Hazard Analysis Critical

Control Points (HACCP)

HACCP
• is a quality assurance system
which identifies, evaluates, and
controls/reduces food hazards.
• Food safety hazards are chemical,
biological, or physical agents in
food that can affect consumers'
health adversely.
HAZARD ANALYSIS CRITICAL
CONTROL POINTS

Food safety management

system designed to control
hazards at points critical to food
safety
An evaluation system to identify,
monitor, and control
contamination risks in
foodservice establishments
HACCP
can only be applied in food
processing plants where Good
Manufacturing Practice (GMP) is
already in place.
 HACCP
Definitions:

Contamination: presence or introduction of a

hazard
Control measures: actions required to prevent or
eliminate a food safety hazard or reduce it to an
acceptable level
Control point: a step in the process at which
control may be applied, but a loss of control would
not result in an unacceptable
Corrective action: action to be taken when a
critical limit is breached
 HACCP
Definitions:

Critical control point: a step in the process at

which control can be applied & is essential to
prevent or eliminate a food safety hazard or
reduce it to an acceptable level
Critical limit: value of a monitored action that
separates the acceptable from the unacceptable
Deviation: failure to meet a critical limit
Flow diagram: a systematic representation of the
sequence of steps or operations involved with a
particular food item or process, usually from
receipt of raw materials to consumer
 HACCP
Definitions:

HACCP team: a group of people with appropriate

expertise who develop & implement a HACCP
system
Hazard: a biological, chemical or physical agent
in, or condition of, food with the potential to cause
harm to the consumer
Hazard analysis: process of collecting &
evaluating information on hazards & conditions
leading to their presence to decide which are
significant for food safety & therefore should be
addressed in the HACCP plan
 HACCP
Definitions:

Monitoring: planned observations &

measurements of control parameters to confirm
that the process is under control & that critical
limits are not exceeded
Risk: probability that (a) condition/s will lead to a
hazard
Severity: seriousness of the consequences of the
results of a hazard
Target level: predetermined value for the control
measure, which will eliminate or control the
hazard at a control point
 HACCP
Definitions:

Tolerance: specified degree of latitude for a

control measure, which if exceeded, requires
immediate corrective action
Validation: obtaining evidence that elements of
the HACCP plan are effective, especially the
critical control points & critical limits
Verification: application of methods, procedures &
tests, & other evaluations, in addition to the
monitoring, to determine compliance with the
HACCP plan
 HACCP
The benefits of having a HACCP system:

Compliance with legislation & third party auditors

Proactive & cost-effective
Controls are easy to monitor & are carried out on
the premises
Complementary to quality management systems
Reduces business risk
Brand protection
Facilitates international trade
 HACCP
The Implementation of HACCP
Task No. 1: Assemble & train the HACCP
Team
Must be proportionate to the size, risk &
complexity of the business
Multidisciplinary
Most members involved with daily food
production operations
Knowledgeable of food product and
production operations
Outside expert with advance technical know-
how
 HACCP
The Implementation of HACCP
Task No. 2: Describe the product.
➘a detailed and complete description of the
product
 Product Name
 Important Product
Characteristics
 Shelf-life, at what condition
 Distribution
 Labeling Instructions
 List of Raw Materials and
Ingredients

The Implementation of HACCP
Task No. 2: Describe the product.
PRODUCT DESCRIPTION
Product Name: Frozen raw beef
patties
Important characteristics: Product
meeting company & regulatory
specifications for sensory, physico-
chemical & microbiological quality
Distribution: Refrigerated vehicles
Labeling instructions: Store below
5ºC; Use-by-date
HACCP
Shelf-life: 3 days at 5ºC
Raw materials: beef
cuts/trimmings; non-meat
ingredients (salt, spices)
Packaging: Shrink wrap
Brief process description: formed,
ground beef, repackaged and
stored until used
 HACCP
The Implementation of HACCP
Task No. 3: Identify intended use and
consumer of the product.

Intended use:
describes how the product is normally
used by end-users
Intended consumers:
refers to the expected group of
individuals who will consume the food
product
 HACCP
The Implementation of HACCP
Task No. 4: Develop the process flow
diagram..
Develop Process Flow
refers to sequential steps in food production
simple and clear
represented by a block/line-type flow
diagram
includes only pertinent technical
parameters (time, temp) per step
 HACCP
The Implementation of HACCP
Task No. 4: Develop the process flow
diagram..

Source: The Foundation HACCP Handbook

 HACCP
The Implementation of HACCP
Task No. 5: Verify flow diagram..

 Inspection of the operation

on-site to check the
accuracy and completeness
of the process flow diagram
 Revision of the draft flow
diagram and plant
schematic
 HACCP
The Implementation of HACCP
Principle 1: Conduct a Hazard Analysis

Involves:
Identifying hazards that may affect the
process;
Identifying the steps at which the hazards
are likely to occur;
Deciding which hazards are significant;
and
Determining measures necessary to
control the hazards
 HACCP
The Implementation of HACCP
Hazard Analysis…

Hazard
- A biological, chemical or physical agent
that would likely cause illness or injury
in the absence of control

Most physical & chemical

hazards affecting catering &
retailing will be removed by
effective prerequisite
programs.
 Hazard Analysis…
Example…

Source: The Foundation HACCP Handbook

HACCP
 HACCP
The Implementation of HACCP
Hazard Analysis…

Control Measures
Actions taken to
prevent, eliminate
or reduce hazards
to an acceptable
level
 HACCP
The Implementation of HACCP
Principle 2: Determine the Critical
Control Points (CCPs)

Critical Control Point

A step or procedure at which
some control can be applied
and is essential to prevent or
eliminate a food safety hazard
or reduce it to an acceptable
level
 HACCP

Critical Control Point Decision Tree

A sequence of
questions to
determine whether
a control point is a
CCP
 CODEX Decision Tree

Source: The Foundation HACCP Handbook

 Critical Control Points

Source: The Foundation HACCP Handbook

HACCP
 HACCP
The Implementation of HACCP
Principle 3: Establish Critical Limits

Represents boundaries used to evaluate whether

an operation is producing safe products
 HACCP

Sources of Information on Critical

limits
Research Data
Scientific Publication
Regulatory requirements
and guidelines
Experts
Experimental Studies
 Critical Limits

Source: The Foundation HACCP Handbook

 HACCP
The Implementation of HACCP
Principle 3: Establish Critical Limits

The difference between a critical limit and a target

level is known as a tolerance.
 HACCP
The Implementation of HACCP
Principle 4: Establish a system to
monitor control of the CCP

Monitoring
planned sequence of
observations or
measurements to assess
whether a CCP is under
control and to produce as
accurate record for future
use in verification
 HACCP

Purposes of
Monitoring
➢ To track system
operations
➢ To determine when
there is deviation
from a critical limit
➢ To establish records
for use in
verifications
 HACCP
The Implementation of HACCP
Principle 4: Establish a system to
monitor control of the CCP

Should state:
• WHAT the critical limits & target levels are;
• HOW the monitoring system should be
undertaken;
• WHERE the monitoring should be
undertaken;
• WHEN the monitoring should be undertaken;
and
• WHO is responsible for monitoring
 Methods of Monitoring

Source: The Foundation HACCP Handbook

HACCP
 Monitoring…

Source: The Foundation HACCP Handbook

 The Implementation of HACCP
Principle 5: Establish Corrective Action
Source: The Foundation HACCP Handbook
 HACCP
The Implementation of HACCP
Principle 5: Establish Corrective Action

Source: The Foundation HACCP Handbook

 Corrective Actions…
HACCP

Source: The Foundation HACCP Handbook

 HACCP
The Implementation of HACCP
Principle 6: Establish Record Keeping
and Documentation

involves development and

documentation of all
procedures and records of
HACCP principles and their
application
 HACCP
The Implementation of HACCP
Principle 6: Establish Record Keeping
and Documentation
Documentation includes:
• HACCP team & responsibilities;
• Hazard analysis including product or process
description;
• Critical control point determination & flow
diagram;
• Critical limit determination;
• HACCP control charts;
• Verification details; and
• Prerequisite programs
 HACCP
The Implementation of HACCP
Principle 6: Establish Record Keeping
and Documentation
Records include:
• CCP monitoring activities;
• Deviations & corrective actions;
• Modifications to the HACCP system;
• Audit reports;
• Customer complaints;
• Calibration of instruments; and
• Prerequisite programs monitoring activities.
 HACCP
The Implementation of HACCP
Principle 7: Establish Verification
Procedures

Involves the application of

methods, procedures, tests
and other evaluation, in
addition to monitoring to
determine if the HACCP
system is working correctly
 HACCP
Verification Procedures

Validation Verification
Activities activities
Scientific and Check if the
technical review of developed HACCP
the developed System is
HACCP plan to functioning as
determine its intended
adequacy in
effectively
controlling the
occurrence of
hazards
 HACCP

Purposes of Verification
To ensure that :
➢flow diagram remains
valid;
➢hazards are being
controlled
➢monitoring is satisfactory;
and
➢When necessary,
appropriate corrective
action has been or will be
taken
 When to conduct a review?

Source: The Foundation HACCP Handbook

HACCP
 HACCP
Reasons for failure of HACCP:
Poor hygiene practices;
Lack of management commitment;
Lack of knowledge/training;
Lack of resources;
System to complex & not understood;
Poor, inaccurate records;
Too much paperwork;
Externally imposed system;
System is only available in the manager’s office;
Wrongly identified critical control points;
Unrealistic critical limits
Logic Sequence for the Application of HACCP

Assemble HACCP Team

Describe product

Identify intended use

Construct flow diagram

On-site confirmation of flow diagram

List all potential hazards

Conduct a Hazard Analysis
Establish Critical Limits for each CCP

Determine CCPs

Establish Critical Limits fro each

CCP
Logic Sequence for the Application of HACCP...

Establish a monitoring system for each CCP

Establish corrective actions

Establish verification procedures

Establish documentation and record

keeping