HACCP Basic Course

8/6/2019 HACCP Basic Course

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HACCPEuropa.com 2010HACCPEuropa.com 2010

HACCPHACCP

Basic CourseBasic Course


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ObjectivesObjectives

To understand the need for HACCP

To understand the benefit of HACCP

To understand the principles of HACCP

To understand the management and resourcerequirements

To understand how to prepare a HACCP plan

To understand how to implement a HACCP plan

To understand how to document the system

To understand how to ensure on going HACCPcompliance


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What Is HACCPWhat Is HACCP??

The Hazard Analysis and CriticalControl Point System

A Preventative ApproachA Powerful Product SafetyManagement Technique

A Proven and Structured Methodfor Hazard Identification andControl


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What Is a HazardWhat Is a Hazard??

A Biological, Chemical or

Physical agent, in, conditionof, food with the potential tocause an adverse health

effect.


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Biological HazardsBiological Hazards

Pathogenic Bacteria- Salmonella, E-Coli, Listeria, etc.

Parasites and Protozoa- Flatworms,Tapeworms, Flukes, etc.

Viruses- Viral Gastroenteritis,Hepatitis A, etc.

Moulds


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Chemical HazardsChemical Hazards

Cleaning Chemicals

Pesticides

Ink/Adhesive

Toxic Metals

Pest ControlRefrigerants

Fumes/Dust


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Physical HazardsPhysical Hazards

People - buttons, jewellery,drawing pins, paper clips,matchsticks, pens.

Natural Material - bone, nutshells, seeds, fruit stones.

Environment glass, wood, chipsfrom tiles, concrete.

Equipment.

Pests


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WhyUse HACCP?WhyUse HACCP?

The management of productsafety- The commercial implicationsof a potential major food incident.

Limitations of traditional QualityControl Traditional reliance is

placed on random sampling.External pressures- Customers,Media, Legislation.


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MajorFood IncidentsMajorFood Incidents

Food Eggs, Country-UK, Contaminate-Salmonella, Cause-Contamination duringprocess, Number of Ill/effect- 81, Cost-3

Million Food- French fries, Country-USA,Contaminate-Wire Bristles, Cause-Incorrectaction at metal detector, Number of Ill/effect-8Mlbs of potatoes destroyed, Cost-$4 Million.

Food-Coca Cola, Country-UK, Contaminate-Fungicide, Cause-contamination throughpackaging, Number of Ill/effect-50 Million cansrecalled, Cost-60 Million.


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Legislative RequirementsLegislative Requirements

EC directive on the Hygiene of Foodstuffs

A proprietor of a food business shall

identify any step in the activities of the foodbusiness which is critical to ensure foodsafety and ensure that adequate safety

procedures are identified,implemented,maintained and reviewed on

the basis of the followingprinciples..


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Analysis of the potential food hazards in a food businessoperation;

Identification of the points in these operations where foodhazards may occur;

Deciding which of the points identified are critical toensure food safety;

Identification and implementation of effective control and

monitoring procedures at those points; andReview the analysis of food hazards, the critical points andthe control and monitoring procedures periodically, andwhenever the food businesss operations change.



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General Product Safety Directive ( 92/95EEC)

Producers shall:

Adopt measures commensurate withthe characteristics of the productswhich they supply, to enable them tobe informed of risks which theseproducts might present and to takeappropriate action.


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What Is the Risk?What Is the Risk?

An estimate of the likelihood ofthe hazard occurring and itspotential adverse health effects.


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Definition ofa ControlMeasureDefinition ofa ControlMeasure

Any action or activity that can be

used to prevent or eliminate a foodsafety hazard or to reduce it toacceptable levels.

( Factors capable of control)


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The HACCPTeamThe HACCPTeam

A multi-disciplinary team effort

Team leader to be appointed

Minimum core HACCP team should ideallyconsist of; Quality Assurance/Technical,Operations or Production, Engineering.

Additional expertise may be provided from;Research and Development, Distribution,Purchasing,Human Resources.


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Prerequisite ProgrammesPrerequisite Programmes

Well-planned prerequisiteprogrammes will effectively designout generalised hazards that applyto the whole operation, leavingHACCP to deal with the specific

product-process hazards.


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What Is a PrerequisiteWhat Is a Prerequisite

Programme?Programme?Prerequisites are normally systems in their ownright and can be classified as the following;

Quality Management SystemsGood Manufacturing Systems

Personnel (health screening) and Training

Preventive Maintenance

CalibrationPest Control

Supplier Quality Assurance

Traceability


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How to Do a HACCP StudyHow to Do a HACCP Study

Define the Scope of the Study

Classes of Hazard( Micro/Chemical/Physical)

Process/Food chain segment

Limits of study( define start and finish of the process)

Describe the Product and identify intended use

Principle raw materials

Composition/FormulationPackaging

Storage conditions and durability

Distribution


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Construct a Process FlowDiagram

Raw materials

Process activitiesTemperature and time data

Equipment design features

Storage conditions

Validate the Process FlowDiagram

An accurate representation of the process at ALL times


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Conduct a Hazard Analysis

What are the hazards

What is the riskWhat are the control measures

Identify Critical Control Points

When all hazards and control measures have been

described, the HACCP team establishes the points wherecontrol is critical to assuring the safety of the product.

The CCP is a step which control can be applied and isessential to prevent or eliminate a food safety hazard orreduce it to acceptable levels( Codex Alimentarius)


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Identify Critical Limits

Set a critical limit for each CCP- this describes the

difference between safe and unsafe product at the CCP.They must involve a measurable parameter and may alsobe known as the absolute tolerance or safety limit for theCCP.

Examples as follows;

Chemical limits- Max pH 4.5 ( Hazard:Listeria growth)control measure:formulation pH.

Physical limits- 71.7c for 15 seconds ( Hazard; salmonellasurvival) control measure: milk pasturised


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Critical Limit- Target Levels

Control criteria which are more stringent than Criticallimits.

Can be used to take action and reduce risk of adeviation.

For Example;

During the cooking of raw chicken portions, the criticallimit is 70C for 2 minutes. A target level of 74C hasbeen set which has been determined as the ideal cookingtemperature. This establishes a safety buffer zone toreduce the potential hazard of the survival of salmonella.


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Identifying monitoring procedures

A planned sequence of measurements or observations of

control parameters to assess whether a CCP is undercontrol.

Broken down into 3 main areas; Procedure,Frequency andResponsibility.

Must be able to detect a loss of control at the CCP( whereit has deviated from its critical limits) as it is on the basisof the monitoring results that decisions are made andaction is taken.


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Monitoring procedures may involve

On-Line systems, where critical factors are measuredduring the process - these may be continuous systemswhere critical data are continuously recorded.

Off-Line systems, where samples are taken formeasurement of the critical factors elsewhere - this hasthe disadvantage that the sample taken may not fullyrepresent the whole batch.

Observational procedures, where specific action isobserved by the monitor. For example, observation by asupervisor that the operator is following the correctdebag procedure correctly.


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How to Do a HACCP studyHow to Do a HACCP study

Establish corrective action

The HACCP principle requires that corrective action is to be takenwhen monitoring results show deviation from the critical limit(s) ata CCP.

The HACCP plan is therefore likely to have two levels of correctiveaction, i.e. actions to prevent deviation and actions to correctfollowing a deviation.

Corrective actions should be developed by the HACCP team andshould be specified on the HACCP Control Chart.

Responsibilities must be assigned for corrective action both toprevent and correct deviations.

Senior management will be appropriate where the correctiveactions involve shutting down plant for periods of time or wheredisposal actions are required.


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Putting the Plan into practicePutting the Plan into practice

Validation of the HACCP plan can it work, is the flow diagram accurateto the process, have all hazards been accounted for?- obtain evidencethat the elements of the plan are effective.

Training of all relevant personnel Essential for effective HACCP

implementation, Awareness training for all staff, Specific training for CCPmonitors.

CCP monitoring the act of conducting a planned sequence ofobservations or measurements of control parameters to assess whether aCCP is under control.

Reporting deviations from Critical Limits- records are essential to

provide evidence of safe food production, sign off and review procedures.Taking defined corrective actions- decide who is responsible and at whatlevel.

Keep adequate records.

Review and verify the HACCP.


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Maintaining the HACCP SystemMaintaining the HACCP System

Verification activitiesHACCP Audits - A systematic and independent examination todetermine whether the HACCP plan is effective (validation) andcompliance with the documented HACCP plan ( verification).

Data Analysis and Review Should be reviewed on a regular basis toidentify trends and allow improvements to be made.

Maintenance activitiesKeeping up to date with hazard issues are better control measures

or monitoring procedures now available?Ongoing Training Ensures that new personnel understand theHACCP system and their individual role.

Ensuring the HACCP plan continues to be current manage anychanges in process or equipment to ensure the hazards/risks do not

arise or increase.


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Any Questions?

HACCP Basic Course

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