1 IMPLEMENTATION OF A IMPLEMENTATION OF A HAZARD ANALYSIS HAZARD ANALYSIS CRITICAL CONTROL POINT (HACCP) CRITICAL CONTROL POINT (HACCP) SYSTEM SYSTEM IN FOOD INDUSTRIES IN FOOD INDUSTRIES IN FOOD INDUSTRIES IN FOOD INDUSTRIES Departmen Department of Food Science and Technology of Food Science and Technology Faculty of Agricultural Technology Faculty of Agricultural Technology Bogor Agricultural University Bogor Agricultural University Jul July 2010 2010 Outline • Introduction to HACCP system • Introduction to HACCP system definition, why is it used, history, characteristics, where does it stand in a food safety management system, benefit and its implementation • Preparing a HACCP plan 12 t f HACCP l d i tf t Bogor Agricultural University RDH‐LN‐HACCP Training‐2010 12 steps of HACCP plan and assignments for step 1‐5, 6, 7‐8, 9‐12
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IMPLEMENTATION OF AIMPLEMENTATION OF A HAZARD ANALYSIS HAZARD ANALYSIS CRITICAL CONTROL POINT (HACCP)CRITICAL CONTROL POINT (HACCP) SYSTEM SYSTEM IN FOOD INDUSTRIESIN FOOD INDUSTRIESIN FOOD INDUSTRIESIN FOOD INDUSTRIES
DepartmenDepartmentt of Food Science and Technologyof Food Science and TechnologyFaculty of Agricultural TechnologyFaculty of Agricultural Technology
Bogor Agricultural UniversityBogor Agricultural UniversityJulJulyy 20102010
Outline
• Introduction to HACCP system• Introduction to HACCP system
definition, why is it used, history, characteristics, where does it stand in a food safety management system, benefit and its implementation
• Preparing a HACCP plan
12 t f HACCP l d i t f t
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
12 steps of HACCP plan and assignments for step 1‐5, 6, 7‐8, 9‐12
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Introduction to a HACCP SystemIntroduction to a HACCP System
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
DEFINITION OF DEFINITION OF HACCPHACCP(Hazard Analysis Critical Control Point)(Hazard Analysis Critical Control Point)
HACCP is a preventive system designed to minimize
the risk of food safety hazards; however HACCP is
not a zero‐risk food safety assurance system
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
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WHY WHY IS IS HACCPHACCP USED IN A FOOD USED IN A FOOD SAFETY ASSURANCE SYSTEMSAFETY ASSURANCE SYSTEM
• Food safety is a non‐negotiable requirement for food quality and trade
• Failure in assuring food safety will result in :
• illnesses and death in consumers
• product recall detention or destruction
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
product recall, detention, or destruction
• loss in consumer trust
• government actions
HACCP HACCP CHARACTERISTICSCHARACTERISTICS
‐ Systematic approachy pp
‐ Proactive, not reactive
‐ Team effort, not individual’s
‐ Based on common sense technique
‐ Alive and dynamic system
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
‐ Alive and dynamic system
‐ Not just a paperwork
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RELATIONSHIP BETWEENRELATIONSHIP BETWEEN GMPGMP, , SSOPSSOP, AND HACCP, AND HACCP ININFOOD QUALITYFOOD QUALITY--SAFETY MANAGEMENTSAFETY MANAGEMENT
SSOP
HACCP
Implementation and documentation of sanitationand hygiene program
Control of hazards in critical steps of process
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
GMP
Basic and general recquirement for premises,equipment, workers, and process
FOOD SAFETY MANAGEMENT SYSTEM
• 1959 : Initially deceloped by Pillsbury Co. for astronaut’s food : bite‐size, edible wrapping, safe
HISTORY OF HACCP HISTORY OF HACCP
astronaut s food : bite size, edible wrapping, safe
• 1971 : HACCP concept was first explained to publicin the US in a National Food Safety Conference
• 1972 : Pillsbury obtained a contract in HACCP training for FDA inpectors
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• 1973 : A complete HACCP document was published for the first time, adopted for low acid can food industries
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HISTORY OF HACCP ........... (cont)HISTORY OF HACCP ........... (cont)
•1985 : US National Academy of Sciences) (NAS) recommended HACCP because it was concluded to give more assurance as compared to an end‐product quality control system
•1989 : NAS establish National Advisory Committee on Microbiological Criteria for Foods (NACMCF) and introduced 7 principles of HACCP
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
•1991 : Concept of Biological, Chemical, and Phyisical hazards was developed
•1997 : HACCP concept was adopted by Codex
Initial HACCP Concept
HISTORY OF HACCP ........... (cont)HISTORY OF HACCP ........... (cont)
1. Hazard analysis
2. Determination of critical control points needed for conrolling the identified hazards
3. Determination of procedures to monitor critical control points
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
p
6
HACCP concept by NACMSF
HISTORY OF HACCP ........... (cont)HISTORY OF HACCP ........... (cont)
1. Hazard analysis2. Determination of critical control points (CCP) to control
the identified hazards3. Determination of critical limits for each CCP4. Determination of procedures to monitor CCP5. Determination of corrective actions when a deciation
occurs upon monitoring of a CCP
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
p g6. Detemination of effective recording system as a
documentation of a HACCP plan7. Determination of verification procedures to assure that
a HACCP system is implemented properly
Why is a conventional inspection not Why is a conventional inspection not adequate in assuring food safety?adequate in assuring food safety?
• The number of inspectors in any country is not• The number of inspectors in any country is not sufficient
• Inspection alone doesn not assure food safety• Inspection is anly a “snapshot” of food safety status in a certain period of time
• Contamination at low level is notdetected byconvensional testing
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convensional testing• Industries heavily rely on inspection, testing, consumer’s complaint to detect loss in control of their food quality‐safety management system
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WhyWhy is is HACCP HACCP becoming importantbecoming important??
N d t i th k t i kl• New products appear in the market quickly• Use of new methods, techniques and equipmentin food processing
• World market and changes in consumption patterns
• Emerging pathogens
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• Emerging pathogens• The need for international harmonization in world trade
BENEFIT OF IMPLEMENTATION OFBENEFIT OF IMPLEMENTATION OFHACCPHACCP SYSTEMSYSTEM
1. Prevent or detect unsafe raw materials and1. Prevent or detect unsafe raw materials and ingredients before entering production system
2. Prevent a problem to grow bigger since it is handled earlier with early warning in HACCP
3. Cautious of any hazard in a facility shared for production of various products
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
4. Reduce internal product “holding” and or product destruction
5. Prevent dependence in end product testing that allow unsafe products relesed to the market
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Implementation of a HACCP System in Food Industries
• Specific for each type of product, process and factory
• Prerequisite : GMP and SSOP
• Requires strong commitment of management to
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
provide safe food for the public
REFERENCES FOR HACCP IMPLEMENTATION
• Codex Alimentarius (CAC)• Codex Alimentarius (CAC)• SQF 2000: Safe Quality Food 2000• EQCI: European Quality Certification Institute• ISO 22000 : 2005 on Food Safety Management
System• Indonesia :
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
do es aSNI 01‐4852‐1998 on HACCPPedoman BSN 1004/1999
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STEPS FORSTEPS FOR HACCPHACCP IMPLEMENTATION IMPLEMENTATION (C(Codexodex))
7. Determine CCP Principle 2
Principle 1
6. Identify all potential hazards, analysis of risk and establish preventive measures
1. Establish HACCP team
2. Describe product
3. Identify product use
8. Determine CL for each CCP
9. Determine monitoring system for each CCP
10 . Determine corrective actionsf d i i
Principle 2
Principle 3
Principle 4
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4. Establish a flow chart
5. Verify flow chart on site
for deviation
11. Determine verification procedures
12. Determine recording system
Principle 5
Principle 6
Principle 7
Preparing a HACCP Plan
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
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Establish a HACCP TeamEstablish a HACCP TeamHACCP HACCP Step 1Step 1
• A HACCP team is established to develop a HACCP plan
• The team members is chosen from personnels who are
involved in daily activity of food production they are of
various education/academic/skill background
(multidiscipline) :may consists of personnels from
d i i i QA l b i i i
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
• Details of all process steps including inspection, transportation, storage and or delay :– Input to the process including raw materials, packaging, water and chemicals
– Output from the process including waste
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from packaging, raw materials, in‐progress products, rework and rejected products
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
• All HACCP team members must be invoved in flow chart verification process
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Assignments for Steps 1‐5
For each group consisting of 4‐6 students, • make a HACCP team, appoint the chair, describe each member’s skill or background
• describe the product your team has made• describe the product use, including the consumer
bli h h fl h
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
• establish theflow chart• verify flow chart in your group discussion• Use Form 1‐5 of the HACCP Work book
•The HACCP team evaluates specific hazard in each step and
Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
The HACCP team evaluates specific hazard in each step and or raw materials/ingredient associated to the step, and determine risk or significance of each hazard
•The HACCP team will use references, brainstorms, expert judgment and :
‐ the verified flow chart
raw materials ingredients additives and or processing
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
‐ raw materials, ingredients, additives and or processing aids associated to the steps in the flow chart
‐ product description and use as well as user
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1. Hazard Identification :id tif h d( ) i th t ( ) d
Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
identify hazard(s) in the process step(s) and raw materials, ingredients, additives, processing associated to the steps
2. Determine Preventive MeasuresObtain the source of identified hazard(s) and design the preventive measures, i.e. any activity to eliminate and or minimize the hazard(s) to the acceptable level
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
minimize the hazard(s) to the acceptable level3. Determine Risk or Significance
Classify risk or significance as H (high), M (medium) or L (low) using various approaches
• When identify hazard, a HACCP team must understand and
Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
consider :‐ types of hazard involved, probability (P=likeliness to occur), severity (S), probability of hazard being undetected (U)
‐ common hazard(s) associated to a food or raw material‐ whether quality will be incorporated in HACCP plan
• When determine risk, ONE of the following approaches can be d
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
used :‐ risk as a function of P and S (applicable for process steps) or‐ risk as a function of P, S and U (applicable for process steps)‐ risk as a function of a risk category (applicable for raw material, product)
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Biological• Bacteria
VirusesProtozoa
Types of Food Safety Hazards
ProtozoaParasites
Physical Hazards• Glass • Wooden chips• Stone
Chemical Hazards• Mycotoxin• Mushroom, shellfish,
algae toxins• Pesticides, fungicides,
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
• Metal pieces• Insect parts• Bone• Plastic• Personal accessories
, g ,fertilizer, hormines, antibiotics
• Heavy metals,dioxin• Adulterant : melamine, formaline• Excessive use of additives
Several questions that may arise during Hazard Identification of raw materials :
Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
‐ Can pathogens, toxins, chemical or physical hazards be present in raw mat? What kind?
‐ Is additive used? What’s the limit of use? Is there any possibility of using it at hazardous concentration
‐Will elimination of a certain ingredient support microbial growth?
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
‐ Is acid use or pH of end product affecting microbial growth?
‐ Is aw of end product affecting microbial growth‐ Is cooling necessary to maintain quality during storage and or distribution?
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Several questions that may arise during Hazard Identification of process steps :
Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
Identification of process steps :
‐ Can contaminant(s) or hazard(s) enter the product during processing?
‐ Can personal hygiene, contaminated raw material or equipment, cause cause cross contamination?
‐ Can microorganisms grow and multiply during handling
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
‐ Can microorganisms grow and multiply during handling, process and or storage?
‐ Is the combination of temperature and time adequate to prevent microbial growth?
Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
Identification of Hazard; conducted by :
• Observing list of raw materials, ingredient, additives, processing aids used to produce the food whose HACCP plan is prepared
• Observing flow chart including food handling, operations or processing techniques applied, storage etc
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
• Making a list of hazards((biological, chemical and or physical) potentially occur/associated with materials, process step and identify where they might enter the process steps
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Determination of Risk/Significance of a Hazard
Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
Determination of Risk/Significance of a Hazard
• Is carried out to determine whether a specific hazard associated to a process step or material is significant or risky thus it is potential to be a CCP
• Approach to be used forsignificance determination in this class is : matrix of significance/risk based on P
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
this class is : matrix of significance/risk based on P (probability) and S (severity)
Risk or Significance of A HazardRisk or Significance of A Hazard
Severity : y
Probability(likeliness to occur)
Ll Ml Hl
Lm Mm Hm*
l
m
L M H
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
)Lh Mh* Hh*h
*significant hazard
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Raw material or ingredients sensitive to microbiological hazards
Beef and poultry, Egg, FishMilk and milk products, including cheeseNuts and ingredients containing nutsSpicesChocolateMushroomSoy flourGelatinPasta
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
Frog legVegetablesCereals and their floursCultures for fermentationSeveral natural flavoring and colorants
Salt
S
Raw material or ingredients insensitive to microbiological hazards
Sugar
Chemical preservatives
Acidulant and food grade leavening agents
Gum and thickener (source‐dependent, some are sensitive such as tapioca and gum resulted from fermentation)
Synthetic coloran
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y
High sugar and or salt candy
Most oil and fat (except for butter)
Acid fruits
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Severity of PathogensSevere hazard on general population, life threatening or chronic sequelae or long term illness
Brucella melitensis, B.abortus, B. suis, botulin, EHEC, Salmonella typhi, S. paratyphi A,B,C, Shigella dysenteriae, Burkholderia cocovenenans, V.cholerae O1 dan O139, Mycobacterium bovis, aflatoksin, vCJD/BSE
Campylobacter jejuni serovar O:19, EPEC, ETEC, Clostridium perfringens C, C. botulinum A and B, Enterobacter sakazakii, Listeria monocytogenes, V. vulnificus, Hepatitis A virus, Cryptosporodium parvum
Severe hazard on limited population, life threatening or chronic sequelae or long term illness
S. enteritidis, S.typhimurium, other Salmonella, Yersinia enterocolitica, Y. pseudotuberculosis, Shigella flexneri, S.boydii, S.sonnei, L.
Serious hazard, decrease ion life capacity but not, life threatening, rare sequelae or medium term
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
g f , y , ,monocytogenes, trichotecene, T2, zearalenon, fumonisin, okhratoksin
rare sequelae or medium term illness
Medium hazard, not life threatening, short term, self‐limiting symptoms, causes discomfort
B. cereus and its emetic toxin, C. perfringens A, EPEC, ETEC, enterotoksin Staph. aureus , V. cholerae non O1, dan non O139, SRSV (including Norovirus), histamin
Determination of Preventive MeasuresDetermination of Preventive Measures
Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
‐ Preventive measures are activities used to control the identified hazards
‐ Preventive measures shall be designed to eliminate or reduce the identified hazards to an acceptable level
‐ A hazard may require more than one preventive measures meanwhile one preventive measure may be
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
measures, meanwhile one preventive measure may be used toward reduction and or elimination of more than none hazard
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Examples of Preventive Measures for Microbiological d
Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
Hazards :‐ heating (sterilization or pasteurization)‐ drying (aw reduction)‐ acidification‐ cooling (refrigeration)‐ freezingaddition of preservatives
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
‐ addition of preservatives‐ fermentation‐modified atmosphere packaging (MAP)‐ control atmosphere storage (CAS)
Cl idi b li S ili i d i i ddi i
Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
Examples of Preventive Measures for A Specific Pathogen
Clostridium botulinum(botulism)
Sterilization during canning, addition of salt, nitrite, acidification to pH <4.6, aw reduction to 0.93
S. aureus Implementation of sanitation and SSOP, policy for infected personnels, cooling acidification heating
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cooling, acidification, heating, addituion of bacteriostatic agents
Salmonella Avoid contamination at the source of raw materials, control of raw mat, heating, cooling, pendinginan
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Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
Examples of Preventive Measures for Chemical Hazards
Natural toxicants Guarantee from supplier
Added chemicals Detail specification of raw materialsand or ingredient, supplier guarantee
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
Chemical adulterant Identify all additives, check whetherthe additived are permitted for use
Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
Examples of Preventive Measures for Physical Hazards
Foreign matters in rawmaterials
Implement a specification(s) for rawmaterial(s), supplier guarantee, inspectupon arrival
• CCP (Critical Control Point) is a point or procedure in a food processing steps that will cause health risk to consumers when it is not controlled properly
• CCP can be :
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
‐ a process step : heating, coolong‐ formulation : addition of acidraw materials
• A decision tree can be used to help determining CCPs
• obtain data (information) for decisions made• early warning when deviation occur• prevent/minimize product loss• pin point reasons for problems or deviations that occur• provide documents that a product has been processed in
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
‐ Code, date of production‐ Reasons for proct holding‐ Amount (number) of products withold‐ Evaluation results, signature of person in charge of evaluation‐ Disposition, signature of person in charge of disposition‐ Reasons for deviation‐ Corrective actions taken
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
Corrective actions taken‐ Follow up actions to assess effectivity of corective actions ‐ Date‐ Signature of person in chargeRecords of Corrective Actions must be documented
• periodical reviews on all documented records • carried out when there is a change in procedures, raw materials, ingredients, additives, lay out, storage conditions,di t ib ti k i ti th d
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
distribution, , packaging, consumption methods• new hazard issues emerge
A systematic and independent evaluation to determine whether‐procedures have been implemented effectively‐activities and results comply with the procedure d t
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‐ HACCP plan and all of the supporting documents‐ Document of Monitoring ‐ Document of Corrective Actions‐ Document of Verification Procedures
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
CHANGES IN A HACCP PLAN
Changes in a HACCP plan can be done due to these f ll i hfollowing changes :
‐ raw materials
‐ lay out
‐ equipments
‐ cleaning or sanitation program
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
g p g
‐ implementation of new procedures
‐ new consumer groups
‐ new information on a hazard
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Assignments for steps 9‐12
Using information obtained from step 1‐8 and studies on the reference, team members discuss and determine :
• how a monitoring is designed for the CLs of theCCPs
• what kind of corrective actions are planned in the light of deviation during CL monitoring
• What kind of verification system is planned for the CLs/CCPs effectiveness
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
CLs/CCPs effectiveness
• What kind of documents are to be made to be an effective HACCP system
• Complete the HACCP table
HACCP WorksheetHACCP Plan
Name of Product : ……………………………………………………………………Company :Company : …………………………………………………………………...
Process Principle 1 Principle 2 Principle 3 Principle 4 Principle 5 Principle 6 Principle 7step hazard CCP CL what how where who when corrective action verification documentation
what who
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Selamat BekerjaSelamat Bekerja
Thank YOUThank YOU
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