Hazard Analysis and Critical Control Points (HACCP)

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Hazard Analysis and Critical Control Points
(HACCP)

• STENUM GmbH
• www.stenum.at

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What is HACCP?

• Problems
• Foodborne diseases
• Market access importance of food safety all
  along the food-chain
• Solutions
• Food safety system that focuses on preventing
  problems before they occur
• Industry-led programme used to improve and verify
  food safety
• Answer
• Hazard Danger to health
• Analysis Investigation of the hazard
• Critical Crucial for containment
• Control Handling of conditions
• Points Position in the process

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What is HACCP?

• Hazard Analysis and Critical Points

Science-based, internationally accepted food
safety system
Focused on hazard identification and prevention
Can be applied to all segments of the food chain
Addresses chemical and physical hazards
Source Department of Food Science and
Technology, Virginia Tech.
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Why adopt HACCP?

• A properly functioning HACCP system will result
  in the production of safer food.
• Benefits
• Improved food safety
• Increased market access
• Protection against liability
• Drive for continuous improvement
• Enhanced process control

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Where can HACCP be used?

• HACCP can be used in any food sector from
  production to retail

HACCP
Production
Retail and food service
Processing
Transport
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The seven principles of HACCP
I
II
III
Establish critical limits for each critical
control point
Conduct a hazard analysis
Identify critical points
Establish critical control point monitoring
requirements
IV
Establish procedures for verifying that the HACCP
system is working as intended
Establish corrective actions
Establish record keeping procedures
V
VI
VII
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ISO 22000

• Requirements for a food safety management system
• 4 elements
• Interactive communication
• System management
• Prerequisite programmes
• HACCP principles

Source Van Voorst Consult
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Implementing HACCP

• Preliminary Steps for the introduction of a HACCP
  System
• Gathering the resources and information needed
• Seven principles of HACCP in action
• Completion of all steps will result in a properly
  functioning HACCP plan

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Preliminary steps

• Assemble the HACCP team
• Group of people that will oversee the
  implementation and maintenance of the HACCP
  programme
• Multi-disciplinary (i.e. production, sanitation,
  management, etc.)
• Including a HACCP-trained person

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Preliminary steps

• 2. Description of products and identification of
  intended use and consumers
• Full description of the product(s) being
  manufactured under the programme
• Product information assists with hazard analysis
• Which group(s) will be consuming the food product
• Where will the product be sold
• How will it be prepared

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Preliminary steps

• 3. Development and verification of process flow
  diagram(s)
• The flow diagram should
• Outline all processing steps
• Include all processing steps
• The plant schematic should
• Outline where all of the processing steps occur
• Display the movement of products, people and
  waste

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Preliminary steps

• 4. Grouping of products
• Decide whether products can be grouped using
  process categories
• Slaughter all species
• Raw product ground/not ground
• Thermally processed commercially sterile
• Heat/not heat treated shelf stable
• Fully cooked not shelf stable
• Heat treated but not fully cooked not shelf
  stable
• Product with secondary inhibitors
• Further categories for grouping can be commodity
  group, hazards, etc.
• Products in the same process category may be
  covered by the same HACCP plan

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Principle I

• Conduct a hazard analysis
• Evaluate information regarding potential hazards
  associated with the manufacturing process and
  ingredients
• Determine which hazards are significant to food
  safety
• Consider
• Probability of occurrence
• Severity of consequences

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What are hazards?

• There are 3 types of hazards
• Biological
• Chemical
• Physical
• Do not forget cross-contamination
• Microbiological, allergens

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Biological hazards

• Biological hazards can cause illness and include
• Bacteria E.coli, Salmonella, Listeria,
  Campylobacter, Shigella
• Viruses cold viruses, Hepatitis A, Norwalk virus
• Parasites Giardia, Cryptosporidium, Trichinella,
  tapeworms
• Yeasts and moulds
• Any toxin produced by microbiological organisms
  is also a biological hazard

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Chemical hazards

• Chemical hazards can cause injury or poisoning
  and include
• Naturally occurring substances (e.g. allergens,
  plant specific toxins)
• Excessive, intentionally added chemicals
  antibiotics, pesticides, herbicides, fungicides,
  nitrates
• Accidentally added chemicals cleaning chemicals,
  paint, pest control chemicals

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Physical hazards

• Physical hazards are foreign objects that can
  cause injury
• Glass
• Metal grindings, screws, nuts, bolts
• Stones, pebbles
• Needles
• Hard plastic
• Bones

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Principle II

• Identify Critical Control Points (CCPs)
• A CCP is a point, step or procedure at which a
  control measure has to be applied to prevent,
  eliminate or reduce a food safety hazard
• CCPs are not
• Necessarily located where the hazard occurs, they
  may be located at a subsequent step
• Some hazards cannot be controlled by the operator

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Principle III

• Establish Critical Limits (CL)
• What is a critical limit?
• The maximum and/or minimum value to which a
  parameter must be controlled at a CCP
• The critical limit separates acceptability from
  unacceptability
• The critical limit must be clearly defined and
  measurable

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Principle IV

• Establish monitoring procedures
• Monitoring
• Is the process of conducting a planned sequence
  of measurements to determine if a CCP is under
  control
• Monitoring results must be recorded
• If monitoring shows that
• critical limits are not met,
• then the process is out of
• control and the food may
• be unsafe.

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Principle V

• Establish corrective actions
• Corrective actions are pre-determined measures
  that have to be implemented when monitoring
  indicates that a deviation has occurred.
• Corrective actions must
• Regain control of the process
• Locate and segregate affected product
• Determine disposal of affected product
• Prevent a recurrence

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Principle VI

• Establish verification procedures
• Validation
• Ensures that the HACCP plan is complete and valid
• Ensures that the plan is effective in achieving
  expected food safety outcomes
• Ongoing verification
• Ensures that the HACCP plan is working
  effectively
• Confirms that the plan is operating according to
  written procedures
• Auditing
• Overall review of the HACCP plan
• To be performed whenever any changes occur that
  could affect the hazard analysis or alter the
  HACCP plan

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Principle VII

• Establish record keeping procedures
• Record keeping must be complete and accurate and
  includes
• Documentation pertaining to all steps, including
  the HACCP principles
• Appropriate record storage procedures
• A log book to keep track of changes

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HACCP system Summary

• HACCP systems consist of two elements
• Prerequisite programmes
• Implemented prior to HACCP plans
• Control of the overall plant environment
• Control factors not directly related to food
  (e.g. water quality, transportation and storage,
  plant sanitation, employee training)
• HACCP plans
• Implemented following pre-requisite programmes
• Tailored to a certain product or process
• Control factors directly related to food
  production