AND SEVERITY OF THE
HAZARDS IDENTIFIED
 [Link] ANALYSIS

IDENTIFICATION OF HAZARDS
BIOLOGICAL HAZARDS
• HARMFUL MICROORGANISMS AND THEIR TOXINS
• THE MOST SIGNIFICANT CAUSE OF FOOD-RELATED
ILLNESS
CHEMICAL HAZARDS
• NATURALLY OCCURRING CHEMICALS
• INTENTIONALLY ADDED CHEMICALS
• UNINTENTIONALLY OR ACCIDENTALLY ADDED
CHEMICALS
• FOOD ALLERGENS
 [Link] ANALYSIS

IDENTIFICATION OF HAZARDS
PHYSICAL

Contaminant Sources Types of Control

Glass Light Fixtures, Clock faces, Glass breakage SOP,

mirrors, glass containers shatter proof bulbs,
shields

Metal Ingredients Specifications

Fragments Machinery Inspection, PM
People/process related Training, supervision

Wood Building Inspection, maintenance

Equipment/utensils Eliminate
Palletized goods Inspection

Stones Incoming raw materials Stone traps, floatation

Wire Packaged ingredients Inspection, sieves,

screens
 CONTROL MEASURES, CP’S, CCP’S

CONTROL POINT (CP): Ozone

• ANY POINT, STEP OR PROCEDURE AT WHICH and UV
BIOLOGICAL, PHYSICAL OR CHEMICAL FACTORS
CAN BE CONTROLLED
CONTROL MEASURE:
• ANY ACTION OR ACTIVITY THAT CAN BE USED
TO PREVENT OR ELIMINATE A FOOD SAFETY
HAZARD OR REDUCE TO AN ACCEPTABLE LEVEL
 CONTROL MEASURES-CCPS

Control measures for each identified

hazard. • Chemical Hazards
• BIOLOGICAL HAZARDS
• TIME/TEMPERATURE CONTROLS Physical Hazards – Source control
• HEATING/COOKING PROCESSES – Source control – Production control
• COOKING AND FREEZING
– Production control – Labeling control
• FERMENTATION AND/OR PH CONTROL – Undeclared food
• ADDITION OF PRESERVATIVES allergen
• DRYING contamination
• SOURCE CONTROL
• DIETARY CONTROL
 [Link] CONTROL POINT

• The Codex guidelines define a

critical control point (CCP) as "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".

• Decision tree should be used for

guidance when determining CCPs.

• Identification of CCPs
 [Link] CONTROL POINT

Select criteria for control

– Time and temperature for thermally processed foods
– aw for intermediate moisture foods
– pH and acidity for fermented foods
– Humidity control in storage of dry products
– Temperature during distribution of refrigerated foods
DECISION TREE
 [Link] LIMITS ( CLS)

•A maximum and/or minimum value to

which a parameter must be controlled at a
CCP to prevent, eliminate or reduce to
an acceptable level the occurrence of a
food safety hazard.

•For each CCP, at least one critical limit is

established to signify whether the CCP is
“in” or “out” of control
Eg: Time
Temperature
Humidity
•If the process fails to meet this limit, then Level of acidity
the safety of the product is no longer in Level of alkalinity
control. Amount of water
Preservatives
Salinity
Residual chlorine level
 [Link] LIMITS ( CLS)

TYPES OF CRITICAL LIMITS

CHEMICAL LIMIT
• EXAMPLES INCLUDE MAXIMUM ACCEPTABLE LIMIT FOR MYCOTOXINS,
PESTICIDE RESIDUES, HORMONES, PRESERVATIVES, PH, SALT, WATER
ACTIVITY AND ALLERGEN CARRYOVER.
• PHYSICAL LIMIT
• EXAMPLES INCLUDE ABSENCE OF PHYSICAL HAZARDS, LINE SPEED AND
TIME FOR COOKING, TEMPERATURE REQUIREMENTS.
• MICROBIOLOGICAL LIMIT
• EXAMPLE IS MICROBIOLOGICAL TEST (E.G., ABSENCE OF SALMONELLA IN
250 GRAM SAMPLE).
 9. ESTABLISH PROCEDURES TO MONITOR CCPS

THE DEVELOPMENT AND IMPLEMENTATION

OF AN EFFECTIVE MONITORING SYSTEM TO
VERIFY THAT EVERY CCP IS IN CONTROL.

EFFECTIVE MONITORING PROCEDURES

ENSURE THAT CRITICAL LIMITS ARE MET.
MONITORING TRACKS THE SYSTEM'S
OPERATIONS SO THAT A LOSS OF CONTROL
CAN BE SPOTTED AND CORRECTED BEFORE
A HAZARD OCCURS.

DOCUMENTATION OF ALL MONITORING Ozone

EFFORTS MUST BE KEPT. THIS INCLUDES and UV
CALIBRATION RECORDS OF INSTRUMENTS
USED TO MEASURE CRITICAL LIMITS.
 9. ESTABLISH PROCEDURES TO MONITOR CCPS

• THE MONITORING SYSTEM MUST BE WRITTEN AND SPECIFY WHAT, WHEN, HOW,
AND BY WHOM MONITORING WILL BE DONE.
• TYPES OF MONITORING:
• VISUAL OBSERVATION ‑ EXAMINING RAW MATERIALS, CLEANLINESS OF PLANT
AND EQUIPMENT, WORKER HYGIENE, PROCESSING PROCEDURES, STORAGE AND
TRANSPORTATION FACILITIES
• SENSORY OBSERVATION ‑ INSPECTION OF INGREDIENTS AND RAW MATERIALS
FOR OFF‑ODORS, OFF‑COLORS, TEXTURAL CHANGES.
• PHYSICAL/CHEMICAL TESTS ‑ TEMPERATURE, PH, TOTAL ACIDITY, SALT, WATER
ACTIVITY, AND HUMIDITY; RECORDING LIMITS OR RANGES OF THESE FACTORS.
• MICROBIOLOGICAL ‑ MONITORING OF RAW MATERIALS BEFORE PROCESSING.
 10. DEVELOP A CORRECTIVE ACTION PLAN

CORRECTIVE ACTION PLAN INVOLVES IMPLEMENTING CORRECTIVE ACTIONS WHEN RESULTS

OBTAINED BY THE MONITORING PROCEDURE INDICATE THAT A CERTAIN CCP IS OUT OF CONTROL.

IF A CRITICAL LIMIT HAS BEEN VIOLATED, WHICH MEANS A FOOD PRODUCT IS IN DANGER OF
BECOMING UNSAFE, A SPECIFIC CORRECTIVE ACTION MUST BE CARRIED OUT IMMEDIATELY.

CORRECTIVE ACTIONS TAKEN MUST DEMONSTRATE THAT THE CCP HAS BEEN BROUGHT UNDER

CONTROL. RECORDS OF CORRECTIVE ACTIONS MUST ALWAYS BE KEPT.

 11. ESTABLISH PROCEDURES TO VERIFY

VERIFICATION ACTIVITIES COMPRISE:

 REVIEW CRITICAL CONTROL POINTS FOR EFFECTIVENESS
 REVIEW CRITICAL LIMITS TO MAKE SURE THEY ARE ADEQUATE TO CONTROL HAZARDS
 REVIEW CORRECTIVE ACTIONS TAKEN AND ITS EFFECTIVENESS
 INSPECT MONITORING AND CORRECTIVE PROCEDURES
 PERFORM ON-SITE INSPECTIONS OF ALL FOOD SAFETY FLOW CHARTS, FORMS, AND
CCPS TO ENSURE THAT THEY ARE USED CORRECTLY
 IMPLEMENTING AN APPROPRIATE VERIFICATION SCHEDULE WHICH MAY INCLUDE
RANDOM CHECKS
 12. ESTABLISH EFFECTIVE RECORD KEEPING

• THE ONLY REFERENCES AVAILABLE TO TRACE THE

PRODUCTION HISTORY OF FINISHED PRODUCTS.
• DOCUMENT THE SAFETY OF THE PRODUCT.
• CAN ALERT AN OPERATOR OF EQUIPMENT PROBLEMS
OR MALFUNCTIONS AND CORRECT POTENTIAL
PROBLEMS BEFORE THEY LEAD TO CL VIOLATION
• REGULATORY COMPLIANCE AUDITS: RECORDS ARE
THE SINGLE MOST IMPORTANT SOURCE OF
INFORMATION FOR DATA REVIEW.
• PROBLEM AREAS CAN BE QUICKLY IDENTIFIED AND
CORRECTED BECAUSE RECORDS ARE FOCUSED ON
SAFETY ISSUES.
 12. ESTABLISH EFFECTIVE RECORD KEEPING

TYPES OF HACCP RECORDS

• SUMMARY OF THE HAZARD ANALYSIS

• THE HACCP PLAN

• SUPPORT DOCUMENTATION FOR VALIDATION

• DAILY OPERATIONAL RECORDS

• RECORD-KEEPING FOR PRE-REQUISITE PROGRAMS IS

SEPARATE FROM HACCP RECORD-KEEPING
 RISK MANAGEMENT
RISK ANALYSIS
HIGH -3 3 6 9
HIGH SIGNIFICANT HIGH HIGH SIGNIFICANT
SIGNIFICANT
MEDIUM – 2 2 4 6
MEDIUM MEDIUM HIGH SIGNIFICANT
SIGNIFICANT SIGNIFICANT
LOW -1 1 2 3
LOW MEDIUM HIGH SIGNIFICANT
SIGNIFICANT SIGNIFICANT

LOW - 1 MEDIUM - 2 HIGH - 3

SIGNIFICANCE OF HAZARDS
SIGNIFICANCE IMPLICATIONS TYPES OF CONTROL MEASURE
LEVEL
LOW Identify hazard not present in existing Continuous awareness, regular
operation, may be theoretical, not at critical review
levels
MEDIUM Identify hazard likely to occur, present in General control measures,
existing or similar operations, but not at critical verification, with or without records
levels
HIGH Identify hazard likely to occur, widely General control measures, validation
recognized in the industry, at critical levels and verification, with clear records
 HACCP ANALYSIS WORK SHEET
DECISION TREE
POTENTIAL RISK DECI- CONTROL JUSTIFICATION FOR DECISION /
POTENTIAL HAZARDS PREVENTIVE MEASURES
SOURCES LEVEL Q1 Q2 Q3 Q4 SION MEASURE REMARKS
MICROBIOLOGICAL UN MIX ONLY READY TO EAT ITEMS. Y N Y N CCP HACCP PLAN USE OF COOKED/PROCESSED NON
PATHOGENIC MICRO COOKED/PROCESSED ( COOKED OR READY – TO- EAT FOODS) VEGETABLE FOOD ITEMS
ORGANISMS NON VEGETABLES
FOOD ITEMS ( MEATS ,
CHICKEN & FISH)

CROSS 06 CLEANING THE AREA BEFORE SALAD Y N Y Y EFFECTIVE PERSONNEL HYGIENE, GOOD
CONTAMINATION PREPARATION. CP OPRP MANUFACTURING AND GOOD CATERING
PRACTICES CONTROL THE ENTRANCE OF
USE CLEAN & STERILIZED UTENSILS. PATHOGENIC MICROBES, CHEMICAL AND
PHYSICALS.
MAINTAIN THE REQUIRED FOR NON-VEGETABLE SALADS, USE COOKED
TEMPERATURE FOR THE INGREDIENTS FRIED NON-VEGETABLES ITEMS.
AS PER THE SPECIFICATIONS(IN THE CONTROLLING THE USE AND STORE OF
LABEL) CHEMICALS.
USAGE OF CLEAN – STERILIZE TRAYS AND
UTENSILS CONTROL THE MICROBES.
PERSONNEL HYGIENE (GHP & GCP).

CHEMICAL CLEANING CHEMICALS DON’T STORE CLEANING CHEMICALS Y N Y Y

SANITIZER RESIDUES, 06 IN THE VICINITY FOOD . CP OPRP
CLEANING AND OTHER
CHEMICALS PROPER LABELING OF CLEANING
CHEMICALS.
PHYSICAL FROM THE 06 CLEAN THE AREA BEFORE CUTTING Y N Y Y
PRESENCE OF FOREIGN ENVIRONMENT AND VEGETABLES. CP OPRP
BODIES UTENSILS
USE CLEAN & STERILIZED TRAYS.
PERSONNEL HYGIENE ( GHP &
GCP).
 THANK YOU!
QUALITY IS EVERYONE’S RESPONSIBILITY!