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HACCP
Implementation inFood Industries
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CONTENTS
Part I HACCP Introduction, History
HACCP Key Concepts
Why HACCP
Part II HACCP Pre-Requisites Program
Part III How to HACCP
Part IV
HACCP & Quality System (ISO)Part V HACCP Practicing Bottlenecks
Part VI
HACCP Future
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Part IModule 1Introduction to HACCP
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H
CP
AC
HAZARDS
POINTSCONTROL
CRITICALANALYSIS
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HACCP
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HACCP
A preventive approach tofood safety management
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The most
effective tool to
prevent occurrence
of food bornediseases and avoid
consumer illness
and injuries linked
to the
consumption of
our products
H
AC
CP
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H
AC
CP
Systematicapproach to theidentification and
assessment of thehazards and risksassociated with afood operation and
the defining of themeans of theircontrol
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Part IModule 2
WHY HACCP
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WHY HACCP ?
To have safe, reliable
and consistent qualityproduct
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WHY HACCP ?
Management of product safety
Prevention of product safety incidents
Limitations of traditional quality control External pressure
Other benefits
Foundation for the development of effectiveproduct management systems
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WHY HACCP ?Successful implementation of HACCP bringsalong;
Primary benefits Product Safety
Secondary benefits: Quality improvement
Cost effectiveness
Loss and down time reduction
Increase consumer confidence in product safety
Design of line/product Hygiene, housekeeping & improve manufacturing
conditions
Reduce maintenance
Reduce inspection time
Competitive advantage
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EXTERNAL PRESSURE FOR HACCP
Government/Enforcementauthorities
Customers Demand
Media Pressure
Customer Protection Societies
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Part IModule 3W here it has com e from&W here does it work
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WHERE DID HACCP COME FROM
Concept Originated during
NASA SPACE PROGRAMIn 1960
Used Ist time in 1971 BY Pillsbury Company
Basic Idea behind;To provide risk free safe food for astronauts.
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HOW TO ASSURE FOOD SAFETY ?
Traditional Quality Control- Inspection
- Random sampling and testing Prevention base food safety
assurance program
- HACCP
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HISTORY OF HACCP1960 - Concept originated - U.S space program (NASA)1971 - Used in by Pillsbury company in space program1971 - Concept took proper form in National Conference
on Food Protection.1985 - Recommended by National Academy of Science
(NAS) USA1989 - Final approval by National Advisory Committee on
Microbiological Criteria for Foods (NACMCF)1991 - Accepted by Codex Committee.1995/6 - HACCP was first time used in US Regulations
1997 - UN/Codex Alimentarious HACCP System wasdeveloped and adopted by US regulatoryauthorities.
2000 - Embraced by USA, UK, European Union, Japan,Canada, Australia and New Zealand till now.
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HACCP SCOPEHACCP is for every one !!
From;
Farm to Fork Stable to Table
and Gate to Plate.
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HACCP SCOPECommercially -This system is mainly applicable to;
All food processing facilities/factories:
Sea Food/Meat ConfectioneryJuice & Beverage CerealDairy Industries Rice IndustryCulinary/ Spices industry Food raw materialsHotels & Restaurants Hospitals
Air line kitchens Pharmaceuticals
&AllSpecialized areas/operations where
effect of food may become critical.
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Part IModule 3HACCP Key Concepts&Basic philosophy
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HACCP KEY CONCEPTS
FOOD QUALITY
&FOOD SAFETY
MODERN CONCEPT OF FOOD QUALITY
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CLASSIFICATION OF FOOD
HACCP KEY CONCEPTS -Food Spoilage
According to Perisability;
1.Non perishable e.g. Flour2.Semi Perisability e.g Apple
3.Perishable e.g. Raw meat
Key Perisability factors
Water Activity (aw)storage
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CLASSIFICATION OF FOOD
HACCP KEY CONCEPTS-Food Spoilage
According to Acidity;
Low Acid Food Medium Acid Food
Acid food High Acid food
1. Acidity or pH plays important role inProduct shelf life..
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Products with pH value of 4.6 or above thatthe sterilized in hermetically sealed containers,or sterilized and aseptically filled into sterilehermetically sealed containers for ambient
distribution.
Products containing fish, egg, vegetable, cerealand/dairy ingredients (any substitute of these)which need to be refrigerated. i.e. Raw meat,
fish and dairy products.
Infant Formula
HACCP KEY CONCEPTS
CATEGORY 1 - PRODUCTS (HIGH RISK)
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Dried or frozen products containing fish, meat, egg,vegetable or cereal and/or dairy ingredients or anysubstitute for these or other products excluded inthe food hygiene regulations.
Sandwiches and meat pies for fresh consumption.
Fat-based products e.g. chocolate, margarine,spreads, mayonnaise and dressings.
HACCP KEY CONCEPTS
CATEGORY 2 PRODUCTS (MEDIUM RISK)
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Acid product (pH value below 4.6) such aspickles, fruits, fruit concentrates, fruit juicesand acid beverages.
Unprocessed and unpacked raw vegetables.
Jams, marmalades and conserves.
Sugar-based confectionery products.
Edible oils and fats
HACCP KEY CONCEPTS
CATEGORY 3 PRODUCTS (LOW RISK)
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HACCP KEY CONCEPTS
A subject dealing with the study ofmicrobial life
Microbial Growth Factors
NutrientsTemperatureMoisture
OxygenpHPresence of inhibitory substances
FOOD MICROBIOLOGY
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HACCP KEY CONCEPTS
Presence of any any objectionablething in food
Nature of contaminants could be;
PhysicalChemical
Microbiological
FOOD CONTAMINATION
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FOOD SPOILAGE
HACCP KEY CONCEPTS
Any change in food which makes itunacceptable for human consumption.
It may be caused by variety of reasons;
1. Insect damage2. Physical Injury3. Enzyme activity4. Chemical change
5. Micro-organismsProduct shelf depends upon rate of spoilage1. Food preservation is done to stop spoilage
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HACCP KEY CONCEPTS
Wide variety of illness or clinicalcondition affecting the gastro-intestinaltract.
CausesBacteriaVirusFungi
PlantsChemical
In the form of food allergins and toxicants
FOOD POISONING
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HACCP KEY CONCEPTS
Diseases caused by food productscarrying pathogens
1. Bacteria
2. Viruses3. Parasites4. Chemical/toxins5. Enzymatic changes
FOOD BORNE ILLNESS
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HACCP KEY CONCEPTS
Two TypesInfectious;Caused by ingestion of number of micro-organism
of public health significance to cause illness e.g.Salmonellosis & Listeriosis
Intoxication;Caused by ingestion of a performed bacterial toxin
e.g.Staphylococcus aureus and botulism.
FOOD BORNE ILLNESS
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HACCP KEY CONCEPTS
Having contact with food, it plays vitalrole in product safety
Type of packaging Resistance to damage Labelling
FOOD PACKAGING & CONSUMER SAFETY
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Food Type
Contaminants
Cause
Effect
Cost
IMPLICATION OF MAJOR FOOD INGREDIENTS
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Worldwide occurrence
Involve physical. Chemical or microbiologicalhazards
Wide range of causes Raw materials
Mishandling
Change of process or formulations
Cross contamination
Inadequate maintenance
Wrong addition Malicious contamination
Direct & indirect costs
SUMMARY OF FOOD INCIDENTS
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HACCP KEY CONCEPTS
Pre harvesting Post harvesting Transportation During Processing
Post processing care Storage/Ware Housing By distributors By consumer
SAFE FOOD HANDLING
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Part IIModule 4HACCP Pre -Requisites
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38The HACCP Basic Support Network
HACCP IncidentManagement
Plant design& Lay out
StatisticalProcessControl
SupplierQuality
Assurance
GoodLaboratoryPractices
GoodManufacturing
Practices
QualityManagement
System
Environmentmonitoring
Preventivemaintenance
System
Managementcommitment
Training &education
Recourses(finance &
manpower)
HACCP PRE-REQUISITES
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BASIC REQUIREMENTS
Management commitment
A trained multidisciplinary team
Product Knowledge Time
Resource
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GOOD PRACTICES SYSTEMS
Manufacturing - GMP
Distribution GDP
Laboratory - GLP
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HEALTH & SAFETY SYSTEMS
Hazardous Chemical Control
Occupational Health
Procedures
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ISO 14001
Recycling and product safety
ENVIRONMENT MANAGEMENT SYSTEMS
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Reliability of Key processequipment
Breakdown maintenance not
enough
Poor maintenance may lead tomore hazards
PLANNED PREVENTIVE MAINTENANCE
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Specifications Audit program
Auditors training
Approval of supplier
Approved supplier list
Code of practice Third party audit and accreditation
SUPPLIER QUALITY ASSURANCE
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Assure capability of meeting the
process requirements
Use in CCP monitoring provides
trend information
STATISTICAL PROCESS CONTROL
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Monitoring critical limits
Trained panelists
Application of HACCP techniques
SENSORY EVALUATIONS PRACTICES
INCIDENT MANAGEMENT & RECALL
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Must effectively manage potentially unsafeproduct incident
Must be able to recall potentially unsafeproduct from the market place
INCIDENT MANAGEMENT & RECALL
PROCEDURES
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Part IIIHow to HACCP
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HOW TO HACCP ?
Planningand
preparation
Studiesand
the plandevelopment
Implementation
of theHACCP
Plan
Maintenance
of theHACCPSystem
12
43
In 4 - STAGES
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Part IIIModule 1Planning & Preparation
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HACCP ConceptAwareness for
Top Management
External
Expert
HACCP Team Training
Plan the Project
Team formation
STAGE - 1
Gap Analysis to
Assess Current Status
Planning & Preparation
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HACCP TEAM
Team Leader (HACCP Expert)A MicrobiologistAn Engineer
A Production representativeA Quality. Assurance representativeAny other person having crucial concern
with the project.
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HACCP TEAM RESPOSIBILITIES
Plans the projectCompletes study and generates HACCPDocumentation
Ensures verification of the PlanCommunicates and trainsReview deviation from CCPsReview HACCP activities in response to
changeschedules and conducts internal audits
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ROLE OF HACCP TEAM LEADER
Keep management inform about theprogress of the projectEnsure that the right level of expertise isavailable
Help the team to achieve its common taskMaintain the team unityEnsure that each team member contributeshis/her best
Mange time effectively and help the team toappraise its progress
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Basic awareness HACCP philosophy & scope Why HACCP Food Quality & Safety HACCP pre -requisites HACCP Plan development Role of Team members Gap Analysis HACCP documentation at planning
stage
HACCP TEAM TRAINING - STAGE I
HACCP KEY CONCEPTS
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HACCP KEY CONCEPTS
(Pre-designing assessment)
Objectives to achieve
Current status
GAP ANALYSIS
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HACCP KEY CONCEPTS
Considerable points Supplier QA GMP GLP
QMS Preventive maintenance Recall & incident management SPC
Calibration Personnel/Plant Hygiene & House keeping Sanitation
GAP ANALYSIS
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HACCP Milestone Plan
PERFORMANCE CHALLENGE PROJECT PRIORITY : HIGH PROJECT TEAM LEADER : MABTo implement a system of Hazard Analysis ofCritical Control Points in the process to ensure
production of safe and quality products.PROJECT TEAM : IDA, MA, QR, MNN, LIA, MDB
January February March April May June July AugustID Tasks
TargetDates
W 02 04 06 08 10 12 14 16 18 20 22 24 26 28 30 32
01 Start of project 01:01:00
02 HACCP Steering groupawareness training
01:01:00
03 Team development and training 07:01:00
04 Baseline audit and gap analysis 17:01:00
05 Establish process capability 01:04:00
06 Plan the HACCP study 10:01:00
07 Determine method ofimplementation
05:05:00
08 Agree actions and time table 25:01:00
09 Process flow diagram 01:02:00
10 Hazard analysis 21:02:00
11 Identify CCPs 15:03:00
12 Complete control charts 30:03:00
13 Validate the HACCP plan 03:04:00
14 Conduct awareness training ofoperators
10:04:00
15 Set up monitoring system20:04:00
16 Train monitoring personnel 30:04:00
17 Set up facilities and equipment 10:05:00
18 Implementations actioncompleted
07:08:00
19 Verify implementation actionthrough audit
15:08:00
20 HACCP plan re-validation 31:08:00
Time of Completion
Project Duration :
32 weeksDate of initiation of project :
01 : 01 : 00Issuance of status report :
after every 15 daysDate of project completion :
31:08:00
PLAN THE PROJECT
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Part IIIModule 2HACCP Studies
&
Plan Development
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Define Termsof Reference
Hazard Analysis
Describe theProduct &
Intended use
ConstructFlow Diagram
ValidateFlow Diagram
CCP Identification
Establish Critical Limits
Identify Monitoring Sys
Establish Corrective Action
Validate HACCP Plan
STAGE - 2
HACCP Studies & Plan Development
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Product & associated hazards Use of HACCP Principles Risk Assessment Usage of decision tree & CCP identification Establishing Critical limits Establishing monitoring system training
monitoring people Corrective action HACCP documentation
Establishing HACCP Validation system
HACCP TEAM TRAINING - STAGE II
HACCP KEY CONCEPTS
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Type of hazard Physical Chemical Microbiological
Scope Which Product Which Process Whole process or any module Start and end points
DEFINE TERMS OF REFERENCE
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Product Introduction Principle Raw materials used Recipe/Intrinsic control factors
Process Parameter Packaging and finished product stage Storage Condition Shelf Life
Consumer target group Usage Abuse potential
PRODUCT DESCRIPTION & INTENDED USE
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PRODUCT DESCRIPTION & INTENDED USE
PRODUCT DESCRIPTIONSName: ShangoType: Standardized and pasteurized Juice drink available in four flavors (Mango, Apple,
Mango Orange mix and Orange)
PACKAGING / DISTRIBUTION / STORAGE / DESCRIPTIONPackaging: Filled in tetrapak and shrink wrapped in trays/packed in curuwall cartonsDistribution: Trucks and small vansStorage: Normal room temperature
Shelf Life: 6 months
INTENDED USE & SPECIAL CONSUMER CONSIDERATIONSProduct is taken as nutritious juice drink by all age groups.Keep in refrigerator after opening
INGREDIENT
1. Pulp/Concentrate2. Sugar 3. Stabilizer 4. Flavors 5. Colors 6. Citric Acid 7. Malic Acid 8. Sodium Benzoate9. Sodium Citrate
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Raw materials Packaging Process activities
Temperature & Time profile Equipment design Re-work Storage condition
Distribution Waste handling
CONSTRUCT FLOW DIAGRAM
l i i i / i k
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Process Flow Diagram - Fruit Juices/Drinks
Batch
Preparation
Tank
Batchpreparation
Raw Materials
Weighing
Standardization
Stabilizer
mixing
Balance Tank of
aseptic filler
Stacking
Final Analysis
Pasteurization
Temperature
Product Pump
Balance Tank
Storage
Pump
Aseptic Storage
Pasteurization
Section
- Regenerator-1
- Homogenizer-1
- Regenerator-2
- Sterilizer
- Holding Tube
- Regenerator-2
- Homogenizer-2
- Regenerator-1- Cooler
Aseptic
Tetra Filling
Tray Packing/ Shrink
Filling Tube
Forming
Conveyer
Sealing
Warehousing
- Hydrogen per oxide
- Quality
- Quantity
T BA 19
- M ain heater Temperature
- Accurate & Careful
weighing
- Pulp/Concentrate
- Sugar
- Flavor
- Vit - C
- Color
- Stabilizer
- Sodium Benzoat e
- Citric acid/M alice acid- Sodium Citrate
- etc...
- Proper storage
of materials
Sugar Syrup
Preparation
Filtration
Pulp & Other
Ingredients
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ON SITE
CONFIRMATION
&VERIFICATION
FLOW DIAGRAMS VERIFICATION
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HACCP PRINCIPLES
1. Conduct Analysis2. Identify Critical Control Points (CCPs)3. Establish target levels/critical limits4. Establish monitoring system
5. Establish corrective action system6. Establish verification System7. Establish documentation system
1
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Hazard Analysis&Risk Assessment
HACCP PRINCIPLES 1
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1. A potential to cause harm to theconsumer Safety
2. A property that may cause aproduct to be unsafe forconsumption
HAZARDS
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PHYSICAL
CHEMICAL
BIOLOGICAL
HAZARDS TYPES
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PHYSICAL HAZARDS
Dirt Fruit pits Stones Wood
Glass Metal Hairs Bones Insects broken parts
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CHEMICAL HAZARDS
1.Agricultural Chemicals
Pesticide, Antibiotics, Growth stimulators,
Growth hormones and Fertilizers etc..2. Industrial ChemicalsCleaners, Sanitisers, Oils, Lubricants & GreasesAmmonia and Polychlorinated biphenol etc...3. Naturally Occurring ChemicalsAflatoxins4. Environmental contaminants
Lead, Arsenic, cadmium, mercury and PCVs5. Food ChemicalsSeasoning, Preservatives, acids, additives,sulfites and processing aids
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MICROBIOLOGICAL HAZARDS
Clostridium botulinum Clostridium perfringens
Salmonella
Listeria monocytogenes
Staphylococcus aureus
Shegella sp.
Vibrio parahaemoliticus
Bacillus cereus
Vibrio cholera
Comphaylobactor sp. Brucella sp.
Streptococus sp.
E. coli
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The chance (probability) that a givenhazard will occur.
HIGH RISK
MEDIUM RISK
LOW RISK
RISK
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HOW TO CARRY OUT HAZARD ANALYSISBy answering following questions for eachraw materials & process step;
What can go wrong leading to unsafeproduct
How can we prevent it going wrong What is the best control approach
Is this currently in place
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HAZARDS ANALYSIS
Considerable points;Ingredients
Intrinsic factorsProcedures used for processing
Microbial contents of foodFacility designEquipment design and usePackaging
SanitationEmployee health, health and educationStorage conditionIntended useIntended consumer
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HAZARD ANALYSIS & RISK ASSESSMENTIdentify Hazards
IdentifyContamination
Point
DetermineProbability
DeterminePreventive Measures
Assess riskseverity
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HAZARD ANALYSIS TOOLS Fishbone diagram Brain Storming Documentation
Hazard analysis chart HACCP Softwares Statistics
Researching and evaluating the information
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Physical, Chemical or other factorscan be used to prevent or eliminatean identified hazard or reduce it toacceptable level
PREVENTIVE MEASURES
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Factors capable of control Process steps
Use of approved supplier
Control storage
Time management] Segregation
Application of effective cleaning methods
Application of effective training methods
Effective pest control
These are used to control not monitoring
PREVENTIVE MEASURES EXAMPLES
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HACCP ANALYSIS CHART
Process Step Hazard and source Preventive Measures
Raw MaterialsChicken portions
Metal from de-boningknives
1. Knife control procedures2. Effective metal detection of
finish products
Cooking Survival of Salmonella Correct lethal temperature andtime regime
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HACCP ANALYSIS CHART
Process Step Hazard and source Preventive Measure
Raw materials:
Sodium Benzoate
Physical ,Chemical andBiological
Sources: Raw materials itselfbefore reception or in storageif not stored properly
Reception of risk free materials and
store them properly
Process:
UHT
Temperature
Biological, Raw milk &Environment
CIP
Risk free milk, Perform (adulteranttests)
Hygienic Environment.
Temperature sensor calibration.
(Monthly)
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Team members Scientific literature
Technical consultants &
research organizations Company specialists
Supplier/ Customers
Trade associations
Experimental data
Mathematical models
INFORMATION SOURCES
HACCP PRINCIPLES 2
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Identification
ofCritical Control
Points (CCPs)
HACCP PRINCIPLES 2
CCP IDENTIFICATION
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What is a Critical ControlPoint (CCP)
How do we find them
CCP IDENTIFICATION
CRITICAL CONTROL POINTS (CCP)
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A point, step or procedure atwhich control can be appliedand a food safety hazard can beprevented, eliminated orreduced to an acceptablelevel.
CRITICAL CONTROL POINTS (CCP)
RAW MATERIAL DECISION TREE
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RAW MATERIAL DECISION TREE
Q1.Is there hazard associatedwith raw materials?
Yes
Q2. Are you or the consumer going to
process this hazard out of this product?
Yes
Q3. Is there a cross contamination risk to the
facility or to other products which will not
be controlled?
YesSensitive raw materials
High level of control required .. CCP
No
Process to next raw
materials
No
No
Sensitive raw materials
High level of control required .. CCP
Process to next raw
materials
RAM MATERIAL DECISION TREE MATRIX
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RAM MATERIAL DECISION TREE MATRIX
Raw Materials Q1 Q2 Q3 CCP HACCP TeamComments
PROCESS DECISION TREE
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PROCESS DECISION TREE
Q1.Is there a hazard at this process step?What is that ?
Yes
Q2. Do preventive measure(s) exist for
the identified hazard?
YesQ3. Is the step specifically designed to
eliminate or reduce the likely occurrence
of the hazard to an acceptable level?
NoQ4. Could contamination occur at or
increase to an unacceptable level?Yes
Q5. Will a subsequent step or action eliminate
or reduce the hazard to an accpteptible level?
Yes
No
Not aCCP Stop*No
Yes
No Is control necessary atthis step for safety
YES
Modify step, process or
product
Not aCCP Stop *
CCP
No Not aCCP Stop *
Not aCCP Stop *No
* Proceed to next step or process step
PROCESS DECISION TREE MATRIX
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PROCESS DECISION TREE MATRIX
Process Stepand Hazard
Q1 Q2 Q3 Q4 Q5 CCP HACCP TeamComments
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Controllingthe Critical Control Points
(CCPs)
CONTROLLING THE CCP S
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BY: Critical Limits & Target levels
Monitoring
Corrective Actions Responsibility
Validation
Principles 3, 4, & 5
CONTROLLING THE CCP S
HACCP CONTROL CHART
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HACCP CONTROL CHARTFruit Juice/Drinks
Monitoring Corrective ActionCCPNo.
Process steps Hazard
Types
Preventive
Action
Critical limits
Procedure Frequency Responsibility Procedure Responsibility
HACCP CONTROL CHART
IDENTIFIED CCPS
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HACCP CONTROL CHARTFruit Juice/DrinksMonitoring Corrective ActionCCP
No.
Process steps Hazard
Types
Preventive
Action
Critical limits
Procedure Frequency Responsibility Procedure Responsibility
Blending Section/Batch Preparation01 Sodium Benzoate
UHT Section/Pasteurizationst.incharge/ Instrumentation incharge02 Balance tank
strainer
03 UHTTemperature
Aseptic Tetra Filling04 Hydrogne per-
oxide
Quality/dosagequantity
05 Main heaterTemperature
IDENTIFIED CCPS
CCPS WITH HAZARDS TYPES & PREVENTIVEMEASURES
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HACCP CONTROL CHART
Fruit Juice/DrinksMonitoring Corrective ActionCCP
No.Process steps Hazard
TypesPreventive
ActionCritical limits
Procedure Frequency Responsibility Procedure Responsibility
Blending Section/Batch Preparation01 Sodium Benzoate C Proper weighing
UHT Section/Pasteurizationst.incharge/ Instrumentation incharge02 Balance tank
strainer
P, B Weekly Cleaning
03 UHTTemperature
B Temperaturesensor calib.(Monthly)
Aseptic Tetra Filling04 Hydrogne per-
oxide
Quality/dosage
quantity
C Qualityevaluation forbeing food grade
Measure and addexact dosage/badge
05 Main heaterTemperature
B Temperaturesensor calib.
Annually
MEASURES
HACCP PRINCIPLES 3
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Establishingtarget levels/critical limits
HACCP PRINCIPLES 3
WHAT ARE CRITICAL LIMITS
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The value of a preventive measure,determined during monitoring, thatdistinguishes acceptable and
unacceptable.
WHAT ARE CRITICAL LIMITS
CRTICAL LIMITS
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CRTICAL LIMITS
Considerable points;
Chemical LimitsPhysical limits
Procedural limitsMicrobiological limits
Must be measurable by test or observation
Criteria which must be met for eachpreventive measures at CCP
Not necessary the same as the existingprocessing parameters
TARGET LEVEL/CRTICAL LIMITS
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TARGET LEVEL/CRTICAL LIMITS
82
75
Temp OC
Critical Limit
Target Level
Safety Buffer Zone
ESTABLISHING CRITICAL LIMITS
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HACCP CONTROL CHARTFruit Juice/Drinks
Monitoring Corrective ActionCCPNo.
Process steps HazardTypes
PreventiveAction
Critical limits
Procedure Frequency Responsibility Procedure Responsibility
Blending Section/Batch Preparation01 Sodium Benzoate C Proper weighing Permissible limits
UHT Section/Pasteurizationst.incharge/ Instrumentation incharge02 Balance tank
strainerP, B Weekly Cleaning No choking or
leakage/damage
03 UHTTemperature
B Temperaturesensor calib.(Monthly)
Set point140oC
Aseptic Tetra Filling04 Hydrogne per-
oxide
Quality/dosagequantity
C Qualityevaluation forbeing food grade
Measure and add
exact dosage/badge
Food gradeNo heavy metalsNo arsenic or lead
Exact quantity as
per standard
05 Main heaterTemperature
B Temperaturesensor calib.
Annually
Set pointTemperature360 0oCPressure 0.5 bar
ESTABLISHING CRITICAL LIMITS
HACCP PRINCIPLES 4
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Establishing
MonitoringSystems
HACCP PRINCIPLES 4
MONITORING
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Observations or measurements to assesswhether preventive measures at criticalpoints are being implemented
effectively.
Observation at CCPs that the process isoperating within critical limits
MONITORING
CCP MONITORING
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CCP MONITORING
Considerable points;1. Continuous2. Non Continuous
Monitoring On line Off Line Observational procedures
FrequencyResponsibility
CCP MONITORING
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HACCP CONTROL CHART
Fruit Juice/DrinksMonitoring Corrective ActionCCP
No.Process steps Hazard
TypesPreventive
ActionCritical limits
Procedure Frequency Responsibility Procedure Responsibility
Blending Section/Batch Preparation01 Sodium Benzoate C Proper weighing Permissible limits Careful
weighingPer batch Pasteurization
operator
UHT Section/Pasteurizationst.incharge/ Instrumentation incharge02 Balance tankstrainer P, B Weekly Cleaning No choking orleakage/damage Physicalinspection for
choking andleakage
Hourly UHT operator
03 UHTTemperature
B Temperaturesensor calib.(Monthly)
Set point140oC
Temperaturemonitoringfrom panel &graph
Hourly UHT operator
Aseptic Tetra Filling04 Hydrogne per-
oxide
Quality/dosagequantity
C Qualityevaluation for
being food grade
Measure and addexact dosage
/badge
Food gradeNo heavy metals
No arsenic or lead
Exact quantity asper standard
Check labrelease for
quality
Recorddosage/ checkend usage
Per can/Every can
Tetraoperator/Foreman
05 Main heaterTemperature
B Temperaturesensor calib.
Annually
Set pointTemperature360 0oCPressure 0.5 bar
Temperaturemonitoringfrom regulatorPressure formgauge
Hourly Tetra operator
CCP MONITORING
CCPS LOG SHEET
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CCPS LOG SHEET
Time Results Deviation? Action taken Signature
Reviewed by : Date:
Line/product:
Monitoring Procedures:.
Monitoring frequency:
Target levels:
CCP Ref. No.
Date:Shift:
Corrective action ..
HACCP PRINCIPLES 5
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Establishing
CorrectiveActions
HACCP PRINCIPLES 5
ESTABLISHING CORRECTIVE ACTIONS
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ESTABLISHING CORRECTIVE ACTIONS
Prevent deviation- Only possible if target levels in place
Correction following deviations;- Adjust the process to bring it back to control
- Deal with the materials produced during the deviationperiod
Destroy non complying products Re-work
Direct into less sampling products Release following sampling and testing Release?
CORRECTIVE ACTIONS
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HACCP CONTROL CHART
Fruit Juice/Drinks Monitoring Corrective ActionCCPNo.
Process steps Hazard
Types
Preventive
Action
Critical limits
Procedure Frequency Responsibility Procedure Responsibility
Blending Section/Batch Preparation01 Sodium Benzoate C Proper weighing Permissible limits Careful
weighingPer batch Pasteurization
operatorDont use the
productShift Inchargeerator
UHT Section/Pasteurizationst.incharge/ Instrumentation incharge02 Balance tank
strainerP, B Weekly Cleaning No choking or
leakage/damagePhysicalinspection forchoking andleakage
Hourly UHT operator Urgentlyreplace onchoking ordamage
UHT operator
03 UHTTemperature
B Temperaturesensor calib.(Monthly)
Set point140oC
Temperaturemonitoringfrom panel &graph
Hourly UHT operator Immediatecalibration
UHT incharge/Instrumentationincharge
Aseptic Tetra Filling04 Hydrogne per-
oxide
Quality/dosagequantity
C Qualityevaluation forbeing food grade
Measure and addexact dosage
/badge
Food gradeNo heavy metalsNo arsenic or lead
Exact quantity asper standard
Check labrelease forquality
Recorddosage/ checkend usage
Per can/Every can
Tetraoperator/Foreman
Ask lab forproductresults/Safe productshould bereleased
Tetraoperator/Foreman
05 Main heaterTemperature
B Temperaturesensor calib.
Annually
Set pointTemperature360 0oCPressure 0.5 bar
Temperaturemonitoringfrom regulatorPressure formgauge
Hourly Tetra operator ImmediatecalibrationProcess getsstop in caseof deviationinbuilt securitysystem
Tetra incharge/Instrumentationincharge
CORRECTIVE ACTIONS
HACCP PRINCIPLES 6
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EstablishingHACCPValidation
HACCP PRINCIPLES 6
VALIDATION OF HACCP PLAN
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VALIDATION OF HACCP PLAN
1. What is validation2. How it can be done
WHAT ?
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WHAT ?
The assessment of the HACCP plan beforeimplementation to provide confirmationthat it is accurate and complete
HOW TO VALIDATE ?
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HOW TO VALIDATE ?
Use personnel with audit skillsAssess all elements of the HACCP plan
- Process flow diagram- HACCP Control chart
Assess the process area- Preventive measures
- Process capability
HACCP PRINCIPLES 7
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Establishing
HACCPDocumentation
HACCP PRINCIPLES 7
HACCP DOCUMENTATION
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HACCP DOCUMENTATION
Main Records A summary of Hazards analysis, with rationale of
determining hazards and control measures. The HACCP Plan
Support documentation such as validationrecords
Records that are generated during the operationof the plan.
RECORDS OF POSSIBLE RETENTION
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RECORDS OF POSSIBLE RETENTION
Hazard analysis chart
HACCP Control Chart CCP log sheet Hold/ Trace/ Recall records Training records
Audit records HACCP Team meeting records Calibration records HACCP Plan
History of amendments
Records are essential to provide evidenceof safe production
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Part IIIModule 3
Implementation ofHACCP Plan
STAGE - 3
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Determine TheMethod of
Implementation
Awareness
TrainingSet UpImplementation
Team
Agree actions & Time table
Take Necessary Corrective Actions
Confirm Implementation Actions Completed
Set upMonitoring
Sys
EstablishProcess
Capability
Set up
Facilities
TrainMonitoringPersonnel
EstablishRecord Keep
Requirements
VerifyImplementation
Through Audit
STAGE 3
Implementation Of HACCP Plan
HACCP PLAN IMPLEMENTATION
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HACCP PLAN IMPLEMENTATION
Determine Method ofImplementation
HACCP IMPLEMENTATION
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HACCP IMPLEMENTATION
Method Big BangMethod Advantages Disadvantages
All at
once
1. Rapid
implementationpotential2. Works well in
companies with wellestablished QualitySystems
3. Whole work forceinvolved
4. Ease of work forcebriefing
1. May take longer period overall than
anticipated- All HACCP monitoring andcontrol procedure will have to bedeveloped before implementationstarts
2. No trial of individual system elements3. Loss of credibility If employ see that it is poorly managed If CCP fails through poor support
network Large immediate training requirement Resource thinly spread e.g. HACCP
Team
HACCP IMPLEMENTATION
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HACCP IMPLEMENTATION
Method - PhasedMethod Advantages Disadvantages
Phased 1. Quality managementsystem support can be
developed as requiredand alongside
2. Staged training allowsmore individualattention
3. System can be trailedand refined asimplementation
progress4. More manageable
approach5. HACCP Resource can
be focused on eachstage
1. Longer over all implementation timetable
2. Working of small group in isolationdifficult to change culture
3. Implementation may loose momentum
HACCP IMPLEMENTATION TEAM
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HACCP IMPLEMENTATION TEAM
Team Leader (HACCP Expert)An Maintenance Engineer (Optional)A Production representativeA Q. Assurance representatives
Any other person who has the main concern
PERSONNEL CONSIDERATIONS
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PERSONNEL CONSIDERATIONS
Fundamentals to HACCP effectiveness
Key Questions
- Enough people- Ability- Time- Supervisor- Training
TRAINING PERSONNEL
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TRAINING PERSONNEL
All personnel- An understanding of HACCP- How HACCP applies to process- Why monitoring is vital
CCP monitors and their Supervisors- How to monitor- Monitoring frequency required- Record keeping /Deviation reporting
- Use of critical limits/Target levels- Adjusting the process to maintain control- Corrective action
ESTABLISHING PROCESS CAPABILITY
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ESTABLISHING PROCESS CAPABILITY
Equipments Considerations;
- Availability
- Capability- Reliability- Ease of use
- Special facilities- Other implications
Facility Considerations;
- Production
- Additional space requirements
- Extra facilities- Training and briefing staff
- Space- Environment- Equipment
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Part IIIModule 4
Maintaining the
HACCP System
STAGE- 4
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Define standardsand regular audits
Data
analysis
Corrective &
PreventiveAction
HACCP Plan
Validation
Documentationcontrol Update
Ongoing Maintenance
ProblemSolving
Maintaining the HACCP System
HACCP AUDITING
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Types of audits
The system Audit- Where ISO is used
The compliance audit Against- HACCP Plan
The investigative audit- To solve any problem)
AUDIT CHECK LIST
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Process step Considerations Auditors findings
Raw materials(List of raw materials)
Process(List of process steps)
Packaging anddispatch(List of packaging here)
DATA CHECKING BY AUDITORS
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CCP log sheet Process control charts
Audit reports
Customers complaints data
Pest control records
Minutes of meeting
- HACCP
- Hygiene
- Quality
HACCP NON COMPLIANCE NOTE
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HACCP Audit Non Compliance Note NO:
Location: Date:
Area under review:
Non Compliance:
Action required by (date):
Auditors:
Accepted by Audi tee:Corrective Action:
Verified (Auditor): Date:
ON GOING TRAINING REQUIREMENT
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Refresher Training New Personnel
- HACCP- CCP monitors- Others
Updating training- New emerging hazards
- Developments in HACCP Awareness training
HACCP MAINTENANCE PLAN
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HACCP System Approved By:
Maintenance Requirements
Date:
Quarterly audit of HACCP plan
annual plan revalidation HACCP plan to be revised for all process ingredients changes
Quarterly CCP log sheet review for deviation trend analysis
Monthly review of consumer complaints data for trends
6 monthly simulation of trace/recall procedures
Ongoing technical update through symposia and technical journals
Quarterly analysis of training needs
HACCP Team Leader
HACCP PLAN REVIEW/AMENDMENTS
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Amendments Protocol
Product safety assessments Maintain a history sheet
Incorporate changes Frequency of review
AMENDING THE HACCP PLAN
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New raw materials suppliers Changes in the process Factory enviroionment alterations New packaging
HACCP audit changes after improvements HACCP review
Changes need to be documented
FOOD FOR AMENDMENTS
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New technologies New natural foods New combinations of foods Changing legislations
New information on existing issues New ways of packaging foods Changing eating habits
HISTORY OF AMENDMENTS
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HACCP Plan Ref.Page:
Date Amendment Reason ApprovalSignature
HACCP VERIFICATION
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1. Initial validation of plan2. Subsequent validation of plan3. Verification of CCP monitoring as per plan4. Review of monitoring, corrective action records
to show compliance with plan5. Comprehensive HACCP system verification.
HACCP VERIFICATION
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1. Establish procedures
2. Responsibility
3. Frequency of Verification
ROLE OF REGULATORY AGENCIES
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Review theHACCP plan Review the CCP record Review the corrective action records on deviation Review of the critical limits
Review of all the records pertaining to theHACCP plan Direct measurement or observation at CCP Sample collection & analysis product safety On-site observation and record review
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Part IVModule 1FOOD SAFETY &
Quality System
FOOD SAFETY INTEGRATED QUALITY SYSTEM
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HACCP&
Quality ManagementSystem e.g ISO
QUALITY MANAGEMENT & FOOD SAFETY
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ISO 9000 ensures the products meetsspecification 100% of the time.
HACCP specifies and ensures a safe product.
Managing HACCP using ISO 9000 ensuresthat the specific safe product is made everytime
Documented procedures & records provideessential evidence of safe productmanufacture
ISO/QS WITHOUT FOOD SAFETY
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The Danger
If unsafe product is specified ..
..then it will always be produced
LINKING HACCP TO Q. MGT. TECHNIQUES
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Quality Management system : 1SO 9000
Good Practice System : Manufacturing
: Distribution
: Laboratory
Health & Safety System : Chemical control
: Occupational health
procedures Environment Management system : ISO 14001
Supplier Quality Assurance : Specification
: Audit
Statistical Process Control
Sensory Evaluation
Incident Management and
recall procedures
QUALITY PLANS ( 4.2.3 Quality Planning)
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HACCP & Quality Control Chart
DATE : Supersedes
Approved By: Ref No:
Process
stepsControl Points Preventive
measuresCritical
limitsMonitoring Corrective
actionResponsibility
CCP QCP LQP Procedure Frequency
CCP = Critical Control Points = Food Safety
QCP = Quality Control Points = Quality other than food safety
LCP = Legal Control Points = Legal Compliance
QUALITY PLANS - KEY POINTS
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Keep CCPs separate from QCPs/LCPs Enable same degree of control product
spoilage, sensory attributes, legalcompliance etc..
Assists with ensuring clear understandingand separation of food safety control versusnon food safety control.
More meaningful within processenvironment.
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Part VModule 1System Bottlenecks
BOTTLENECKS IN HACCP PROJECTTENANCE)
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Managements diluted vision/Lack of interest
Wrong selection of team Clarityof concept of food safety and quality
Weak Supplier QA/supplier support Too many CCPs Take too long to put modifications
in place
Resources to implement modifications
BOTTLENECKS IN HACCP PROJECTTENANCE)
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Coordination of HACCP Team andavailability to attend the
HACCP maintenance meetings People reluctance for change/
Conservation of ideas Unavailability of like GMP, GLP,
preventive maintenance, sanitation and lack of personnel health Unavailability of experts Poor Traceability & Improper recall system
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Part VIModule 1HACCP FUTURE
HACCP FUTURE
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Outside Pakistan
In Pakistan
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