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HACCP

Implementation inFood Industries

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CONTENTS

Part I HACCP Introduction, History

HACCP Key Concepts

Why HACCP

Part II HACCP Pre-Requisites Program

Part III How to HACCP

Part IV

HACCP & Quality System (ISO)Part V HACCP Practicing Bottlenecks

Part VI

HACCP Future

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Part IModule 1Introduction to HACCP

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H

CP

AC

HAZARDS

POINTSCONTROL

CRITICALANALYSIS

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HACCP

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HACCP

A preventive approach tofood safety management

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The most

effective tool to

prevent occurrence

of food bornediseases and avoid

consumer illness

and injuries linked

to the

consumption of

our products

H

AC

CP

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H

AC

CP

Systematicapproach to theidentification and

assessment of thehazards and risksassociated with afood operation and

the defining of themeans of theircontrol

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Part IModule 2

WHY HACCP

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WHY HACCP ?

To have safe, reliable

and consistent qualityproduct

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WHY HACCP ?

Management of product safety

Prevention of product safety incidents

Limitations of traditional quality control External pressure

Other benefits

Foundation for the development of effectiveproduct management systems

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WHY HACCP ?Successful implementation of HACCP bringsalong;

Primary benefits Product Safety

Secondary benefits: Quality improvement

Cost effectiveness

Loss and down time reduction

Increase consumer confidence in product safety

Design of line/product Hygiene, housekeeping & improve manufacturing

conditions

Reduce maintenance

Reduce inspection time

Competitive advantage

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EXTERNAL PRESSURE FOR HACCP

Government/Enforcementauthorities

Customers Demand

Media Pressure

Customer Protection Societies

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Part IModule 3W here it has com e from&W here does it work

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WHERE DID HACCP COME FROM

Concept Originated during

NASA SPACE PROGRAMIn 1960

Used Ist time in 1971 BY Pillsbury Company

Basic Idea behind;To provide risk free safe food for astronauts.

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HOW TO ASSURE FOOD SAFETY ?

Traditional Quality Control- Inspection

- Random sampling and testing Prevention base food safety

assurance program

- HACCP

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HISTORY OF HACCP1960 - Concept originated - U.S space program (NASA)1971 - Used in by Pillsbury company in space program1971 - Concept took proper form in National Conference

on Food Protection.1985 - Recommended by National Academy of Science

(NAS) USA1989 - Final approval by National Advisory Committee on

Microbiological Criteria for Foods (NACMCF)1991 - Accepted by Codex Committee.1995/6 - HACCP was first time used in US Regulations

1997 - UN/Codex Alimentarious HACCP System wasdeveloped and adopted by US regulatoryauthorities.

2000 - Embraced by USA, UK, European Union, Japan,Canada, Australia and New Zealand till now.

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HACCP SCOPEHACCP is for every one !!

From;

Farm to Fork Stable to Table

and Gate to Plate.

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HACCP SCOPECommercially -This system is mainly applicable to;

All food processing facilities/factories:

Sea Food/Meat ConfectioneryJuice & Beverage CerealDairy Industries Rice IndustryCulinary/ Spices industry Food raw materialsHotels & Restaurants Hospitals

Air line kitchens Pharmaceuticals

&AllSpecialized areas/operations where

effect of food may become critical.

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Part IModule 3HACCP Key Concepts&Basic philosophy

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HACCP KEY CONCEPTS

FOOD QUALITY

&FOOD SAFETY

MODERN CONCEPT OF FOOD QUALITY

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CLASSIFICATION OF FOOD

HACCP KEY CONCEPTS -Food Spoilage

According to Perisability;

1.Non perishable e.g. Flour2.Semi Perisability e.g Apple

3.Perishable e.g. Raw meat

Key Perisability factors

Water Activity (aw)storage

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CLASSIFICATION OF FOOD

HACCP KEY CONCEPTS-Food Spoilage

According to Acidity;

Low Acid Food Medium Acid Food

Acid food High Acid food

1. Acidity or pH plays important role inProduct shelf life..

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Products with pH value of 4.6 or above thatthe sterilized in hermetically sealed containers,or sterilized and aseptically filled into sterilehermetically sealed containers for ambient

distribution.

Products containing fish, egg, vegetable, cerealand/dairy ingredients (any substitute of these)which need to be refrigerated. i.e. Raw meat,

fish and dairy products.

Infant Formula

HACCP KEY CONCEPTS

CATEGORY 1 - PRODUCTS (HIGH RISK)

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Dried or frozen products containing fish, meat, egg,vegetable or cereal and/or dairy ingredients or anysubstitute for these or other products excluded inthe food hygiene regulations.

Sandwiches and meat pies for fresh consumption.

Fat-based products e.g. chocolate, margarine,spreads, mayonnaise and dressings.

HACCP KEY CONCEPTS

CATEGORY 2 PRODUCTS (MEDIUM RISK)

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Acid product (pH value below 4.6) such aspickles, fruits, fruit concentrates, fruit juicesand acid beverages.

Unprocessed and unpacked raw vegetables.

Jams, marmalades and conserves.

Sugar-based confectionery products.

Edible oils and fats

HACCP KEY CONCEPTS

CATEGORY 3 PRODUCTS (LOW RISK)

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HACCP KEY CONCEPTS

A subject dealing with the study ofmicrobial life

Microbial Growth Factors

NutrientsTemperatureMoisture

OxygenpHPresence of inhibitory substances

FOOD MICROBIOLOGY

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HACCP KEY CONCEPTS

Presence of any any objectionablething in food

Nature of contaminants could be;

PhysicalChemical

Microbiological

FOOD CONTAMINATION

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FOOD SPOILAGE

HACCP KEY CONCEPTS

Any change in food which makes itunacceptable for human consumption.

It may be caused by variety of reasons;

1. Insect damage2. Physical Injury3. Enzyme activity4. Chemical change

5. Micro-organismsProduct shelf depends upon rate of spoilage1. Food preservation is done to stop spoilage

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HACCP KEY CONCEPTS

Wide variety of illness or clinicalcondition affecting the gastro-intestinaltract.

CausesBacteriaVirusFungi

PlantsChemical

In the form of food allergins and toxicants

FOOD POISONING

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HACCP KEY CONCEPTS

Diseases caused by food productscarrying pathogens

1. Bacteria

2. Viruses3. Parasites4. Chemical/toxins5. Enzymatic changes

FOOD BORNE ILLNESS

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HACCP KEY CONCEPTS

Two TypesInfectious;Caused by ingestion of number of micro-organism

of public health significance to cause illness e.g.Salmonellosis & Listeriosis

Intoxication;Caused by ingestion of a performed bacterial toxin

e.g.Staphylococcus aureus and botulism.

FOOD BORNE ILLNESS

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HACCP KEY CONCEPTS

Having contact with food, it plays vitalrole in product safety

Type of packaging Resistance to damage Labelling

FOOD PACKAGING & CONSUMER SAFETY

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Food Type

Contaminants

Cause

Effect

Cost

IMPLICATION OF MAJOR FOOD INGREDIENTS

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Worldwide occurrence

Involve physical. Chemical or microbiologicalhazards

Wide range of causes Raw materials

Mishandling

Change of process or formulations

Cross contamination

Inadequate maintenance

Wrong addition Malicious contamination

Direct & indirect costs

SUMMARY OF FOOD INCIDENTS

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HACCP KEY CONCEPTS

Pre harvesting Post harvesting Transportation During Processing

Post processing care Storage/Ware Housing By distributors By consumer

SAFE FOOD HANDLING

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Part IIModule 4HACCP Pre -Requisites

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38The HACCP Basic Support Network

HACCP IncidentManagement

Plant design& Lay out

StatisticalProcessControl

SupplierQuality

Assurance

GoodLaboratoryPractices

GoodManufacturing

Practices

QualityManagement

System

Environmentmonitoring

Preventivemaintenance

System

Managementcommitment

Training &education

Recourses(finance &

manpower)

HACCP PRE-REQUISITES

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BASIC REQUIREMENTS

Management commitment

A trained multidisciplinary team

Product Knowledge Time

Resource

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GOOD PRACTICES SYSTEMS

Manufacturing - GMP

Distribution GDP

Laboratory - GLP

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HEALTH & SAFETY SYSTEMS

Hazardous Chemical Control

Occupational Health

Procedures

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ISO 14001

Recycling and product safety

ENVIRONMENT MANAGEMENT SYSTEMS

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Reliability of Key processequipment

Breakdown maintenance not

enough

Poor maintenance may lead tomore hazards

PLANNED PREVENTIVE MAINTENANCE

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Specifications Audit program

Auditors training

Approval of supplier

Approved supplier list

Code of practice Third party audit and accreditation

SUPPLIER QUALITY ASSURANCE

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Assure capability of meeting the

process requirements

Use in CCP monitoring provides

trend information

STATISTICAL PROCESS CONTROL

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Monitoring critical limits

Trained panelists

Application of HACCP techniques

SENSORY EVALUATIONS PRACTICES

INCIDENT MANAGEMENT & RECALL

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Must effectively manage potentially unsafeproduct incident

Must be able to recall potentially unsafeproduct from the market place

INCIDENT MANAGEMENT & RECALL

PROCEDURES

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Part IIIHow to HACCP

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HOW TO HACCP ?

Planningand

preparation

Studiesand

the plandevelopment

Implementation

of theHACCP

Plan

Maintenance

of theHACCPSystem

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In 4 - STAGES

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Part IIIModule 1Planning & Preparation

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HACCP ConceptAwareness for

Top Management

External

Expert

HACCP Team Training

Plan the Project

Team formation

STAGE - 1

Gap Analysis to

Assess Current Status

Planning & Preparation

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HACCP TEAM

Team Leader (HACCP Expert)A MicrobiologistAn Engineer

A Production representativeA Quality. Assurance representativeAny other person having crucial concern

with the project.

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HACCP TEAM RESPOSIBILITIES

Plans the projectCompletes study and generates HACCPDocumentation

Ensures verification of the PlanCommunicates and trainsReview deviation from CCPsReview HACCP activities in response to

changeschedules and conducts internal audits

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ROLE OF HACCP TEAM LEADER

Keep management inform about theprogress of the projectEnsure that the right level of expertise isavailable

Help the team to achieve its common taskMaintain the team unityEnsure that each team member contributeshis/her best

Mange time effectively and help the team toappraise its progress

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Basic awareness HACCP philosophy & scope Why HACCP Food Quality & Safety HACCP pre -requisites HACCP Plan development Role of Team members Gap Analysis HACCP documentation at planning

stage

HACCP TEAM TRAINING - STAGE I

HACCP KEY CONCEPTS

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HACCP KEY CONCEPTS

(Pre-designing assessment)

Objectives to achieve

Current status

GAP ANALYSIS

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HACCP KEY CONCEPTS

Considerable points Supplier QA GMP GLP

QMS Preventive maintenance Recall & incident management SPC

Calibration Personnel/Plant Hygiene & House keeping Sanitation

GAP ANALYSIS

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HACCP Milestone Plan

PERFORMANCE CHALLENGE PROJECT PRIORITY : HIGH PROJECT TEAM LEADER : MABTo implement a system of Hazard Analysis ofCritical Control Points in the process to ensure

production of safe and quality products.PROJECT TEAM : IDA, MA, QR, MNN, LIA, MDB

January February March April May June July AugustID Tasks

TargetDates

W 02 04 06 08 10 12 14 16 18 20 22 24 26 28 30 32

01 Start of project 01:01:00

02 HACCP Steering groupawareness training

01:01:00

03 Team development and training 07:01:00

04 Baseline audit and gap analysis 17:01:00

05 Establish process capability 01:04:00

06 Plan the HACCP study 10:01:00

07 Determine method ofimplementation

05:05:00

08 Agree actions and time table 25:01:00

09 Process flow diagram 01:02:00

10 Hazard analysis 21:02:00

11 Identify CCPs 15:03:00

12 Complete control charts 30:03:00

13 Validate the HACCP plan 03:04:00

14 Conduct awareness training ofoperators

10:04:00

15 Set up monitoring system20:04:00

16 Train monitoring personnel 30:04:00

17 Set up facilities and equipment 10:05:00

18 Implementations actioncompleted

07:08:00

19 Verify implementation actionthrough audit

15:08:00

20 HACCP plan re-validation 31:08:00

Time of Completion

Project Duration :

32 weeksDate of initiation of project :

01 : 01 : 00Issuance of status report :

after every 15 daysDate of project completion :

31:08:00

PLAN THE PROJECT

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Part IIIModule 2HACCP Studies

&

Plan Development

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Define Termsof Reference

Hazard Analysis

Describe theProduct &

Intended use

ConstructFlow Diagram

ValidateFlow Diagram

CCP Identification

Establish Critical Limits

Identify Monitoring Sys

Establish Corrective Action

Validate HACCP Plan

STAGE - 2

HACCP Studies & Plan Development

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Product & associated hazards Use of HACCP Principles Risk Assessment Usage of decision tree & CCP identification Establishing Critical limits Establishing monitoring system training

monitoring people Corrective action HACCP documentation

Establishing HACCP Validation system

HACCP TEAM TRAINING - STAGE II

HACCP KEY CONCEPTS

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Type of hazard Physical Chemical Microbiological

Scope Which Product Which Process Whole process or any module Start and end points

DEFINE TERMS OF REFERENCE

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Product Introduction Principle Raw materials used Recipe/Intrinsic control factors

Process Parameter Packaging and finished product stage Storage Condition Shelf Life

Consumer target group Usage Abuse potential

PRODUCT DESCRIPTION & INTENDED USE

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PRODUCT DESCRIPTION & INTENDED USE

PRODUCT DESCRIPTIONSName: ShangoType: Standardized and pasteurized Juice drink available in four flavors (Mango, Apple,

Mango Orange mix and Orange)

PACKAGING / DISTRIBUTION / STORAGE / DESCRIPTIONPackaging: Filled in tetrapak and shrink wrapped in trays/packed in curuwall cartonsDistribution: Trucks and small vansStorage: Normal room temperature

Shelf Life: 6 months

INTENDED USE & SPECIAL CONSUMER CONSIDERATIONSProduct is taken as nutritious juice drink by all age groups.Keep in refrigerator after opening

INGREDIENT

1. Pulp/Concentrate2. Sugar 3. Stabilizer 4. Flavors 5. Colors 6. Citric Acid 7. Malic Acid 8. Sodium Benzoate9. Sodium Citrate

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Raw materials Packaging Process activities

Temperature & Time profile Equipment design Re-work Storage condition

Distribution Waste handling

CONSTRUCT FLOW DIAGRAM

l i i i / i k

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Process Flow Diagram - Fruit Juices/Drinks

Batch

Preparation

Tank

Batchpreparation

Raw Materials

Weighing

Standardization

Stabilizer

mixing

Balance Tank of

aseptic filler

Stacking

Final Analysis

Pasteurization

Temperature

Product Pump

Balance Tank

Storage

Pump

Aseptic Storage

Pasteurization

Section

- Regenerator-1

- Homogenizer-1

- Regenerator-2

- Sterilizer

- Holding Tube

- Regenerator-2

- Homogenizer-2

- Regenerator-1- Cooler

Aseptic

Tetra Filling

Tray Packing/ Shrink

Filling Tube

Forming

Conveyer

Sealing

Warehousing

- Hydrogen per oxide

- Quality

- Quantity

T BA 19

- M ain heater Temperature

- Accurate & Careful

weighing

- Pulp/Concentrate

- Sugar

- Flavor

- Vit - C

- Color

- Stabilizer

- Sodium Benzoat e

- Citric acid/M alice acid- Sodium Citrate

- etc...

- Proper storage

of materials

Sugar Syrup

Preparation

Filtration

Pulp & Other

Ingredients

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ON SITE

CONFIRMATION

&VERIFICATION

FLOW DIAGRAMS VERIFICATION

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HACCP PRINCIPLES

1. Conduct Analysis2. Identify Critical Control Points (CCPs)3. Establish target levels/critical limits4. Establish monitoring system

5. Establish corrective action system6. Establish verification System7. Establish documentation system

1

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Hazard Analysis&Risk Assessment

HACCP PRINCIPLES 1

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1. A potential to cause harm to theconsumer Safety

2. A property that may cause aproduct to be unsafe forconsumption

HAZARDS

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PHYSICAL

CHEMICAL

BIOLOGICAL

HAZARDS TYPES

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PHYSICAL HAZARDS

Dirt Fruit pits Stones Wood

Glass Metal Hairs Bones Insects broken parts

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CHEMICAL HAZARDS

1.Agricultural Chemicals

Pesticide, Antibiotics, Growth stimulators,

Growth hormones and Fertilizers etc..2. Industrial ChemicalsCleaners, Sanitisers, Oils, Lubricants & GreasesAmmonia and Polychlorinated biphenol etc...3. Naturally Occurring ChemicalsAflatoxins4. Environmental contaminants

Lead, Arsenic, cadmium, mercury and PCVs5. Food ChemicalsSeasoning, Preservatives, acids, additives,sulfites and processing aids

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MICROBIOLOGICAL HAZARDS

Clostridium botulinum Clostridium perfringens

Salmonella

Listeria monocytogenes

Staphylococcus aureus

Shegella sp.

Vibrio parahaemoliticus

Bacillus cereus

Vibrio cholera

Comphaylobactor sp. Brucella sp.

Streptococus sp.

E. coli

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The chance (probability) that a givenhazard will occur.

HIGH RISK

MEDIUM RISK

LOW RISK

RISK

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HOW TO CARRY OUT HAZARD ANALYSISBy answering following questions for eachraw materials & process step;

What can go wrong leading to unsafeproduct

How can we prevent it going wrong What is the best control approach

Is this currently in place

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HAZARDS ANALYSIS

Considerable points;Ingredients

Intrinsic factorsProcedures used for processing

Microbial contents of foodFacility designEquipment design and usePackaging

SanitationEmployee health, health and educationStorage conditionIntended useIntended consumer

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HAZARD ANALYSIS & RISK ASSESSMENTIdentify Hazards

IdentifyContamination

Point

DetermineProbability

DeterminePreventive Measures

Assess riskseverity

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HAZARD ANALYSIS TOOLS Fishbone diagram Brain Storming Documentation

Hazard analysis chart HACCP Softwares Statistics

Researching and evaluating the information

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Physical, Chemical or other factorscan be used to prevent or eliminatean identified hazard or reduce it toacceptable level

PREVENTIVE MEASURES

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Factors capable of control Process steps

Use of approved supplier

Control storage

Time management] Segregation

Application of effective cleaning methods

Application of effective training methods

Effective pest control

These are used to control not monitoring

PREVENTIVE MEASURES EXAMPLES

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HACCP ANALYSIS CHART

Process Step Hazard and source Preventive Measures

Raw MaterialsChicken portions

Metal from de-boningknives

1. Knife control procedures2. Effective metal detection of

finish products

Cooking Survival of Salmonella Correct lethal temperature andtime regime

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HACCP ANALYSIS CHART

Process Step Hazard and source Preventive Measure

Raw materials:

Sodium Benzoate

Physical ,Chemical andBiological

Sources: Raw materials itselfbefore reception or in storageif not stored properly

Reception of risk free materials and

store them properly

Process:

UHT

Temperature

Biological, Raw milk &Environment

CIP

Risk free milk, Perform (adulteranttests)

Hygienic Environment.

Temperature sensor calibration.

(Monthly)

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Team members Scientific literature

Technical consultants &

research organizations Company specialists

Supplier/ Customers

Trade associations

Experimental data

Mathematical models

INFORMATION SOURCES

HACCP PRINCIPLES 2

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Identification

ofCritical Control

Points (CCPs)

HACCP PRINCIPLES 2

CCP IDENTIFICATION

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What is a Critical ControlPoint (CCP)

How do we find them

CCP IDENTIFICATION

CRITICAL CONTROL POINTS (CCP)

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A point, step or procedure atwhich control can be appliedand a food safety hazard can beprevented, eliminated orreduced to an acceptablelevel.

CRITICAL CONTROL POINTS (CCP)

RAW MATERIAL DECISION TREE

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RAW MATERIAL DECISION TREE

Q1.Is there hazard associatedwith raw materials?

Yes

Q2. Are you or the consumer going to

process this hazard out of this product?

Yes

Q3. Is there a cross contamination risk to the

facility or to other products which will not

be controlled?

YesSensitive raw materials

High level of control required .. CCP

No

Process to next raw

materials

No

No

Sensitive raw materials

High level of control required .. CCP

Process to next raw

materials

RAM MATERIAL DECISION TREE MATRIX

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RAM MATERIAL DECISION TREE MATRIX

Raw Materials Q1 Q2 Q3 CCP HACCP TeamComments

PROCESS DECISION TREE

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PROCESS DECISION TREE

Q1.Is there a hazard at this process step?What is that ?

Yes

Q2. Do preventive measure(s) exist for

the identified hazard?

YesQ3. Is the step specifically designed to

eliminate or reduce the likely occurrence

of the hazard to an acceptable level?

NoQ4. Could contamination occur at or

increase to an unacceptable level?Yes

Q5. Will a subsequent step or action eliminate

or reduce the hazard to an accpteptible level?

Yes

No

Not aCCP Stop*No

Yes

No Is control necessary atthis step for safety

YES

Modify step, process or

product

Not aCCP Stop *

CCP

No Not aCCP Stop *

Not aCCP Stop *No

* Proceed to next step or process step

PROCESS DECISION TREE MATRIX

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PROCESS DECISION TREE MATRIX

Process Stepand Hazard

Q1 Q2 Q3 Q4 Q5 CCP HACCP TeamComments

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Controllingthe Critical Control Points

(CCPs)

CONTROLLING THE CCP S

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BY: Critical Limits & Target levels

Monitoring

Corrective Actions Responsibility

Validation

Principles 3, 4, & 5

CONTROLLING THE CCP S

HACCP CONTROL CHART

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HACCP CONTROL CHARTFruit Juice/Drinks

Monitoring Corrective ActionCCPNo.

Process steps Hazard

Types

Preventive

Action

Critical limits

Procedure Frequency Responsibility Procedure Responsibility

HACCP CONTROL CHART

IDENTIFIED CCPS

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HACCP CONTROL CHARTFruit Juice/DrinksMonitoring Corrective ActionCCP

No.


Types

Preventive

Action

Critical limits


Blending Section/Batch Preparation01 Sodium Benzoate

UHT Section/Pasteurizationst.incharge/ Instrumentation incharge02 Balance tank

strainer

03 UHTTemperature

Aseptic Tetra Filling04 Hydrogne per-

oxide

Quality/dosagequantity

05 Main heaterTemperature

IDENTIFIED CCPS

CCPS WITH HAZARDS TYPES & PREVENTIVEMEASURES

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HACCP CONTROL CHART

Fruit Juice/DrinksMonitoring Corrective ActionCCP

No.Process steps Hazard

TypesPreventive

ActionCritical limits


Blending Section/Batch Preparation01 Sodium Benzoate C Proper weighing


strainer

P, B Weekly Cleaning

03 UHTTemperature

B Temperaturesensor calib.(Monthly)


oxide

Quality/dosage

quantity

C Qualityevaluation forbeing food grade

Measure and addexact dosage/badge


B Temperaturesensor calib.

Annually

MEASURES

HACCP PRINCIPLES 3

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Establishingtarget levels/critical limits

HACCP PRINCIPLES 3

WHAT ARE CRITICAL LIMITS

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The value of a preventive measure,determined during monitoring, thatdistinguishes acceptable and

unacceptable.

WHAT ARE CRITICAL LIMITS

CRTICAL LIMITS

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CRTICAL LIMITS

Considerable points;

Chemical LimitsPhysical limits

Procedural limitsMicrobiological limits

Must be measurable by test or observation

Criteria which must be met for eachpreventive measures at CCP

Not necessary the same as the existingprocessing parameters

TARGET LEVEL/CRTICAL LIMITS

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TARGET LEVEL/CRTICAL LIMITS

82

75

Temp OC

Critical Limit

Target Level

Safety Buffer Zone

ESTABLISHING CRITICAL LIMITS

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HACCP CONTROL CHARTFruit Juice/Drinks

Monitoring Corrective ActionCCPNo.

Process steps HazardTypes

PreventiveAction

Critical limits


Blending Section/Batch Preparation01 Sodium Benzoate C Proper weighing Permissible limits


strainerP, B Weekly Cleaning No choking or

leakage/damage

03 UHTTemperature


Set point140oC


oxide



Measure and add

exact dosage/badge

Food gradeNo heavy metalsNo arsenic or lead

Exact quantity as

per standard



Annually

Set pointTemperature360 0oCPressure 0.5 bar

ESTABLISHING CRITICAL LIMITS

HACCP PRINCIPLES 4

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Establishing

MonitoringSystems

HACCP PRINCIPLES 4

MONITORING

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Observations or measurements to assesswhether preventive measures at criticalpoints are being implemented

effectively.

Observation at CCPs that the process isoperating within critical limits

MONITORING

CCP MONITORING

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CCP MONITORING

Considerable points;1. Continuous2. Non Continuous

Monitoring On line Off Line Observational procedures

FrequencyResponsibility

CCP MONITORING

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HACCP CONTROL CHART

Fruit Juice/DrinksMonitoring Corrective ActionCCP

No.Process steps Hazard

TypesPreventive

ActionCritical limits


Blending Section/Batch Preparation01 Sodium Benzoate C Proper weighing Permissible limits Careful

weighingPer batch Pasteurization

operator

UHT Section/Pasteurizationst.incharge/ Instrumentation incharge02 Balance tankstrainer P, B Weekly Cleaning No choking orleakage/damage Physicalinspection for

choking andleakage

Hourly UHT operator

03 UHTTemperature


Set point140oC

Temperaturemonitoringfrom panel &graph

Hourly UHT operator


oxide


C Qualityevaluation for

being food grade

Measure and addexact dosage

/badge

Food gradeNo heavy metals

No arsenic or lead

Exact quantity asper standard

Check labrelease for

quality

Recorddosage/ checkend usage

Per can/Every can

Tetraoperator/Foreman



Annually


Temperaturemonitoringfrom regulatorPressure formgauge

Hourly Tetra operator

CCP MONITORING

CCPS LOG SHEET

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CCPS LOG SHEET

Time Results Deviation? Action taken Signature

Reviewed by : Date:

Line/product:

Monitoring Procedures:.

Monitoring frequency:

Target levels:

CCP Ref. No.

Date:Shift:

Corrective action ..

HACCP PRINCIPLES 5

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Establishing

CorrectiveActions

HACCP PRINCIPLES 5

ESTABLISHING CORRECTIVE ACTIONS

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ESTABLISHING CORRECTIVE ACTIONS

Prevent deviation- Only possible if target levels in place

Correction following deviations;- Adjust the process to bring it back to control

- Deal with the materials produced during the deviationperiod

Destroy non complying products Re-work

Direct into less sampling products Release following sampling and testing Release?

CORRECTIVE ACTIONS

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HACCP CONTROL CHART

Fruit Juice/Drinks Monitoring Corrective ActionCCPNo.


Types

Preventive

Action

Critical limits


Blending Section/Batch Preparation01 Sodium Benzoate C Proper weighing Permissible limits Careful

weighingPer batch Pasteurization

operatorDont use the

productShift Inchargeerator


strainerP, B Weekly Cleaning No choking or

leakage/damagePhysicalinspection forchoking andleakage

Hourly UHT operator Urgentlyreplace onchoking ordamage

UHT operator

03 UHTTemperature


Set point140oC

Temperaturemonitoringfrom panel &graph

Hourly UHT operator Immediatecalibration

UHT incharge/Instrumentationincharge


oxide



Measure and addexact dosage

/badge

Food gradeNo heavy metalsNo arsenic or lead

Exact quantity asper standard

Check labrelease forquality

Recorddosage/ checkend usage

Per can/Every can


Ask lab forproductresults/Safe productshould bereleased




Annually


Temperaturemonitoringfrom regulatorPressure formgauge

Hourly Tetra operator ImmediatecalibrationProcess getsstop in caseof deviationinbuilt securitysystem

Tetra incharge/Instrumentationincharge

CORRECTIVE ACTIONS

HACCP PRINCIPLES 6

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EstablishingHACCPValidation

HACCP PRINCIPLES 6

VALIDATION OF HACCP PLAN

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VALIDATION OF HACCP PLAN

1. What is validation2. How it can be done

WHAT ?

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WHAT ?

The assessment of the HACCP plan beforeimplementation to provide confirmationthat it is accurate and complete

HOW TO VALIDATE ?

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HOW TO VALIDATE ?

Use personnel with audit skillsAssess all elements of the HACCP plan

- Process flow diagram- HACCP Control chart

Assess the process area- Preventive measures

- Process capability

HACCP PRINCIPLES 7

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Establishing

HACCPDocumentation

HACCP PRINCIPLES 7

HACCP DOCUMENTATION

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HACCP DOCUMENTATION

Main Records A summary of Hazards analysis, with rationale of

determining hazards and control measures. The HACCP Plan

Support documentation such as validationrecords

Records that are generated during the operationof the plan.

RECORDS OF POSSIBLE RETENTION

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RECORDS OF POSSIBLE RETENTION

Hazard analysis chart

HACCP Control Chart CCP log sheet Hold/ Trace/ Recall records Training records

Audit records HACCP Team meeting records Calibration records HACCP Plan

History of amendments

Records are essential to provide evidenceof safe production

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Part IIIModule 3

Implementation ofHACCP Plan

STAGE - 3

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Determine TheMethod of

Implementation

Awareness

TrainingSet UpImplementation

Team

Agree actions & Time table

Take Necessary Corrective Actions

Confirm Implementation Actions Completed

Set upMonitoring

Sys

EstablishProcess

Capability

Set up

Facilities

TrainMonitoringPersonnel

EstablishRecord Keep

Requirements

VerifyImplementation

Through Audit

STAGE 3

Implementation Of HACCP Plan

HACCP PLAN IMPLEMENTATION

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HACCP PLAN IMPLEMENTATION

Determine Method ofImplementation

HACCP IMPLEMENTATION

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Method Big BangMethod Advantages Disadvantages

All at

once

1. Rapid

implementationpotential2. Works well in

companies with wellestablished QualitySystems

3. Whole work forceinvolved

4. Ease of work forcebriefing

1. May take longer period overall than

anticipated- All HACCP monitoring andcontrol procedure will have to bedeveloped before implementationstarts

2. No trial of individual system elements3. Loss of credibility If employ see that it is poorly managed If CCP fails through poor support

network Large immediate training requirement Resource thinly spread e.g. HACCP

Team


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Method - PhasedMethod Advantages Disadvantages

Phased 1. Quality managementsystem support can be

developed as requiredand alongside

2. Staged training allowsmore individualattention

3. System can be trailedand refined asimplementation

progress4. More manageable

approach5. HACCP Resource can

be focused on eachstage

1. Longer over all implementation timetable

2. Working of small group in isolationdifficult to change culture

3. Implementation may loose momentum

HACCP IMPLEMENTATION TEAM

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HACCP IMPLEMENTATION TEAM

Team Leader (HACCP Expert)An Maintenance Engineer (Optional)A Production representativeA Q. Assurance representatives

Any other person who has the main concern

PERSONNEL CONSIDERATIONS

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PERSONNEL CONSIDERATIONS

Fundamentals to HACCP effectiveness

Key Questions

- Enough people- Ability- Time- Supervisor- Training

TRAINING PERSONNEL

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TRAINING PERSONNEL

All personnel- An understanding of HACCP- How HACCP applies to process- Why monitoring is vital

CCP monitors and their Supervisors- How to monitor- Monitoring frequency required- Record keeping /Deviation reporting

- Use of critical limits/Target levels- Adjusting the process to maintain control- Corrective action

ESTABLISHING PROCESS CAPABILITY

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ESTABLISHING PROCESS CAPABILITY

Equipments Considerations;

- Availability

- Capability- Reliability- Ease of use

- Special facilities- Other implications

Facility Considerations;

- Production

- Additional space requirements

- Extra facilities- Training and briefing staff

- Space- Environment- Equipment

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Part IIIModule 4

Maintaining the

HACCP System

STAGE- 4

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Define standardsand regular audits

Data

analysis

Corrective &

PreventiveAction

HACCP Plan

Validation

Documentationcontrol Update

Ongoing Maintenance

ProblemSolving

Maintaining the HACCP System

HACCP AUDITING

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Types of audits

The system Audit- Where ISO is used

The compliance audit Against- HACCP Plan

The investigative audit- To solve any problem)

AUDIT CHECK LIST

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Process step Considerations Auditors findings

Raw materials(List of raw materials)

Process(List of process steps)

Packaging anddispatch(List of packaging here)

DATA CHECKING BY AUDITORS

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CCP log sheet Process control charts

Audit reports

Customers complaints data

Pest control records

Minutes of meeting

- HACCP

- Hygiene

- Quality

HACCP NON COMPLIANCE NOTE

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HACCP Audit Non Compliance Note NO:

Location: Date:

Area under review:

Non Compliance:

Action required by (date):

Auditors:

Accepted by Audi tee:Corrective Action:

Verified (Auditor): Date:

ON GOING TRAINING REQUIREMENT

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Refresher Training New Personnel

- HACCP- CCP monitors- Others

Updating training- New emerging hazards

- Developments in HACCP Awareness training

HACCP MAINTENANCE PLAN

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HACCP System Approved By:

Maintenance Requirements

Date:

Quarterly audit of HACCP plan

annual plan revalidation HACCP plan to be revised for all process ingredients changes

Quarterly CCP log sheet review for deviation trend analysis

Monthly review of consumer complaints data for trends

6 monthly simulation of trace/recall procedures

Ongoing technical update through symposia and technical journals

Quarterly analysis of training needs

HACCP Team Leader

HACCP PLAN REVIEW/AMENDMENTS

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Amendments Protocol

Product safety assessments Maintain a history sheet

Incorporate changes Frequency of review

AMENDING THE HACCP PLAN

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New raw materials suppliers Changes in the process Factory enviroionment alterations New packaging

HACCP audit changes after improvements HACCP review

Changes need to be documented

FOOD FOR AMENDMENTS

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New technologies New natural foods New combinations of foods Changing legislations

New information on existing issues New ways of packaging foods Changing eating habits

HISTORY OF AMENDMENTS

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HACCP Plan Ref.Page:

Date Amendment Reason ApprovalSignature

HACCP VERIFICATION

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1. Initial validation of plan2. Subsequent validation of plan3. Verification of CCP monitoring as per plan4. Review of monitoring, corrective action records

to show compliance with plan5. Comprehensive HACCP system verification.

HACCP VERIFICATION

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1. Establish procedures

2. Responsibility

3. Frequency of Verification

ROLE OF REGULATORY AGENCIES

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Review theHACCP plan Review the CCP record Review the corrective action records on deviation Review of the critical limits

Review of all the records pertaining to theHACCP plan Direct measurement or observation at CCP Sample collection & analysis product safety On-site observation and record review

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Part IVModule 1FOOD SAFETY &

Quality System

FOOD SAFETY INTEGRATED QUALITY SYSTEM

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HACCP&

Quality ManagementSystem e.g ISO

QUALITY MANAGEMENT & FOOD SAFETY

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ISO 9000 ensures the products meetsspecification 100% of the time.

HACCP specifies and ensures a safe product.

Managing HACCP using ISO 9000 ensuresthat the specific safe product is made everytime

Documented procedures & records provideessential evidence of safe productmanufacture

ISO/QS WITHOUT FOOD SAFETY

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The Danger

If unsafe product is specified ..

..then it will always be produced

LINKING HACCP TO Q. MGT. TECHNIQUES

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Quality Management system : 1SO 9000

Good Practice System : Manufacturing

: Distribution

: Laboratory

Health & Safety System : Chemical control

: Occupational health

procedures Environment Management system : ISO 14001

Supplier Quality Assurance : Specification

: Audit

Statistical Process Control

Sensory Evaluation

Incident Management and

recall procedures

QUALITY PLANS ( 4.2.3 Quality Planning)

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HACCP & Quality Control Chart

DATE : Supersedes

Approved By: Ref No:

Process

stepsControl Points Preventive

measuresCritical

limitsMonitoring Corrective

actionResponsibility

CCP QCP LQP Procedure Frequency

CCP = Critical Control Points = Food Safety

QCP = Quality Control Points = Quality other than food safety

LCP = Legal Control Points = Legal Compliance

QUALITY PLANS - KEY POINTS

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Keep CCPs separate from QCPs/LCPs Enable same degree of control product

spoilage, sensory attributes, legalcompliance etc..

Assists with ensuring clear understandingand separation of food safety control versusnon food safety control.

More meaningful within processenvironment.

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Part VModule 1System Bottlenecks

BOTTLENECKS IN HACCP PROJECTTENANCE)

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Managements diluted vision/Lack of interest

Wrong selection of team Clarityof concept of food safety and quality

Weak Supplier QA/supplier support Too many CCPs Take too long to put modifications

in place

Resources to implement modifications

BOTTLENECKS IN HACCP PROJECTTENANCE)

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Coordination of HACCP Team andavailability to attend the

HACCP maintenance meetings People reluctance for change/

Conservation of ideas Unavailability of like GMP, GLP,

preventive maintenance, sanitation and lack of personnel health Unavailability of experts Poor Traceability & Improper recall system

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Part VIModule 1HACCP FUTURE

HACCP FUTURE

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Outside Pakistan

In Pakistan