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Hazard Analysis & Critical Control Point



Prepared By:
Eng / Walid I. Gahfer
Quality Shift Leader In Senyorita Co.
One Of Americana Group for Food Industries
 Trainer : Walid Gahfer
Agenda
       Introduction To HACCP
       HACCP Benefits
       HACCP Principles
       Implementation Of HACCP
       HACCP Plan
       HACCP Preparation :
                         -> Preliminary steps
                         -> Pre-requisite programs

Trainer : Walid Gahfer
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.
 Trainer : Walid Gahfer
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
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
Trainer : Walid Gahfer
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
Principle (1)
                         Analysis Of Hazards
                             Assessment



Trainer : Walid Gahfer
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.




Trainer : Walid Gahfer
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
Principle (2)
               Identification Of Process
                Critical Control Points
                        (CCPs)


Trainer : Walid Gahfer
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
Steps to Identify (Determine) CCPs Using A
                      Decision Tree
Q1: Do preventive measures exist for this hazard?
if yes go to Q2,             if no, that means it’s required of safety
if no = not CCP*,            (if yes modify process or product).
Q2: Does this step specifically designed to eliminate/reduce the likely
occurrence of this hazard to an acceptable level?
if yes = CCP              if no go to Q3
Q3: Could contamination occur in excess of acceptable level? (Unacceptable
level occur)?
if yes go to Q4          if no = not CCP*
 Q4: Will a subsequent step eliminate/reduce this hazard to an acceptable
level ?
if yes = not CCP*                      if no = CCP
* (go to the next step in production)
Trainer : Walid Gahfer
Principle (3)
           Establish Critical Limits For
              Preventative Measures
              Associated With Each
                  Identified CCP


Trainer : Walid Gahfer
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.


Trainer : Walid Gahfer
Principle (4)
                 Establish Procedures For
                  Monitoring The CCPs



Trainer : Walid Gahfer
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
Principle (5)
       Establish Of Corrective Actions
       To Be Taken When Monitoring
        Indicates Deviation From An
           Establish Critical Limit


Trainer : Walid Gahfer
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
Principle (6)
           Establish Procedures For
          Verification That HACCP
         System Is Working Correctly



Trainer : Walid Gahfer
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 every 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
Principle (7)
      Establish Effective Record-
       Keeping Procedures That
     Document The HACCP System



Trainer : Walid Gahfer
The documents/records shall include all
the elements of the HACCP system, including:
 Description of HACCP system.
 The records of all HACCP Prerequisite procedures,
 The records of hazard analysis and their control methods,
 CCP determination,
 Critical Limit determination,
 CCP monitoring activities and results,
 Deviations and associated corrective actions,
 Other activities like (Sanitation control, Audit,Meetings, Training
 Verification, Compliant, Recall, etc…).
Trainer : Walid Gahfer
How To Implement A HACCP System
 1. Assemble HACCP team.
 2. Describe food and its distribution.
 3. Identify intended use and consumers of food.
 4. Develop process flow diagram.
 5. Verify flow diagram.
 6. Conduct a hazard analysis.
 7. Determine the critical control points (CCPs) in the process.
 8. Establish critical limits.
 9. Establish monitoring procedures.
 10.Establish corrective actions.
 11.Establish verification procedures.
 12.Establish record-keeping and documentation procedures.

Trainer : Walid Gahfer
How To Apply HACCP To Our
                 Product?
1) Identify the potential hazards associated with
   our product.
2) Explore how to prevent them.
3) Identification of CCPs
4) Establishment of A HACCP plan critical limits.
5) Monitoring procedures.
6) Corrective actions.
Trainer : Walid Gahfer
Trainer : Walid Gahfer
What is the HACCP Plan?
 HACCP plan is a formal document which pulls
together the key information from the HACCP
study and holds details of all that is critical for food
safety management.
 HACCP plan is mainly consists of two essential
components:
                          (1) Process Flow Diagram
                          (2) HACCP Control Chart
Trainer : Walid Gahfer
Define Your Terms Of Reference


                         Describe The Product & The Intended Use


                            Constract a Process Flow Diagram


                             Validate Process Flow Diagram


                         Identify Hazards & preventative Measures


                              Identify Critical Control Points


                                 Establish Critical Limits


                              Identify Monitoring Procedures


                          Establish Corrective Action Procedures


                                  Validate HACCP Plan

Trainer : Walid Gahfer
(1) The Process Flow Diagram
• Process Flow Diagram is a sequence of events
  through the whole process, giving a clear and
  simple description of how the end product is made.
• Process Flow Diagram enables the HACCP Team
  to understand the production process and the basis
  for the hazard analysis.
• Process Flow Diagram shall includes all the
  process inputs (Row materials) & all the process
  outputs (Wastes).
 Trainer : Walid Gahfer
(2) HACCP Control Chart
• It’s a table of control parameters which contains
  details of the steps/stages in the production process
  where there are CCPs.

• It also contains details of the hazards and
  preventative measures associated with each CCP.



 Trainer : Walid Gahfer
Trainer : Walid Gahfer
Preliminary Steps For A HACCP System
              Application

   o Senior Management Commitment.
   o Assembling A HACCP Team.
   o Product Description.
   o Establishing the Process Flow Diagram.
   o Verification of Process Flow Diagram.

Trainer : Walid Gahfer
Prerequisite Programs For Establishing A
              HACCP Plan
 •   Good Manufacturing Procedures (GMPs).
 •   Sanitation Standard Operation Procedures (SSOP).
 •   Specifications & Suppliers monitoring.
 •   Pest Control.
 •   Training.
 •   Non-Compliance & Corrective Action procedures.
 •   Recall procedures.
 •   Consumer Complaints Analysis procedures.
 •   Calibration & Preventative Maintenance procedures.
Trainer : Walid Gahfer
Good Manufacturing Procedures (GMP’s)
              includes
 1) Prevention of food contamination.
 2) Cleanliness of Clothing and garments.
 3) Employee Personal Hygiene & Disease control.
 4) Prevention of Eating , Drinking & Smoking
    inside processing & producing areas.
 5) Proper Labeling.


Trainer : Walid Gahfer
Sanitation Standard Operation Procedures
             (SSOP) includes
      1) Safety of used water.
      2) Cleanliness of product contact surfaces.
      3) Cleanliness of employee clothes.
      4) Prevention of cross contamination
      5) Maintenance of hand washing & hand sanitizing &
         toilet facilities.
      6) Proper labeling of toxic materials..
      7) Personal Hygiene.
      8) Pests exclusion.

Trainer : Walid Gahfer

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Haccp Training

  • 1. Hazard Analysis & Critical Control Point Prepared By: Eng / Walid I. Gahfer Quality Shift Leader In Senyorita Co. One Of Americana Group for Food Industries Trainer : Walid Gahfer
  • 2. Agenda  Introduction To HACCP  HACCP Benefits  HACCP Principles  Implementation Of HACCP  HACCP Plan  HACCP Preparation : -> Preliminary steps -> Pre-requisite programs Trainer : Walid Gahfer
  • 3. 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. Trainer : Walid Gahfer
  • 4. 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
  • 5. 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
  • 7. 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
  • 8. Principle (1) Analysis Of Hazards Assessment Trainer : Walid Gahfer
  • 9. 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
  • 10.  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. Trainer : Walid Gahfer
  • 11. 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
  • 12. Principle (2) Identification Of Process Critical Control Points (CCPs) Trainer : Walid Gahfer
  • 13. 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
  • 14. Steps to Identify (Determine) CCPs Using A Decision Tree Q1: Do preventive measures exist for this hazard? if yes go to Q2, if no, that means it’s required of safety if no = not CCP*, (if yes modify process or product). Q2: Does this step specifically designed to eliminate/reduce the likely occurrence of this hazard to an acceptable level? if yes = CCP if no go to Q3 Q3: Could contamination occur in excess of acceptable level? (Unacceptable level occur)? if yes go to Q4 if no = not CCP* Q4: Will a subsequent step eliminate/reduce this hazard to an acceptable level ? if yes = not CCP* if no = CCP * (go to the next step in production) Trainer : Walid Gahfer
  • 15. Principle (3) Establish Critical Limits For Preventative Measures Associated With Each Identified CCP Trainer : Walid Gahfer
  • 16. 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. Trainer : Walid Gahfer
  • 17. Principle (4) Establish Procedures For Monitoring The CCPs Trainer : Walid Gahfer
  • 18. 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
  • 19. 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
  • 20. Principle (5) Establish Of Corrective Actions To Be Taken When Monitoring Indicates Deviation From An Establish Critical Limit Trainer : Walid Gahfer
  • 21. 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
  • 22. Principle (6) Establish Procedures For Verification That HACCP System Is Working Correctly Trainer : Walid Gahfer
  • 23. 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
  • 24. 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 every 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
  • 25. Principle (7) Establish Effective Record- Keeping Procedures That Document The HACCP System Trainer : Walid Gahfer
  • 26. The documents/records shall include all the elements of the HACCP system, including: Description of HACCP system. The records of all HACCP Prerequisite procedures, The records of hazard analysis and their control methods, CCP determination, Critical Limit determination, CCP monitoring activities and results, Deviations and associated corrective actions, Other activities like (Sanitation control, Audit,Meetings, Training Verification, Compliant, Recall, etc…). Trainer : Walid Gahfer
  • 27. How To Implement A HACCP System 1. Assemble HACCP team. 2. Describe food and its distribution. 3. Identify intended use and consumers of food. 4. Develop process flow diagram. 5. Verify flow diagram. 6. Conduct a hazard analysis. 7. Determine the critical control points (CCPs) in the process. 8. Establish critical limits. 9. Establish monitoring procedures. 10.Establish corrective actions. 11.Establish verification procedures. 12.Establish record-keeping and documentation procedures. Trainer : Walid Gahfer
  • 28. How To Apply HACCP To Our Product? 1) Identify the potential hazards associated with our product. 2) Explore how to prevent them. 3) Identification of CCPs 4) Establishment of A HACCP plan critical limits. 5) Monitoring procedures. 6) Corrective actions. Trainer : Walid Gahfer
  • 29. Trainer : Walid Gahfer
  • 30. What is the HACCP Plan?  HACCP plan is a formal document which pulls together the key information from the HACCP study and holds details of all that is critical for food safety management.  HACCP plan is mainly consists of two essential components:  (1) Process Flow Diagram  (2) HACCP Control Chart Trainer : Walid Gahfer
  • 31. Define Your Terms Of Reference Describe The Product & The Intended Use Constract a Process Flow Diagram Validate Process Flow Diagram Identify Hazards & preventative Measures Identify Critical Control Points Establish Critical Limits Identify Monitoring Procedures Establish Corrective Action Procedures Validate HACCP Plan Trainer : Walid Gahfer
  • 32. (1) The Process Flow Diagram • Process Flow Diagram is a sequence of events through the whole process, giving a clear and simple description of how the end product is made. • Process Flow Diagram enables the HACCP Team to understand the production process and the basis for the hazard analysis. • Process Flow Diagram shall includes all the process inputs (Row materials) & all the process outputs (Wastes). Trainer : Walid Gahfer
  • 33. (2) HACCP Control Chart • It’s a table of control parameters which contains details of the steps/stages in the production process where there are CCPs. • It also contains details of the hazards and preventative measures associated with each CCP. Trainer : Walid Gahfer
  • 34. Trainer : Walid Gahfer
  • 35. Preliminary Steps For A HACCP System Application o Senior Management Commitment. o Assembling A HACCP Team. o Product Description. o Establishing the Process Flow Diagram. o Verification of Process Flow Diagram. Trainer : Walid Gahfer
  • 36. Prerequisite Programs For Establishing A HACCP Plan • Good Manufacturing Procedures (GMPs). • Sanitation Standard Operation Procedures (SSOP). • Specifications & Suppliers monitoring. • Pest Control. • Training. • Non-Compliance & Corrective Action procedures. • Recall procedures. • Consumer Complaints Analysis procedures. • Calibration & Preventative Maintenance procedures. Trainer : Walid Gahfer
  • 37. Good Manufacturing Procedures (GMP’s) includes 1) Prevention of food contamination. 2) Cleanliness of Clothing and garments. 3) Employee Personal Hygiene & Disease control. 4) Prevention of Eating , Drinking & Smoking inside processing & producing areas. 5) Proper Labeling. Trainer : Walid Gahfer
  • 38. Sanitation Standard Operation Procedures (SSOP) includes 1) Safety of used water. 2) Cleanliness of product contact surfaces. 3) Cleanliness of employee clothes. 4) Prevention of cross contamination 5) Maintenance of hand washing & hand sanitizing & toilet facilities. 6) Proper labeling of toxic materials.. 7) Personal Hygiene. 8) Pests exclusion. Trainer : Walid Gahfer