Uploaded byPallavi B S (Food Technologist)
HACCP PRESENTATION
The document provides detailed insights into Hazard Analysis and Critical Control Points (HACCP), emphasizing its importance in food safety management by identifying, evaluating, and controlling hazards throughout the food production process. It outlines the definitions of key terms like hazards and critical control points, explains the principles of HACCP, and describes the systematic steps necessary for implementing an effective HACCP system. The document also highlights the necessity of multidisciplinary HACCP teams, validation and verification processes, and the importance of training in ensuring compliance with food safety standards.
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HACCP PRESENTATION
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- 2. •What is HACCP? •Whydo we need it? •How can we learn about HACCP?
- 3. 2 PRP-Pre-Requisite Programme OPRP -Operational PreRequisite Programme CCP - Critical Control Point HACCP -Hazard Analysis & Critical Control Point DÉFINITION OF FEW TERMES IN HACCP Before knowing HACCP you should know about………..
- 4. DEFINITION OF “HAZARD “ “ the potential to cause harm” In HACCP we are looking at 5 classes of Hazards Microbiological (pathogens, toxins) Physical (foreign bodies) Chemical (pesticides, cleaning agents) Allergenic Nutritional (Over- or Underdosing)
- 5. • CCP =ELIMINATES • OPRP = CONTROLS likeli-hood of introducing contamination & prolifération • PRP = ENSURES hygienic production environment PRP – OPRP – CCP RELATION TO PROCESS - Upgraded GMPs - Downgraded CCPs - linked to control measure of safety- relevant CP in QMS
- 6. WHAT DIFFERENTIATES PRPs OPRPs may contribute to reduction of the hazard but may not be essential for control apply to a specific identified hazard apply to a specific product or process are essential to reduce the level of the hazard Validation: are we doing the right things? (example: right past temp? Can metal detector achieve targets?) Verification: are we doing things right? (example: requested temperature in pasteurization achieved over whole run, metal detector functioning) Verification and Validation an OPRP from a PRP?
- 7. HACCP is aself-contained system that allows us to deal with important food safety issues. • It answers to key questions about the safety of the food that we produce or handle: What type of business am I involved in? What are the food safety hazards associated with my business? What causes those hazards? How can i control or remove those hazards? How can i show that i have controlled or removed those hazards? What will i do if things go wrong? WHAT IS HACCP?
- 8. • Hazard assessmentof critical control points (HACCP) aims the Identification, evaluation and control of steps that are critical to product safety in the food technological chain. HACCP enables the management of a cost-effective, Ongoing food safety program. HACCP is a tool to assess hazards and establish control systems that focus on Prevention rather then end product testing
- 9. • Assemble HACCPteam • Describe product(s) and processes • Identify intended use • Construct flow diagram • Onsite verification of flow diagram 5 preliminary steps HOW IT WILL WORK ?????
- 10. 1.Assemble HACCP team TheHACCP team should be multidisciplinary in nature. It includes supply chain department, production, engineering, electrical, quality all departments to have a better ideas.
- 11. 2.PRODUCT DESCRIPTION Full descriptionof the food product. Include information on what it contains, How it is made or prepared, stored and distributed The ‘intended use’ of the food product is the expected use of the product by the end user or consumer.. e.g. IN NEXT SLIDE
- 13. 3. IDENTIFY INTENDEDUSE: The intended use should be based on the expected uses of the product by the end user or consumer. In specific cases, vulnerable groups of the population, e.g. institutional feeding, may have to be considered. Table 6: examples for intended use Intended Use Examples Applicable for plant Y/N Frozen Snacks Ready-to-Cook (RTC) – including Retail & Food Service Further Processing Food for further processing (customer or consumer)
- 14. 4. PROCESS FLOWCHART The flow diagram describes the process and shows the raw materials, processing steps, packaging, storage and distribution stages. Include the information needed for hazard analysis – such as information on micro– organisms that may be associated with the product. Do they form spores or toxins? What is their potential for survival and growth? Other information includes: process times and temperatures, chemical usage, premises conditions and hygienic design, cleaning, equipment characteristics, storage conditions, and instructions for consumer use.
- 15. OK Not Ok 1) Receipt,Weighing and Unloading ofherbs a) QA Rejection (Defects: Yellowleaves, damage, shrinked, foreign particle (plastic, mud, dead insect, stone,metal piece,thread) 10) Final Inspection 9) IQF Freezing at -18 C 7) Slicing as per Specification/Customer Requirement 2) Grading/Cutting/Sorting 14) Storage in Freezer room at -18 Deg Cen 13) Metal Detector (2mm Fe, 2.5mm Non Fe & 3mm SS ) 11) Weighing & Packing 15) Dispatch in refrigerated truck to customer. Return to vendor Online Reject Waste Scrap b) QA 6) Washing with 0.03% of Per acetic acid g) QA Rejection / Return to the Supplier Material i) QA Sorted Waste Scrap f) QA 4) Receipt ofUV treated water through UG Sump. 3) Receipt & Storage of Per acetic acid. 5) Addition of per acetic acid in UV treated water in the washing tub. OPRP-1 OPRP-2 Metal detector rejected sent for Scrap CCP-1 CCP-2 Waste water / rejected pieces ETP 12) Receipt, Inspection and Storage of Packing d) QA 8) Feeding to IQF If temp is not meeting -15 to -18 C Not OkOK e) QA Not Ok c) QA h) QA 9a) Refreezing Flow Chart for Herbs EXAMPLE : PROCESS FLOW FOR FREEZING OF HERBS
- 16. • Check theflow diagram • Compare the actual processes being carried out with the flow diagram. 5. ON SITE VERIFICATION
- 17. 1. Conduct ahazard analysis 2. Determine critical control points 3. Establish critical limits 4. Establish monitoring procedures 5. Establish corrective actions 6. Establish recordkeeping and documentation procedures 7. Establish verification procedures HOW HACCP WORKS – THE PRINCIPLES
- 19. CONDUCT HAZZARD ANALYSIS(PRINCIPLE 1) Check that all potential microbiological, chemical and physical hazards have been considered for each stage in the business – from raw materials to finished product. Physical hazard Chemical hazard Allergen
- 20. Hazard Assessment Likely Hoodof occurrence Improbable 1 once a Year Unlikely 4 Once a Month Occasional 7 Once a Week Frequently 1 0 Once a Day Consequences/Severity Minor/No Injuries 1 No Injuries Medium 4 Small Injuries High 7 Illness Very High 1 0 Catastrophic Control Measure scoring No controls 1 0 Not documented /No Validation Medium Controls 7 Documented but Not validated High controls 4 Manual control and validated Bench Mark 1 Auto/Robust control with validated For assessing significance of a hazard score accordingly as mentioned below RISK MATRIX SEVIERITY/ CONSEQUENCES 10 100 400 790 1000 10 CONTROL 7 49 196 343 490 7 4 16 64 112 160 4 1 1 4 7 10 1 1 4 7 10 FREQUENCY/LIKELYHOOD Non Significant 1 - 160 Significant 161 - 490 Unacceptable Above 491 A multidisciplinary HACCP team identifiers All the hazards that may be reasonable expected to occur at each step from Primary production, processing, manufacture, and distribution up to Consumption; should identify which hazards are such nature that their Elimination or reduction to acceptable levels is essential to the production Of safe food; should evaluated likely occurrence of hazards and severity of Their adverse effects.
- 21. 2. DETERMINE CRITICALCONTROL POINTS After risk assessment the significant hazard was taken for the decision tree to make correct decision whether it is OPRP or CCP. There may be more than one CCP at which control is applied to address the same hazard. The determination of a CCP in the HACCP system can be facilitated by the application of a decision tree) which indicates a logic reasoning approach. Application of a decision tree should be flexible, given whether the operation is for production, slaughter, processing, storage, distribution or other. It should be used for guidance when determining CCPs. Training in the application of the decision tree is recommended. If a hazard has been identified at a step where control is necessary for safety, and no control measure exists at that step, or any other, then the product or process should be modified at that step, or at any earlier or later stage, to include a control measure.
- 22. DECISION TREE 1. Iscontrol measure available for identified hazard NO YES 1.A is a control measure neccessary ?? not a CCP STOP modify the process YES NO 2. Is the step specifically designed to eliminate the hazard ?? YES CCP stopNO 3. can contamination with identified hazard occur at this stage ? 4. will the hazard be removed in subsequent stage ? not a CCP STOP NO YES not a CCP STOP CCP NO YES
- 23. • Establish criticallimits for each critical control point (where possible), how the critical limits can be monitored, and decide on the action to take if these limits are exceeded. • Critical limits must be specified and validated for each Critical Control Point. In some cases more than one critical limit will be elaborated at a particular step. Criteria often used include measurements of temperature, time, moisture level, pH, Aw, available chlorine, and sensory parameters such as visual appearance and texture. Where HACCP guidance developed by experts has been used to establish the critical limits, care should be taken to ensure that these limits fully apply to the specific operation, product or groups of products under consideration. These critical limits should be measurable. 3.ESTABLISH CRITICAL LIMITS STEPS
- 24. 4. ESTABLISH AMONITORING SYSTEM FOR EACH CCP, OPRP, Monitoring is the scheduled measurement or observation of a CCP relative to its critical limits. The monitoring procedures must be able to detect loss of control at the CCP. Further, monitoring should ideally provide this information in time to make adjustments to ensure control of the process to prevent violating the critical limits. Where possible, process adjustments should be made when monitoring results indicate a trend towards loss of control at a CCP. The adjustments should be taken before a deviation occurs. Data derived from monitoring must be evaluated by a designated person with knowledge and authority to carry out corrective actions when indicated. If monitoring is not continuous, then the amount or frequency of monitoring must be sufficient to guarantee the CCP is in since the publication of the decision tree by Codex, its use has been implemented many times for training purposes. E.g. Process Step & Critical Control Point Significant Hazards Critical Limits for each preventive measure Monitoring Critical What How Frequenc y W h o
- 25. 5. ESTABLISH CORRECTIVEACTIONS The actions must ensure that the CCP has been brought under control. Actions taken must also include proper disposition of the affected product. Deviation and product disposition procedures must be documented in the HACCP record keeping. Establish procedures for verification. Verification and auditing methods, procedures and tests, including random sampling and analysis, can be used to determine if the HACCP system is working correctly. The frequency of verification should be sufficient to confirm that the HACCP system is working effectively. Verification should be carried out by someone other than the person who is responsible for performing the monitoring and corrective actions. Where certain verification activities cannot be performed in house, verification should be performed on behalf of the business by external experts or qualified third parties. E.g.
- 26. 6. ESTABLISH VERIFICATIONP OCEDURE CONTROL MEASURE CORRECTIVE ACTION RECORDS VERIFICATI ON Product Temperature every 30 minutes between -15 degree cen to -18 deg cen (IQF OPRP 2) Product: Keep the product Under hold and immediately product to be refreeze. Process: Check for the calibration of the thermometer. Check for the IQF and back end process. In process Record. HOLD record. Reprocess record. Verification of Log sheet & Re process Quantity. Example:
- 27. • Decide thelevel of documentation and record keeping needed that will meet the needs of the business to demonstrate the effectiveness of the food safety programme. • Documentation may include: • A plan of the layout of the food business • Hazard worksheets • Action plan worksheets • Procedural documentation • Checklists • RM /in process /production log sheets or diaries • Training programmes • Maintenance • Control points. 7.ESTABLISH RECORD KEEPING AND DOCUMENTATION (PRINCIPLES 6 & 7)
- 28. TRAINING Training of personnelin industry, government and academia in HACCP principles and applications and increasing awareness of consumers are essential elements for the effective implementation of HACCP. As an aid in developing specific training to support a HACCP plan, working instructions and procedures should be developed which define the tasks of the operating personnel to be stationed at each Critical Control Point. Cooperation between primary producer, industry, trade groups, consumer organizations, and responsible authorities is of vital important. Opportunities should be provided for the joint training of industry and control authorities to encourage and maintain a continuous dialogue and create a climate of understanding in the practical application of HACCP.
- 29. • Establish aregular internal audit of the system, or parts of it and review or modify it to accommodate new information or problems as they are identified. • The frequency of internal audits will depend on the complexity of the operation and whether there are any changes or problems experienced in the Process. REVIEW AND AUDIT
- 30. 12 February 2019NCE 30 Control measure Clamp Critical Limits Opening 60cm +/- 5 GMP Clamp Maintenance Lion Feeding Monitoring Frequency of Tail Wagging Corrective Actions Change clamp Replace operator Verification Incidence of "Headless bodies" HACCP is so easy !
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