HACCP

At the end of this chapter students should:

Understand the 7 principles of HACCP
Able to describe the basic term in HACCP such as
Critical Control Point (CCP) , Risk, Critical Limit
(CL), Hazard, Control Measure and Hazard
Analysis
Able to determine points where CCP should be
implemented in HACCP system and the relation
with CL.

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Describe a process to reduce risk of food

borne illness through proper food
handling, monitoring of procedures and
record keeping
In foodservice operation HACCP focuses
on controlling five risk factors:
Food from unsafe sources
Poor personal hygiene
Inadequate cooking
Improper holding temperature &
Contaminated equipment

To carry out sucessfully, a food service operation/food

factory need to make an individualized HACCP plan.
HACCP focusses on prevention of foodborne illness at
every step as food/raw materials flows through the
process from purchasing through serving/final product.
HACCP helps:
Identity food & procedures that most likely to cause
foodborne illness.
Develop procedures to reduce risk of foodborne illness
Monitor the use of procedures to keep food/product
safe
Verify that food served/product us safe to consume.

HACCP plan is developed around seven principles.

Based on scientific observation and data

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Preventive method

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It systematically identifies specific hazards and

measures for their control to ensure food safety.
Reduce Cost of re-production
More effective use of resource
More timely response to food safety problems

HACCP system should be capable of

accommodating change, such as advances
in equipment design, changes in processing
procedures or technological developments.

The system can be applied throughout food

chain to enhance food safety
Can aid inspection by food regulatory
authorities

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Promote internationalization trade by increasing

buyers confidence
Why? Because HACCP is being recognized by
Codex Alimentarious (Recommended International
Code of Practice - General Principles of Food
Hygiene[CAC/RCP 1-1969, Rev 3 (1997)] was
adopted by the Codex Alimentarius Commission
during its twenty-second session in June 1997)

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Conduct a hazard analysis

Determine critical control points (CCPs)
Establish critical limits
Establish monitoring procedures
Establish corrective actions
Establish verification procedures
Established record-keeping and
documentation procedures

Control(verb):To take all necessary actions to ensure

and maintain compliance with criteria established in the
HACCP plan.
Control(noun):To state wherein correct procedures are
being followed and criteria are being met.
Control measure:Any action and activity that can be
used to prevent or eliminate a food safety hazard or reduce
it to an acceptable level.
Corrective action:Any action to betaken when the results
of monitoring at the CCP indicate a loss of control.
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.
Critical limit:A criterion which separates acceptability
from unacceptability.
Deviation:Failure to meet a critical limit.

Plow diagram:A systematic representation of the sequence of steps or operations

used in the production or manufacture of a particular food item.
HACCP:A system which identifies, evaluates, and controls hazards which are
significant for food safety.
HACCP plan:A document prepared in accordance with the principles of HACCP to
ensure control of hazards which are significant for food safety in the segment of the
food chain under consideration.
Hazard:A biological, chemical or physical agent in, or condition of, food with the
potential to cause an averse health effect.
Hazard analysis:The process of collecting and evaluating information on hazards
and conditions loading to their presence to decide which are significant for food
safety and therefore should be addressed in the HACCP plan.
Monitor:The act of conducting a planned sequence of observations or
measurements of control parameters to assess whether a CCP is under control.
Step:A point, procedure, operation or stage in the food chain including raw
materials, from primary production to final consumption.
Validation:Obtaining evidence that the elements of the HACCP plan are effective.
Verification:The application of methods, procedures, tests and other evaluations, in
addition to monitoring to determine compliance with the HACCP plan.


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Possible food hazards:

Biological/Microbiological hazards:
pathogenic, bacteria, viruses, parasites,
protozoa, mycotoxin
Chemical hazards: allergen, toxic metals,
cleaning fluids, pesticides, plasticizers and
packing migration, polychlorinated biphenyls
(PCBs), chemical additives and veterinary
residues.
Physical hazards, glass, metal, stones, wood,
plastic, parts of pest
Allergenic hazard- Protein that cause
allergenic reaction---Eggs, Shellfish, Nuts,
Soy, Meat, Sulfide,etc


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To identify hazards the processing facility must

be thoroughly assessed with regard to:
Raw Materials

2.

Design of plant & equipment

3.

Possibilities of cross-contamination
Microbiological, chemical & physical hazards.

Extrinsic parameters

4.

Microbial count
Temperature upon receipt

Natural of food additives present

Reduction of microbial count

Process design

heating steps, reduction in microbial count

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Facility design

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Personnel

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adequate training, personnel practices

Packaging

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Cross contamination
Temperature control
Segregation of raw and ready-to-eat products
Personnel movement and equipment causing cross
contamination

aerobic or anaerobic condition

labelling & instruction for safe handling & use

Storage & distribution

Storage temperature, effect on shelf life

In all stages of food production, from

growing to finished products.
Review recipe/ingredient list for potentially
hazardous food (PHFs)
Prepare a flow chart of steps in process.

Identify potential hazards associated with

food and measure to control those hazards
Document the hazards and specify the
existing control measures
Potential hazards can be biological (eg.
microbe), chemical (toxin) or physical
(ground glass or metal fragments that can
harm consumers)

Any food that contains in whole or in part:

Shell eggs
Milk & poultry
Fish & shellfish
Edible crustaces (eg. shrimp, lobster, crab)
Tofu or other soy protein products
Baked or boiled potatoes
Plant food that have been heat treated (eg.
beans)
Sliced melon
Synthetic ingredients (eg. textured soy protein)
- PHF does not include foods with pH of < 4.6 or Aw
< 0.85

CCP-is a point procedure in a specific food system

where loss of control may result in unacceptable
health risk.
These are point in food production from its raw
state through processing and shipping to
consumption by consumer at which the potential
hazard can be controlled or eliminated, eg: cooking,
packing, cooling & metal detection
Identify CCPs in the process where hazard can be
controlled or prevented. Identify procedures to
prevent, reduce, eliminate recontamination hazards
at each step.

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Inspection of goods on delivery and before

use include temperature checks where
applicable
Separate storage & handling of
ingredients & finished products
Corrects temperatures ranges for
refrigerated & frozen products.
Cleaning procedures for equipments &
utensils
Personal hygiene

In order to be sure a food passes safely through a

critical control point, Critical Limits should be
established.
These Critical Limits (CLs) are standard that are
observable and measurable.
Usually specified by using temperature & time.
Others CLs that might be used include pH,
humidity, salt concentration.
Established criteria or standard that must be meet
for each CCP based on proven methods; research
data; federal state or local food regulation.

Ideally these are numerical values that if

exceeded or not met, will result in loss of
control of the particular CCP.
Specify exactly what should be done to
meet each particular standard (CL). For eg.
Instead of stating food must be thoroughly
cooked the standard should be stated
Heat rapidly to a required safe internal
temperature of 165F for 15 seconds

Monitoring consist of conducting procedures

that enable determination of whether a
critical limits is being maintained or not.
Determine whether criteria & standards are
being met at all CCPs & throughout the
process.
Involve employees responsible for the
procedures in monitoring.
Such procedures may include determining
how & by whom cooking time &
temperature are monitored.

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Physical measurement (dimension, colour,

appearance)
Visual observation (workers practices,
inspect raw materials)
Sensory evaluation (odour, colour, texture)
Chemical measurement (pH, aw , salt
content, etc.)

When a critical limits has not been met,

corrective action is needed. Eg.
reprocessing or disposing of food if
minimum cooking temperature is not met.
Actions consists of specific outlined steps
that dictate what is to be done to correct
the cause of violation, & what is to be done
with the product that was produced while
the critical limits was violated.

Immediate corrective action must be incorporated if

the standards at any CCP are not being met.
Corrective actions must be clear & based on
individual situation.
Example: a corrective action for food not being held
at a proper warming temperature of 140F (60C)
may be different depending on how long the food
has been at the improper temperature.
If it has been held improperly (< 140F ) for < 2hrs,
reheat at 165F (73.9 C) before serving.
If it has been held at (< 140F ) for > 2hrs, discard
the food.

Verity that the HACCP process in food

factory/services works.
Procedures are outlined that will help to
determine whether control of CCP is being
maintained.
Example: testing time & temperature
recording to verify that a cooking unit is
working properly.
Procedures can include calibration of
thermometers used in monitoring analysis
of product.

Establish a record keeping system to document the

HACCP process & monitor results. This can be any
simple, quick system, such as a printed
temperature forms in which employees can record
their compliance with standards at CCPs.
Written records are extremely important & may
provide proof to any foodborne cases.
Records must be kept of all procedures, including
hazard analysis, justification for decision,
identification of CCPs within the flow diagram,
monitoring records, corrective action records,
verification records, & other documentation.

1st step towards implementing HACCP is to

assemble a HACCP team.
Ideally consists production manager,
engineer, microbiologists, & QA staff.
Multidisciplinary team prerequisite for
identifying all the hazards.
Should have 1st hand information
concerning production process.
Construct a process flow diagram which
identifies all the hazards.

Quality Assurance deals with:

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Evaluation of raw materials & final product

standards
Design of the factory
Process line layout
Design of machinery
Packaging, storage & distribution

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HACCP deals with:

Approach towards hygienic food production by
prevention of problems
Does not cover quality control of the product
Production process evaluated for hazards & their
relative risks
Monitoring and verification procedures to
maintain production of hygienically acceptable
products
Provides mechanism to ensure product safety is
continuously achieved.

Foodservice Process Example with HACCP

Application
How the 7 principles of HACCP can be used during
the 8-steps foodservice process to prevent illness?

Best practice:
Identify the food and procedures that most likely to
cause foodborne illness.
Develop procedures to reduce risk of foodborne
illness outbreak
Monitor how the procedures are used to keep food
safe
Verify that the food served is safe to eat.

To assess hazards present at each stage of

preparation process, track each food from
purchasing & receiving through serving &
reheating.
Review menus.
Identify PHFs on menu because they are especially
venerable to food safety problems during
foodservice process.
For each menu, think where & how it could become
contaminated (microorganism, chemical, physical
contaminants) during foodservice process.

8-steps foodservice process but not every

steps present in every food prepared.
Step1:Purchasing
Step2:Receiving
Step3:Storing
Step4:Preparing
Step5:Cooking
Step6:Holding & Serving
Step7:Cooling
Step8:Reaheating

Section 3 - THE HAZARD ANALYSIS AND

CRITICAL CONTROL POINT (HACCP)
SYSTEM (FAO)
:http://www.fao.org/docrep/w8088e/w8088e05.htm