Common

Common HACCP
HACCP Mistakes
Mistakes
Mark Smith
Cell: (317) 417-1654
E-mail: mark.e.smith1@pepsico.com
Goals:

• Each participant shall by the end of this Webinar have

an understanding of:
– What HACCP means
– What the 12 steps of HACCP are
– The difference between CCP’s and oPRP’s
– Common mistakes made when planning and
implementing HACCP

3
Background

• What does HACCP mean?

• Who has responsibility for HACCP?
• The difference between CCP and oPRP?
What does HACCP Mean?

Hazard analysis and critical control points,

or HACCP /ˈhæsʌp/, is a systematic preventive
approach to food safety and that identifies
physical, allergenic, chemical,
and biological hazards in production processes
that can cause the finished product to be unsafe,
and designs measurements to reduce these risks
to a safe level. In this manner, HACCP is referred
as the prevention of hazards rather than finished
product inspection.
Who has responsibility for HACCP?

Simple Answer:

Everyone
Key Definition Review

PRP

basic conditions and activities that are

necessary to maintain a hygienic
environment throughout the food chain
suitable for the production, handling and
provision of safe end products and safe food
for human consumption
Prerequisite Programs (PRP)

• The program will be overarching for the entire

facility, not process or line specific
• The program will not control a specific hazard, but
will provide a hygienic and food safe production for
the entire supply chain

Examples: (Think AIBI Consolidated or ISO22002-1)

 Master Sanitation Program
 GMP Policy
 Material Receiving Procedure
 Training Program
 Approved Supplier list for ingredients
 Truck Inspection Policy
 Engineering Standards
 Rinser Verification Procedure
 Preventative Maintenance Procedure
Key Definition Review

operational PRP

identified by the hazard analysis as essential in

order to control the likelihood of introducing food
safety hazards to and/or the contamination or
proliferation of food safety hazards in the
product(s) or in the processing environment.
Operational Pre-Requisite Programs (oPRP)

 Measurable, but not necessarily in real time

 They are specific and actionable
 May include visual checks

Examples:
 UV Light Checks
 Container Washing – caustic concentration and
temperature
 Clinistix (for CSD)
 Sanitation Checks – chemical concentration
and contact time, or, temperature and time
 In-line magnets
Key Definition Review

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 Control Points (CCPs)

 Hazard must present a significant risk

 Critical control point must be measurable in real time
 Must be the last point in the process where the hazard can
be controlled
 Actionable and achievable
 Representative of the entire lot or batch
 Method to control the hazard must be validatable and
error-proof.
 Empirical evidence must exist that the control eliminates
the hazard or reduces it to an acceptable level

Examples:
 pH control for acidified foods
 pasteurization for 100% juice
 metal detection for dry foods
Traditional CCP vs. FSSC
LET’S GET STARTED
Prerequisite Programs (PRP)
12 Steps of HACCP
1.Assemble HACCP Team
•Develop a team that has the appropriate product specific
knowledge and expertise to develop an effective food safety
plan.
2.Describe Product
•Draw up a full description of the product including
composition, physical/chemical structure, microcidal/static
treatments, packaging, storage conditions, and
distribution methods.
•Identify the intended use
•Usage should be based on expected intended use of the
product by the end user.
•Construct flow diagram
•Create a diagram that covers all steps of the operation
including steps preceding and following the specified operation.
1.On-site confirmation of flow diagram
•Determine that the flow diagram is aligned with actual
operations.
12 Steps of HACCP

6. Conduct a hazard analysis

•Identify any biological, chemical or physical hazards.
7. Determine Critical Control Points (CCPs).
•CCPs are areas where previously identified hazards
may be eliminated.
8. Establish Critical Limits
•Develop processes that limit risk at CCPs.
9. Monitor CCPs
•Develop process for ensuring critical limits are
followed.
10. Establish preplanned corrective actions to be taken
11. Establish procedures for verification
12. Ensure proper documentation and records of HACCP
process are maintained
 Determination of CCPs and oPRPs
Raw STORAGE
Raw material
material STORAGE Type of Cause of Significance of Hazard Justification for
CONDITION
CONDITION
(Including
(Including packaging)
packaging) A=Ambient
A=Ambient Hazard Hazard Decision
F=Frozen
F=Frozen
R+Refrigerated
R+Refrigerated
Severity
Severity of
of Likelihood
Likelihood of
of Hazard
Hazard RPN
RPN Significant
Significant
Hazard
Hazard Occurring
Occurring Hazard
Hazard
Water
Water (Municipal/Well)
(Municipal/Well) A
A Biological:
Biological: 55 44 20
20 YES
YES Not
Not likely
likely to
to occur
occur
E
E Coli
Coli Unsanitary
Unsanitary storage,
storage,
Cryptosporidium
Cryptosporidium environmental
environmental
Girardia
Girardia conditions
conditions such
such as
as
surface
surface water
water
conditions,
conditions, draught
draught
conditions
conditions
Chemical:
Chemical: Heavy
Heavy 33 33 99 MAYBE
MAYBE Not
Not likely
likely to
to occur
occur
metals,
metals, pesticides
pesticides Environmental
Environmental
personal
personal care
care conditions
conditions such
such as
as
products,
products, storm
storm water
water run
run off,
off,
medications
medications medicine
medicine flushed
flushed
down
down drains.
drains.
Physical:
Physical: Storm
Storm water
water run
run off,
off, 33 11 33 NO
NO Not
Not likely
likely to
to occur
occur
dirt
dirt and
and debris
debris poor
poor distribution
distribution
(piping)
(piping)
 Severity of Hazard
Severity
if
controls Severity of affect if Hazard Occurs Multiplier
fail
Mild disappointment to the consumer. May lead to a complaint, no business
Little
Damage interruption. Minor consequences.
1

Illness at home. Medical treatment not necessary. Consumer disappointed.

Damage
Likely to lead to a complaint to the Company.
2

Medical treatment may be necessary (for example a broken tooth). A

Serious disappointed consumer very likely to lead to a complaint to a regulatory
Damage
3
authority.
Very Illness at home with medical treatment necessary. A very disappointed
Serious
consumer. A significant risk of prosecution.
4
Damage
Disaster Hospitalization required. Significant risk of proscecution. Media coverage.
Serious
Intervention by ‘Crisis management team’. Damage to ‘branded’ image.
5
Illness
Death. Top level ‘crisis management’ Certain risk of proscecution.
Catast-
rophic Destruction of ‘brand’
6
 Likelihood of Occurrence
Probability of hazard
occurring under current Likelihood That Hazard Could Occur Multiplier
conditions

Almost Impossible No history of it occurring 1

Un-Likely Very occasional, has been known to occur 2

Could be an isolated event that results after

Small Risk 3
manual operations
Product or operational factors that can be
Likely 4
expected to be present

Product or operational factors that are always

Certain 5
present that the process is expected to control
 Risk Level
Risk Score
Risk Level Description
Low risk - Probably controlled by a Prerequisite Program.
1–5
Check nature of problem against existing pre-requisite programs.

Some risk.
6–9
Control by a Prerequisite Program.

Elevated Risk. Use Codex decision tree for hazards.

10 – 16
Definitely a Prerequisite Program, may be a CCP.

Significant risk! Likely to be a Critical Control Point (CCP). Use Codex decision tree for
16 +
hazards. Initiate special HACCP review.
 Determination of CCPs and oPRPs

Raw STORAGE
Raw material
material STORAGE Type of Cause of Significance of Hazard Justification for
CONDITION
CONDITION
(Including
(Including packaging)
packaging) A=Ambient
A=Ambient Hazard Hazard Decision
F=Frozen
F=Frozen
R+Refrigerated
R+Refrigerated
Severity
Severity of
of Likelihood
Likelihood of
of Hazard
Hazard RPN
RPN Significant
Significant
Hazard
Hazard Occurring
Occurring Hazard
Hazard
Water
Water (Municipal/Well)
(Municipal/Well) A
A Biological:
Biological: 55 44 20
20 YES
YES Not
Not likely
likely to
to occur
occur
E
E Coli
Coli Unsanitary
Unsanitary storage,
storage,
Cryptosporidium
Cryptosporidium environmental
environmental
Girardia
Girardia conditions
conditions such
such as
as
surface
surface water
water
conditions,
conditions, draught
draught
conditions
conditions
Chemical:
Chemical: Heavy
Heavy 33 33 99 MAYBE
MAYBE Not
Not likely
likely to
to occur
occur
metals,
metals, pesticides
pesticides Environmental
Environmental
personal
personal care
care conditions
conditions such
such as
as
products,
products, storm
storm water
water run
run off,
off,
medications
medications medicine
medicine flushed
flushed
down
down drains.
drains.
Physical:
Physical: Storm
Storm water
water run
run off,
off, 33 11 33 NO
NO Not
Not likely
likely to
to occur
occur
dirt
dirt and
and debris
debris poor
poor distribution
distribution
(piping)
(piping)
It’s either a CCP
- or -
Or It’s Not
ISO Decision Tree

OR Its a CCP

Its an oPRP In FSSC, it is either a

CCP or an oPRP!
12 Steps of HACCP

6. Conduct a hazard analysis

•Identify any biological, chemical or physical hazards.
7. Determine Critical Control Points (CCPs).
•CCPs are areas where previously identified hazards
may be eliminated.
8. Establish Critical Limits
•Develop processes that limit risk at CCPs.
9. Monitor CCPs
•Develop process for ensuring critical limits are
followed.
10. Establish preplanned corrective actions to be taken
11. Establish procedures for verification
12. Ensure proper documentation and records of HACCP
process are maintained
Key Definitions Review
• Monitoring
– conducting a planned sequence of observations
or measurements to assess whether control
measures are operating as intended
• Verification
– confirmation, through the provision of objective
evidence, that specified requirements have been
fulfilled
• Validation
– obtaining evidence that the control measures
managed by the HACCP plan and by the
operational PRPs are capable of being effective
ANY FOLLOW-UPS?