HACCP-Hazard Analysis & Critical Control Point System.

An Approach to Food Safety

-Gargi Ramtirtha

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Contents:

• HACCP- Definition , History

• Pre-requisite programs.

• Guidelines for application of HACCP System.

• Preliminary steps

• The “7 HACCP Principles”

• A sample HACCP Plan for Manufacture of chicken patties

• Summary

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• HACCP System is a scientifically based systematic approach to

identification, evaluation & control of food safety hazards.

• “Farm to Fork-concept”.

• Design to minimize risk of Food Safety & not a Zero Risk System.

• History of HACCP: The HACCP concept developed by Pillsbury for NASA in the 1960s 1973 1st regulatory use by FDA 1993 HACCP applied to all food service & food retail systems through the food code by the USDA/FDA.

HACCP-Introduction

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HACCP System-Pre-Requisite programs

Procedures, including Good Manufacturing Practices, that address operational conditions providing the foundation for the HACCP.

• Premise control

• Receiving & storage control

• Equipment performance & maintenance control.

• Personnel Training

• Sanitation

• Healthy & safety recall procedures

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HACCP Pre-requisites:

• Premises:

i. Outside property

ii. Building

iii. Proper ventilation

iv. Drainage & sewage

v. Washroom-lunchroom location.

• Receiving & storage control:

i. Package material/raw material handling & storage.

ii. Carriers hygiene.

iii. FIFO rotation of items.

iv. Label & date every item stored

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HACCP Pre-requisites:

• Equipment performance & maintenance control.

i. Equipment, utensils MOC.

ii. Adequate space between equipments, allowances for working space.

iii. Written calibration & maintenance program

iv. Construction & installation of equipments as per sanitary principles.

v. Instruments and controls used for regulating or recording be adequately maintained

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HACCP Pre-requisites:

• Sanitation

i. Sanitation facilities like washrooms and sink area be provided.

ii. House-keeping schedules followed

iii. Sanitation of equipments-CIP & COP.

iv. C & S agents used as per manuf. instructions, chemical safety data sheet.

v. Effectiveness of sanitation gauged by micro-testing.

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HACCP Pre-requisites:• Personnel Training.

i. All employees should receive documented training in personal hygiene ,GMP , cleaning & sanitation procedures, personal safety & their role in HACCP.

ii. Everyone at the facility in contact with the products should receive training regarding company’s HACCP policies and procedures.

• Health & safety recall

i. Written recall program.

ii. Proper product identification with proper Date code & Batch No. For traceability.

iii. The health & safety complaint file should be maintained ,as well as resolving of the concern.

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Guidelines of application of HACCP System

Assemble the HACCP Team

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Describe the Food and its Distribution

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Describe the Intended Use and Consumers of the Food

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Develop a Flow Diagram Which Describes the Process

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On site Verification of the Flow Diagram

Application of 7 HACCP Principles

 

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The “7 HACCP Principles”

1. Conduct hazard analysis.

2. Identify Critical Control Points (CCP’s) in the process.

3. Establish critical limits.

4. Monitor each CCP.

5. Establish Corrective Actions.

6. Establish verification procedures.

7. Establish record-keeping and documentation procedures.

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The “7 HACCP Principles”

1.Hazard Analysis

• The process of collecting and evaluating information on hazards associated with the food under consideration .

• Provides a Basis for determining CCPs , to be done at every step of process.

• For hazard analysis consider Raw Material & ingredients, processing procedures, Packaging material, storage, Facility & Equipment Design, Plant Sanitation & Personal Hygiene.

Step Potential Hazard(s) Justification Hazard to be addressed in

plan?Y/N

ControlMeasure

5. Cooking Enteric pathogens:e.g., Salmonella,E. coli

enteric pathogens have been associated with outbreaks of

foodborne illness from undercooked ground chicken

Y AdequateCooking

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The “7 HACCP Principles”

2.Identify Critical Control Points (CCP’s) in the process.

A point, step or procedure at which control is applied to prevent or eliminate a hazard or reduce it to an acceptable level.

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The “7 HACCP Principles”

3.Establish critical limits.

• A max or min value to which PCB parameter must be controlled at CCP to prevent, eliminate or reduce to an acceptable level of Food Safety Hazard.

• Operating limit is more stringent than critical limit & that are used to reduce the risk of a deviation

• Critical limits for chicken patties processing:

Process Step CCP Critical Limits

5. Cooking YES 1.Oven temperature:74° C2.Time:16 Seconds3.Patty thickness: ½ in.4.Oven humidity: 40-95%

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The “7 HACCP Principles”

4.Monitoring each CCP:

• Monitoring is a planned sequence of observations or measurements to establish whether a CCP is under control & maintain an accurate record.

• Monitoring can be continuous or intermittent, as per planned frequency

– Examples of monitoring activities include: visual observations and measurement of temperature, time, pH, and moisture level.

• Table for monitoring Time-Temperature Profile during chicken patties production:

Product 0 hours 2 hours 4 hours 6 hours Production officer initial

Comments

Time Temp. Time Temp.

Time Temp.

Time Temp.

Chicken patties

1

2

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The “7 HACCP Principles”5.Establish Corrective Actions.• Includes isolating & holding the

product for safety evaluation

• Reprocessing or destroying the product.

• Specific corrective actions must be developed in advance for each CCP & included in the HACCP Plan.

6.Establish verification procedures.

• Those activities, determine the validity of the HACCP plan & verify that the system is operating according to the plan.

• Verification Activities:

– Initial Validation of HACCP Plan

– Verification of CCP Monitoring as Described in the Plan (e.g., monitoring of patty cooking temperature)

– Review of Monitoring, Corrective Action Records

– Comprehensive HACCP System Verification

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The “7 HACCP Principles”7.Record keeping & documentation procedures:

Generally, the records maintained for the HACCP System should include:

– A summary of the hazard analysis

– The HACCP Plan

– Listing of the HACCP team and assigned responsibilities.

– Verified flow diagram.

HACCP Plan Summary Table that includes information for:

– Steps in the process that are CCPs

– Critical limits

– Monitoring*

– Corrective actions*

– Verification procedures and schedule*

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Advantages of HACCP:

1. Helps food companies compete more effectively in the world market &

reduces barriers to international trade.

2. Permits government oversight, as record keeping allows investigators to

see how well a firm is complying with food safety laws over a period

3. Places responsibility for ensuring food safety on the food manufacturer or

distributor.

Summary:

Points covered

Summary:

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THANK YOU!!ation