An introduction to HACCP (Hazard Analysis Critical Control Point)

HACCP has its origins in the US space programme and was further developed by the Codex Alimentarius Commission is a methodology and a management system. It is used to identify, prevent, and control food safety hazards. 

What are some of the basic definitions?

Hazard

A biological, chemical or physical agent in, or condition of, food with the potential to cause an adverse health effect.

Food safety hazard analysis

A food safety hazard analysis is done in order to determine which potential hazards need to be controlled, how much control is needed, and which combination of control measures should be used in order to make sure that food is safe.

Good Manufacturing Practice (GMP)

A production and testing practice that helps to ensure a quality product. Basic preventive guidelines for plant and facility operations. Guidelines aimed at food processors aim to include all HACCP methods and procedures and typically address (1) plant design and construction material, (2) water supply, (3) plumbing and toilet facilities, (4) equipment and utensils, (4) raw food handling and testing practices, (5) personal hygiene, (6) pest control, and (7) waste disposal.

Risk analysis

A process consisting of three interconnected components: risk assessment, risk management and risk communication.

Risk assessment

A scientifically based process consisting of four steps (i) hazard identification (ii) hazard characterisation, exposure assessment (iii) and (iv) risk characterisation.

Verification

Act or process of establishing (confirming) the accuracy or existence of something; in the quality field, verification is a systematic, objective, and documented process of confirming that a product or service conforms to various requirements (customer, regulatory, etc.). A process that uses objective evidence to confirm that specified requirements have been met.

HACCP management systems consist of seven principles and use a logical methodology. What are these seven prociples?

What are the seven principles of HACCP are:

1. Hazard Analysis

Identify any Physical (P), Chemical (C) or Micro Biological (M)

Hazard that might occur at each stage

2. Critical Control Points (CCP’s)

CCP’s are the stages of your process where the hazards must be controlled for the food to be safe to eat. Example: Cooking, metal detection or pasteurisation

3. Critical Limit

Critical limits are specified safety limits at your CCP’s, which separates acceptable (safe food) from unacceptable (unsafe food). Critical limits are usually numerical values based on scientific finding.

Example: Critical limit for cooking: 80C; Critical limit for pasteurisation = 75.5 C / 15 Seconds / Flow 17000L.

4. Monitoring

Monitoring procedures would need to be established to ensure hazards are controlled at CCP’s. Such monitoring activity may involve temperature checks, visual inspection and time recording

Example:  Checking with a probe thermometer the internal temperature of cooked food; Automatic temperature recording with a probe (within +/- 0.05 C) / filter checks and identifying who is responsible for this (Operators & management)

5. Corrective Action

Corrective actions are procedures to be taken when monitoring (at CCP’s) has identified that the critical limit has been or is likely to be exceeded.

Example:  The act of returning cooked undercooked food to oven (65C) to continue to cook till 80C; Immediate correction: automatic flow divert / RCA: 5 Why / Ishikawa.

6. Verification

This involves taking an overview of your HACCP based system to ensure it is working effectively. It is checking that the checks already done are true and effective at controlling your hazards. Refer to company heat treatment plan (MPI HTST tables).

Example:  Checking the checker activity ; internal audits; Activity (Check such as: temperature, holding time, filters) / Frequency (how often? Daily, weekly or monthly) / Responsibility (who? Operators & management) Verification includes, pasteuriser checks, daily log sheets checks, calibration checks, flow & valve checks and internal audits.

7. Documentation and record keeping requirements

A HACCP based system must have appropriate documentation to demonstrate it is working effectively. These will usually incorporate HACCP charts, work instructions, written procedures/policies.

Example: Food safety (cooking) records; Pasteuriser records, daily log sheets, calibration records both soft and hard, training records, annual flow & valve checks, internal audits and third party audits.

Review To ensure the HACCP is working effectively, it is important to review the food safety system at regular intervals. This may be when there is a change of process, flow rate, HACCP plan or a non-compliance related to the current plan.

Is there an example of a HACCP flow chart?

Is there an example of a HACCP table?

What are the microbiological limits for food service and catering?

Where can I go for on-line resources towards a HACCP Plan?

Ministry for Primary Industries

How is HACCP practically applied in the food industry?

The video below explain how HACCP is practically applied