Prepared by:

Jared L. EspeletaTarek al mouradHACCP Team Coordinator

IntroductionIntroduction ToTo HACCPHACCP

What is HACCP?Hazard analysis critical control points is a preventive approach to Food Safety from Biological, Chemical , and physical hazards in the whole life cycle of the product, starting production till it reach the customer level. These processes might cause harm to the finished product, making it unsafe for human consumption. HACCP serve as measurements to reduce these risks to a safe level.

Food PoisoningMishandling the product might cause damage to it. Food poisoning might result in such situations.

Common symptoms:– stomach aches– vomiting– diarrhea– feverCan result in long-term diseases and death.Often caused by food that looks, smells and tastes normal.

Types of Hazards in Food

Food can be contaminated by:

– Chemical hazard

– Physical hazard

– Micro-Biological hazard

Chemical Hazards

Chemical HazardsChemicals in the home include those used:

– to clean surfaces and equipment

– as pesticides.

Chemicals can be very harmful if they are:

– spilt on or near food

– mistaken for food or drink.

Chemical Hazards: Natural Toxins

Toxins are poisonous substances produced by some micro-organisms, plants and animals.

Most toxins that cause food poisoning are tasteless and remain toxic even after cooking.

In warehouse: It is essential to make sure cleaning chemicals , oil or any type of chemical material will not be kept in direct contact with the product. During both storing and distribution

For this cleaning chemical must stored and labeled in specified area.

Physical Hazards

Physical HazardsForeign matter can:

– physically injure people

– introduce harmful bacteria into food.

Examples of foreign matter include:

– Dead insects

– Hair

– Jewelry

– Glass

– Pieces of metal.

The above mentioned hazard mostly happens during production , but still precaution must be taken and proper preservation of the product is needed during storing and distribution

Microbiological Hazards

Microbiological Hazards

This hazard comes from microorganisms that can make us sick such as :

– Viruses (rotavirus, norwalk virus..)

– Bacteria (Salmonella, E. coli, Listeria…)

– Parasites (Toxoplasma gondii, Trichinella spiralis..)

– Mould (Aspergillus flavus..)

Viruses and bacteria are the most common causes of food poisoning.

Most foodborne disease is preventable with proper food handling .Temperature monitoring during storage and distribution is an OPRP .

Temperature should be ≤ 5 for fresh

And ≤ 25 for UHT and Processed jar cheese

Pre-requisite Programs

Pre-Requisite Programs Supplier Approval Management Pest Control Systems Hygiene Regulations and Training Cleaning & Disinfection Systems Waste Management Pre-Planned Maintenance Hygienic Premises Design Effective Temperature and Storage Controls

Supplier Approval Management

•We need to be sure that we use reputable suppliers so that food we produce is made from ingredients that are known to be safe in the first place.

–In practice this means that we:• Carry out supplier audits and/or• Request a supplier questionnaire each year• Maintain records on supplier issues and corrective actions taken

Pest Control SystemWe need to be sure that we have good pest control and detection systems in place so that we minimize the risks of infestations.

In practice this means that we:

Appoint a pest control Company ( Nadec have signed a contract with SAMES as national contract)

Have good Pest Prevention & detection measures in place

Maintain records on pest issues and corrective actions taken. It is mandatory to implement .

Hygiene Regulations & Trainings

We need to be sure that all Food handling staff are trained in hygiene and are aware of the rules and regulations◦ In practice this means that we:

◦ Train all staff in food hygiene practices

◦ Enforce a hygiene Policy◦ Provide good clean protective

clothing◦ Maintain records on training and

staff illness.

Cleaning and Disinfection Systems

We need to be sure that all processing equipment and Food rooms cleaned on regular basis and that we can monitor levels of cleanliness◦ In practice this means that we:

◦ Require a cleaning schedule◦ Require professional cleaning

equipment and chemicals◦ Keep records of cleaning and micro

results◦ Maintain records on all corrective

actions

Waste Management We need to be sure that waste is stored and processed properly and it does not encourage pests or cause cross contamination◦ In practices this means that:

◦ Wastes are stored in professional waste bins

◦ Regular removal of waste◦ Wastes are stored in areas away from

food processing ◦ Records of waste and its removal

from site

Pre-Planned Maintenance

We need to ensure that crucial equipment such as coolers pasteurizers, filling machines etc. are well maintained and do not breakdown or malfunction.◦ In practice this means:

◦ Regular service of equipment◦ A maintenance schedule◦ Engineers trained in hygiene

practices◦ Records of maintenance carried

out

Hygienic Premises Design

We need to ensure that the premises that we store and manufacture food has been designed and is kept in a hygienic manner.◦ In practice this means:

◦ Smooth, non-porous surfaces◦ Easy to clean equipment◦ Modern wall cladding◦ Adequate drainage

Effective Temperature and Storage Conditions

We need to ensure that (Coolers, chillers for stores etc. are adequate for the job and work effectively on an on-going basis◦ In practice this means:

◦ Coolers, chillers are properly size for the job

◦ On-going maintenance records.◦ Adequate storage capacity◦ Contingency plan for coolers, chillers

failure

Preparation & HACCP Team

Before you start to HACCP plan you need a HACCP team capable of working together to build your HACCP system.

The HACCP Team should consist of a range of skills from the business and ideally have the following knowledge or experience.• Product knowledge• Senior Managers of the business

operations• Knowledge of bacteria/advanced food

Hygiene• Trained in HACCP principles

Preparation & HACCP Team

•Clear roles need to be decided in the HACCP team so that it functions effectively.

•The HACCP team should appoint the following roles and responsibilities,– Chairperson– Meeting documenter– Policy and procedure coordinator– HACCP documenter– System Implementation and training– System supervisor

One person may take one or more than one role in the HACCP team but they should not do all roles.

The Seven Principles of HACCP

1. Conduct a hazard analysis2. Determine critical Control Points3. Establish Critical Limits4. Establish Monitoring Procedures5. Establish Corrective Actions6. Establish Verification Procedures7. Document the System

The Seven Principles the logical way….• If you decide a Hazard is critical to

food safety then it needs Limits that are monitored.

• Monitoring rings the Alarm Bell when it finds bad results.

• Corrective action is required to bring things under control once more.

• Everything needs to be documented so we can prove food is safe for human consumption.

7 HACCP Principles

The 14 Stages of HACCP1.Define the terms of reference2.Select the HACCP Team 3.Describe the product4.Define the intended use

5.Draw up the flow diagram6.Verifiy the flow diagram7.Identify and analyze hazards8.Determine the CCP’s9.Establish Critical Limits10.Establish Monitoring procedures11.Establish corrective actions

The 14 Stages of HACCP12.Verify the HACCP plan13.Document the HACCP plan14.Review the HACCP Plan

Phase 1 – Terms of Reference, HACCP Team, Product Intended UseThis phase of HACCP planning involves planning the foundation of the HACCP by outlining in a document called “Terms of Reference”.

In this phase we need to:Document the terms of reference

•Products, Process, Activities to be Analyzed.•What types of Hazards are being considered, usually microbiological, chemical, physical and sometimes, Allergenic hazards.•Decide if pre-requisite program hazards are to be included.•Describe the product/process in words from start to finish.•Describe the intended use of finished product.•Record the HACCP Team details, roles and responsibilities.

It is important to determine the scope of HACCP , Study the process and analyze what are the Hazard that might happen to the product

Nadec List of Products

Product Description and Intended UseProduct Name

Product type: e.g. cooked, raw processed, ready to eat

Product Characteristics: (e.g. pH, Aw, salinity, state, other qualities)

Finished product and recipe meets of Food and Drug Act (Y/N)

Label Meets requirements of Consumer Packaging and Labeling Act and Regulations

Product contains restricted ingredients as per Food and Drug Act (Y/N)? If yes, list restricted ingredients

Product contains allergens as per Health Guidelines (Y/N)? If yes, list allergens.

Shelf-Life of product

Storage Instruction (e.g. Keep fresh, Keep Frozen, Humidity control, ready to cook)

Intended use of the product; include special delivery instruction, special consumers group (e.g. elderly , immuno-compromised

Product DescriptionProduct Name:

Product Description:

Characteristics:

Chemical:

Microbiological:

Ingredients:

Important Preservation Characteristics:

Shelf Life:

Packaging:

Primary Packaging:

Secondary Packaging:

Labeling Instruction:

Where the product is Sold:

Special Distribution Control:

Product Use:

Identification of Consumer Suitability:

The National Agricultural Development Company Form No.: HM-003

Depot HACCP Manual - Product Description and Intended UseRev. No.: 03

Issue Date: 12.12.15

Fresh Juice and Cavita

Fruit Concentrates, pulps, natural flavours, vitamin C, stabil izers, colours. Sugar

Keep closed and refrigerated after opening

30 Days

Wholesaler and Retailer

Avoidance from any bottles or caps damage. Keep at temperature <5OC

For direct consumption as Fresh Juices

Product Suitable for general population

Please refer to Raw and Packaging Materials SpecificationsPET, HDPE and LDPE bott les and Caps, Aluminum Foil Seal for 1.0 L, 1.75 L, 3.0 LiterPack in HDPE Crates or corrugated box.Hijira Calendar , Gregorian and English text on Print Code

Refrigerate after opening

Page No.: 1 of 23

Fresh Juices

Apple Juice - Golden coloured apple juice, smooth light texture, sweet.

Berry Cocktail Juice – Dark Violet coloured Berry Cocktail juice, smooth light texture, sweet.

Mango Juice - Orange colour mango juice, smooth thick texture, sweet

Strawberry Juice - Strawberry fruits with seeds crushed and dissolved in a syrup solution, with added colour and flavour. Sweet , Thick product with rich mouth feel. No smooth texture due to crushed strawberry seeds.

Mixed Fruit - Red coloured cocktail juice, smooth l ight texture, sweet.

Lemon Mint Juice – cloudy colorless lemont juice, smooth l ight texture, sweet

Kiwi Lime Juice – lime green Kiwi and Lime juice, smooth l ight texture, sweet

Pomegranate Juice – Dark red pomegranate juice, smooth l ight texture, sweet

Pineapple Juice – Cloudy yellow pineapple juice, smoth l ight texture, sweet

Mango Cherry Juice – Brick Red mango cherry juice. Smooth thick product with rich mouth feel. Sweet

Mango Lychee Juice – Dark Orange juice. Smooth thick product with rich mouth feel. Sweet

Please refer to finished product specifications sheet (Ref.SP-016/6.1)

Please refer to finished product specifications sheet (Ref.SP-016/6.1)

Full details of Fresh juice are mentioned in product description. Information such as color of the product, specifications and packaging material are highlighted.

Information's stated on the label must follow SASO and GSO regulatory standards.

Phase 2 – Flow Diagram and Hazard Analysis

This phase of HACCP planning involves sketching out the process flow diagram and listing all possible hazards and their control measures.

In this phase we need to:

•Draw and verify a process flow diagram.•List all possible hazards for the process or product.•Identify Pre-requisite program hazards.•Carry out a risk assessment for each hazards•Record and discard hazards of very low significance•Agree the control measure for each hazard

Flow Diagram

<5◦c

<5◦c

<5◦c

WarehouseWarehouseWarehouse <5◦c

Customer

Process Flow Diagram

It is required to maintain proper record for temperature monitoring in addition to taking corrective and preventive action.

Decide whether to show or not to show the PRP’s in the HACCP Plan

Decide before proceeding to the risk assessment.

Document your decision in the terms of reference document.

There are benefits in including them, such as:

•Ease of staff training•One overall, integrated management system•A “ones stop shop” for all food safety information.

“ If we assess these two questions together in a grid we can easily arrive to a decision of overall significance and set a threshold above which we deem the hazard as a “Not significant” and therefore not to be included in the HACCP Plan

Risk AssessmentThe risk assessment can be carried out by asking two simple questions about each hazard as follows:

Q1. What are the consequence of this hazard

Q2. What is the likelihood that this hazard will occur

Likelihood Description

A - Daily

B - Once a Week

C - Once a Month

D - Once a Year

E - Once Every Five Years

Note: Severity Description

1 - 10 considered as significant hazards 1 Fatality with long term sequels

2 Serious Sickness with long term sequels

3 Sickness without long term sequel

4 moderate sickness (fast recovery)

5 Not significant

25

17 20

4 10 14 18 21 23

5 15 19 22 24

11

2 3 5 8 12 16

7

Seve

rity

1 1 2 4

3 6 9 13

The National Agricultural Development Company Form No.: HM-015

HACCP Manual Rev. No.: 01Issue Date: 01.04.15

Risk Assessment Page No.: 1 of 1

Risk Assessment Matrix

Likelihood

A B C D E

Hazard Analysis

“Any hazard that you identify as not significant should not appear in you main HACCP plans but instead it should be documented why you arrived at this decisions in terms of its significance”

Step No. Cause Likelihood Severity SignificanceDoes this step eliminate, reduce

hazards to acceptable levels?

Does this step need a high level of monitoring/regular monitoring all

day long in order to prevent all proliferation cases?

Final Significance Q1 Q2 Q3 Q4

CCP/OPRP/PRP Control Measures

Biological Microbiological Growth Microbiological growth due to insufficient cooling or high temperature at trailer.

C 2 8 No No No - - - - PRP Vehicle Inspection during receiving.SOP, GWP, Training in place

Biological Microbiological Growth Bad handling practices. Microbiological growth on damaged product due to improper handling.

E 2 16 - - - - - - - - -

Biological Microbiological Growth

Bad Practices - Staff handling products without washing their hands. Staff may observe some loosed cap and tighten it by their bare hands, eventually the product will be sent to market.

E 2 16 - - - - - - - - -

PhysicalInsects/pest contamination

Contamination of pest/insects migrating through damaged packs.

D 2 12 - - - - - - - PRP Pest Control in Place, SOP,GWP, Training

Physical Wood pieces from pallets Wood pieces due to the use of broken or damaged pallets.

E 2 16 - - - - - - - - -

Physical Broken glass pieces Broken glass pieces from lights inside the trailers E 2 16 - - - - - - - - -

ChemicalHazardous chemicals/cleaning chemicals

Cross contamination of hazardous chemicals/cleaning chemicals from trailers previously used to transport chemicals. Trailer previously cleaned using cleaning chemicals but not properly rinsed.

E 3 20 - - - - - - - - -

The National Agricultural Development Company Document No.: HMD-004DEPOT HACCP Manual Rev. No.: 00

Hazard Analysis Issue Date: 01.08.15Page No.: 3 of 4

Hazard

Receiving of finished products

Phase 3 – Determine CCP’s, Critical Limits, Monitoring Corrective Action

Some key tips when using the decision tree questions

Q1. Are control measures in place to control the hazard?

Tip: Because we have already identified the possible control measure during Phase 1 the answer to this question is always yes.

Q2. Is the process step designed to eliminate the hazard to an acceptable level?

Tip: Substitute the process step and the hazard name into the question and read it back to answer this question e.g.

Is UHT Processing designed to eliminate pathogens or reduce to acceptable level?

Q3. Could the hazard increase to an unacceptable level?

Tip: You need to consider what changes might occur that could cause the hazard to occur more frequently. Things like changes in staff, Management, The process step, ingredients, suppliers, even the seasons can affect the answer to this question.

Q4. Does a later process step control this hazard/

Tip: Make a list of the later process steps “downstream” of the current process step and decide if any of those process steps will control the hazard

Best Practices

Best PracticesProduct must be highlighted and specified displaying Production Date for better tracking of FEFO and FIFO

Best Practices

Best Practices

Best Practices

Best Practices

Best Practices

Thank youThank you