HACCP

The HACCP system, which is science based and systematic, identifies specific hazards and
measures for their control to ensure the safety of food. HACCP is a tool to assess hazards and
establish control systems that focus on prevention rather than relying mainly on end-product
testing. Any HACCP system is capable of accommodating change, such as advances in
equipment design, processing procedures or technological developments.
HACCP can be applied throughout the food chain from primary production to final
consumption and its implementation should be guided by scientific evidence of risks to
human health. As well as enhancing food safety, implementation of HACCP can provide
other significant benefits. In addition, the application of HACCP systems can aid inspection
by regulatory authorities and promote international trade by increasing confidence in food
safety.
The successful application of HACCP requires the full commitment and involvement of
management and the work force. It also requires a multidisciplinary approach; this
multidisciplinary approach should include, when appropriate, expertise in agronomy,
veterinary health, production, microbiology, medicine, public health, food technology,
environmental health, chemistry and engineering, according to the particular study. The
application of HACCP is compatible with the implementation of quality management
systems, such as the ISO 9000 series, and is the system of choice in the management of food
safety within such systems.

Building a HACCP System

Implementing a HACCP System requires that both Prerequisite Programs and HACCP Plans
are implemented.

Prerequisite programs are programs that are put in place in the facility to control hazards in
the environment, preventing contamination of the product. Prerequisite programs ensure a
hygienic environment, and good manufacturing processes for personnel that reduce the risk
of contamination of the food product.

HACCP Plans are prepared for each process or product, and identify possible hazards and
controls in place to make sure the hazards are eliminated or controlled to ensure acceptable
levels in the food product.

Why use HACCP?

Awareness of food-borne illness is increasing and concern throughout the industry is driving
the use of HACCP and HACCP based certification programs.

HACCP is based on 7 principles:

This is where you evaluate your processes and identify where hazards can be
introduced. Hazards can be physical (i.e. metal contamination), chemical (i.e. can a
cleaning product contaminate the product, are there toxins that could contaminate the
product?) or biological (at what points could bacteria or virus contaminate your
product?). You will need to make sure that you have the expertise to make an accurate
evaluation of the hazards. This means that if you do not have sufficient expertise in
your organization you will need to identify external resources that you can use to
perform the hazard analysis.

The hazard identification is done in two steps, first the identification of hazards, then
an evaluation of the hazard. The hazard evaluation is a determination of the degree of
risk to the user from the identified hazard. Once the hazard is identified and evaluated
the team must identify critical control points. These are points where the hazard must
be controlled or it will present a risk to the end user.

2. Identify the Critical Control Points

At what steps in your process can controls be applied to prevent or eliminate the
hazards that have been identified? These are your critical control points. For each
critical control point you will identify the preventive measure.

3. Establish a maximum or minimum limit for temperature, time, pH, salt level, chlorine
level or other processing characteristic that will control the hazard. This is the critical
limit for the CCP. If this limit is ever exceeded corrective action must be taken, and
all affected product controlled.
4. Establish Critical Limits

Your next step is to establish criteria for each critical control point. What criteria must
be met to control the hazard at that point? Is it a minimum temperature? Are there
regulatory limits that you must meet for this control point?

5. Establish Monitoring Procedures

You need to monitor the process at the critical control point and keep records to show
that the critical limits have been met.
 The monitoring that takes place at the critical control points is essential to the
effectiveness of the HACCP program. The monitoring program will be made up of
physical measurement or observations that can be done in a timely manner, to provide
the information in a time frame that allows you to take action and control product if
an out of control situation occurs.

6. Establish Corrective Actions

You will establish what actions need to be taken if a critical limit is not met. This will
be identified ahead of time for each CCP. The action must make sure that no unsafe
product is released. There must also be an evaluation of the process to determine the
cause of the problem and an elimination of the cause.
The action or actions taken have two purposes, to control any nonconforming product
resulting from the loss of control, and to identify the cause, eliminate it and prevent
the situation from reoccurring. By identifying the corrective action before an out of
control situation occurs, you are prepared to take action quickly if and when it does
occur.

7. Establish Record Keeping Procedures

You will determine what records are needed to show that the critical limits have been
met, and the system is in control. Address regulatory requirements and include
records from the development of the system and the operation of the system.

8. Establish Verification Procedures

The HACCP plan must be validated. Once the plan is in place, make sure it is
effective in preventing the hazards identified. Test the end product, verify that the
controls are working as planned. Perform ongoing verification of the system. Are
measuring and monitoring equipment in control? What are corrective actions
showing? Are records being maintained as required?

The Food Safety Management Systems reaches beyond the hazard analysis critical control
point and also incorporates management systems principles similar to those found in ISO
9001. You will be building a system to manage quality and continual improvement
throughout your organization. It will reach beyond the control systems that we have discussed
above and into how you plan and manage quality into your organization.

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