Hazard Analysis & Critical Control Point PDF

Hazard Analysis & Critical Control Point Mr. Msoni Eden University  der Foods C a z a rHd n aAl y s i s & Cr i t i c aCl o n tPr o l o ea L o. Agenda Introduction To HACCP HACCP Benefits HACCP Principles...

Hazard Analysis & Critical Control Point Mr. Msoni Eden University  der Foods C a z a rHd n aAl y s i s & Cr i t i c aCl o n tPr o l o ea L o. Agenda Introduction To HACCP HACCP Benefits HACCP Principles Implementation Of HACCP HACCP Plan HACCP Preparation : -> Preliminary steps -> Pre-requisite programs 2  der Foods C a z a rHd n aAl y s i s & Cr i t i c aCl o n tPr o l o ea L o. Introduction to HACCP HACCP Is :- A system of control based on prevention of problems by identifies specific hazards and control measures to ensure total food safety management. The system requirements are generic and applicable to all food organisations concerned with the food chain from production preparation, processing, packaging, storage and distribution until the point of customer consumption. 3  der Foods C a z a rHd n aAl y s i s & Cr i t i c aCl o n tPr o l o ea L o. Steps Of HACCP System Look at your Process/ Product from A to Z; Decide where hazards could occur; Put in controls and monitor them; Write it all down and keep records; Ensure that it continues to work effectively. Trainer : Walid Gahfer 4  der Foods C a z a rHd n aAl y s i s & Cr i t i c aCl o n tPr o l o ea L o. HACCP Benefits Maximize product safety. Improved management responsibility. Improved process control. Improved inspection testing. Moving the company towards a Quality Management System. Trainer : Walid Gahfer 5  HACCP Principles Trainer : Walid Gahfer  der Foods C a z a rHd n aAl y s i s & Cr i t i c aCl o n tPr o l o ea L o. Principle (1) Analysis Of Hazards Assessment. Principle (2) Identification Of Process Critical Control Points (CCPs). Principle (3) Establish Critical Limits For Preventative Measures Associated With Each Identified CCP. Principle (4) Establish procedures for Monitoring the CCPs. Principle (5) Establish of corrective actions to be taken when monitoring indicates deviation from an establish critical limit. Principle (6) Establish effective record-keeping procedures that document the HACCP system. Principle (7) Establish procedures for verification that HACCP system is working correctly. Trainer : Walid Gahfer 7  der Foods C a z a rHd n aAl y s i s & Cr i t i c aCl o n tPr o l o ea L o. Principle (1) Analysis Of Hazards Assessment Trainer : Walid Gahfer 8 Hazard: Is any factor which may be present in the product that can cause harm to the consumer either through injury or illness. PREVENTATIVE MEASURE: AN ACTION TO PREVENT A HAZARD OR REDUCE IT TO AN ACCEPTABLE LEVEL. Trainer : Walid Gahfer  Prepare a list of the process (process flow diagram containing all process steps from raw material receiving TO end product) & identify where significant hazards could occur and describe preventive measures. The hazard could be biological, chemical, or physical. And the measure that can be applied to prevent the occurrence of hazards must be determined accordingly.  der Foods C a z a rHd n aAl y s i s & Cr i t i c aCl o n tPr o l o ea L o. ▪Types Of Hazards Associated With Our Product: Biological Hazards: It’s any pathogenic microorganism like Bacteria, Parasites & Viruses. EX: Bacteria:- ((Shigella, Salmonella, Staphylococcus aureus, Escherichia coli, Standard plate count, Total Yeast & moulds, Total Coliforms, Bacillus cereus)). Chemical Hazards: 1. Naturally-occurring chemicals. EX: (( Allergens, Mold toxins -mycotoxins- )) 2. Intentionally-added chemicals. EX: (( Packaging materials, Sanitizers )) 3. Unintentional or incidental chemical additives. EX: ((Agricultural chemicals -pesticides, fertilizers- & Toxic elements / compounds - lead, tin, copper, zinc, arsenic, mercury, cyanide- & Cross-contaminating food allergens from inadequately cleaned shared processing equipment.)) Physical Hazards: Any potentially harmful matter not normally found in packet EX: Metal, Wood, Glass Fragments. Trainer : Walid Gahfer 11 PRINCIPLE (2) IDENTIFICATION OF PROCESS CRITICAL CONTROL POINTS (CCPS) Trainer : Walid Gahfer  der Foods C a z a rHd n aAl y s i s & Cr i t i c aCl o n tPr o l o ea L o. 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. ❑ After determination of hazards, we must determine where hazards could occur. ❑ And for performing this identification we use the Decision Tree. CCP Decision Tree: A sequence of questions to be considered in the process to decides where is CCP. Trainer : Walid Gahfer 13  Steps to Identify (Determine) CCPs Using A Decision Tree Q1: DO PREVENTIVE MEASURES EXIST FOR THIS HAZARD? I F Y E S G O TO Q 2 , I F N O, T H AT M E A N S I T ’ S R E Q U I R E D O F SAFETY I F N O = N OT C C P *, ( I F Y E S M O D I F Y P R O C E S S O R P R O D U CT ). Q 2 : D O E S T H I S S T E P S P E C I F I C A L LY D E S I G N E D TO E L I M I N AT E / R E D U C E T H E L I K E LY O C C U R R E N C E O F T H I S H A Z A R D TO A N A C C E P TA B L E L E V E L? IF YES = CCP I F N O G O TO Q 3 Q 3 : C O U L D C O N TA M I N AT I O N O C C U R I N E XC E S S O F A C C E P TA B L E L E V E L? ( U N AC C E P TA B L E L E V E L O C C U R ) ? I F Y E S G O TO Q 4 I F N O = N OT C C P * Q 4 : W I L L A S U B S E Q U E N T ST E P E L I M I N AT E / R E D U C E T H I S H A Z A R D TO A N A C C E P TA B L E L E V E L ? I F Y E S = N OT C C P * IF NO = CCP * ( G O TO T H E N E X T S T E P I N P R O D U C T I O N ) Trainer : Walid Gahfer  der Foods C a z a rHd n aAl y s i s & Cr i t i c aCl o n tPr o l o ea L o. Principle (3) Establish Critical Limits For Preventative Measures Associated With Each Identified CCP Trainer : Walid Gahfer 15 Critical Limit (CL): - Is the criteria that specifies safe product from unsafe product. - Is the maximum /or minimum value that must be controlled at a CCP to prevent, eliminate, or reduce to an acceptable level the occurrence of the identified food hazard. OPERATION LIMIT: A CRITERIA THAT IS MORE STRICT THAN CRITICAL LIMITS, WHICH THE OPERATOR USE TO REDUCE THE POSSIBILITY OF DEVIATION. When there is any deviation from CL; the product became un safe.  der Foods C a z a rHd n aAl y s i s & Cr i t i c aCl o n tPr o l o ea L o. Principle (4) Establish Procedures For Monitoring The CCPs Trainer : Walid Gahfer 17 Monitoring: - to conduct a planned sequence of observations or measurements of control parameters to assess whether the ccp’s are controlled by the food organisation or not. Monitoring is performed to identify when there is a loss of control (a deviation at a CCP). Monitoring equipments shall be calibrated precisely. Trainer : Walid Gahfer Monitoring WHAT: USUALLY A MEASUREMENT OR OBSERVATION TO ASSESS IF THE CCP IS OPERATING WITHIN THE CRITICAL LIMIT. HOW: USUALLY PHYSICAL OR CHEMICAL MEASUREMENTS (FOR QUANTITATIVE CRITICAL LIMITS) OR OBSERVATIONS (FOR QUALITATIVE CRITICAL LIMITS). FREQUENCY: CONTINUOUS OR PERIODIC. WHO: RESPONSIBLE INDIVIDUAL TRAINED TO PERFORM THE SPECIFIC MONITORING ACTIVITY OR EVALUATE MONITORING RECORDS. Trainer : Walid Gahfer  der Foods C a z a rHd n aAl y s i s & Cr i t i c aCl o n tPr o l o ea L o. Principle (5) Establish Of Corrective Actions To Be Taken When Monitoring Indicates Deviation From An Establish Critical Limit Trainer : Walid Gahfer 20 Corrective Action: Is the procedures under following to satisfy system requirements when a deviation occurs. CORRECTIVE ACTION PROCEDURES INCLUDES THE ACTIONS THAT BRINGS THE PROCESS BACK UNDER CONTROL. IT ALSO INCLUDES ACTION TO DEAL WITH PRODUCT MANUFACTURED WHILE THE PROCESS WAS OUT OF CONTROL. Trainer : Walid Gahfer  der Foods C a z a rHd n aAl y s i s & Cr i t i c aCl o n tPr o l o ea L o. Principle (6) Establish Procedures For Verification That HACCP System Is Working Correctly Trainer : Walid Gahfer 22 Verification: The application of methods, procedures, tests and other evaluations, in addition to monitoring to determine compliance with the HACCP plan. Validation: the process of proving that a system is acceptable for its intended purpose. Trainer : Walid Gahfer The verification procedures of the overall HACCP system shall includes: Initial validation of the elements of the HACCP plan, such as process flow diagram, hazards analysis, determination of ccps, critical limits, monitoring procedures, corrective action, documents /records keeping system, etc. Internal audit that covers all activities under haccp system, which shall be performed at least once ever y six months. The feedback system of audit data for improvement of the HACCP system. Any changes made that may affect the haccp system. External audit. Trainer : Walid Gahfer  der Foods C a z a rHd n aAl y s i s & Cr i t i c aCl o n tPr o l o ea L o. Principle (7) Establish Effective Record-Keeping Procedures That Document The HACCP System Trainer : Walid Gahfer 25