HACCP

1
HACCP

• A Scientific Approach to Food Safety
• Presented by
• Mike Myatt
• Stacey Olsen
• Kris Nilsson
• Dave Loogman

2
HACCP-A Brief History

• Hazard
• Analysis and
• Critical
• Control
• Points Commonly referred to
  as Hassip

3

• HACCP is a comprehensive system for prevention of
  food safety hazards
• HACCP is a systematic approach to hazard
  assessment
• HACCP is applicable to any food processing
  facility
• HACCP is a total food safety program, not just a
  plan

4
Original HACCP Principles

• Identification and assessment of hazards
  associated with growing/harvesting to
  marketing/preparation
• Determination of the Critical Control Points to
  control any identifiable hazard
• Establishment of systems to monitor Critical
  Control Points

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HACCP Principles Today

• Conduct hazard analysis and identify preventive
  measures
• Identify Critical Control Points
• Establish Critical Limits
• Monitor each CCP
• Establish corrective actions to be taken when a
  critical limit deviation occurs
• Establish verification procedures
• Establish a record keeping system

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PREREQUISITE PROGRAMS

• Strong prerequisite programs must be developed
  and implemented before HACCP can be effective.

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Examples of Prerequisite Programs

• Sanitation
• Good Manufacturing Practices
• Employee Training Programs
• Plant and Equipment Design
• Traffic Patterns
• Material and Ingredient Receiving
• Product Specifications
• Environment Monitoring Program

• Customer Complaint Program
• Maintenance
• Good Laboratory Practices
• Process Control
• Vendor Certification
• Lotting/Coding/Product Traceback System
• Allergen Control Program

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Common Problem

• Mindset that prerequisite programs are not
  important.

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Example of a recall associated with a
prerequisite program

• Salemville Amish Cheese Recalled
• For Immediate Release
• Indianapolis, IN March 23,2000 routine
  surveillance by the Indiana State Board of Animal
  Healths Dairy Division revealed high levels of
  E.coli in some Wisconsin made cheeses. Consumers
  should not consume two products manufactured by
  Salemville Amish Cheese of Kingston, WI.

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General Requirements

• Written Procedures
• Standard Operating Procedures (SOPs)
• Work Instructions
• Informal, Verbal, Passed down
• Actual Measurements or Observations
• Corrective actions
• Documentation
• Training
• Verification

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Programs that are the Foundation for HACCP

• Sanitation
• GMPs
• Allergens
• Training
• Maintenance
• Traceability

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Important!

• HACCP is most effective when it is very narrow
  and focused strictly on the most serious threats
  to food safety. This can only be achieved when
  all the prerequisite programs are in good shape.

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Common Critical Control Points Included in
Prerequisite Programs
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Problems That Can Affect Product Safety
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HAZARD ANALYSIS AND REASSESSMENT

• The purpose of hazard analysis is to develop a
  list of hazards, which are of such significance
  that they are reasonably likely to cause injury
  or illness if not effectively controlled
• Hazard analysis is also necessary for determining
  Critical Control Points

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Important!

• If the hazard analysis is not conducted correctly
  and the hazards warranting control within the
  HACCP system are not identified, the plan may not
  be effective in protecting consumers regardless
  of how well it is followed

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Hazard Analysis Steps

• Step 1 Description of product and method of
  distribution
• Step 2 Identify intended use and consumers
• Step 3 Develop and verify process flow diagram
• Step 4 Identify any potential hazards
  (microbiological, physical, or chemical)

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Hazard Identification

• Conduct a literature search, including past
  outbreaks in similar or related products
• Review all product recalls
• Use expert consultation or international sources
  of data
• Review internal data
• Review activities at each step of the process
• Consider the equipment used to manufacture the
  product

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Hazard Evaluation

• Based on two factors severity and likelihood of
  occurrence
• Consider susceptibility of intended consumer,
  impact of secondary problems, and magnitude or
  duration of illness

20
Hazard Reassessment

• Should be done at least annually
• Changes to a product or process
• Whenever there is new evidence that suggests a
  hazard is reasonably likely to occur, such as
• Knowledge of incoming pathogen levels
• Validation of lethality treatments
• Post-process environmental contamination
• Evidence of finished product contamination

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How to Reassess Hazards

• Industry knowledge and internal data
• Epidemiology, outbreak, and recall data
• Customer complaint records
• Computer modeling data
• Risk Assessment

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Risk Assessment

• Has four components
• 1. Hazard Identification
• 2. Dose/Response Assessment
• 3. Exposure Assessment
• 4. Risk Characterization
• Based on severity and risk
• How serious is the hazard?
• How likely, or with what frequently will this
  hazard occur?

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Managing CCPs

• Critical Control Point Defined
• A point, step, or procedure at which control can
  be applied and a food-safety hazard can be
  prevented eliminated, or reduced to acceptable
  levels.

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Selecting CCPs

• What is an acceptable level?
• What hazards are likely to occur?
• If critical limit is exceeded, will the product
  be unsafe?
• Can the step be controlled be another facility?

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CCP Modification

• Use the minimum number of CCPs possible
• Modify the CCP as necessary
• Only alter CCPs based on scientific data or
  regulatory, never for cost reduction

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CCP Validation

• Tests are conducted to validate that the CCP
  measures taken are effective
• Microbial-Establishing time/temperature
  parameters provide desired microbial reductions
• Chemical/Physical-validation involves testing the
  measuring equipment for accuracy, sensitivity

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HACCP Validation vs. Verification

• Validation asks if the all of the hazards have
  been identified in the plan, and if the plan has
  been designed to properly reduce these hazards
• Verification asks if the HACCP plan is being
  followed as it is written

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HACCP Records

• Federal required documents include
• Hazard analysis of likely problems
• Written HACCP plan including decision making
  documentation (How the CCPs were chosen,
  verification procedures)
• Records of the maintenance and monitoring of the
  CCPs
• Record Retention
• 1 year refrigerated products
• 2 years frozen, preserved products

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Recalls

• HACCP allows the company to narrow the scope of
  product recalls
• CCPs must be separate for each product or process
  the company makes
• HACCP records can protect the company from
  litigation