HACCP

• Hazard Analysis and Critical Control Point
• A systemwhich identifies, evaluates and controls hazards which are significant for food safety
• Concept synonymous with food safety
• Uses approach of controlling CPs in food handling
• Addresses physical, chemical and biologicalhazards
• Science based and systematic
•  Food control based on prevention of problems
• Applied throughout the food chain from primaryproduction to the final consumer

Hazard Analysis in HACCP

Hazard identification and determination of acceptance levels

• Hazard assessment
• Selection and assessment ofcontrol measures
• Categorization of measures
• Establishingthe HACCP plan
• PRPs
• Establish OPRPs
• Verification planning

HACCP: Five preliminary steps & Seven principles

HACCP: Preliminary steps

1. Assemble HACCP team
2.  Describe product
3.  Identify intended use
4.  Construct flow diagram
5.  On-site confirmation of flow diagram

Principle 1 : Hazard analysis

• List allpotential hazards at each step
• Identify significant hazards
• Preventive measure for each hazards
• Requires technical expertise & scientificguidelines
• Knowledge of food science / HACCP
• One control may control more than one hazardand one hazard may require more than one control
• Risk and severity
• Can be expressed qualitatively /quantitatively

Hazards will vary for same product, by different firms

• Sourceof ingredients
• Formulations
• Processing equipment
• Processing and preparation methods
•  Duration of process
• Storage conditions
•  Experience / knowledge and attitude of personnel

Principle 2: Determine critical control points

• CPP is defined as a step at which control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to acceptable levels
• CP: any point where loss of control does not lead to an unacceptable health risk
• Use ofdecision tree
• CCPs should be identifiednumerically

Principle 3: Establish critical limits for each CCP

•  Critical limit : criteria which separate acceptability from unacceptability
• At eachCCP critical limits are established
• Deviation indicates loss of control
• Violationwarrants immediate corrective action
• CLs can be qualitative/quantitative
• Validation if possible
• Sourcesof information
• Published data /scientific literature
• Expert advice /consultants / process engineers
• Experimental data/ challenge tests
• Mathematicalmodelling / computer simulation

Principle 4: Establish a monitoring system for each CCP

• Conductinga planned sequence of observations or measurements of control parameters to assess whether a CCP is under control
• Acts asan early warning system
• Monitoringprocedure to detect loss of control at CCP
• Preventiveaction to prevent violation
• Designateauthority to evaluate monitoring data
• Two types of monitoring procedures
• online systems
• offline systems
• Calibrationof measuring instruments
• Physical/chemicalmeasurements
• pH/aw/time/temp

Monitoring activity should include:

      What    – describe the critical limit
      How     – Describe monitoring procedure
      Where – Relevant step shown in flow diagram
      Who     – Trained CCP monitor
      When   – Continuous or scheduled

Principle 5: Establish corrective action

• Anyaction to be taken when the result of monitoring at the CCP indicate a loss of control
• Developspecific corrective action for each CCP
• Correctiveaction should ensure control of CCP
• Developproduct disposition procedures
• Productrecall procedures
• Documentationof results

Principle 6: Establish verification procedures

• Verificationis proof of doing what the plan says to do
• To checkthe effectivity of the plan
• To confirm that system adheres to the plan
• Each CCPand entire HACCP plan to be verified
• Verification activity include
• HACCPsystem
• HACCP plan validation
• Equipment calibration
• Challenge tests
• Re-verification
• Change in product/ ingredient
• When deviation occurs
• Newly identified hazards
• At pre-determined intervals
• Validation
• Is proof of doing the right thing
• Review of HACCP audit reports
• Review of hazard analysis
• CCP determination
• Review of deviation reports

Principle 7: Establish documentation & record keeping

• Recordkeeping is essential in HACCP system
• HACCPprocedures be documented
• Provideevidence during audits
• Fourtypes of records should be kept
• Support documentation
• Records generated by HACCP system
• Records generated by HACCP system
• Documentation of procedures
• Records of employees training programme
• Supportdocumentation
• product description
• Flow diagram
• Hazard analysis
• Identification of CCPs
• Identification of critical limits
• Documented deviation & correctiveaction
• Verification procedures
• Preventive measures for each hazard
• Recordsgenerated by HACCP system
• Monitoring records for all CCPs
• Deviation and corrective action records
• Verification / validation records
• Calibration records
• Supplier quality assurance records