food-safety-and-haccp-by-trevor-larson.ppt

Food Safety and HACCP
Presenter: Trevor Larson

What is HACCP ?
 Hazard Analysis Critical Control Point
 Food Safety Management System
- preventative
- systematic
- structured
 Safety through Hazard Identification & Control

How does HACCP work?
 Define how the process works
 Identify what can go wrong-the hazards
 Identify control points critical to product safety
 Manage these points effectively
 Verify

Developments in HACCP
 International acceptance
 ICMSF
 1988 produced the first international
publication
 Covered microbiological hazards only
 NACMCF and Codex Elementarius (WHO)
 Published approaches based on seven
principles
 Codex Alimentarius accepted as
international standard

InternationalAcceptance
General Principles of Food Hygiene
 primary production
 design and facilities
 control of operation
 maintenance and sanitation
 personal Hygiene
 transportation
 product information and consumer
awareness
 training

National Developments
 SANS 10049 (SABS 049: 2001)
 Regulation 918 of 1999
 SABS 0330 : 1999
 Regulation 908 of 2003

The Codex Principles
 1. Identify hazards and preventative
measures
 2. Identify Critical Control Points (CCP’s)
 3. Establish Critical Limit
 4. Establish a CCP monitoring system
 5. Establish corrective action procedures
 6. Establish verification procedures
 7. Establish documentation and records

Why use HACCP
 Management of product safety
 Prevention of product safety incidents
 Limitations of traditional quality control
 External pressures
 Many benefits
 Effective product management

Benefits of HACCP
 Preventative system
 Systematic
 Increases confidence
 Cost effective control system
 Effective use of resources

Benefits of HACCP
 Internationally accepted
 Strengthens quality management systems
 Facilitates regulatory inspection / external
audit
 Demonstrates management commitment
 Helps demonstrate “due diligence”

PREREQUISITE PROGRAMMES
 Required prior to HACCP development
 Universal steps
 Simplifies HACCP plans
 Also referred to as GAP’S, GMP’S, SSOP’S

Prerequisite Programs
TQM
HACCP
GAP’S / GMP’S / SSOP’S

Good Agricultural Practices (GAP’S)
 Water
 Organic and inorganic fertilizers
 Animal exclusion
 Pest control
 Worker health and safety
 Harvesting

Premises
 Outside property
 Building
 Sanitary facilities
 Water / steam / ice quality program

2. Transportation and storage
 Food carriers
 Temperature control
 Storage of incoming materials, non-food
chemicals and finished product

3. Equipment
 General equipment design
 Equipment installation
 Equipment maintenance and calibration

4.Personnel
 Training
 Hygiene and health requirements

5.Sanitation and pest control
 Sanitation program
 Pest control program

6.Recalls
 Traceability
 Recall procedures
 Distribution records

HOW TO DO A HACCP STUDY
DESCRIBE THE PRODUCT AND INTENDED USE
DESCRIBE THE PRODUCT AND INTENDED USE
ASSEMBLE A HACCP TEAM
CONSTRUCT A PROCESS FLOW DIAGRAM
CONSTRUCT A PROCESS FLOW DIAGRAM
VALIDATE A PROCESS FLOW DIAGRAM
VALIDATE A PROCESS FLOW DIAGRAM
IDENTIFY HAZARDS
IDENTIFY HAZARDS &
& PREVENTATATIVE MEASURES
PREVENTATATIVE MEASURES
DEFINE THE TERMS OF REFERENCE
DEFINE THE TERMS OF REFERENCE

HACCP STUDY (CONT.)
IDENTIFY CRITICAL CONTROL POINTS
IDENTIFY CRITICAL LIMITS (TARGET LEVELS)
IDENTIFY CRITICAL LIMITS (TARGET LEVELS)
IDENTIFY MONITORING PROCEDURES
IDENTIFY MONITORING PROCEDURES
ESTABLISH CORRECTIVE ACTIONS
ESTABLISH CORRECTIVE ACTIONS
ESTABLISH VERIFICATION PROCEDURES
ESTABLISH VERIFICATION PROCEDURES
ESTABLISH RECORD
ESTABLISH RECORDS
S AND
AND D
DOCUMENTATION
OCUMENTATION

1.Assemble a HACCP Team
Form 1
Product: Facility:
Date:
HACCP Team Leader
HACCP Team Members

2.Define the terms of reference
Form 2
Starting Point
End Point
Hazards to be covered

3.Product description and intended use
Form 3
1. Product name(s)
2. Important product characteristics
3. How it is to be used
4. Type of packaging
5. Shelf life
6. Where it is to be sold
7. Labeling instructions
8. Distribution
9. Consumer target groups

4.Construct a process flow diagram
Form 4
Product:

5.Validate the process flow diagram
 Checked for accuracy and completeness
 On-site inspection

6.Identify hazards and preventative measures
Form 5
(1)
Incoming
material
(2)
Potential hazard
(3)
Significance
of the
hazard
(4)
Justify decision
in column 3
(5)
Preventative measures
(6)
Is this step
a critical
control
point

Identify hazards and preventative measures
Form 5
(1)
Process
Step
(2)
Potential hazard
(3)
Significance
of the
hazard
(4)
Justify decision
in column 3
(5)
Preventative measures
(6)
Is this step
a critical
control
point

Definition of a hazard
 A biological, chemical or physical
property which may cause a food to be
unsafe for consumption

Biological Hazards
 Bacteria
 Moulds
 Viruses
 Parasites

Chemical Hazards
 Raw materials
 Pesticides
 antibiotics
 Process contaminants
 Cleaning agents
 lubricants
 Packaging
 Ink
 adhesives

Physical Hazards
 Sharp items causing injury
 Hard items causing dental damage
 Items causing air blockages / choking

Identification of Critical Control
Points : HACCP Principle 2
 What is a Critical Control Point?
 How do we find them?

What is a CCP?
 A point, step or procedure where control
can be applied and a hazard can be
prevented, eliminated or reduced to
acceptable levels
 Essential for safety
 Kept to a minimum to ensure correct
focus

How are CCPs identified
 Team expertise and judgment
 CCP decision trees
 Software

CCP Decision Tree
 Incoming material and process steps
 Category and identified hazard
 Determine if fully controlled by prerequisite
programs.
 If yes, indicate the prerequisite program and
proceed to next identified hazard
 If no, proceed to Question 1

CCP Decision Tree (cont.)
 Q1. Do preventative measures exist for the
identified hazard
 If no, not a CCP and proceed to next identified
hazard
 If yes, describe and proceed to next question

 Q2. Is the process step specifically designed
to eliminate/reduce the likely occurrence of
the identified hazard to an acceptable level?
 If no, proceed to next question
 If yes, CCP and proceed to last column

 Q3. Could contamination with the identified
hazard occur in excess of acceptable levels
or could these increase to unacceptable
levels
 If no, not a CCP and proceed to the next
identified hazard
 If yes, proceed to next question

 Q4. Will a subsequent step eliminte the
identified hazard or reduce the likely
occurrence to acceptable level?
 If no, CCP and proceed to the last column
 If yes, not a CCP, identify the subsequent step and
proceed to the next identified hazard
 CCP number

Controlling CCPs :
HACCP Principles 3, 4 and 5
 Establish critical limits and target levels
 Establish monitoring procedures
 Establish corrective action procedures

HACCP Control Chart
 Used to build up the day to day control
requirements for each CCP identified
 Documents information relating to
identified CCPs only

Critical limits or Target Levels:
HACCP Principle 3
 Definition: A value which separates
acceptable from unacceptable
 Must be measurable
 Criteria must be met for each preventative
measure at a CCP
 A target level is control criteria which is
more stringent than Critical Limits

Establish monitoring procedures:
HACCP Principle 4
 Monitoring is the measurement or
observation at a CCP that the process is
operating within the critical limits (or
target levels)
 It must be able to detect loss of control

Establish corrective action
procedures : HACCP Principle 5
 Corrective action is taken when monitoring
indicates that there is a deviation from a
critical limit
 Correction following deviation
 Adjust the process
 Destroy non-complying product
 Re-work

Completing the HACCP Control
Chart : HACCP Principle 6 and 7
 Establish verification procedures
 To verify that the system is working
 To determine compliance with the HACCP
Plan
 Establish records and documentation
procedures
 Objective evidence of all actions and
results

food-safety-and-haccp-by-trevor-larson.ppt

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