HACCP – What is It?

Food Safety Management

Food Safety - is it expected?
Your customer/consumer expects that your
product is
 Free from microbial contamination

 free from insect/rodent contamination

 free from pesticides / chemicals Groceries

 free from physical hazards

22 Nov 07 HACCP 2
What Causes Food Safety
Incidents
 direct causes include biological /
physical / chemical hazards
 indirect causes are the result of
managerial and employee deficiencies
 company needs to address changes in
people’s behavior to prevent
reoccurrence → have the right attitude!

22 Nov 07 HACCP 3
How can We Achieve Better Food
Safety in our Product
 Think about the best way to do things
right
 Implement a HACCP plan that protects
food going through our plant
 Tackle underlying causes of
food contamination
 Have a clean and sanitary
environment

22 Nov 07 HACCP 4
Why do we worry about Food
Safety?
 Consumers / buyers / governments
demand that we produce safe food
 Recalls are expensive → can cost jobs
 We can get sick
 our families: children, parents - not some
unknown person in a far away place

22 Nov 07 HACCP 5
How do we achieve food safety in
our product?
 Be aware of food hazards
 Biological / chemical / physical
 Keep out / minimize food hazards
 Develop system to ensure food safety in
product

22 Nov 07 HACCP 6
Managing Food Safety
 Managing Food Safety is most
effectively done through the
implementation of a HACCP system
utilizing documented references to meet
the requirements of BC CDC
 BC CDC Abbattoir Code of Good Practices
 National Meat Code

22 Nov 07 HACCP 7
Brief history of HACCP
 HACCP was developed by Pillsbury for
the NASA space program in the 1970’s
 Codex Alimentarius (FAO) has developed
it for international use
 Canada refined it in 1992 as the
Food Safety Enhancement Program
(FSEP)

22 Nov 07 HACCP 8
What is HACCP?
 Hazard Analysis
 What are Hazards?
 Where can they be found?
 How can they be controlled?
 Critical Control Points
 How do we control hazards?
 CCPs – measuring product acceptabilty

 Prerequisite Programs – creating an

environment to produce safe product

22 Nov 07 HACCP 9
 Food Safety Hazards
Potential hazards can include:
 Biological
 Microorganisms: bacteria / yeasts / molds /
viruses
 insects
 Chemical
 Cleaners
 Lubricants / fuel / hydraulic fluid / coolants
 pesticides
 Physical
 Glass / plastic / wood / rocks
 Metals
22 Nov 07 HACCP 10
What is a food safety
management system?
A food safety mgt system helps the
process & people to produce a safe
product by controlling hazards
A food safety mgt system needs:
 Effective procedures

 Delegated responsibilities

 Trained people

22 Nov 07 HACCP 11
What are the components of a
food safety program?
 Programs supporting food safety in the
following areas:
 Sanitation and Pest Control
 Preventive Maintenance
 Traceability / Recall Program
 Making employees more knowledgeable
 Employee Training
 Doing things right the first time
 Standard Operating Procedures
 Policies
22 Nov 07 HACCP 12
Food Safety Management
System
 Good Manufacturing Practices (GMP) /
Prerequisite Programs
 must-do / should-do
 Operational controls and Standard Operating
Procedures (SOP)
 HACCP Plan(s) for product(s)
 Critical Control Points (CCP)  must do
 Review / verification procedures
 Self-inspection or audit
 Government inspection or audit
22 Nov 07 HACCP 13
 What are Prerequisite
Programs?
They are the foundation of a
food safety management
system:
1. Premises
2. Transportation and Storage
3. Equipment
4. Personnel
5. Sanitation and Pest Control
6. Recall / Traceability

22 Nov 07 HACCP 14
Having effective Prerequisite
Programs
 Well maintained premises
 Proper receiving / storage / shipping practices
 Sanitation and pest control programs
 Well maintained and correctly operated
equipment
 Properly trained employees
 Tracking/Recall program

22 Nov 07 HACCP 15
Critical Control Points (CCP)
 Control Point - A step in the process
where the product can be stopped and
a measurement taken
 Critical Control Point
 Measurement is taken to determine if
product is acceptable or not
 Has corrective actions that:
 Bring the process back to acceptablity
 Takes care of product that is unacceptable

22 Nov 07 HACCP 16
What is FarmCrest doing about
HACCP?
 Developing a HACCP-based plan for each
product with CCPs
 Developing Prerequisite Programs
 Providing employee
training

22 Nov 07 HACCP 17
HACCP and the employee
 Observe Good Manufacturing Practices
 Know Critical Control Points
 Who is responsible?
 Why is it a CCP?
 Monitoring procedure
 Frequency of monitoring
 Keep records as required

22 Nov 07 HACCP 18
Preliminary Task
All information concerning for hazard analysis must be
collected and up date record data system.

CODEX Reqs.
Preliminary Task
 Step 1 : Creating HACCP Team

 Step 2 : Product Description

 Step 3 : Customer identification and method of

consumption

 Step 4 : Processing flow process

 Step 5 : Verification flow process in field

CODEX Reqs.

HACCP PRINCIPLE

 Principle 1 : Performing Risk Assessment

 Principle 2 : Defining critical control point
 Principle 3 : Defining Critical Limit
 Principle 4 : To define monitoring procedure
 Principle 5 : To define corrective action
 Principle 6 : To determine documentation
system
 Principle 7 : To define verification
procedure
Step 1: Food Safety Team
Food safety team must be detailed according to function,
process, equipment and control hazard according to Food
Safety Management System. CODEX Reqs.
HACCP TEAM
1. Specific knowledge and experience according to
process and product.
2. From various working scope area.
3. Team member must have specific knowledge:
 Raw material and finished product
 Technology and equipment
 Operational activity: production process.
 Quality aspect and process
 Storage aspect and hazard control for material and
product.
 Physical, biology, chemical hazard concerning for
process detail
 HACCP principles
 Step 2: Product Description
Product Specification

Raw material, food additive and supporting material must be

clearly identified:

 Physical, chemical, and biology characteristic;

 Material formula and composition
 Material source
 Production method;
 Packaing and delivering method;
 Storage condition and shelf life;
 Preparation and handling before using or processing.
 Material acceptance criteria for purchasing process ( concerning with
food safety aspect, according to material function )
Step 3: Product Customer Identification

Product use must identify for 5 high risk

customer group.
1. 5 customer sensitive population :
• Senior customer group
• Children group
• Pregnant woman group
• Sickness people group
• Allergic group
2. If product is not compatible with certain population, it must
be used for warning sign.

3. To define consumption method concernig for normal

consumption.
Step 4: Flow diagrem, processing step and control
process

Flow Diagram

 Sequence process regarding to production process;

 To be included for sub contractor process;
 Input process : raw material, additive, packing, etc.
 Output process : finished product, by product, waste
 Reprocess
 Team verification
 CODEX Reqs.
Step 5: Flow Process Verification

On site review concerning flow process

 Flow process verification

 Verify completeness regarding to flow process

 Performing concerning regarding to flow process

needed.

 Performing HACCP Team di every process concerning

regarding operational activities.

 Routine process and non routine process.

Risk Assessment

 Risk assessment :
 Identification of occurrence possibilities
 Identification of risk level

 Method and criteria regarding to written procedure.

 Implementation : Risk Asessment

a. Identification of possibility occurrence

b. Identification of risk level
c. To define “significance “ in every risk level

Risk Level

L M H

L yes

Occurrence M yes yes

Possibilities
H
yes yes
RISK ASSESSMENT

Risk level concerning for Low, Medium and High to serious level
concerning to hazard impact considering for human impact
considering for consumption process.
 LOW, small size contamination (or total amount) and hazard
impact concerning for small effect on health.
 MEDIUM,middle contamination concerning for hazard impact
resulting to heavy damages on health and unconciousness.
 HIGH, big size contamination ( or amount ) and impacting
concerning to hazard identification in causing death.
 RISK ASSESSMENT
In defining risk level, food safety team in refference concerning to
scientific background, field data or input information..

Regarding to possibilities regarding to hazard occurrence possibilities: :

• Low, concerning for apearance on ≤ 1 case per month
• Medium, concerning for appearance in between 2-3 cases per month
• High, concerning for appearance ≥ 5 cases per month

To define possibitiles concerning for prior process before and after,

environmental process, equipment, GMP implementation, pest control,
good hygiene and also including employee activities.
Assessment and Control Action

Every control process must be classified as Operational PRP(s) or to be included

in HACCP Plan :

 Control level in hazard application

 Easies monitoring process for proper correction action ;
 Control action relevant status;
 Risk level status concerning for hazard control.
 Control design for specific purpose in hazard elimination.
 Possibilities regarding to failure risk of control action.
 Sinergy effect of combination activities for control process.
 Assessment process usig POHON KEPUTUSAN ( DECISION TREE ).
 Principle 2: CCP Control
(For Raw Material)
Q1: Is raw material containing risk level with harmful for customer

yes No

Q2: Is processing steps, including proper customer application, ensuring

Hazard elimination until accepated level

yes
No CCP
Q3: Is there any uncontrollable contamination
from equipment or other product

No
CCP yes
 RAW MATERIAL CCP STEP

Cause/ Control
possibili
Source/ Severity action/ Q5
STEP Hazard ty (h, l, Q1 Q2 Q3 Q4 CCP/ CP Reason
Hazard (H, L, M) preventive
m)
Justification action
Orange Biology S. aureus L M Fruit washing N CP Pasteurization
fruit before will eliminate
receivi processing biological risk
ng

Chemic Residu M H Supplier and Y N CCP Pesticide

al pestisia dan CoA residue will
pupuk examination not eliminated
in next process

ASSIGNMENT : PERFROMING RISK ASSEMENT FOR RAW MATERING IN

PROCESSING AREA
 Principle 2: CCP Decition Tree
(For Material Recipe)
Q1: Is recipe/ product structure concerning for intermediate
product/ finsihed product in preventing risk level to
endangerous level?

Yes No

CCP
 HACCP FOR MATERIAL
RECIPE
Cause/ Source/ Possibili Corrective/
Severity( CCP/
Stafe Hazard Hazard ties (h, l, preventove Q1 Q2 Q3 Q4 Q5 Decision Reason
(H, L, M) CP
Justification m) action
2. Sugar Yeast and Raw material M L Sugar N CP The acid content of
additional Mold concentration fruit, sugar
application control additional value will
not influence for
product
characteristic.

ASSIGNMENT: DEFINING HAZARD ANALYSIT FOR PRODUCT RECIPE

 CCP DECISION TREE (FOR
PROCESSING STEP)
Q1: Is raw material having significant hazard

Modification
steps
Yes No
Ya
Q2: Is there any preventive actions?
Not CCP

Yes No No
Q3: is ther any process to prevent Apakah pengendalian
hazard? Pada tahap ini penting
Untuk keamanan pangan?

No
Yes
A CCP
 CCP DECISION TREE (FOR
PROCESSING STEPS)
A

Q3: Is there any possibilities in controlling hazard

until acceptable limit?

Yes No

Q5: Is there any process in preventing

risk assessment? Not CCP

Tidak Ya

CCP
Prinsip 3: Penentuan batas kritis untuk Titik
Kendali kritis

 Penetapan batas kritis untuk monitoring setiap CCP.

 Untuk menjamin bahaya terkendali di produk akhir

( tidak melebihi batas penerimaan )

 bila berdasarkan data subjektif (seperti pemantauan

visual produk, pemantauan visual proses dll.) harus
didukung oleh instruksi yang terperinci dan training
ke personil terkait.
Principle 4: CCP Monitoring System

 To be established for CCP

 Measuring or observing in determine proper time
 Measurement or observing regarding to responsive time;
 To determine critical limit if any deviation appeared
 Equipment monitoring and calibration;
 Monitoring frequency;
 Responsibility and authority concerning for monitoring and
evaluation result;
 Monitoring result record.
Principle 5: Correction action
Action concerning to deviation of critical limit

Establishing concering corrective action for any deviation

appeared on CCP.
 To set corrective action concerning for any deviations in critical
limit.
 Corrective action must be identified regarding to deviation cause in
ensuring effectiveness of CCP.
 Correction action concerning for :
 Process
 Product
 To have equipment concerning to product disposition
 Written procedure and record related to correction process.
Principle 6: Verification Plan

 Setting purpose, method, frequency and responsibility for

verification action.

 Scope of work:
 PRP(s) implementation,
 Hazard input data analysis,
 PRP(s) and HACCP Plan implementation,
 Risk level into controllable level.
 Other procedure implementation.

 Result must be recorded, analyzed and being communicate

thorughout to team member.