WHAT IS HACCP

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WHAT IS HACCP

• HAZARD
• ANALYSIS
• CRITICAL
• CONTROL
• POINT

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WHY DO WE NEED HACCP?

• 1948 Salmonella in hospital food 350 cases with
  19 deaths.
• 1985 Salmonella in baby milk formula 76 cases
  with 1 death.
• 1996 E Coli 0157 in beef 400 cases with 18
  deaths
• We need it to protect the consumer.
• We need it to protect the business.
• We need it to satisfy customers.
• We need it to comply with the law.
• We need it to show Due Diligence

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A way of making sure that-

• Food Safety hazards are known.
• The places where they occur are identified.
• Methods to control the hazards are in place.
• Action is taken if control is lost.
• Records are kept which prove the company makes
  safe products.

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WHAT IS HAZARD ANALYSIS?

• A systematic approach to food hazard
  identification and the implementation of controls
  necessary to achieve safe food production

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HAZARD ANALYSIS

• Is a legal requirement of the Food Safety
  Regulations 1995
• Requires a food business to
• Identify any step in the activities of the
  business critical to ensuring food safety
• Ensure that adequate safety procedures are
  identified, implemented, maintained reviewed

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SAFETY PROCEDURES MUST BE BASED ON-

• Analysing the potential food hazards
• Identifying where the hazards may occur
• Deciding which points in the process are critical
  to food safety
• Identifying and implementing control and
  monitoring procedures
• Periodically reviewing the system

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HAZARD ANALYSIS

• No single recommended method or system
• It is the responsibility of the food business to
  decide what is enough to be effective
• Level of detail depends on size and extent of the
  business and the type of hazards involved.

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BENEFITS OF HACCP

• HACCP is a systematic approach covering all
  aspects of food safety from raw materials to
  final product.
• Provides a cost-effective control of food-bourne
  hazards
• A correctly applied HACCP should identify all
  hazards including those which can realistically
  be predicted to occur
• The use of HACCP leads to reduced product losses
• Implementation of HACCP will be useful in
  supporting a defence of Due Diligence
• HACCP complies with legal requirements.

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TYPICAL HAZARDS INCLUDE

• Pathogenic bacteria/toxins
• Insecticides, pesticides fungicides
• Cleaning products process chemicals
• Metal nails, nuts, bolts, staples etc.
• Plastic, glass, cardboard
• Building materials
• Personal items hair, jewellery, buttons etc

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7 PRINCIPLES OF HACCP

• PRINCIPLE 1 - Identify Hazards
• PRINCIPLE 2 - Determine CCPs
• PRINCIPLE 3 - Establish Critical Limits ( below
  5C)
• PRINCIPLE 4 - Establish a system to monitor
  CCPs
• PRINCIPLE 5 - Establish corrective action to be
  taken when control is lost
• PRINCIPLE 6 - Establish a system for verifying
  that the HACCP system is working effectively
• PRINCIPLE 7 - Document the HACCP system and keep
  records of its operation

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DETERMINE CCPs

• A critical control point means that at this step
  the control point is critical in ensuring food
  safety.
• It is at that point where loss of control would
  result in an unacceptable risk of harm or injury
  to the customer.
• CCPs should eliminate all hazards or reduce them
  to an acceptable level.
• A CCP is the point of no return.
• Use the decision tree to determine whether a
  point is critical in ensuring safe food product.

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CCP Decision Tree

• Answer each question in sequence at each step for
  each identified hazard.

Modify step, process or product
Are control measures in place for the hazard?
Yes
Is control at this step necessary For safety?
No
YES
STOP
Not a CCP
Does the step eliminate or reduce the hazard to
an Acceptable level?
YES
NO
Could contamination occur at unacceptable levels
or increase To unacceptable levels?
STOP
Not a CCP
Yes
No
Will a subsequent step eliminate or reduce the
hazard to an Acceptable level?
CCP
NO
Not CCP
STOP
Yes
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WHAT IS A CRITICAL LIMIT

• The critical limit is the criteria which
  separates acceptability from unacceptability.
• OR
• A point beyond which the product is out of
  control, therefore the product may need to be
  rejected.
• E.G pasturisation, time/temperature, moisture
  PH.

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ESTABLISH CRITICAL LIMITS

• Once you have identified the CCPs, you then need
  to identify a critical limit for the control
  measure at each point.
• E.g Temperatures
• Cooling Times
• Ph levels
• When product outside the critical limit it must
  be rejected.

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ESTABLISH A SYSTEM TO MONITOR CONTROL OF THE CCPs

• Why Monitor?
• To confirm that a CCP is under control.
• To give early warning of a deviation or loss of
  control.
• To initiate corrective action.
• To provide records for verification and due
  diligence purposes.

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EFFECTIVE MONITORING SYSTEMS

• An effective monitoring system needs to cover
• What Is the critical limit/tolerance
• How What equipment is needed from process
  through to calibration.
• Where Monitoring must be carried out at the
  CCP.
• Who Decide which person is responsible for
  monitoring.
• When Is the monitoring continuous or at set
  intervals?

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MONITORING OF CONTROL POINTS

• Should be continuous
• Should keep detailed records
• Should include calibration of equipment,
  recording the findings
• Direct measuring weighing

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WHAT IS CORRECTIVE ACTION?

• Corrective action is the action taken to correct
  a process before it gets out of control.
• Corrective action must be taken when critical
  limits are exceeded.

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ESTABLISH CORRECTIVE ACTIONS

• A corrective action is a planned procedure
  designed to bring a process back under control.
• Well designed actions include
• Who is responsible to ensure action is followed.
• Whether or not product should be rejected.
• Details of how to correct the problem.
• Instructions for the disposal of the product.

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ESTABLISH PROCEDURES FOR VERIFICATION

• The need to put into place procedures that
  demonstrate compliance with the HACCP plan.
• Examples of verification procedures include
• Internal/external review of HACCP and associated
  records
• Audits of records and associated procedures to
  observe if CCPs are under control
• A review of deviations (failure to meet critical
  limits)

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ESTABLISH DOCUMENTATION AND RECORD KEEPING

• Efficient and accurate record keeping is
  essential
• To demonstrate all the principles of HACCP have
  been correctly applied documentation must be
  kept.

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EXAMPLES OF RECORDS SHOULD INCLUDE

• A documented HACCP system
• Procedures and work instructions
• Nature, source quality of raw materials
• Processing records time, temperatures
• Cleaning/disinfection records
• Corrective action records
• Verification records ( check the system is
  working through daily audits)
• Review records - Systems Auditor

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STAGE 1 DEFINE THE TERMS OF REFERENCE

• A HACCP study should be carried out on specific
  products and processes.
• Define whether the HACCP should consider
  biological, chemical or physical hazards or all
  of them.
• The terms of reference must clearly state storage
  and use instructions.
• Group together similar meals for HACCP plan.

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STAGE 2 SELECT THE HACCP TEAM

• Select all the necessary expertise to ensure that
  all possible hazards and
• Controls are identified.
• Food Product Development Specialist
• Microbiologist
• Quality Assurance/Quality Control Specialist
• Production Specialist
• Engineer
• Other Specialists Food technologist, hygiene
  experts
• The teams should be flexible, available for
  consultation as required
• Someone trained in HACCP technique to facilitate

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STAGE 3 DESCRIBE THE PRODUCT, PROCESS AND
INTENDED USE.

• Raw Materials Van clean, temperature of
  product. Condition of product.
• Process/Equipment
• Packaging
• Storage and Distribution Conditions
• Required Shelf Life
• Instructions for Use

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STAGE 4 CONSTRUCT A FLOW DIAGRAM

• Flow Diagram should include-
• Raw materials, processing, distribution
• Processing steps conditions e.g times and
  temperature
• Re-work loops
• Packaging/storage
• Cleaning Hygiene activities

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STAGE 5 ON SITE VERIFICATION OF FLOW DIAGRAM

• Verify each step is an accurate representation of
  the operation
• Include night and weekend running
• If a proposed operation, identify most likely
  options and verify later
• Amend flow diagram to reflect deviations
• THIS WALKING THE LINE STAGE IS VITAL THIS
  WILL ENSURE NOTHING IS MISSED OUT!

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STAGE 6 LIST ALL HAZARDS AND CONTROL MEASURES

• List all hazards which may be reasonably expected
  to occur at each process step, together with
  measures that can be used to control them.
• Control measures are those actions/activities
  that can eliminate hazards, or reduce them to
  acceptable levels.
• HAZARDS MAY BE
• Microbiological Contamination, Multiplication,
  Survival
• Physical
• Chemical

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IDENTIFY SIGNIFICANT HAZARDS

• Based on
• Severity of outcome
• Likelihood of occurrence
• Vulnerable groups of customers (Elderly, ill,
  children, pregnant ladies)

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CONTROLLING HAZARDS

• Generic controls include
• Supplier assessments
• Pest Control
• Personal Hygiene Standards
• Cleaning/disinfection schedules
• Training programmes
• Customer complaints procedures
• Glass Policy