Learning Outcomes for this course
1. Know the purpose of a HACCP system
2. Know the features of a HACCP system
3. Know how hazards are controlled
4. Know how to manage a Critical Control Point
Discussion
Why is Food Safety Important?
1.
Why is Food Safety Important?
To protect the consumer
To protect your business
To comply with the law
So who is responsible for Food Safety in YOUR business?
EVERYONE!
What are the Laws?
The Food Safety Act 1990
EC 852/2004 Regulation on the Hygiene of
Foodstuffs
Apply principles of HACCP to hazards specific to
business and process
Based on risk assessment
Discussion
1.What do you think are the Consequences of NOT Managing Food
Safety?
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Consequences of a Hazard reaching
the Consumer
• Illness or injury/complaints – DEATH
• Customer and EHO scrutiny
• Prosecution, fines/imprisonment
• Loss of business/customers
• Loss of jobs as production reduced/ company closed
and consequences for the workforce
Discussion
What Makes Food Safe?
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What Makes Food Safe?
Freedom from contamination
Microbiological (Pathogens)
Physical
Chemical (including Allergens
Making sure pathogens cannot grow
Safe food is obtained by
Correct and careful processing
Protecting the food from further contamination
Preventing Contamination
Use of reputable suppliers
Effective cleaning
Compliance with personal hygiene requirements
Correct food storage
Preventing Growth of Microorganisms
How?
By making sure microorganisms
(bacteria, moulds, viruses or yeasts)
cannot get what they need
So what do microorganisms need?
Preventing Growth of Microorganisms
How?
By making sure microorganisms
(bacteria, moulds, viruses or yeasts)
cannot get what they need
So what do microorganisms need?
o d Time
F o Warmth
The Ri
g ht
Moisture Acidity
ACTIVITY HOW IS DONE AT YOUR
WORKPLACE
1.----------------------------------------------------------------------------------------------------
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2.
3.
Common Preservation Techniques
• Heating
• Drying
• Use of Chemicals
• Chilling/Freezing
• Acidity
• Manipulation of gases
around the product
The Food Chain
Primary Secondary Retailing/
Agriculture Processing Processing Catering Consumer
FARM TO FORK
So what do we do?..........
The Approach to Food Safety Management
All ‘links’ in the food chain are responsible for food safety in their
own operations
Confidence and trust in suppliers is vital
Traceability is needed in case there are any problems
Design food safety systems to prevent problems rather than rely on
end product testing
Food companies need a good ‘food safety system’
The ‘Foundations’ -
Having a Food Safety Culture
What does a Food Safety Culture involve for the
people involved in the Company?
The ‘Foundations’ -
Having a Food Safety Culture
Clear Commitment to Food Safety from Management
Knowledge and Skills to Manage Food Safety
Ensure Levels of Supervision are in Place and Right for the
Business
Members of Staff given Responsibility and Authority
A Food Safety ‘Culture’
WHAT
Food Safety Culture & Management Commitment
A Food Safety ‘Culture’
Food Safety Culture and Management Commitment
The ‘Walls’ –
Making sure that Good
Practices
(or Pre-Requisite Programmes)
are in Place
The ‘Walls’
Making sure that Good Practices
(or Pre-Requisite Programmes) are in Place
Hygiene & Housekeeping
Planned Maintenance of Buildings and Equipment
Pest Control
Waste Control
Supplier Controls
Personal Hygiene
Training
Control of allergens
Good Practices or Pre-requisites
Manage hazards not specific to a particular process or
product
Support and underpin HACCP
Allow HACCP to focus on what are the most significant
hazards for a particular product or process
Hygiene & Housekeeping
Planned Maintenance
Pest Control
Personal Hygiene
Training
Supplier Controls
Food Safety Culture and
A Food Safety ‘Culture’
Calibration
Management Commitment
Hygiene & Housekeeping
Planned Maintenance
Pest Control
Personal Hygiene
HACCP
The Process
Training
Supplier Controls
A Food Safety ‘Culture’
Calibration
Food Safety Culture and Management Commitment
The ‘Roof’: ‘Doing’ HACCP
Preparation
Grouping products & processes to decide on the
different HACCP Plans required
Makes applying HACCP efficient &
effective
Saves time and complexity
HACCP
Hazard Analysis Critical
Control Point
A food safety management
system which identifies and
controls hazards which are
significant for food safety
Food safety
management system
The policies, practices and
documentation that ensure the
food sold is safe to eat.
1960’s originated by collaboration between NASA and Pillsbury
Company
1970’s Introduced to Food Industry
1997 Codex Alimentarius Commission (Codex) set out guidelines
for implementing HACCP
2006 Regulation (EC) No. 852/2004 made Codex HACCP a legal
requirement for all food businesses
Food business operators to implement a food safety
management system based on HACCP principles:
a) Identify hazards
b) Identify critical control points (CCPs)
c) Establish critical limits
d) Implement monitoring at CCPs
e) Establish corrective actions
f) Establish verification procedures
g) Establish documentation
h) Review if changes
NB. Hazard analysis, the first principle of HACCP includes control
measures.
• Annex 11 Chap XII
• Food handlers should be trained commensurate with their work
activities
• Persons responsible for HACCP should receive HACCP training .
1. Conduct a hazard analysis
2. Determine critical control points
3. Establish critical limits
4. Establish monitoring procedures
5. Establish corrective actions
6. Establish procedures for verification and review of HACCP
plan
7. Establish record keeping & documentation
• Step1: The HACCP team
• Step 2: Describe the product
• Step 3: Identify intended use
• Step 4: Process flow diagram
• Step 5: Verify flow diagram
• Step 6:Conduct a hazard analysis
• Step 7 Determine critical control points
• Step 8 Establish critical limits
• Step 9 Establish monitoring procedures
• Step 10 Establish corrective actions
• Step 11 Establish procedures for verification and review of
HACCP plan
• Step 12 Establish record keeping & documentation
Prerequisite programmes
Are the good hygiene practices a
business must have in place before
implementing HACCP
Prerequisite programmes ensure
the HACCP plan concentrates on
the most significant hazards.
Management commitment/adequate resources
Prerequisite programmes
•Approved suppliers
•Good design
•Equipment calibration
•Preventive maintenance
•Personal hygiene/competency
•Stock rotation
•Cleaning and disinfection
•Pest management
•Good housekeeping
•Waste management
•Labelling and traceability
•Contingency plans.
Conduct a hazard analysis
• what product, or group of products, are to be included in the plan?
• where will the plan start and end?
• which class of hazard, or classes of hazards, are to be included?
• Multi – disciplinary
• Inter – hierarchical - different levels of personnel
• Workable size – usually 4 – 6
• Expertise needed from – technical/microbial, production, maintenance,
purchasing, development, distribution, service
• ingredients and formulation
• raw materials
• storage conditions
• processing conditions
• packaging
• shelf life
• consumer instructions
• distribution methods
• microbiological data
• physical/chemical parameters (e.g. pH, aw)
• Will the product be consumed by any vulnerable groups?
• What is its shelf life?
• Will it need to be refrigerated, frozen or can it be stored at ambient
temperatures?
• Are there any special requirements?
A flow diagram
Is a pictorial representation of the steps involved in a
particular process
Consider:
• raw materials – list separately
• Don’t forget:
• Packaging
• Water/air
• Rework
• Transfer stages
Delivery and
Validate (audit) the
unloading process flow chart. Is
it right for every
Storage (chilled
( ) occasion?.
Preparation
Cooking
Slicing
Cooling
Storage (chilled) Reheating
Service (Hot) Service (Cold) Service (Hot)
• Accuracy is essential as the process flow diagram forms the basis of
the HACCP plan
• “Walk the line” to confirm detail
• Usually carried out by someone not involved in the design
• Carries out at different times/shifts
• Amend where necessary, record changes
“The process of collecting & evaluating information on
hazards & conditions leading to their presence to decide
which are significant for food safety & therefore should be
addressed in the HACCP plan. “
Codex 2001
A hazard is anything with the potential to cause harm
Risk is the likelihood of the hazard occurring
(Micro) biological (C M S ) Physical (C)
Cuts to mouth, choking,
Foodborne illness broken teeth, internal injury, burning
e.g. Glass, nails/bolts, string,
e.g. Salmonella jewellery
Chemical (C) Allergenic (C)
Food poisoning, chronic illness Immune reaction,
anaphylactic shock
weedkillers, additives, e.g. Peanuts, milk, eggs, shellfish,
poisonous foods gluten, soy, sesame seeds.
Key: C = Contamination M = Multiplication S = Survival
Any action or activity that can be used to prevent or
eliminate a food safety hazard or reduce it to an
acceptable level.
Remember:
• More than one hazard may be controlled by a particular control
measure
• An individual hazard may require more than one control measure
‘Actions required to
prevent or eliminate a
food safety hazard or
reduce it to an
acceptable level’
Controls can be applied to:
Temperature Time
pH aw
Size/shape/weight Additives
Appearance/
texture/colour.
Critical control point
‘A step in a process where
control is essential to prevent
or eliminate a food safety
hazard, or reduce it to an
acceptable level’.
Effective control
procedures must be
provided at all CCPs
Control Point
No (good hygienic
practice)
If I lose control is it
likely that food
Yes
poisoning/injury/
harm will result?
Will a subsequent
Yes step eliminate the
hazard, or reduce it to
an acceptable level?
No
CCP
Critical control point.
Critical limits must be
unambiguous and
measurable
Critical limits
“values of monitored
actions which separate the
acceptable from the
unacceptable”.
Critical
limit Target
Refrigerator 8°c 5°c
Target levels
Cooking temperature 75°c 78°c “control criteria that are
more stringent than the
critical limits”.
Monitoring
“The planned observations
and measurements of
control parameters to
confirm the process is under
control and critical limits are
not exceeded”.
Rapid detection and
correction
Automatic or manual
• Should state:
• Who - who's responsible for the monitoring?
• When - frequency?
• How – e.g. equipment used, supported by documented
procedure (SOP)
• What – critical limit, targets & tolerances
• Where – at what CCP?
Measuring Visual inspections
Observation/
(temp/weight/volume) (of premises,
supervision
e.g. refrigerator vehicles or practices)
Daily checking of
Competency Organoleptic
controls/records
Testing (senses)
(e.g. date codes).
Corrective action
The action to be taken when
a critical limit is breached
Remedial action should be
taken before a critical limit is
breached
Corrective action should bring
the CCP under control and
deal with any affected
product.
Corrective action should specify the treatment of affected product
(quarantine, testing, reprocessing, disposal and recall)
Continue process, e.g. extend cooking time
Change shelf life, e.g. use immediately
Release after examination/
sampling/testing
Use for different purpose
Release
Destroy.
Validation
Obtaining evidence that elements of
the HACCP plan are effective,
especially the critical control points
and critical limits
Verification
The methods, procedures, tests, and
other evaluations, in addition to
monitoring, to establish if the HACCP
system is functioning as planned
Audits
Analysis of complaints
Microbiological/chemical tests.
A reassessment of the HACCP
system to ensure its continued
validity.
The HACCP system should be reviewed:
• If things go wrong,
e.g. food poisoning
• If there are significant changes, e.g. new ingredients, law,
process or product.
• Essential to the application of the HACCP system
• Appropriate to the size and nature of the business
• Demonstrates importance of CCP monitoring to staff
•Company policy
Why is it•Verification/internal
required? audits
•Complaint/illness investigation
•Due-diligence defence
•Legal compliance
•External auditors/EHO/EHP
•Prove business is well managed.
• Reduces the risk of food poisoning and food complaints
• Compliance with the law (due-diligence defence)
• Resources concentrated at critical points
• Reduced costs, e.g. waste/recall
• Generates a food safety culture/all staff involved
• Proactive not reactive
• Safety introduced in product development
• Demonstrates management commitment
• More effective than end-product testing
• Over complicated
• Lack of management commitment
• Lack of training = lack of understanding
• Lack of resources
• Poor communication
