HACCP Training

Trainer : Walid Gahfer1

Hazard Analysis & Critical Control Point

Prepared By:Eng / Walid I. GahferQuality Shift Leader In Senyorita Co.One Of Americana Group for Food Industries


Agenda Introduction To HACCPHACCP BenefitsHACCP Principles Implementation Of HACCPHACCP PlanHACCP Preparation : -> Preliminary steps -> Pre-requisite programs


Introduction To HACCPHACCP Is :-

•A system of control based on prevention of problems by identifies specific hazards and control measures to ensure total food safety management.

•The system requirements are generic and applicable to all food organisations concerned with the food chain from production preparation, processing, packaging, storage and distribution until the point of customer consumption.


Steps Of HACCP System

• Look at your Process/ Product from A to Z;

• Decide where hazards could occur;

• Put in controls and monitor them;

• Write it all down and keep records;

• Ensure that it continues to work effectively.


HACCP Benefits

• Maximize product safety.

• Improved management responsibility.

• Improved process control.

• Improved inspection testing.

• Moving the company towards a Quality Management System.



Principle (1) Analysis Of Hazards Assessment.

Principle (2) Identification Of Process Critical Control Points (CCPs).

Principle (3) Establish Critical Limits For Preventative Measures Associated With Each

Identified CCP. Principle (4)

Establish procedures for Monitoring the CCPs.Principle (5)

Establish of corrective actions to be taken when monitoring indicates deviation from an establish critical limit.

Principle (6) Establish effective record-keeping procedures that document the HACCP

system.Principle (7)

Establish procedures for verification that HACCP system is working correctly.


Principle (1)Analysis Of Hazards

Assessment


Hazard:Is any factor which may be present in the product that can cause harm to the consumer either through injury or illness.

Preventative Measure:An action to prevent a hazard or reduce it to an acceptable level.


Prepare a list of the process (Process Flow Diagram containing all process steps from Raw Material receiving TO End Product) & Identify where significant hazards could occur and describe preventive measures.

The hazard could be biological, chemical, or physical. And the measure that can be applied to prevent the occurrence of hazards must be determined accordingly.


Types Of Hazards Associated With Our Product:

Biological Hazards:It’s any pathogenic microorganism like Bacteria, Parasites & Viruses.EX: Bacteria:- ((Shigella, Salmonella, Staphylococcus aureus, Escherichia coli, Standard

plate count, Total Yeast & moulds, Total Coliforms, Bacillus cereus)).

Chemical Hazards:1. Naturally-occurring chemicals. EX: (( Allergens, Mold toxins -mycotoxins- ))2. Intentionally-added chemicals. EX: (( Packaging materials, Sanitizers ))3. Unintentional or incidental chemical additives. EX: ((Agricultural chemicals -pesticides, fertilizers- & Toxic elements / compounds -lead, tin,

copper, zinc, arsenic, mercury, cyanide- & Cross-contaminating food allergens from inadequately cleaned shared processing equipment.))

Physical Hazards:Any potentially harmful matter not normally found in packetEX: Metal, Wood, Glass Fragments.


Principle (2)Identification Of Process Critical Control Points

(CCPs)


Critical Control Point (CCP):A step at which control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level.

After determination of hazards, we must determine where hazards could occur. And for performing this identification we use the Decision Tree.

CCP Decision Tree:A sequence of questions to be considered in the process to decides where is CCP.


Steps to Identify (Determine) CCPs Using A Decision Tree

Q1: Do preventive measures exist for this hazard?

if yes go to Q2, if no, that means it’s required of safety

if no = not CCP*, (if yes modify process or product).

Q2: Does this step specifically designed to eliminate/reduce the likely occurrence of this hazard to an acceptable level?

if yes = CCP if no go to Q3

Q3: Could contamination occur in excess of acceptable level? (Unacceptable level occur)?

if yes go to Q4 if no = not CCP*

Q4: Will a subsequent step eliminate/reduce this hazard to an acceptable level ?

if yes = not CCP* if no = CCP

* (go to the next step in production)


Principle (3)Establish Critical Limits For

Preventative Measures Associated With Each

Identified CCP


Critical Limit (CL):- Is the criteria that specifies safe product from unsafe product.- Is the maximum /or minimum value that must be controlled at a CCP to prevent, eliminate, or reduce to an acceptable level the occurrence of the identified food hazard.

Operation Limit:A criteria that is more strict than critical limits, which the operator use to reduce the possibility of deviation.

When there is any deviation from CL; the product became un safe.


Principle (4)Establish Procedures For

Monitoring The CCPs


Monitoring: - To conduct a planned sequence of observations or measurements of control parameters to assess whether the CCP’s are controlled by the food organisation or not.

• Monitoring is performed to identify when there is a loss of control (a deviation at a CCP).•Monitoring equipments shall be calibrated precisely.


Monitoring

What: usually a measurement or observation to assess if the CCP is operating within the critical limit.

How: usually physical or chemical measurements (for quantitative critical limits) or observations (for qualitative critical limits).

Frequency: continuous or periodic.

Who: responsible individual trained to perform the specific monitoring activity or evaluate monitoring records.


Principle (5)Establish Of Corrective

Actions To Be Taken When Monitoring Indicates Deviation

From An Establish Critical Limit


Corrective Action:Is the procedures under following to satisfy system requirements when a deviation occurs.

Corrective action procedures includes the actions that brings the process back under control. It also includes action to deal with product manufactured while the process was out of control.


Principle (6)Establish Procedures For Verification That HACCP

System Is Working Correctly


Verification:The application of methods, procedures, tests and other evaluations, in addition to monitoring to determine compliance with the HACCP plan.

Validation:The process of proving that a system is acceptable for its intended purpose.


The verification procedures of the overall HACCP system shall includes:

Initial validation of the elements of the HACCP plan, such as process flow diagram, hazards analysis, determination of CCPs, critical limits, monitoring procedures, corrective action, documents /records keeping system, etc. Internal audit that covers all activities under HACCP system, which shall be performed at least once every six months. The feedback system of audit data for improvement of the HACCP system. Any changes made that may affect the HACCP system.External audit.


Principle (7)Establish Effective Record-Keeping Procedures That

Document The HACCP System


The documents/records shall include allthe elements of the HACCP system, including:

Description of HACCP system.The records of all HACCP Prerequisite procedures,The records of hazard analysis and their control methods,CCP determination,Critical Limit determination,CCP monitoring activities and results,Deviations and associated corrective actions,Other activities like (Sanitation control, Audit,Meetings, Training Verification, Compliant, Recall, etc…).


How To Implement A HACCP System1. Assemble HACCP team.2. Describe food and its distribution.3. Identify intended use and consumers of food.4. Develop process flow diagram.5. Verify flow diagram.6. Conduct a hazard analysis.7. Determine the critical control points (CCPs) in the process.8. Establish critical limits.9. Establish monitoring procedures.10.Establish corrective actions.11.Establish verification procedures.12.Establish record-keeping and documentation procedures.


How To Apply HACCP To Our Product?

1) Identify the potential hazards associated with our product.

2) Explore how to prevent them.3) Identification of CCPs4) Establishment of A HACCP plan critical limits.5) Monitoring procedures.6) Corrective actions.



What is the HACCP Plan? HACCP plan is a formal document which pulls

together the key information from the HACCP study and holds details of all that is critical for food safety management.

HACCP plan is mainly consists of two essential components:

(1) Process Flow Diagram (2) HACCP Control Chart


Validate HACCP Plan

Establish Corrective Action Procedures

Identify Monitoring Procedures

Establish Critical Lim its

Identify Critical Control Points

Identify Hazards & preventative Measures

Validate Process Flow Diagram

Constract a Process Flow Diagram

Describe The Product & The Intended Use

Define Your Term s O f Reference


(1) The Process Flow Diagram

• Process Flow Diagram is a sequence of events through the whole process, giving a clear and simple description of how the end product is made.

• Process Flow Diagram enables the HACCP Team to understand the production process and the basis for the hazard analysis.

• Process Flow Diagram shall includes all the process inputs (Row materials) & all the process outputs (Wastes).


)2( HACCP Control Chart

• It’s a table of control parameters which contains details of the steps/stages in the production process where there are CCPs.

• It also contains details of the hazards and preventative measures associated with each CCP.



Preliminary Steps For A HACCP System Application

o Senior Management Commitment.

o Assembling A HACCP Team.

o Product Description.

o Establishing the Process Flow Diagram.

o Verification of Process Flow Diagram.


Prerequisite Programs For Establishing A HACCP Plan

• Good Manufacturing Procedures (GMPs).

• Sanitation Standard Operation Procedures (SSOP).

• Specifications & Suppliers monitoring.

• Pest Control.

• Training.

• Non-Compliance & Corrective Action procedures.

• Recall procedures.

• Consumer Complaints Analysis procedures.

• Calibration & Preventative Maintenance procedures.


Good Manufacturing Procedures (GMP’s) includes

1) Prevention of food contamination.

2) Cleanliness of Clothing and garments.

3) Employee Personal Hygiene & Disease control.

4) Prevention of Eating , Drinking & Smoking inside processing & producing areas.

5) Proper Labeling.


Sanitation Standard Operation Procedures (SSOP) includes

1) Safety of used water.2) Cleanliness of product contact surfaces.3) Cleanliness of employee clothes.4) Prevention of cross contamination5) Maintenance of hand washing & hand sanitizing & toilet

facilities.6) Proper labeling of toxic materials..7) Personal Hygiene. 8) Pests exclusion.

Documents

HACCP Training