FOOD SAFETY (HACCP)

FOUNDATION COURSE

COURSE AGENDA

What & why of food safety

The Pre-requisite program

HACCP Preliminary steps

HACCP Principles

System Maintenance

WHAT WILL YOU LEARN?

Introduction of HACCP

Understand the common best practices, such as GHP and GMP

Understand 7 HACCP principles and their implementation

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HOW THIS COURSE IS BUILT UP

Introduction of HACCP,

Group activities
Brainstorming

Pre-requisite Program &

HACCP Principles

Theoretical input
System Maintenance

Reflection

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HOW TO CONTRIBUTE TODAY

Illustration coming

Learning new things is demanding, but fun

Illustration coming

Illustration coming

Active participation

Illustration coming

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No stupid questions

Benefit from sharing experiences

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Lets get started!

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Introduction to HACCP
Development of HACCP

WHAT WILL YOU LEARN?

Understand why product safety is important

How HACCP is developed and its benefits

What are various legislations

Foodsafety

Why Food Safety Safety ?

Legislative Requirement
Consumers awareness

Consequences

unrecoverable market loss

Limitations of quality
inspection
More complex processes /
food operations
External pressure

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STRUCTURE OF FOOD SAFETY

MANAGEMENT SYSTEM
Food Safety Elements

2
HACCP Principles

1
Prerequisites
GMP, GHP, others

System Elements
ISO 9001 or general
principles on
management
system
requirements
e.g.: Management Review,
Internal Audits,
Corrective-Preventive
Actions, Document control
etc
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Beginningofjourney
HACCPsystem

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HACCP- ORIGIN AND MILESTONES

Origin

Pilsbury,

NASA and US Army LAB (Natick) - Principal object

was to develop safe food for astronauts
Based on engineering system - Failure Modes and Effect Analysis
(FMEA)

Milestones

NACMCF

guidelines for USA Defined terminology

HACCP
Implementation of EU Directive
USDA/FDA prescribe industry specific HACCP guidelines shellfish, meat, horticulture
White paper on Food Safety published in Jan 2000 - Farm13
To-Fork concept was introduced

DEVELOPMENT OF HACCP

Codex Alimentarius Commission

FAOs and WHOs joint Food Standards Programme

Executive body: Codex Alimentarius Commission

Document Recommended Code of Practice General
Principles of Food Hygiene and
Hazard

Analysis and Critical Control Point (HACCP) system and

guidelines for its application

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BENEFITS
Preventative System
Systematic Approach
Effective use of Resources
Cost Effective Control System
Helps Demonstrate Due Diligence
Internationally Accepted
Complements Quality Management Systems
Facilitates regulatory inspection
Demonstrates Management Commitment
Product Quality Bonus
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Legalrequirements

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GROUP WORK

What are applicable statutory & regulatory requirement

related to your industry.

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Pre-requisite Program
GAP, GMP, GHP, GLP

WHAT WILL YOU LEARN?

What is Pre-requisite program

What are elements of pre-requisite program

FSSAI Schedule IV Part II and V requirements

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TheFoundationtoHACCP
prerequisiteprogram

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IMPLEMENTATION OF FOOD SAFETY SYSTEM

Maintenance

Food Safety
Management System

Prerequisites
GMP

Basic
steps of
HACCP

7 HACCP
principle
s

Implement
ation

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PRE REQUISITE PROGRAM

What is Prerequisite Program?

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DEFINITION OF PRE-REQUISITES
universal steps or procedures that control the operational conditions
within a food establishment allowing for environmental conditions that
are favourable for the production of safe food
Codex Alimentarius Commission

(food safety) basic conditions and activities that are necessary to

maintain a hygienic environment throughout the food chain, suitable
for production, handling and provision of safe end product and safe
food for human consumption.
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ELEMENTS OF GHP, GMP

1. Objectives

6. Establishment: Maintenance and Sanitation

2. Scope, Use and Definition

7. Establishment: Personal Hygiene

3. Primary Production

8. Establishment: Transportation

4. Establishment: Design and Facilities

9.Product Information and Consumer Awareness

5. Control of Operation

10. Training
As defined in CAC-Basic Code of Hygiene

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CASE STUDY
Define a pre-requisite program for the company for your company
Group I : Production
Group II : Storage requirements
Group III : Packing area
Group IV

: Staff facilities

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HACCP Implementation

WHAT WILL YOU LEARN?

12 steps of HACCP Implementation
Maintenance of the system
Group Work and Case study

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HACCP SO FAR
GHP
7 HACCP
GMP preparation
Implementation Maintenance
principles
others

Prerequisites

HACCP Method

System Elements

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HACCP STEPS PREPARATORY

Step 0

Management Commitment

Step 1

Assemble HACCP Team

Step 2

Describe the Product

Step 3

Identify Intended Use

Step 4

Construct a flow diagram

Step 5

On Site verification of flow diagram

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HACCP STEPS PRINCIPLES

Step 6

Step 7

Step 8

Step 9

Principle 1 Identification of hazards, hazard assessment

and establish control measures
Principle 2 Determine Critical Control Point (CCP)
Principle 3 Establish Critical Limit
Principle 4 Determine a monitoring system for CCP

Step 10

Principle 5 Determine Corrective Actions

Step 11

Principle 6 Establish a verification system

Step 12

Principle 7 Establish a documentation and record system

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PreparatorystepsofHACCP

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HACCP STEPS PREPARATORY

Step 0

Management Commitment

Understands benefits and impacts

Policy and Objectives
Provides resources

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HACCP STEPS PREPARATORY

Step 1

Assemble HACCP Team

Multidisciplinary with a HACCP Team Leader

Size can vary depending upon the company
Conducts a gap analysis before start
Adequate training to the HACCP Team

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HACCP STEPS PREPARATORY

Step 2

Describe the Product

Full description of the product describing

Raw Material Ingredients and composition in final product
Physical Chemical Microbiological characteristics of end product
Preservation Method
Packaging details
Shelf life
Labeling requirements
Handling , Preparatory , Storage requirements
Distribution method

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HACCP STEPS PREPARATORY

Identify Intended Use

Step 3

Identify potential users

Safe storage, preparation and serving described

Unintended handling and potential abuse of the

product

Specification for the final product based on info from

customers, internal experts

Determine sensitive consumers (Allergens - YOPI)

-

Young
Old
Pregnant
Immuno-disordered

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CASE STUDY I : PRODUCT

DESCRIPTION

Using Step 2 & 3, describe your product

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HACCP STEPS PREPARATORY

Step 4

Construct a flow diagram

A flow diagram is A systematic representation of the
sequence of steps or operations used in the production or
manufacture of a particular food item.
all steps in manufacturing process included
indicated where raw materials join flow
where reworking and recycling takes place
where intermediates, by-products and waste are removed
Flow diagrams sufficiently clear and detailed for potential
hazards to be identified
includes relevant process data

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FLOW DIAGRAM - EXAMPLE

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HACCP STEPS PREPARATORY

On site verification flow diagram

Step 5

The ready flow diagram compared with the

operation and layout.

All team members visit on the site to confirm

- the diagram is complete
- is valid trough all operational period

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CASE STUDY II FLOW DIAGRAM

Construct a flow diagram

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HACCPPrinciples

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HACCP STEPS HACCP PRINCIPLES

Step 6

Principle 1 - List all potential hazards associated with

each step,
conduct a hazard analysis, and consider any measures
to control identified hazards
Content principle 1:
Identify all existing and potential hazards associated
with each process step
Evaluate the risk of each hazard
Establish control measures

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DEFINITIONS
Hazard
A biological, chemical or physical agent in, or condition of, food
with potential to cause an adverse health effect.
Codex Alimentarius Commission

Biological

Chemical

Physical

E. Coli (0157:H7)

Naturally occurring toxins

Glass

Salmonella

Food Additives in excess

Metal, Machine fillings

Clostridium perfringens

Pesticide residues

Paper

Listeria monocytogens

Antibiotic residues

Plastic

Staphylococcus aureus

Environmental
contaminants

Dead Insects

Camphylobacter

Chemical contaminants
from packaging
Allergens

Jewellery
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SOME CONSIDERATIONS .
pH
best grow values : 6.6-7.5
Molds > Yeasts > Bacteria
Salmonella spp. 3.5 - 9.5
Clostridium botulinum : 4.5 - 8.5

Moisture / Water activity (aW)

The ratio of the vapour pressure
of food substrate to the vapour
pressure of pure water, at the
same temperature aw= p/p0
Gram- have higher
requirements than Gram+
Most spoilage bacteria dont
grow below aw= 091

Nutrient Content
water
source of energy
source of nitrogen
vitamins, minerals

Oxidation-Reduction Potential
The O/R potential of a substrate
the ease with which the
substrate loses or gains
electrons
anaerobic (e.g.: Clostridium
spp.) - Eh
aerobic (e.g.: Bacillus spp.) + Eh

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THE SOURCES OF THE

INFORMATION
ram
g
a
i
d
flow
Use of

Screening Analysis (SPC)

Intern
a
Exper l and Exte
rnal
ts

Literature

Reg

ulat
ory
g

es in
c
i
t
c
a
r
p
Basic
ry
indust

uide
line
s

Epidemiological data

the

Customer Complaints

nal and
r
e
t
n
i
f
o
Results
udits
a
l
a
n
r
e
t
ex

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DEFINITIONS
Hazard / Risk analysis:
The process of collecting and evaluating information on hazards and
conditions leading to their presence to decide which are significant for food
safety
RISK = PROBABILITY*SEVERITY
Likeli
hoo
d/
Pro Low
bab
ilit Medium
y High

Consequences / Severity
Low

Medium

High

Significant
Significant

Significant

Significant

Significant

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DEFINITIONS
Control Measure
Control Measures are those systems in place at a process step that eliminate
hazards or reduce their impact or occurrence to acceptable levels.
Codex Alimentarius Commission

Control measure examples:

-

Pre-requisite program e.g. GMP, GHP, GAP etc.

Training
Additional controls e.g. Metal detector

More than one control measure may be required to control a specific

hazard (s) and more than one hazard may be controlled by a specified
control measure.

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CASE STUDY III: PRINCIPLE 1

Identify potential hazards for at least 2 steps
Conduct an hazard assessment
Establish Control Measures
(60 Min)
Present your Hazard Analysis Worksheet (10 min
each)

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HACCP STEPS HACCP PRINCIPLES

Step 7

Principle 2 Determine Critical Control Points (CCP)

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

Aided by use of a decision tree:

consider each step in the flow diagram
must be applied on each (significant) hazard
use common sense

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HACCP STEPS HACCP PRINCIPLES

Step 8

Principle 3 Establish Critical Limit

A criteria that separate acceptability from unacceptability.

Limits associated with

Temperature- time,
pH,
titratable acidity,
concentrations,
moisture level,
water activity,
available chlorine,
viscosity,
food additives quantity
sensory parameters (texture, smell) etc.

Consider National legislations

Target Value and Action Value may also be defined.

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CRITICAL LIMITS AND CONTROL MEASURES

Level of control
strict

Target Level
all
CCPs
Safety Buffer Zone

lower

Critical Limit

all hazards
Control measure
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Step 9

Principle 4 Establish Monitoring System

The act of conducting a planned sequence of observations or
measurements of control parameters to assess whether a critical
control point (CCP) is under control.
Purpose:

to show the state of control at a CCP

as a trigger for corrective actions when critical limits are

exceeded

provides data for trend analysis

Should include:
What, When, Where , How, Who
Monitoring Records
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HACCP STEPS HACCP PRINCIPLES

Step 10

Principle 5 Establish Corrective Actions

Any action to be taken when the results of monitoring at
the CCP indicate a loss of control.

Corrective actions but bring CCP back in control

Procedure to describe handling of non-conforming

products

- Destroy the non-conforming product

- Recycling in production process

- satisfy another product specification of a less sensitive

product.

Responsibilities for information and action

Notification and Recall procedures

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CASE STUDY IV: HACCP PLAN

Determine CCP

Establish Critical limit

Determine a monitoring system for one CCP.

Establish procedure for Corrective action

( Time : 45 min)

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HACCP STEPS HACCP PRINCIPLES

Principle 6 Establish Verification procedure

Step 11

Purpose of verification is to determine, if the HACCP

system:
- complies with the HACCP plan
- is effective
- is appropriate for the current situation

Procedures for verification can include as a minimum:

-

Purpose;
Methods, standard operating procedures or tests applied;
Tasks and responsibilities;
Frequency;
Records.

Internal Audits can be a part of verification activity

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DEFINITIONS
Validation :
Obtaining evidence that the elements of the HACCP plan are effective.
Codex Alimentarius Commission

Prior to implementation of HACCP System

Validation of
Pre requisite program (as applicable)
Critical Limits
Hazard identification on sound scientific data
Control measures
the parameters and methods used to monitor the control
measures are appropriate

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DEFINITIONS
Verification :
The application of methods, procedures, tests and other evaluations, in
addition to monitoring to determine compliance with the HACCP plan.
Codex Alimentarius Commission

Examples
Review of the HACCP system documents and records;
Analysis of (near) recalls and product dispositions;
Verify control measures are effective
Analysis of customer and consumer complaints related to hygiene and food
safety;
Review of analytical outcome of random sampling and analysis of products;
Evaluation of conformity with applicable legislation and regulations
Review of gaps competency gaps staff with respect to hygiene and food
safety, resulting in effective (on-the-job) training sessions;

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VALIDATION VS VERIFICATION
Are we doing the right things?

Validation
Literature

Our plans

Different vocabulary to ISO

9001
Are we doing things right?

Verification
Our plans

Our activities

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HACCP STEPS HACCP PRINCIPLES

Step 12

Principle 7 Establish Documentation and Records

Purpose:

documentation to demonstrate that the HACCP system

can be adequately understood and effectively and
efficiently operated

records to demonstrate that the system operates

effectively, and that processes have been carried out under
hygienically conditions

Examples of Documents

Policy

Hazard Analysis & HACCP Plan

Internal Audits

Procedures describing pre-requisite

program

Product Recall

Examples of Records

Records of team meetings

Records of product and process

data and flow diagrams

Records of deviations and

corrective actions taken

Audit reports

Training records
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MaintainingtheHACCP
system

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HACCP STEPS HACCP PRINCIPLES

On going activity

Maintenance, Awareness and Training

review of system may necessary:

-

new product, new process, new ingredients

new technology, machinery, etc
new legislation, discovery of new hazards

Identify training needs

- Typically on functional or individual basis

- to be recorded, e.g. through matrix etc
- reviewed on regular basis

Determine the training program

- Priority to be risk based

Maintain comprehensive records

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