Hazard Analysis and Critical

Control Points (HACCP)

STENUM GmbH
www.stenum.at
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What is HACCP?
 Problems
 Foodborne diseases
 Market access – importance of food safety all
along the food-chain
 Solutions
 Food safety system that focuses on preventing
problems before they occur
 Industry-led programme used to improve and
verify food safety
 Answer
Hazard Danger to health
Analysis Investigation of the
hazard
Critical Crucial for containment
Control Handling of conditions
Points Position in the process
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What is HACCP?
Hazard Analysis and Critical Points
Science-based,
internationally accepted
food safety system

Focused on hazard
Can be applied to all
identification and
segments of the food
prevention
chain

Addresses chemical and

physical hazards

Source: Department of Food Science and Technology, Virginia

Tech.
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Why adopt HACCP?

 A properly functioning HACCP system will
result in the production of safer food.

 Benefits:
 Improved food safety
 Increased market access
 Protection against liability
 Drive for continuous improvement
 Enhanced process control
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Where can HACCP be used?

HACCP can be used in any food sector from
production to retail

Production

Retail and
Processing food service
Transport
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The seven principles of HACCP

I II III
Conduct a Identify Establish critical
hazard critical limits for each
analysis points critical control
point

Establish
critical
control point IV
monitoring
requirements

Establish
procedures for Establish record Establish
verifying that the keeping corrective
HACCP system is procedures actions
working as intended
VII VI V
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ISO 22000
 Requirements for a food
safety management
system
 4 elements
 Interactive communication
 System management
 Prerequisite programmes
 HACCP principles

Source: Van Voorst Consult

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Implementing HACCP

1. Preliminary Steps for the introduction

of a HACCP System
 Gathering the resources and information needed

2. Seven principles of HACCP in action

 Completion of all steps will result in a properly
functioning HACCP plan
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Preliminary steps
1. Assemble the HACCP team
 Group of people that will oversee the implementation
and maintenance of the HACCP programme
 Multi-disciplinary (i.e. production, sanitation,
management, etc.)
 Including a HACCP-trained person
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Preliminary steps
2. Description of products and identification of
intended use and consumers
 Full description of the product(s) being manufactured
under the programme
 Product information assists with hazard analysis
 Which group(s) will be consuming the food product
 Where will the product be sold
 How will it be prepared
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Preliminary steps
3. Development and verification of process flow
diagram(s)

 The flow diagram should

 Outline all processing steps
 Include all processing steps

 The plant schematic should

 Outline where all of the processing steps occur
 Display the movement of products, people and waste
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Preliminary steps
4. Grouping of products
 Decide whether products can be grouped using
process categories
 Slaughter – all species
 Raw product – ground/not ground
 Thermally processed – commercially sterile
 Heat/not heat treated – shelf stable
 Fully cooked – not shelf stable
 Heat treated but not fully cooked – not shelf stable
 Product with secondary inhibitors
 Further categories for grouping can be commodity
group, hazards, etc.
 Products in the same process category may be
covered by the same HACCP plan
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Principle I
 Conduct a hazard analysis
 Evaluate information regarding potential hazards
associated with the manufacturing process and ingredients
 Determine which hazards are significant to food safety
 Consider:
• Probability of occurrence
• Severity of consequences
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What are hazards?

 There are 3 types of hazards
 Biological
 Chemical
 Physical

 Do not forget cross-contamination

 Microbiological, allergens
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Biological hazards
 Biological hazards can cause illness and
include:
 Bacteria: E.coli, Salmonella, Listeria, Campylobacter, Shigella
 Viruses: cold viruses, Hepatitis A, Norwalk virus
 Parasites: Giardia, Cryptosporidium, Trichinella, tapeworms
 Yeasts and moulds
 Any toxin produced by microbiological organisms is also a
biological hazard
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Chemical hazards
 Chemical hazards can cause
injury or poisoning and include:
 Naturally occurring substances (e.g.
allergens, plant specific toxins)

 Excessive, intentionally added chemicals:

antibiotics, pesticides, herbicides, fungicides,
nitrates

 Accidentally added chemicals: cleaning

chemicals, paint, pest control chemicals
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Physical hazards
 Physical hazards are
foreign objects that
can cause injury:
 Glass
 Metal grindings, screws,
nuts, bolts
 Stones, pebbles
 Needles
 Hard plastic
 Bones
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Principle II
 Identify Critical Control Points (CCPs):
 A CCP is a point, step or procedure at which a control
measure has to be applied to prevent, eliminate or
reduce a food safety hazard
 CCPs are not:
 Necessarily located where the hazard occurs, they
may be located at a subsequent step
 Some hazards cannot be controlled by the
operator
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Principle III
 Establish Critical Limits
(CL)
What is a critical limit?
 The maximum and/or minimum
value to which a parameter must be
controlled at a CCP
 The critical limit separates
acceptability from unacceptability
 The critical limit must be clearly
defined and measurable
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Principle IV
 Establish monitoring procedures
 Monitoring:
 Is the process of conducting a planned sequence of
measurements to determine if a CCP is under control
 Monitoring results must be recorded

If monitoring shows that

critical limits are not met,
then the process is out of
control and the food may
be unsafe.
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Principle V
 Establish corrective actions
 Corrective actions are pre-determined measures
that have to be implemented when monitoring
indicates that a deviation has occurred.
 Corrective actions must:
• Regain control of the process
• Locate and segregate affected product
• Determine disposal of affected product
• Prevent a recurrence
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Principle VI
 Establish verification procedures
 Validation
 Ensures that the HACCP plan is complete and valid
 Ensures that the plan is effective in achieving expected
food safety outcomes
 Ongoing verification
 Ensures that the HACCP plan is working effectively
 Confirms that the plan is operating according to written
procedures
 Auditing
 Overall review of the HACCP plan
 To be performed whenever any changes occur that could
affect the hazard analysis or alter the HACCP plan
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Principle VII
 Establish record keeping procedures
 Record keeping must be complete and
accurate and includes:
 Documentation pertaining to all steps, including the
HACCP principles
 Appropriate record storage procedures
 A log book to keep track of changes
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HACCP system – Summary

 HACCP systems consist of two elements
 Prerequisite programmes
• Implemented prior to HACCP plans
• Control of the overall plant environment
• Control factors not directly related to food (e.g.
water quality, transportation and storage, plant
sanitation, employee training)
 HACCP plans
• Implemented following pre-requisite programmes
• Tailored to a certain product or process
• Control factors directly related to food production