Lecture 4: H.A.A.C.P. plan

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A. Food Safety and H.A.C.C.P.6. Introduction to
H.A.C.C.P.
4. H.A.C.C.P. Plan
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HACCP plan

• List of the HACCP team and assigned
  responsibilities
• Description of finished product, including its
  distribution, intended use and target consumer
• List of product ingredients and incoming
  materials
• Plant schematic
• Verified flow diagram
• List of hazards identified
• Critical control point determination - decision
  tree
• HACCP Plan Summary Table that includes
  information for
• Steps in the process that are critical control
  points
• The hazard(s) of concern
• Critical limits
• Monitoring
• Corrective actions
• Verification procedures and schedule
• Record keeping procedures

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Developing a HACCP plan

• 1. Establish a HACCP team
• it is important that the HACCP team is made up
  of people from a wide range of disciplines. The
  team should include
• composition of the HACCP team
• tasks of responsibility
• training of members of the HACCP team
• support from the company management
• 2 - Describe the product
• To start a hazard analysis, a full description of
  the product, including customer specification, is
  needed
• This should include
• information relevant to safety, e.g. mycotoxin
  regulation/target level, composition,
  physical/chemical properties of the raw materials
  and the final product, the amount of water
  available for microbiological growth (aw), the
  amount of acid or alkali in the product (pH).
• information regarding how the product is to be
  packaged, stored and transported (labelling
  information and an example of the label should be
  included)

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Developing a HACCP plan I

• 3 - Identify the product's intended use
• How the product is intended to be used
• Information on whether the product will be
  consumed directly, or be cooked, or be further
  processed, will all have a bearing on the hazard
  analysis
• 4 - Draw up the commodity flow diagram
• The first function of the team is to draw up a
  detailed commodity flow diagram (CFD) of the
  commodity system, or that part of it which is
  relevant
• The expertise of the commodity specialist is
  important at this stage

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Developing a HACCP plan II

• 5 - On site confirmation of flow diagram
• Information such as time of harvest, drying
  procedures, storage conditions, the marketing
  chain, are necessary
• The site for which the HACCP plan is being
  designed should be visited as many times as
  possible to ensure that all relevant information
  has been collected
• 6 - Identify and analyse hazard(s) - (Principle
  1)
• Effective hazard identification and hazard
  analysis are the keys to a successful HACCP Plan
• All real or potential hazards that may occur in
  each ingredient and at each stage of the
  commodity system should be considered.

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Developing a HACCP plan III

• 7 - Determine the critical control points (ccps)
  - (Principle 2)
• Each step in the commodity flow diagram, within
  the scope of the HACCP study, should be taken in
  turn and the relevance of each identified hazard
  should be considered
• The team must determine whether the hazard can
  occur at this step, and if so whether control
  measures exist
• If the hazard can be controlled adequately, and
  is not best controlled at another step, and is
  essential for food safety, then this step is a
  CCP for the specified hazard

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Developing a HACCP plan IV

• 8 - Establish critical limits for each ccp -
  (Principle 3)
• Critical limits must be specified and validated
  for each CCP
• We must include measurements of temperature,
  time, moisture level, pH, water activity, and
  sensory parameters such as visual appearance
• All critical limits, and the associated
  permissible tolerances, must be documented in the
  HACCP Plan Worksheet, and included as
  specifications in operating procedures and work
  instructions

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Developing a HACCP plan V

• 9 - Establish a monitoring procedure - (Principle
  4)
• It can be carried out by observation or by
  measurement, on samples taken in accordance with
  a statistically based sampling plan.
• monitoring by visual observation is basic but
  gives rapid results, and can therefore be acted
  upon quickly
• the most common measurements taken are time,
  temperature and moisture content

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Developing a HACCP plan VI

• 10 - Establish corrective action - (Principle 5)
• The corrective action must also be based on the
  assessment of hazards, risk and severity, and on
  the final use of the product
• Operatives responsible for monitoring CCPs
  should be familiar with and have received
  comprehensive training in how to effect a
  corrective action.

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Developing a HACCP plan VII

• 11 - Verify the HACCP plan - (Principle 6)
• the HACCP plan must be verified and reviewed at
  regular intervals
• This includes
• collecting samples for analysis by a method
  different from the monitoring procedure
• asking questions of staff, especially CCP
  monitors
• observing operations at CCPs
• formal audit by independent person

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Developing a HACCP plan VIII

• 12 - Keep records - (Principle 7)
• It demonstrates that the correct procedures have
  been followed from beginning to end of the
  process, offering product traceability.
• It provides a record of compliance with the
  critical limits set, and can be used to identify
  problem areas

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Summary of 4thLecture

• The H.A.C.C.P. Plan
• Developing a H.A.C.C.P. Plan