Create Food Safety HACCP Guide

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By Irwan Arief irwan_arief87@yahoo.co.id
IMPLEMENTATION HACCP
FOOD SAFETY SYSTEM

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Food Safety!!
Consumers
Raw Material
SupplyProducers Food Process
Markets /
StoreFood Distributions

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Food safety management system aimed to identifying, evaluating and
controlling HAZARD of
by monitoring and controlling critical points (CCP) through the
establishment of critical limits.
H A C C P
Biological Hazard Chemical Hazard

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Glass
Metal
Stones
Woods
Rope or YarnPLASTICS
Physical HazardPhysical Hazard

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Chemical HazardChemical Hazard
Lead and
carbon
Pesticide
Oli non
Food
Soap
Dyes and
Colors non
food grade

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 Aflatoxin from peanute (Aspergillus flavus –amur)
 Bactery Patogen ( Salmonella, Shigella , E coli
Stapylococcus etc)
 Listeria, pseudomonas and other type of bactery patogrn
which commonly will find in stockbreeding
Microbiology HazardMicrobiology Hazard

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Long
hairedDirty
body
/ face
Dirty
Hands
Dirty
shoes /
slippers
Mouth
Beard/
mustache
Dirty
Clothes
SOURCE CONTAMINATION MICROORGANISM
OF WORKERS

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Commitment
MUST
TOP MANAGEMENT
FOLLOWED BY ALL
THE LEVEL BELOW

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DEVELOPMENT PLAN HACCP
Step 1. Assemble HACCP Team
Step 2. Description of the product and its distribution
Step 3. Identify the use
Step 4. Develop a flowchart
Step 5. Verify the flow diagram
12 STEP and 7 PRINCIPLES of HACCP

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Step 6 Principle 1. Conduct a hazard analysis
Step 7 Principle 2. Determine CCP
Step 8 Principle 3. Establish critical limits
Step 9 Principle 4. Establish monitoring procedures
Step 10 Principle 5. Determine corrective action
Step 11 Principle 6. Establish procedures for verification
Step 12 Principle 7. Establish procedures for storage

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1. HACCP team consists from personnel with knowledge
and experience relating to products and processes
2. Multidisciplinary and multidepartemen..
3. Choosing a companion who acted as external experts
who understand the potential danger of physical,
chemical and biological correlates with the production
process (if necessary).
4. Decision Team = Decision Management.
Step 1 BUILD HACCP TEAM

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• Product name / tradename
• The composition of the product
• The quality standards according to ISO
• Buyer requirements
• Product Standards to be achieved
• Handling and processing
• Methods of Storage
• Methods of Packaging
• How to distribution (frozen, refrigerated or normal
temperature).
• Serving method
• Etc
Step 2 Description Product

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Describes the types of customers who are able to consume such food.
Some consumers are vulnerable to food products, for example:
• Infants
• Immunocompromised individual
• Elderly
• Allergen Control.
• Halal (Country/consumer muslim)
• Etc.
Step 3 IDENTIFICATION USER

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Prepared by the HACCP team which has
been designated and authorized.
Specifically reflects the actual process flow.
All production steps in the process.
Able to use symbols.
Step 4 FLOW DIAGRAM

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STEP PROCESS
INSPECTION
TRANSPORTATION
FLOW PRODUCT
and MATERIALS
STORAGE
ACTIVITIES
WITH DECISION
GENERAL EXAMPLES OF SYMBOLS
INPUT
MATERIAL

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The HACCP team should verify the flow diagram with field
operations, including the timing of each step of the process.
Verification in the field also includes sampling, interviews,
product regular / non-regular, routine / non-routine.
Ensuring the accuracy of the information needed, including
checks on the night shift.
Step 5 Verification Flow Chart On Field

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Naturally occurring chemical
hazards By adding chemical
Mycotoxins, Allergen, PAH
Scombrotoksin (histamine)
Mushroom toxin
shellfish toxin
Paralitic shellfish poisoning (PSP)
Diarrheic shellfish poisoning (DSP)
Neurotoxic shellfish poisoning
Nitrites, nitrates, compounds n-nitrosa
Toxic materials used in the farm
(antibiotics, pesticides, hormones, etc.).
Lead, arsenic, zinc, mercury and
cyanide
BTP (preservative, flavor, nutritional
and coloring).
Lubricants, sanitizers, detergents,
lamination etc.
Migration plastic components
Type of Chemical Hazard
Step 6 (Principle 1) Hazard Analysis

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Physical Hazard
(Material concern)
Source
INSECT including raw material, dirty environment,
processing place.
CUTTING GLASS
PIECES
including raw materials, containers, lamps,
inspection equipment, processing tools
METALS including raw materials, office equipment,
containers, equipment, cleaning tools
STONE, TWIGS,
LEAVES
including raw materials, environtment around the
office and area process
JEWELRY Human
PLASTIC including raw materials, containers, pest control
material.
Type of Physical Hazard

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Product category of high risk
1. Products containing fish, eggs, vegetables, cereals and dairy ingredients that need to be fermented.
2. The meat, raw fish and dairy products.
3. The product has a pH> 4.6 were sterilized in a closed container in hermetic
Product categories of intermediate risk
1. Products containing dried or frozen fish, meat, eggs, vegetables or cereals or products yanag not included in the
regulation of food hygiene.
2. Sandwich and pie meat for fresh consumption.
3. The fat-based products such as cocoa, margarine, mayonnaise, spreads and dressings.
Product categories of low risk
1. Product acidic (pH <4.6)
2. Raw vegetables that are not processed and packaged
3. Jam, marmalade and conserves
4. The products based on sugar
5. Oil and fat meal

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 Farm or through the intermediary of raw materials
 Storage
 Peocess
 Packaging
 Distribution
 Handling in retail, store, Restaurant, House, etc
Critical Control Point can identify on:
Step 7 (Principle 2) Determination CCP

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Control Point (CP)
(Preventive/legal/Quality)
Critical Control Point(CCP)
(Food Safety)
Critical Limits Validation
HACCP Plan
Maintain by:
Limit of
process
parameters
Program
prerequisite
MANAGEMENT SYSTEM FOOD SAFETY
Maintain by :
CONTROL POINT DIFFERENCE

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Are there any precautions?
Does that step made specifically to control hazards?
Can contamination occur?
Is the next step to control the hazard?
Is there any control at this stage for safety?
Not CCP CCP
Not CCP
Not CCP
No
No
No
Modification process
Yes
Yes
Yes
Yes
No
No
Yes
P1
P2
P3
P4

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Determain ofDetermain of Critical Control Points (CCP)Critical Control Points (CCP)
CCP or CP ?
QUESTION:?
If not controlled, if possible hazard to health
YES
CCP CP
NOT

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Time
Temparature
Moisture
The water content / water activity
pH
The level of acidity
The concentration of salt
available chlorine
Step 8 (Principle 3) Establish Critical Limits

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Survey (literature & Valid data).
Technical regulations (USDA, FDA, Codex, Deptan,
Depkes Etc)
The research has been published
Experts (microbiologists, sanitation experts,
consultants, etc.)
RESOURCES

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CCP Critical components
Vibrosparator (Mesh 6)
The addition of acid.
• Calibration
• Sensitivity / capabilities
• pH at the end of the temperature
of the product

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Shows the difference between products that are safe and
unsafe the process can be managed in a safe level
Example: Critical limits on Metal Detector, Which is:
1. Fe 1.5 mm
2. Non Fe 2 mm
3. Stainless Steel 2.5 mm
>
StepStep 8 (Principle 3)8 (Principle 3)
EstablishEstablish Critical LimitsCritical Limits

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Step
Process
CCP Critical Limits
5. Cooking CCP-4
Oven Temperature ____C
Duration Cooking___Hour/minute/Second
Humidity ______%

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What is Monitoring??
1. Checking whether the handling procedures or processing
procedures at critical control point is under control (ICMSF 1988).
2. Examination or observation of the effectiveness of a process for
controlling the CCP and its limits (FDA 1990).
3. Planned sequence of observations measuring critical limits are
designed to obtain accurate records and shown to ensure a
critical limit maintains product safety (NACMCF 1990).
Step 9 (Principle 4) Establish Monitoring Procedure

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Based on :
4 W + 1 H
• What,
• Who,
• Where,
• When,
• + How
Step 9 (Principle 4) Establish Monitoring Procedure

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CCP
Monitoring
Records
Corrective
action
records
Monitoring
Procedure
Corrective
Action
Procedure
StepStep 9 (Principle 4)9 (Principle 4)
EstablishEstablish Monitoring ProcedureMonitoring Procedure

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 Flow chart has been compiled that explains each step / process
flow has been put under surveillance
 Food and identification of the use has been described clearly.
 Potential hazards have been identified and prioritized in
accordance risks and hazards seriousness (severity)..
 The critical point in the operation have been identified and under
supervision.
 The criteria (time, temperature, pH, water activity, etc.) specifically
have been determined and the watchdogs.
 Test quickly assigned to monitor CCPs.
Corrective Action include:
StepStep 1010 (Principle(Principle 5)5)
Determine Corrective ActionDetermine Corrective Action

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Visual Observation
Evaluation Sensory
Physical Testing
Chemical Testing
Microbiology Testing
How to Monitoring CCP can be done by:
Step 10 (Principle 5)
Determine Corrective Actionc

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Corrective measures are written procedure where specific actions
that must be done if the results of monitoring at the CCP
storage was found.
Corrective Action :
TwoTwo stages of correctivestages of corrective actionsactions
Immediate action
Preventive action
Determine Corrective ActioncDetermine Corrective Actionc

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Detention product (hold)
Testing and analysis conducted by experts.
Reprocessed
Processed into other products
Annihilate
detachable
Disposition of nonconforming product:Disposition of nonconforming product:

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Contoh tindakan koreksi :
Procedures CCP Critical Limits
Person in
charge
Frequency
CA Verification
by Record
Cooking CCP1
Cooking is more
than or equal to
85ºC
Operator
Continue
cooking
until 85ºC
Supervisor Log book
Cooking

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Verification is an action that is essential for a
successful HACCP program
Verification :
Methods or procedures or tests that are used to
restore a system or work process in accordance with
the role that has been established, in order to ensure
the system is running normally and according to the
requirements that have been set.
Establish Procedures for Verification

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HACCP Plan
Record CCP
Deviation and corrective action
Raw material specifications
Reception and storage (temperature, RH, quarantine
programs, stock control, etc).
Processing tools (testing / calibration standard,
time, temperature, sanitizers, pest control, etc).
Some examples are verified
Establish Procedures for Verification

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RECORDS are written proof of the things that have been done.
TYPES OF RECORDING :
• Recording prevention TKK
• Records pertaining to monitoring the critical limit
• Recording deviation (correction)
• recording verification
Establish Monitoring Procedure

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Thank You..

Create Food Safety HACCP Guide

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