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19 June 2012
Pre-Requisite Programs
(PRP)
and
Critical Control Points (CCP)
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Presentation Guide
Introduction
Pre-Requisite Program PRP
PRPs & oPRPs
Critical Control Point (CCP) & Its
Determination
Summary
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Introduction
FOOD SAFETY
PLAN
PRP/support
programs
(GMP, SOP,
SSOP, etc.)
+
HACCP
+
Effective training
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HACCP
= Hazard Analysis & Critical Control Point
A system that identifies, evaluates &
emphasize controls of hazards which are
significant for food safety
Other hazards are controlled under
GHP/GMP (PRP)
Identifies specific hazards & preventive
measures for their control
Consists of seven principles
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HACCP PRINCIPLES
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References:
Malaysian standards
MS 1480:2007 Food safety according to HACCP
MS 1514: 2009 Good Manufacturing Practices (GMP)
Equivalent: Codex Food Hygiene Basic Text, Rev. 2003
Others:
o ISO 22000: 2005 Food Safety Mgt Systems
Requirements for any organization in the food chain
o USFDA cGMP Regulations & specific HACCP regulations
o EU legislations on Hygiene of Foodstuff, and specifics
for different food products
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PRE-REQUISITE PROGRAMS
(PRP)
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PRE-REQUISITES TO HACCP
Establishment is legal - food premises must
be registered
Operate according to relevant by-laws
Products comply with appropriate regulatory
requirements such as:
Food Act 1983: Food Regulations 1985;
Food Hygiene 2009; etc.
mandatory codes of hygienic practice
Products comply with:
customer/importer requirements
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PRP
Required conditions can be achieved through:
Good Manufacturing Practices (GMP) / Good
Hygienic Practices (GHP)
Sanitation Standard Operating Procedures
(SSOP)
Coverage depends on :
regulatory requirement
size of business
types of product
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Operational PRP
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PERSONNEL HYGIENE
what active records are needed
which needs to be filled in every
shift, every day, etc.
Hygiene and health requirements
Communicable diseases & Injuries
Attire and conduct of workers
Policy on visitors
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CHEMICAL CONTROL
Documented procedures in place to ensure segregation,
storage and proper use and control of non-food chemicals
in the plant. Includes cleaning chemicals, fumigants, baits,
etc. Chemical safety data sheets available
Chemicals should be:
correctly labeled including containers for mixing
stored in designated and well ventilated area, hazardous
chemicals under lock
protected from cross-contamination with food or food
contact surfaces or packaging material
dispensed and handled by trained and authorized staff with
procedures for receiving & issuing in place > records
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PEST CONTROL
PRP
oPRP
In-house monitoring
activities
What
How
Who
Frequency
CA
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WASTE MANAGEMENT
Solid and liquid waste disposal
SSOP
Schedule of waste disposal from processing
area and from plant
Drains to have proper flow & traps for solids
Proper covering of waste disposal containers,
including those in the processing area
Cleaning of waste containers &
Central waste collection bins away from
processing area
Discharge must comply with DOE requirements
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SPECIFICATIONS
Written specifications for raw (including origin) and
packaging materials and finished products
Based on regulations, standards, scientific references or
own experiments
Ensure raw materials meet companys requirements
Prevent / reduce hazards in raw materials
Prevent unsuitable raw materials being used in production
Ensure uniform products
Contribute to HACCP implementation, e.g. reduce cost of
analysis, etc.
Meet regulatory requirements
Meet customers requirements
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CUSTOMER COMPLAINTS
Documented procedure for customer complaints
(including auditing)
Records of complaints and actions taken. Use as
feed back
Returned products isolated & appropriate action
taken (destroyed, reworked or reprocessed)
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Maintenance of PRP
Maintenance is essential to ensure continuous
control of favourable operational conditions
The premises & equipment should be kept in
good state of repair
Sanitation control should be monitored for their
suitability & verified for effectiveness
Good record keeping to provide evidence on
continuous adherence to sanitation control
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GENERAL REQUIREMENTS
All PRPs should be:
- Documented (including plant lay-out for materials,
equipment, workers amenities, footbaths, bait stations)
- Monitored and records/checklists kept
- Corrective actions taken and documented
- Records and CA verified
- PRPs maintained & verified where applicable, e.g. hygiene
& sanitation, raw materials, clean rooms
- Use results to update and improve PRPs if necessary
- Reviewed before implementing HACCP Plan, to verify if all
requirements have been met, and if all the necessary
controls and documentation are in place
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24
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PRINCIPLE 1
Conduct a hazard analysis
Prepare a list of steps of the plants
processes
Identify where significant hazards could
occur
Also identifies all possible hazards
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Hazard Analysis
A thorough hazard analysis is the key to preparing an
effective HACCP plan
When conducting a hazard analysis, safety concerns
must be differentiated from quality concerns
Hazard analysis & identification of associated control
measures accomplish three objectives:
Those hazards and associated control measures are
identified
The analysis may identify needed modifications to a process
or product so that product safety is further assured or
improved
The analysis provides a basis for determining CCPs in
Principle 2
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29
significant hazards =
likelihood x severity
reasonably likely to
occur
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likely to result in an
unacceptable risk to
consumers
30
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Hazard-Analysis Worksheet
Set up the hazard-analysis worksheet
Identify the potential species-related
hazards
Identify the potential process-related
hazards
Complete the hazard-analysis
worksheet
Understand the potential hazard
Determine if the potential hazard is
significant
Identify the critical control points
(Identify the oPRPs)
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Process
Step
Potential
hazard
State
whether
B, C or P
Rational for
inclusion or
exclusion as
a hazard
What
preventive
measure
Is this a
or control
significant can be
hazard? applied to
prevent
(Yes / No) this
significant
hazard?
Is this
step a
critical
control
point?
(Yes /
No)
B=
CCP 1 C =
P=
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Control Measures
Actions and activities that can be used to
prevent or eliminate a food safety hazard
or reduce it to an acceptable level
Control measures must be validated for
effectiveness
Column 5 on Hazard-Analysis Worksheet
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Process Step
Example
1. Receiving of
semi-process
raw soya sauce
Potential
hazard1
State whether
B, C or P
Rational for
inclusion or
exclusion as a
hazard
Is this a
significant
hazard?
(Yes / No)
What preventive
measure or
control can be
applied to
prevent this
significant
hazard?
Biological
In / Ex: justify
Chemical
In / Ex: justify
Physical
In / Ex: justify
2B:
Pathogens:
S aureus
3C:
Ex: Strict
control of
suppliers under
Approved
Supplier
Program
(Leave
Blank)
Testing every 6
months to ensure
compliance. PRP #5
Chemical Analysis
Records
(Leave Blank)
(Leave
Blank)
(Leave Blank)
3 MCPD (3-
chloro-1,2propanediol)
4P:
None
Yes
based on
historical data
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Control water
activity below (aw)
0.75; salt content
above 20%.
6
Is this
step a
CCP?5
(Yes/No)
No
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PRP or CCP?
How to know if the hazard
is to be controlled under
PRP or HACCP
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Process
Step
Potential
hazard1
State
whether
B, C or P
Rational for
inclusion or
exclusion as
a hazard
Is this a
significa
nt
hazard?
(Yes /
No)
What
preventive
measure or
control can be
applied to
prevent this
significant
hazard?
Is this
step a
CCP?5
(Yes
/No)
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Process
Step
Example
1.
Receiving
of semiprocess
raw soya
sauce
2
Potential
hazard1
State
whether
B, C or P
2B:
Is this a
significant
Rational for
hazard?
inclusion or
(Yes /
exclusion as a
No)
hazard
In: Likely to
Yes
What preventive
measure or
control can be
applied to
prevent this
significant
hazard?
Is this
step a
CCP?5
(Yes
/No)
Control water
activity
below (aw)
0.75; salt
content
above 20%.
No
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Process Step
Example
1.
Receiving
of semiprocess
raw soya
sauce
2
Potential
hazard1
State whether
B, C or P
3C:
3
MCPD (3chloro1,2propanedi
ol)
3
Rational for
inclusion or
exclusion as a
hazard
Ex: Strict
control of
suppliers
under
Approved
Supplier
Program
Is this a
significant
hazard?
(Yes / No)
What preventive
measure or
control can be
applied to
prevent this
significant
hazard?
(Leave
Blank)
6
Is this
step a
CCP?5
(Yes/No)
Testing every
6 months to
ensure
compliance.
PRP #5
Chemical
Analysis
Records
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Process Step
Example
1.
Receiving
of semiprocess
raw soya
sauce
2
Potential
hazard1
State whether
B, C or P
4P:
None
Rational for
inclusion or
exclusion as a
hazard
Is this a
significant
hazard?
(Yes / No)
What preventive
measure or
control can be
applied to
prevent this
significant
hazard?
(Leave
Blank)
(Leave
Blank)
(Leave
Blank)
6
Is this
step a
CCP?5
(Yes/No)
4If
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1. Pasturization (soy
sauce)
Potential
hazard1
State
whether
B, C or P
Rational for
inclusion or
exclusion as a
hazard
Is this a
significant
hazard?
(Yes / No)
What preventive
measure or control
can be applied to
prevent this
significant hazard?
Is this step
a CCP?5
(Yes/No)
B: 1. S
aureus
Inc. Known to
occur due to x
contn from fd
handler
2. A.
oryzae
Exc. Quality
issue
(Inc.)*
Exc. Quality
issue
(Inc)*
3. Film
yeast
No
(Yes)*
(Yes)*
- Testing of fd
handlers every 3
months to
ensure not a
carrier, oPRP #7.
*
- Fd handlers
hygiene in place. No/Yes
SOP 1
Ensure time-To
met
Ensure time-To
met
C: Nil
P: Nil
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More examples
1
Process Step
Potential
hazard1
State whether
B, C or P
Rational for
inclusion or
exclusion as a
hazard
Is this a
significant
hazard?
(Yes / No)
What preventive
measure or control
can be applied to
prevent this
significant hazard?
Is this step
a CCP?5
(Yes/No)
2. Pasturi- B:
zation
Salmonella
(milk)
Brucella, S.
aureus
Inc.
Known to
occur in
milk
Yes
Ensure time-To
to destroy
pathogens met
(>65oC,
>15min)
Yes
C: Nil
P: Nil
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More examples
1
Process
Step
2
Potential
hazard1
State
whether
B, C or P
3. Washing B: E coli, S.
aureus,
of hands
Salmonella
(bakery/
catering/
restaurant)
C: free
chlorine
P: Nil
Is this a
Rational for
significant
inclusion or
hazard?
exclusion as a
(Yes / No)
hazard
Inc:
Happen ned before.
Likely to
occur from
fd handlers
hands
Yes
Exc: Residue
validated for
SOP
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What preventive
measure or
control can be
applied to prevent
this significant
hazard?
1. Ensure fd
handlers wash
& sanitize
hands every h
2. Fd handlers
undergo
medical check
every 6 month
to isolate
carriers
Ensure correct
amount used,
strict adherence to SOP
-
6
Is this
step a
CCP?5
(Yes
/No)
Yes
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PRODUCT DESCRIPTION:
FIRM ADDRESS:
INGREDIENT/
PROCESSING
STEP
IDENTIFY
POTENTIAL B,
C&P
HAZARDS
ASSOCIATED
WITH THIS
PRODUCT &
PROCESS
ARE ANY
POTENTIAL
FOOD
SAFETY
HAZARDS
SIGNIFICANT
AT THIS
STEP?
(YES/NO)
JUSTIFY
YOUR
DECISION
FOR
COLUMN
3
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WHAT
PREVENTIVE
MEASURE(S)
CAN BE
APPLIED FOR
THE
SIGNIFICANT
HAZARDS?
IS THIS
STEP A
CRITICAL
CONTROL
POINT?
(YES / NO)
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Relationship between a
significant hazard and a CCP
CCPs are steps in the process where
HACCP control activities will occur
For every significant hazard identified
during the hazard analysis (principle 1)
there must be one or more CCPs where
the hazard is controlled
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DETERMINING CCP
CCP - step where control can be applied & is
essential to prevent, eliminate or reduce a
food safety hazard to acceptable levels
CCPs can be determined through the Use of
the CCP Decision Tree
Caution - CCP must be correctly identified
too many CCPs will dilute effort
too few could result in unsafe food
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YES
YES
NO
NO
Not a CCP
STOP
YES
NO
Q3. Could contamination occur at unaccept.
levels or increase to unaccept. levels?
YES
NO
Not a CCP
YES
Q4. Will a subsequent step eliminate or
reduce hazard to an acceptable level?
NO
STOP
CCP
YES
Q2.
NO
NOT A CCP
YES
NO
IS
CONTROL
AT THIS
STEP
NECESSARY
FOR
SAFETY?
Q3
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NO
MODIFY THIS
STEP, PROCESS
OR PRODUCT
YES
NOT A CCP
STOP*
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YES
NO
NOT A CCP
STOP*
CCP
This decision tree is derived from one that was developed by the National
Advisory Committee on Microbiological Criteria for Foods, USA
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HAZARD
A biological, chemical or
physical
agent in, or condition of,
food
with the potential
to cause an adverse health
effect
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SUMMARY
HACCP is not a stand alone system
depends on management commitment
depends on a solid foundation of PRPs: GMP/
GHP; SSOPs & relevant codes of practice
HACCP does not replace nor diminish PRP
attention must be focused on basic hygienic
practices before embarking on HACCP
The effectiveness of PRP has to be assessed
during the development & implementation of the
HACCP Plan
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Pre-requisite Programs
PRPs must be developed, documented and
implemented
They have to be effectively monitored and
controlled, including proper record keeping,
validation and verification
They are required to control factors that may or
may not be directly related to the processing
controls, but support the HACCP Plan
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