SlideShare a Scribd company logo
1 of 7
Download to read offline
PuRDuE ExTEnSiOn
                             Safe food guidelines for small meat and poultry processors                             FS-20-W


                                 Overview of HACCP
                                  Hazard Analysis Critical Control Point

                                                                                    Introduction
                                                                                      Federal regulations, phased in from
                                                                                    1998 until 2000, require all large, small,
Kevin Keener, Ph.D., P.E.              Outline                                      and very small meat and poultry
Food process engineer, Extension       1.   Brief background of HACCP               processors to implement a HACCP
specialist, and associate professor    2.   What is HACCP?                          plan. For a small or very small processor,
of food science                        3.   Prerequisite programs and HACCP         sorting all of the vast information on
                                       4.   Developing a HACCP program              HACCP can seem overwhelming,
                                       5.   Meeting state and federal regulations   especially when time and resources
                                       6.   Action steps for the processor          are limited. This fact sheet explains
                                                                                    the benefits of HACCP, presents an
                                                                                    overview of HACCP principles, and
                                                                                    looks at the big picture. It answers the
                                                                                    questions: “Why is HACCP important?”
                                                                                    and “Where does sanitation fit into
                                           The Purdue Department of                 HACCP?” This fact sheet also
                                         Food Science has long been a               provides steps the small processor can
                                         leader in training students to             take to implement a HACCP system.
                                         work in the food processing
                                                                                    1. Brief background of HACCP
                                         industry. For many years, food                Since the Federal Meat Inspection
                                         science Extension specialists              Act of 1906 and the Poultry Product
                                         have provided food safety and              Inspection Act of 1957, meat and
                                         HACCP training to the food                 poultry manufacturers have been
                                         industry. For small meat                   directly charged with producing safe,
                                         processing plants, an effective            wholesome, and unadulterated foods.
                                         HACCP program requires                     As a whole, the U.S. food industry has
                                         trained and highly motivated               done an excellent job of maintaining
                                         individuals. Each meat                     the safety of its products. Unfortunately,
                                         processing plant’s HACCP plan              over the years, foodborne illnesses have
                                         is unique. A successful HACCP              resulted in thousands of sicknesses
                                         plan identifies and controls all           and many deaths. Investigators have
                                         food safety hazards found in the           always tried to trace foodborne illness
                                         food processing operation.                 outbreaks back to the food processor,
                                                                                    determine what went wrong, and then
                                                                                    require them to fix the problem. Over
                                                                                    time, it became clear that taking
                                                                                    action after the fact was inadequate
                                                                                    to protect consumers from foodborne
                                                                                    illness.
Overview of HACCP (FS-20-W)




      In response to consumer concerns, the U.S.                       The timeframe to implement a HACCP program
    Department of Agriculture (www.usda.gov) and the                was based on the size of the processing plant, starting
    Food and Drug Administration (www.fda.gov) have                 with the very largest. However, all meat and poultry
    required plants to implement a food safety program              plants were required to phase in a working HACCP
    called Hazard Analysis Critical Control Point. This             plan by January 2000. The very small plants were the
    program was developed by the Pillsbury Co. for NASA             last required to implement a HACCP program in
    in the late 1960s to ensure the complete safety of food         January 2000. Many very small meat processors have
    for space missions. The program provides a proactive            had difficulty developing, writing, and implementing
    approach to food safety by requiring plants to identify         a HACCP plan because of limited expertise and
    all potential avenues of contamination (hazards) and            resources. This fact sheet provides background
    determine how to control, reduce, and/or prevent them           information on HACCP requirements, steps a small
    to ensure that safe food will be produced.                      processor can take to develop a HACCP plan, and a
      On July 25, 1996, the Food Safety and Inspection              list of available resources.
    Service (www.fsis.usda.gov) of the USDA published               2. What is HACCP?
    a final rule on Pathogen Reduction: Hazard Analysis                HACCP stands for Hazard Analysis Critical
    Critical Control Point Systems. The PR/HACCP rule               Control Point. HACCP is a systematic approach to
    requires all meat and poultry plants to take                    the identification, evaluation, and control of food
    responsibility for identifying and controlling, reducing,       safety hazards. It is a proactive strategy where hazards
    or eliminating chemical, physical, and biological               are identified and assessed, and control measures are
    hazards (including pathogenic bacteria). The HACCP              developed to prevent, reduce, or eliminate a hazard.
    requirements that all plants must meet are described            For example, one identified hazard in ready-to-eat
    in Title 9, Part 417, of the Code of Federal Regulations        turkey (deli meat) is the presence of Salmonella
    (www.access.gpo.gov/nara/cfr/waisidx_02/9cfr417_                bacteria. To eliminate Salmonella, one control measure
    02.html). (As part of complying with HACCP,                     is a cooking process where a minimum internal
    processing plants must also develop a written                   product temperature of 165°F for 15 seconds is
    sanitation program (9 CFR 416, www.access.gpo.gov/              achieved and documented.
    nara/cfr/waisidx_02/9cfr416_02.html).



                                                                2
Overview of HACCP (FS-20-W)

There are seven fundamental HACCP principles:                 be trained in food safety practices and that wholesome
  Principle 1 — Conduct a hazard analysis.                    meat and poultry products are produced under sanitary
  Principle 2 — Determine the critical control points.        conditions. The minimum allowable sanitary conditions
                                                              for the equipment and facilities are identified as
  Principle 3 — Establish critical limits.                    Sanitation Standard Operating Procedures. SSOPs
  Principle 4 — Establish monitoring procedures.              consist of written cleaning and sanitizing procedures,
  Principle 5 — Establish corrective actions.                 validation procedures, and records regarding sanitary
  Principle 6 — Establish record-keeping and                  conditions both pre-processing and during processing.
                  documentation procedures.                   The SSOP verifications by USDA-FSIS are frequently
                                                              performed on a daily basis.
  Principle 7 — Establish verification procedures.
                                                                Because of management challenges, many plants
3. Prerequisite programs and HACCP                            have chosen to subdivide the Sanitation program
  Before developing the HACCP program, one                    requirements into separate programs. Also, some
prerequisite program is required: Sanitation (9 CFR           plants have determined additional prerequisite
416). This prerequisite program requires that employees       programs are needed to ensure food and worker safety.
                                                              Examples of these are shown in Table 2, along with the
                                                              relevant portion of the Sanitation regulations. It is
           HACCP is a systematic approach to                  important to note that when FSIS verifies the regulatory
           the identification, evaluation, and                requirements, it will only examine those records
           control of food safety hazards.                    required by 9 CFR 416.


Examples of common prerequisite programs (Sanitation – 9 CFR 416 citations provided where appropriate)
 Maintenance         416.1–3. 416.6             Equipment is designed and constructed with sanitary practices in
                                                mind. Preventive maintenance and calibration schedules
                                                established and documented.
 Personal Hygiene 416.1, 416.5                  All employees and other persons who enter and work in the
                                                manufacturing plant must follow the proper hygienic practices.
 Pre-operational     SSOPs 416.1, 416.11–17 This program documents that food is produced using sanitary
 Sanitation                                     practices in a sanitary facility using sanitary equipment prior to the
                                                start of daily operations.
 Operational         SSOPs 416.1, 416.11–17 This program documents that sanitary practices are maintained
 Sanitation                                     during processing.
 Pest Control        416.2                      Effective pest control programs should be in place and monitored.
 Storage and         416.1–416.4                All raw materials and products should be stored under sanitary
 Shipping                                       conditions and proper environmental conditions to assure their
                                                safety.
 Traceability and Requirement of the            All raw material and finished products should be lot-coded and a
 Recall†             Bioterrorism Act of        recall system in place so that rapid and complete traces and recalls
                     2002, Section 306          can be done when a product retrieval is necessary.
 Supplier Control                               Facility should ensure that supplier has in place effective Good
                                                Management Practices and food safety programs.
 Personal Safety                                This program discusses all nonfood safety issues including
 (not part of                                   repetitive stress injuries, general health, MSDS (Material Safety
 HACCP)                                         Data Sheets), etc. Inspections performed by Occupational Safety
                                                and Health Administration.



                                                          3
Overview of HACCP (FS-20-W)

    Figure 1

                                                                  Food Safety Pyramid
      Plant Food Safety
          Pro-active




                                                                                 HACCP
                                                                                  Plan
                                                                           based on 7 Principles
                                                            n




                                                                                                                     Va
                                                      tio




                                                                                                                       lid
                                                    ca




                                                                                                                          at
              Safety and Suitability




                                                                                                                            io
                                                  i




                                                                      Sanitation Standard
                                                r




                                                                                                                                 n
                                             Ve




                                                                  Operating Procedures (SSOP’s)



                                       Supplier   Traceability   Biosecurity   Employee      Storage   Maintenance    Personal     Pest
                                       Control    & Recall                     Training        and                    Hygiene      Control
                                                                                            Shipping


                                                       Shaded programs are viewed by USDA as the Sanitation Program (9 CFR 416).



      Further details on Sanitation and other prerequisite                                The HACCP plan is a proactive, continual assessment
    programs, along with the HACCP principles, are                                        of ongoing food safety during the processing of the
    covered in other fact sheets in this series. It is                                    food. For the HACCP plan to be successful, all of the
    important to note that from USDA’s perspective, only                                  underlying programs must be working properly.
    those activities indicated in 9 CFR 416 are considered                                  In the pyramid, the prerequisite programs and
    “Sanitation” and will be verified as appropriate. USDA                                written Sanitation program uphold the HACCP plan
    will review other prerequisite programs only to the                                   as the critical food safety system.
    extent they support decisions made in the hazard
    analysis (HACCP Principle 1) when developing the                                      4. Developing a HACCP program
    HACCP plan.                                                                             Once a Sanitation program and necessary
      The underlying Sanitation and prerequisite programs                                 prerequisite programs are implemented, a HACCP
    prevent the introduction of food safety hazards into the                              plan can be developed. Several tasks are required prior
    plant, and thus are a foundation for the HACCP plan.                                  to HACCP program development. Those preliminary
    For example, not having an equipment maintenance                                      tasks include:
    program may lead to the physical hazard of broken                                       •	Assemble the HACCP team — The team consists
    machinery parts contaminating a ground product. One                                       of individuals who have specific knowledge and
    way of looking at the HACCP requirement is to think                                       expertise appropriate to the product and process.
    of the HACCP plan as a pyramid (Figure 1). The                                            Other team members include the person(s)
    HACCP program is built upon the sanitation program                                        responsible for plan maintenance. One person on
    and other prerequisite programs. These programs                                           the HACCP team must be HACCP-trained. A
    address the suitability and food safety of the process.                                   team can be as few as one or two people.



                                                                                    4
Overview of HACCP (FS-20-W)

  •	Describe the food and its distribution —
    This provides information on the ingredients,
    processing methods, and distribution methods
    (frozen, refrigerated, or at ambient temperature).
    Classification of the product into a USDA process
    allows the processor to focus on likely hazards
    associated with this type of product.
  •	Describe the intended use and consumers of
    the food — These may be the general public or a
    segment of the population such as infants, elderly,
    military, hospital patients, etc.
  •	Develop a flow diagram describing the process —
    This diagram provides a clear, simple outline
    of the steps involved in the making the product.
    A block flow diagram is usually sufficient.
  •	Verify the flow diagram — The HACCP team
    should perform an on-site review of the operation           3. Establish critical limits — Provides a maximum or
    to verify the accuracy and completeness of the flow            minimum value to which the biological, chemical, or
    diagram. Perform a walk-through of the process to              physical hazard must be controlled at a CCP to
    make sure all process steps are covered.                       prevent, eliminate, or reduce to an acceptable level
  Once those preliminary tasks are completed, a                    the occurrence of a food safety hazard. The critical
meat processor can develop the actual HACCP plan                   limit distinguishes between safe and unsafe operating
by taking the following steps.                                     conditions at a CCP. Each control measure has one or
1. Conduct a hazard analysis — First, the HACCP                    more critical limits, and they must be scientifically
   team reviews the ingredients used, activities at each           based. For example, if a chilling step is selected as a
   processing step, and method of storage and                      CCP for controlling bacterial growth, a certain time
   distribution of final product, including intended               and rate would be specified (e.g. product temperature
   use by consumers. Then the team makes a list of                 must be reduced from 140°F to 40°F in six hours).
   food safety hazards that are reasonably likely to            4. Establish monitoring procedures — These are a
   cause injury or illness if not controlled. Next, each           planned sequence of observations or measurements
   hazard is evaluated and its likelihood of occurrence            (e.g. collection of data) to assess whether a CCP is
   is determined. The hazards are categorized as                   under control, and to produce an accurate record
   chemical, physical, and biological. Supporting                  for future use in verification. Monitoring facilitates
   documentation is needed to justify all decisions                tracking of an operation, shows if there is a loss of
   about whether or not something is a hazard. For                 control at a CCP, and provides written
   example, a physical hazard of metal shavings from               documentation for use in verification. For example,
   grinding may not be a hazard likely to occur if your            if the chilling step as indicated above was used as a
   maintenance program (and its records) documents                 CCP, then you may want to monitor and record
   that periodic checks of the grinder are performed               temperatures every half hour.
   and worn parts are replaced.                                 5. Establish corrective actions — This part of the
2. Determine critical control points (CCPs) — This                 HACCP program specifies what is done when a
   identifies a step in the process at which control must          deviation occurs: Who is responsible for
   be applied to prevent, eliminate, or reduce to an               implementing the corrective actions? What happens
   acceptable level a food safety hazard. Examples of              to the product? What caused the deviation? How
   CCPs may include cooking times and temperatures,                can it be prevented from reoccurring? Producers
   chilling times and temperatures, or pH control.                 must generate a record documenting these decisions.




                                                            5
Overview of HACCP (FS-20-W)
                                                                 7. Establish verification procedures — Verification
                                                                    consists of those activities that determine the
                                                                    validity of the HACCP plan and show that the
                                                                    system is operating according to the plan. Part of
                                                                    verification is validation. Validation is the scientific
                                                                    information, in-plant data, or expert opinions
                                                                    documenting that the existing process(es) — and
                                                                    their respective critical control points, critical limits,
                                                                    and monitoring procedures — produce a safe food
                                                                    product. A validation example might be the
                                                                    documentation used to select a cook step to control
                                                                    salmonella in a ready-to-eat product, the minimum
                                                                    time and temperature needed to cook the product,
                                                                    and the frequency of temperature monitoring to
                                                                    ensure safety. The second part of verification is to
                                                                    “verify” that the validated plan is being followed
                                                                    correctly. Examples of “verifying” include: calibration
                                                                    of process monitoring instruments, direct observation
                                                                    of monitoring activities and corrective actions, and
                                                                    review of records generated and maintained in
                                                                    accordance with 9 CFR 417.5(a)(3) (http://a257.
                                                                    g.akamaitech.net/7/257/2422/14mar20010800/
                                                                    edocket.access.gpo.gov/cfr_2002/janqtr/9cfr417.5.htm).
                                                                    Verification procedures are the most difficult part of
                                                                    developing a HACCP plan for small and very small
                                                                    processors. A separate fact sheet in this series deals
                                                                    specifically with those issues.
                                                                 5. Meeting state and federal regulations
                                                                    Two laws directly pertain to meat and poultry
    6. Establish record-keeping and documentation                processing food safety: the Federal Meat Inspection
       procedures — These records should include the             Act and the Poultry Products Inspection Act. In order
       following:                                                to process meat or poultry, processors must comply
       •	 Sanitation program records — SSOPs and others          with the regulations developed to assure that these laws
          required in 9 CFR 416.                                 are obeyed. These regulations are maintained in the
       •	 Prerequisite program records — USDA-FSIS               Code of Federal Regulations in Title 9. Requirements
          will view prerequisite program records that are        for a sanitation program are contained in 9 CFR 416.
          identified in HACCP plan.                              Regulations mandating a written HACCP plan are
       •	 Hazard analysis and decision-making                    contained in 9 CFR 417. At least one employee or their
          information — these records should include the         representative at a meat or poultry slaughter or
          rationale for identifying hazards and selecting        processing plant must meet minimum HACCP
          critical control points.                               training requirements (9 CFR 417.7). HACCP training
       •	 HACCP records — monitoring, pre-shipment               is offered through many university Extension programs,
          review, corrective actions, verification, annual       private food consulting firms, the Food Products
          HACCP reassessment.                                    Association, and numerous trade organizations.




                                                             6
Overview of HACCP (FS-20-W)
                                                                                                    PuRDuE ExTEnSiOn
        6. Action steps for the processor                                       Additional resources
          Look up, print, and read the sanitation regulation
         	                                                                     Purdue Department of Food Science,
          for meat and poultry processing in the Code of                         } www.foodsci.purdue.edu/outreach
          Federal Regulations Title 9, Part 416.                                Food Safety and Inspection Service of the USDA,
          } www.access.gpo.gov/nara/cfr/waisidx_                                 } www.fsis.usda.gov
            02/9cfr416_02.html
                                                                                FSIS food safety resources for the small and
          Select the person(s) who will make up the HACCP
         	                                                                     very small plants,
          team. Look up, print, and read the HACCP                               } www.fsis.usda.gov/science/HACCP_Resources_
          regulations for meat and poultry processing in                           Brochure/index.asp
          the Code of Federal Regulations Title 9, Part 417.
          } www.access.gpo.gov/nara/cfr/waisidx_                                Acknowledgement
            02/9cfr417_02.html                                                    The author would like to acknowledge the financial
          Enroll in an introductory HACCP course through
         	                                                                     support of the United States Department of
          the Purdue Department of Food Science                                 Agriculture/Food Safety Inspection Service/Strategic
          (www.foodsci.purdue.edu) or another provider.                         Initiatives, Partnerships, and Outreach Office in
                                                                                developing this fact sheet. This fact sheet was developed
        Other publications in this series                                       with a portion of the funds provided from cooperative
        FS-21-W, Small Meat Processing Plants: SSOP and                         agreement FSIS-C-30-2003.
        GMP Practices and Programs (Sanitation Standard
        Operating Procedures and Good Manufacturing                             For additional information
        Practices)                                                              Kevin Keener
         } www.ces.purdue.edu/extmedia/FS/FS-21-W.pdf                           Associate professor, food process engineer, and
                                                                                  Extension specialist
        FS-22-W, Small Meat Processing Plants: A Pest
                                                                                Director, Food Technology Development Laboratory
        Control Program
                                                                                Purdue Department of Food Science
         } www.ces.purdue.edu/extmedia/FS/FS-22-W.pdf
                                                                                West Lafayette, IN 47907-2009
        FS-23-W, Small Meat Processing Plants: A Recall                         Phone: (765) 494-6648
        and Traceability Program                                                kkeener@purdue.edu
         } www.ces.purdue.edu/extmedia/FS/FS-23-W.pdf
        FS-24-W, Small Meat Processing Plants: Verification
        Programs
         } www.ces.purdue.edu/extmedia/FS/FS-24-W.pdf
        FS-25-W, Small Meat Processing Plants: Selection and
        Maintenance of Temperature Measurement Devices
         } www.ces.purdue.edu/extmedia/FS/FS-25-W.pdf




                                                                                                                                                               New 9/07


                                                                                                               In accordance with Purdue policies, all persons have equal
                                                                                                               opportunity and access to Purdue University’s educational
                                                                                                              programs, services, activities, and facilities without regard to
                                                                                                            race, religion, color, sex, age, national origin or ancestry, marital
                                            You can order or download materials on this and other           status, parental status, sexual orientation, disability or status as
                                               topics at the Purdue Extension Education Store.              a veteran. Purdue University is an Affirmative Action institution.
                                                                                                                  This material may be available in alternative formats.
                                                      www.ces.purdue.edu/new

More Related Content

What's hot (20)

HACCP Plan in Meat Industry
HACCP Plan in Meat IndustryHACCP Plan in Meat Industry
HACCP Plan in Meat Industry
 
Chapter 5 haccp
Chapter 5 haccpChapter 5 haccp
Chapter 5 haccp
 
HACCP PRESENTATION
HACCP  PRESENTATIONHACCP  PRESENTATION
HACCP PRESENTATION
 
Haacp implementation in poultry processing plant
Haacp implementation in poultry processing plantHaacp implementation in poultry processing plant
Haacp implementation in poultry processing plant
 
Hazard Analysis Critical Control Point
Hazard Analysis Critical Control PointHazard Analysis Critical Control Point
Hazard Analysis Critical Control Point
 
HACCP a practical approach
HACCP a practical approachHACCP a practical approach
HACCP a practical approach
 
Implementation of Hazard Analysis Critical Control Points (HACCP)
Implementation of Hazard Analysis Critical Control Points (HACCP) Implementation of Hazard Analysis Critical Control Points (HACCP)
Implementation of Hazard Analysis Critical Control Points (HACCP)
 
HACCP training simplified by abdul qudoos
HACCP training simplified by abdul qudoosHACCP training simplified by abdul qudoos
HACCP training simplified by abdul qudoos
 
Training haccp(1)
Training haccp(1)Training haccp(1)
Training haccp(1)
 
HACCP and Food Flow
HACCP and Food FlowHACCP and Food Flow
HACCP and Food Flow
 
HACCP Food Safety Made Easy
HACCP Food Safety Made EasyHACCP Food Safety Made Easy
HACCP Food Safety Made Easy
 
Haccp
HaccpHaccp
Haccp
 
Haccp
HaccpHaccp
Haccp
 
The design of haccp plan for potato chips plant in bangladesh
The design of haccp plan for potato chips plant in bangladeshThe design of haccp plan for potato chips plant in bangladesh
The design of haccp plan for potato chips plant in bangladesh
 
HACCP Plan
HACCP PlanHACCP Plan
HACCP Plan
 
HACCP plan for pastry
HACCP plan for pastryHACCP plan for pastry
HACCP plan for pastry
 
Haccp
HaccpHaccp
Haccp
 
HACCP
HACCPHACCP
HACCP
 
Introduction haccp
Introduction haccpIntroduction haccp
Introduction haccp
 
The haccp seven principles
The haccp seven principlesThe haccp seven principles
The haccp seven principles
 

Similar to Haccp

Haccp and nutrition labelling
Haccp and nutrition labellingHaccp and nutrition labelling
Haccp and nutrition labellingduet36
 
Haccp principles and application guidelines
Haccp principles and application guidelinesHaccp principles and application guidelines
Haccp principles and application guidelinesionessy
 
FQA360S Lecture 02 HACCP 2023 - Week1.pdf
FQA360S Lecture 02 HACCP 2023 - Week1.pdfFQA360S Lecture 02 HACCP 2023 - Week1.pdf
FQA360S Lecture 02 HACCP 2023 - Week1.pdfthechromozonedimingu
 
Food safety standard and HACCP.pdf
Food safety standard and HACCP.pdfFood safety standard and HACCP.pdf
Food safety standard and HACCP.pdfSumanRiaz5
 
Food safety standard and HACCP.pdf
Food safety standard and HACCP.pdfFood safety standard and HACCP.pdf
Food safety standard and HACCP.pdfSumanRiaz5
 
Food safety standard and HACCP.pdf
Food safety standard and HACCP.pdfFood safety standard and HACCP.pdf
Food safety standard and HACCP.pdfSumanRiaz5
 
MEC190-HACCP_History and Principles.pdf
MEC190-HACCP_History and Principles.pdfMEC190-HACCP_History and Principles.pdf
MEC190-HACCP_History and Principles.pdfKaryleCatulong1
 
Hazard analysis critical control point (HACCP)
Hazard analysis critical control point (HACCP)Hazard analysis critical control point (HACCP)
Hazard analysis critical control point (HACCP)DrKamleshKumarBhatt
 
HACCP PRESENTATION SNEHA.pptx
HACCP PRESENTATION SNEHA.pptxHACCP PRESENTATION SNEHA.pptx
HACCP PRESENTATION SNEHA.pptxSneha943172
 
Food safety and quality by bushra
Food safety and quality by bushraFood safety and quality by bushra
Food safety and quality by bushrabushrayousaf3
 
FOOD SAFETY MANAGEMENT SYSTEM
FOOD SAFETY MANAGEMENT SYSTEMFOOD SAFETY MANAGEMENT SYSTEM
FOOD SAFETY MANAGEMENT SYSTEMMDZAFARHASIB
 
HACCP Prerequisites, FSIS vs FDA vs NACMCF vs Codex.pdf
HACCP Prerequisites, FSIS vs FDA vs NACMCF vs Codex.pdfHACCP Prerequisites, FSIS vs FDA vs NACMCF vs Codex.pdf
HACCP Prerequisites, FSIS vs FDA vs NACMCF vs Codex.pdfjavier masangkay jr
 
HACCP in Poultry Industry
HACCP in Poultry Industry HACCP in Poultry Industry
HACCP in Poultry Industry Maira Jabeen
 
A Hazard Analysis Methodology For The South African Abattoir Hygiene Manageme...
A Hazard Analysis Methodology For The South African Abattoir Hygiene Manageme...A Hazard Analysis Methodology For The South African Abattoir Hygiene Manageme...
A Hazard Analysis Methodology For The South African Abattoir Hygiene Manageme...Ashley Smith
 

Similar to Haccp (20)

HACCP System Certification.pdf
HACCP System Certification.pdfHACCP System Certification.pdf
HACCP System Certification.pdf
 
Haccp and nutrition labelling
Haccp and nutrition labellingHaccp and nutrition labelling
Haccp and nutrition labelling
 
Haccp principles and application guidelines
Haccp principles and application guidelinesHaccp principles and application guidelines
Haccp principles and application guidelines
 
FQA360S Lecture 02 HACCP 2023 - Week1.pdf
FQA360S Lecture 02 HACCP 2023 - Week1.pdfFQA360S Lecture 02 HACCP 2023 - Week1.pdf
FQA360S Lecture 02 HACCP 2023 - Week1.pdf
 
Food safety standard and HACCP.pdf
Food safety standard and HACCP.pdfFood safety standard and HACCP.pdf
Food safety standard and HACCP.pdf
 
Food safety standard and HACCP.pdf
Food safety standard and HACCP.pdfFood safety standard and HACCP.pdf
Food safety standard and HACCP.pdf
 
Food safety standard and HACCP.pdf
Food safety standard and HACCP.pdfFood safety standard and HACCP.pdf
Food safety standard and HACCP.pdf
 
MEC190-HACCP_History and Principles.pdf
MEC190-HACCP_History and Principles.pdfMEC190-HACCP_History and Principles.pdf
MEC190-HACCP_History and Principles.pdf
 
presentation on HACCP.pptx
presentation on HACCP.pptxpresentation on HACCP.pptx
presentation on HACCP.pptx
 
MODULE HACCP.docx
MODULE HACCP.docxMODULE HACCP.docx
MODULE HACCP.docx
 
HACCP AND GOOD MANUFACTURING PRACTICES in poultry production
  HACCP AND GOOD MANUFACTURING PRACTICES in poultry production  HACCP AND GOOD MANUFACTURING PRACTICES in poultry production
HACCP AND GOOD MANUFACTURING PRACTICES in poultry production
 
Hazard analysis critical control point (HACCP)
Hazard analysis critical control point (HACCP)Hazard analysis critical control point (HACCP)
Hazard analysis critical control point (HACCP)
 
HACCP PRESENTATION SNEHA.pptx
HACCP PRESENTATION SNEHA.pptxHACCP PRESENTATION SNEHA.pptx
HACCP PRESENTATION SNEHA.pptx
 
Food safety and quality by bushra
Food safety and quality by bushraFood safety and quality by bushra
Food safety and quality by bushra
 
Haccp catering
Haccp cateringHaccp catering
Haccp catering
 
FOOD SAFETY MANAGEMENT SYSTEM
FOOD SAFETY MANAGEMENT SYSTEMFOOD SAFETY MANAGEMENT SYSTEM
FOOD SAFETY MANAGEMENT SYSTEM
 
HACCP Prerequisites, FSIS vs FDA vs NACMCF vs Codex.pdf
HACCP Prerequisites, FSIS vs FDA vs NACMCF vs Codex.pdfHACCP Prerequisites, FSIS vs FDA vs NACMCF vs Codex.pdf
HACCP Prerequisites, FSIS vs FDA vs NACMCF vs Codex.pdf
 
HACCP Part 1
HACCP Part 1HACCP Part 1
HACCP Part 1
 
HACCP in Poultry Industry
HACCP in Poultry Industry HACCP in Poultry Industry
HACCP in Poultry Industry
 
A Hazard Analysis Methodology For The South African Abattoir Hygiene Manageme...
A Hazard Analysis Methodology For The South African Abattoir Hygiene Manageme...A Hazard Analysis Methodology For The South African Abattoir Hygiene Manageme...
A Hazard Analysis Methodology For The South African Abattoir Hygiene Manageme...
 

Recently uploaded

VIT336 – Recommender System - Unit 3.pdf
VIT336 – Recommender System - Unit 3.pdfVIT336 – Recommender System - Unit 3.pdf
VIT336 – Recommender System - Unit 3.pdfArthyR3
 
Material Remains as Source of Ancient Indian History & Culture.ppt
Material Remains as Source of Ancient Indian History & Culture.pptMaterial Remains as Source of Ancient Indian History & Culture.ppt
Material Remains as Source of Ancient Indian History & Culture.pptBanaras Hindu University
 
3.14.24 The Selma March and the Voting Rights Act.pptx
3.14.24 The Selma March and the Voting Rights Act.pptx3.14.24 The Selma March and the Voting Rights Act.pptx
3.14.24 The Selma March and the Voting Rights Act.pptxmary850239
 
DNA and RNA , Structure, Functions, Types, difference, Similarities, Protein ...
DNA and RNA , Structure, Functions, Types, difference, Similarities, Protein ...DNA and RNA , Structure, Functions, Types, difference, Similarities, Protein ...
DNA and RNA , Structure, Functions, Types, difference, Similarities, Protein ...AKSHAYMAGAR17
 
ASTRINGENTS.pdf Pharmacognosy chapter 5 diploma in Pharmacy
ASTRINGENTS.pdf Pharmacognosy chapter 5 diploma in PharmacyASTRINGENTS.pdf Pharmacognosy chapter 5 diploma in Pharmacy
ASTRINGENTS.pdf Pharmacognosy chapter 5 diploma in PharmacySumit Tiwari
 
2024.03.16 How to write better quality materials for your learners ELTABB San...
2024.03.16 How to write better quality materials for your learners ELTABB San...2024.03.16 How to write better quality materials for your learners ELTABB San...
2024.03.16 How to write better quality materials for your learners ELTABB San...Sandy Millin
 
DLL Catch Up Friday March 22.docx CATCH UP FRIDAYS
DLL Catch Up Friday March 22.docx CATCH UP FRIDAYSDLL Catch Up Friday March 22.docx CATCH UP FRIDAYS
DLL Catch Up Friday March 22.docx CATCH UP FRIDAYSTeacherNicaPrintable
 
HỌC TỐT TIẾNG ANH 11 THEO CHƯƠNG TRÌNH GLOBAL SUCCESS ĐÁP ÁN CHI TIẾT - HK2 (...
HỌC TỐT TIẾNG ANH 11 THEO CHƯƠNG TRÌNH GLOBAL SUCCESS ĐÁP ÁN CHI TIẾT - HK2 (...HỌC TỐT TIẾNG ANH 11 THEO CHƯƠNG TRÌNH GLOBAL SUCCESS ĐÁP ÁN CHI TIẾT - HK2 (...
HỌC TỐT TIẾNG ANH 11 THEO CHƯƠNG TRÌNH GLOBAL SUCCESS ĐÁP ÁN CHI TIẾT - HK2 (...Nguyen Thanh Tu Collection
 
BÀI TẬP BỔ TRỢ TIẾNG ANH 11 THEO ĐƠN VỊ BÀI HỌC - CẢ NĂM - CÓ FILE NGHE (FRIE...
BÀI TẬP BỔ TRỢ TIẾNG ANH 11 THEO ĐƠN VỊ BÀI HỌC - CẢ NĂM - CÓ FILE NGHE (FRIE...BÀI TẬP BỔ TRỢ TIẾNG ANH 11 THEO ĐƠN VỊ BÀI HỌC - CẢ NĂM - CÓ FILE NGHE (FRIE...
BÀI TẬP BỔ TRỢ TIẾNG ANH 11 THEO ĐƠN VỊ BÀI HỌC - CẢ NĂM - CÓ FILE NGHE (FRIE...Nguyen Thanh Tu Collection
 
AI Uses and Misuses: Academic and Workplace Applications
AI Uses and Misuses: Academic and Workplace ApplicationsAI Uses and Misuses: Academic and Workplace Applications
AI Uses and Misuses: Academic and Workplace ApplicationsStella Lee
 
Plant Tissue culture., Plasticity, Totipotency, pptx
Plant Tissue culture., Plasticity, Totipotency, pptxPlant Tissue culture., Plasticity, Totipotency, pptx
Plant Tissue culture., Plasticity, Totipotency, pptxHimansu10
 
How to Customise Quotation's Appearance Using PDF Quote Builder in Odoo 17
How to Customise Quotation's Appearance Using PDF Quote Builder in Odoo 17How to Customise Quotation's Appearance Using PDF Quote Builder in Odoo 17
How to Customise Quotation's Appearance Using PDF Quote Builder in Odoo 17Celine George
 
UNIT I Design Thinking and Explore.pptx
UNIT I  Design Thinking and Explore.pptxUNIT I  Design Thinking and Explore.pptx
UNIT I Design Thinking and Explore.pptxGOWSIKRAJA PALANISAMY
 
Research Methodology and Tips on Better Research
Research Methodology and Tips on Better ResearchResearch Methodology and Tips on Better Research
Research Methodology and Tips on Better ResearchRushdi Shams
 
Metabolism , Metabolic Fate& disorders of cholesterol.pptx
Metabolism , Metabolic Fate& disorders of cholesterol.pptxMetabolism , Metabolic Fate& disorders of cholesterol.pptx
Metabolism , Metabolic Fate& disorders of cholesterol.pptxDr. Santhosh Kumar. N
 
LEAD5623 The Economics of Community Coll
LEAD5623 The Economics of Community CollLEAD5623 The Economics of Community Coll
LEAD5623 The Economics of Community CollDr. Bruce A. Johnson
 
3.14.24 Gender Discrimination and Gender Inequity.pptx
3.14.24 Gender Discrimination and Gender Inequity.pptx3.14.24 Gender Discrimination and Gender Inequity.pptx
3.14.24 Gender Discrimination and Gender Inequity.pptxmary850239
 
Dhavni Theory by Anandvardhana Indian Poetics
Dhavni Theory by Anandvardhana Indian PoeticsDhavni Theory by Anandvardhana Indian Poetics
Dhavni Theory by Anandvardhana Indian PoeticsDhatriParmar
 

Recently uploaded (20)

VIT336 – Recommender System - Unit 3.pdf
VIT336 – Recommender System - Unit 3.pdfVIT336 – Recommender System - Unit 3.pdf
VIT336 – Recommender System - Unit 3.pdf
 
Material Remains as Source of Ancient Indian History & Culture.ppt
Material Remains as Source of Ancient Indian History & Culture.pptMaterial Remains as Source of Ancient Indian History & Culture.ppt
Material Remains as Source of Ancient Indian History & Culture.ppt
 
ANOVA Parametric test: Biostatics and Research Methodology
ANOVA Parametric test: Biostatics and Research MethodologyANOVA Parametric test: Biostatics and Research Methodology
ANOVA Parametric test: Biostatics and Research Methodology
 
3.14.24 The Selma March and the Voting Rights Act.pptx
3.14.24 The Selma March and the Voting Rights Act.pptx3.14.24 The Selma March and the Voting Rights Act.pptx
3.14.24 The Selma March and the Voting Rights Act.pptx
 
DNA and RNA , Structure, Functions, Types, difference, Similarities, Protein ...
DNA and RNA , Structure, Functions, Types, difference, Similarities, Protein ...DNA and RNA , Structure, Functions, Types, difference, Similarities, Protein ...
DNA and RNA , Structure, Functions, Types, difference, Similarities, Protein ...
 
ASTRINGENTS.pdf Pharmacognosy chapter 5 diploma in Pharmacy
ASTRINGENTS.pdf Pharmacognosy chapter 5 diploma in PharmacyASTRINGENTS.pdf Pharmacognosy chapter 5 diploma in Pharmacy
ASTRINGENTS.pdf Pharmacognosy chapter 5 diploma in Pharmacy
 
2024.03.16 How to write better quality materials for your learners ELTABB San...
2024.03.16 How to write better quality materials for your learners ELTABB San...2024.03.16 How to write better quality materials for your learners ELTABB San...
2024.03.16 How to write better quality materials for your learners ELTABB San...
 
DLL Catch Up Friday March 22.docx CATCH UP FRIDAYS
DLL Catch Up Friday March 22.docx CATCH UP FRIDAYSDLL Catch Up Friday March 22.docx CATCH UP FRIDAYS
DLL Catch Up Friday March 22.docx CATCH UP FRIDAYS
 
HỌC TỐT TIẾNG ANH 11 THEO CHƯƠNG TRÌNH GLOBAL SUCCESS ĐÁP ÁN CHI TIẾT - HK2 (...
HỌC TỐT TIẾNG ANH 11 THEO CHƯƠNG TRÌNH GLOBAL SUCCESS ĐÁP ÁN CHI TIẾT - HK2 (...HỌC TỐT TIẾNG ANH 11 THEO CHƯƠNG TRÌNH GLOBAL SUCCESS ĐÁP ÁN CHI TIẾT - HK2 (...
HỌC TỐT TIẾNG ANH 11 THEO CHƯƠNG TRÌNH GLOBAL SUCCESS ĐÁP ÁN CHI TIẾT - HK2 (...
 
BÀI TẬP BỔ TRỢ TIẾNG ANH 11 THEO ĐƠN VỊ BÀI HỌC - CẢ NĂM - CÓ FILE NGHE (FRIE...
BÀI TẬP BỔ TRỢ TIẾNG ANH 11 THEO ĐƠN VỊ BÀI HỌC - CẢ NĂM - CÓ FILE NGHE (FRIE...BÀI TẬP BỔ TRỢ TIẾNG ANH 11 THEO ĐƠN VỊ BÀI HỌC - CẢ NĂM - CÓ FILE NGHE (FRIE...
BÀI TẬP BỔ TRỢ TIẾNG ANH 11 THEO ĐƠN VỊ BÀI HỌC - CẢ NĂM - CÓ FILE NGHE (FRIE...
 
AI Uses and Misuses: Academic and Workplace Applications
AI Uses and Misuses: Academic and Workplace ApplicationsAI Uses and Misuses: Academic and Workplace Applications
AI Uses and Misuses: Academic and Workplace Applications
 
Plant Tissue culture., Plasticity, Totipotency, pptx
Plant Tissue culture., Plasticity, Totipotency, pptxPlant Tissue culture., Plasticity, Totipotency, pptx
Plant Tissue culture., Plasticity, Totipotency, pptx
 
How to Customise Quotation's Appearance Using PDF Quote Builder in Odoo 17
How to Customise Quotation's Appearance Using PDF Quote Builder in Odoo 17How to Customise Quotation's Appearance Using PDF Quote Builder in Odoo 17
How to Customise Quotation's Appearance Using PDF Quote Builder in Odoo 17
 
UNIT I Design Thinking and Explore.pptx
UNIT I  Design Thinking and Explore.pptxUNIT I  Design Thinking and Explore.pptx
UNIT I Design Thinking and Explore.pptx
 
Least Significance Difference:Biostatics and Research Methodology
Least Significance Difference:Biostatics and Research MethodologyLeast Significance Difference:Biostatics and Research Methodology
Least Significance Difference:Biostatics and Research Methodology
 
Research Methodology and Tips on Better Research
Research Methodology and Tips on Better ResearchResearch Methodology and Tips on Better Research
Research Methodology and Tips on Better Research
 
Metabolism , Metabolic Fate& disorders of cholesterol.pptx
Metabolism , Metabolic Fate& disorders of cholesterol.pptxMetabolism , Metabolic Fate& disorders of cholesterol.pptx
Metabolism , Metabolic Fate& disorders of cholesterol.pptx
 
LEAD5623 The Economics of Community Coll
LEAD5623 The Economics of Community CollLEAD5623 The Economics of Community Coll
LEAD5623 The Economics of Community Coll
 
3.14.24 Gender Discrimination and Gender Inequity.pptx
3.14.24 Gender Discrimination and Gender Inequity.pptx3.14.24 Gender Discrimination and Gender Inequity.pptx
3.14.24 Gender Discrimination and Gender Inequity.pptx
 
Dhavni Theory by Anandvardhana Indian Poetics
Dhavni Theory by Anandvardhana Indian PoeticsDhavni Theory by Anandvardhana Indian Poetics
Dhavni Theory by Anandvardhana Indian Poetics
 

Haccp

  • 1. PuRDuE ExTEnSiOn Safe food guidelines for small meat and poultry processors FS-20-W Overview of HACCP Hazard Analysis Critical Control Point Introduction Federal regulations, phased in from 1998 until 2000, require all large, small, Kevin Keener, Ph.D., P.E. Outline and very small meat and poultry Food process engineer, Extension 1. Brief background of HACCP processors to implement a HACCP specialist, and associate professor 2. What is HACCP? plan. For a small or very small processor, of food science 3. Prerequisite programs and HACCP sorting all of the vast information on 4. Developing a HACCP program HACCP can seem overwhelming, 5. Meeting state and federal regulations especially when time and resources 6. Action steps for the processor are limited. This fact sheet explains the benefits of HACCP, presents an overview of HACCP principles, and looks at the big picture. It answers the questions: “Why is HACCP important?” and “Where does sanitation fit into The Purdue Department of HACCP?” This fact sheet also Food Science has long been a provides steps the small processor can leader in training students to take to implement a HACCP system. work in the food processing 1. Brief background of HACCP industry. For many years, food Since the Federal Meat Inspection science Extension specialists Act of 1906 and the Poultry Product have provided food safety and Inspection Act of 1957, meat and HACCP training to the food poultry manufacturers have been industry. For small meat directly charged with producing safe, processing plants, an effective wholesome, and unadulterated foods. HACCP program requires As a whole, the U.S. food industry has trained and highly motivated done an excellent job of maintaining individuals. Each meat the safety of its products. Unfortunately, processing plant’s HACCP plan over the years, foodborne illnesses have is unique. A successful HACCP resulted in thousands of sicknesses plan identifies and controls all and many deaths. Investigators have food safety hazards found in the always tried to trace foodborne illness food processing operation. outbreaks back to the food processor, determine what went wrong, and then require them to fix the problem. Over time, it became clear that taking action after the fact was inadequate to protect consumers from foodborne illness.
  • 2. Overview of HACCP (FS-20-W) In response to consumer concerns, the U.S. The timeframe to implement a HACCP program Department of Agriculture (www.usda.gov) and the was based on the size of the processing plant, starting Food and Drug Administration (www.fda.gov) have with the very largest. However, all meat and poultry required plants to implement a food safety program plants were required to phase in a working HACCP called Hazard Analysis Critical Control Point. This plan by January 2000. The very small plants were the program was developed by the Pillsbury Co. for NASA last required to implement a HACCP program in in the late 1960s to ensure the complete safety of food January 2000. Many very small meat processors have for space missions. The program provides a proactive had difficulty developing, writing, and implementing approach to food safety by requiring plants to identify a HACCP plan because of limited expertise and all potential avenues of contamination (hazards) and resources. This fact sheet provides background determine how to control, reduce, and/or prevent them information on HACCP requirements, steps a small to ensure that safe food will be produced. processor can take to develop a HACCP plan, and a On July 25, 1996, the Food Safety and Inspection list of available resources. Service (www.fsis.usda.gov) of the USDA published 2. What is HACCP? a final rule on Pathogen Reduction: Hazard Analysis HACCP stands for Hazard Analysis Critical Critical Control Point Systems. The PR/HACCP rule Control Point. HACCP is a systematic approach to requires all meat and poultry plants to take the identification, evaluation, and control of food responsibility for identifying and controlling, reducing, safety hazards. It is a proactive strategy where hazards or eliminating chemical, physical, and biological are identified and assessed, and control measures are hazards (including pathogenic bacteria). The HACCP developed to prevent, reduce, or eliminate a hazard. requirements that all plants must meet are described For example, one identified hazard in ready-to-eat in Title 9, Part 417, of the Code of Federal Regulations turkey (deli meat) is the presence of Salmonella (www.access.gpo.gov/nara/cfr/waisidx_02/9cfr417_ bacteria. To eliminate Salmonella, one control measure 02.html). (As part of complying with HACCP, is a cooking process where a minimum internal processing plants must also develop a written product temperature of 165°F for 15 seconds is sanitation program (9 CFR 416, www.access.gpo.gov/ achieved and documented. nara/cfr/waisidx_02/9cfr416_02.html). 2
  • 3. Overview of HACCP (FS-20-W) There are seven fundamental HACCP principles: be trained in food safety practices and that wholesome Principle 1 — Conduct a hazard analysis. meat and poultry products are produced under sanitary Principle 2 — Determine the critical control points. conditions. The minimum allowable sanitary conditions for the equipment and facilities are identified as Principle 3 — Establish critical limits. Sanitation Standard Operating Procedures. SSOPs Principle 4 — Establish monitoring procedures. consist of written cleaning and sanitizing procedures, Principle 5 — Establish corrective actions. validation procedures, and records regarding sanitary Principle 6 — Establish record-keeping and conditions both pre-processing and during processing. documentation procedures. The SSOP verifications by USDA-FSIS are frequently performed on a daily basis. Principle 7 — Establish verification procedures. Because of management challenges, many plants 3. Prerequisite programs and HACCP have chosen to subdivide the Sanitation program Before developing the HACCP program, one requirements into separate programs. Also, some prerequisite program is required: Sanitation (9 CFR plants have determined additional prerequisite 416). This prerequisite program requires that employees programs are needed to ensure food and worker safety. Examples of these are shown in Table 2, along with the relevant portion of the Sanitation regulations. It is HACCP is a systematic approach to important to note that when FSIS verifies the regulatory the identification, evaluation, and requirements, it will only examine those records control of food safety hazards. required by 9 CFR 416. Examples of common prerequisite programs (Sanitation – 9 CFR 416 citations provided where appropriate) Maintenance 416.1–3. 416.6 Equipment is designed and constructed with sanitary practices in mind. Preventive maintenance and calibration schedules established and documented. Personal Hygiene 416.1, 416.5 All employees and other persons who enter and work in the manufacturing plant must follow the proper hygienic practices. Pre-operational SSOPs 416.1, 416.11–17 This program documents that food is produced using sanitary Sanitation practices in a sanitary facility using sanitary equipment prior to the start of daily operations. Operational SSOPs 416.1, 416.11–17 This program documents that sanitary practices are maintained Sanitation during processing. Pest Control 416.2 Effective pest control programs should be in place and monitored. Storage and 416.1–416.4 All raw materials and products should be stored under sanitary Shipping conditions and proper environmental conditions to assure their safety. Traceability and Requirement of the All raw material and finished products should be lot-coded and a Recall† Bioterrorism Act of recall system in place so that rapid and complete traces and recalls 2002, Section 306 can be done when a product retrieval is necessary. Supplier Control Facility should ensure that supplier has in place effective Good Management Practices and food safety programs. Personal Safety This program discusses all nonfood safety issues including (not part of repetitive stress injuries, general health, MSDS (Material Safety HACCP) Data Sheets), etc. Inspections performed by Occupational Safety and Health Administration. 3
  • 4. Overview of HACCP (FS-20-W) Figure 1 Food Safety Pyramid Plant Food Safety Pro-active HACCP Plan based on 7 Principles n Va tio lid ca at Safety and Suitability io i Sanitation Standard r n Ve Operating Procedures (SSOP’s) Supplier Traceability Biosecurity Employee Storage Maintenance Personal Pest Control & Recall Training and Hygiene Control Shipping Shaded programs are viewed by USDA as the Sanitation Program (9 CFR 416). Further details on Sanitation and other prerequisite The HACCP plan is a proactive, continual assessment programs, along with the HACCP principles, are of ongoing food safety during the processing of the covered in other fact sheets in this series. It is food. For the HACCP plan to be successful, all of the important to note that from USDA’s perspective, only underlying programs must be working properly. those activities indicated in 9 CFR 416 are considered In the pyramid, the prerequisite programs and “Sanitation” and will be verified as appropriate. USDA written Sanitation program uphold the HACCP plan will review other prerequisite programs only to the as the critical food safety system. extent they support decisions made in the hazard analysis (HACCP Principle 1) when developing the 4. Developing a HACCP program HACCP plan. Once a Sanitation program and necessary The underlying Sanitation and prerequisite programs prerequisite programs are implemented, a HACCP prevent the introduction of food safety hazards into the plan can be developed. Several tasks are required prior plant, and thus are a foundation for the HACCP plan. to HACCP program development. Those preliminary For example, not having an equipment maintenance tasks include: program may lead to the physical hazard of broken • Assemble the HACCP team — The team consists machinery parts contaminating a ground product. One of individuals who have specific knowledge and way of looking at the HACCP requirement is to think expertise appropriate to the product and process. of the HACCP plan as a pyramid (Figure 1). The Other team members include the person(s) HACCP program is built upon the sanitation program responsible for plan maintenance. One person on and other prerequisite programs. These programs the HACCP team must be HACCP-trained. A address the suitability and food safety of the process. team can be as few as one or two people. 4
  • 5. Overview of HACCP (FS-20-W) • Describe the food and its distribution — This provides information on the ingredients, processing methods, and distribution methods (frozen, refrigerated, or at ambient temperature). Classification of the product into a USDA process allows the processor to focus on likely hazards associated with this type of product. • Describe the intended use and consumers of the food — These may be the general public or a segment of the population such as infants, elderly, military, hospital patients, etc. • Develop a flow diagram describing the process — This diagram provides a clear, simple outline of the steps involved in the making the product. A block flow diagram is usually sufficient. • Verify the flow diagram — The HACCP team should perform an on-site review of the operation 3. Establish critical limits — Provides a maximum or to verify the accuracy and completeness of the flow minimum value to which the biological, chemical, or diagram. Perform a walk-through of the process to physical hazard must be controlled at a CCP to make sure all process steps are covered. prevent, eliminate, or reduce to an acceptable level Once those preliminary tasks are completed, a the occurrence of a food safety hazard. The critical meat processor can develop the actual HACCP plan limit distinguishes between safe and unsafe operating by taking the following steps. conditions at a CCP. Each control measure has one or 1. Conduct a hazard analysis — First, the HACCP more critical limits, and they must be scientifically team reviews the ingredients used, activities at each based. For example, if a chilling step is selected as a processing step, and method of storage and CCP for controlling bacterial growth, a certain time distribution of final product, including intended and rate would be specified (e.g. product temperature use by consumers. Then the team makes a list of must be reduced from 140°F to 40°F in six hours). food safety hazards that are reasonably likely to 4. Establish monitoring procedures — These are a cause injury or illness if not controlled. Next, each planned sequence of observations or measurements hazard is evaluated and its likelihood of occurrence (e.g. collection of data) to assess whether a CCP is is determined. The hazards are categorized as under control, and to produce an accurate record chemical, physical, and biological. Supporting for future use in verification. Monitoring facilitates documentation is needed to justify all decisions tracking of an operation, shows if there is a loss of about whether or not something is a hazard. For control at a CCP, and provides written example, a physical hazard of metal shavings from documentation for use in verification. For example, grinding may not be a hazard likely to occur if your if the chilling step as indicated above was used as a maintenance program (and its records) documents CCP, then you may want to monitor and record that periodic checks of the grinder are performed temperatures every half hour. and worn parts are replaced. 5. Establish corrective actions — This part of the 2. Determine critical control points (CCPs) — This HACCP program specifies what is done when a identifies a step in the process at which control must deviation occurs: Who is responsible for be applied to prevent, eliminate, or reduce to an implementing the corrective actions? What happens acceptable level a food safety hazard. Examples of to the product? What caused the deviation? How CCPs may include cooking times and temperatures, can it be prevented from reoccurring? Producers chilling times and temperatures, or pH control. must generate a record documenting these decisions. 5
  • 6. Overview of HACCP (FS-20-W) 7. Establish verification procedures — Verification consists of those activities that determine the validity of the HACCP plan and show that the system is operating according to the plan. Part of verification is validation. Validation is the scientific information, in-plant data, or expert opinions documenting that the existing process(es) — and their respective critical control points, critical limits, and monitoring procedures — produce a safe food product. A validation example might be the documentation used to select a cook step to control salmonella in a ready-to-eat product, the minimum time and temperature needed to cook the product, and the frequency of temperature monitoring to ensure safety. The second part of verification is to “verify” that the validated plan is being followed correctly. Examples of “verifying” include: calibration of process monitoring instruments, direct observation of monitoring activities and corrective actions, and review of records generated and maintained in accordance with 9 CFR 417.5(a)(3) (http://a257. g.akamaitech.net/7/257/2422/14mar20010800/ edocket.access.gpo.gov/cfr_2002/janqtr/9cfr417.5.htm). Verification procedures are the most difficult part of developing a HACCP plan for small and very small processors. A separate fact sheet in this series deals specifically with those issues. 5. Meeting state and federal regulations Two laws directly pertain to meat and poultry 6. Establish record-keeping and documentation processing food safety: the Federal Meat Inspection procedures — These records should include the Act and the Poultry Products Inspection Act. In order following: to process meat or poultry, processors must comply • Sanitation program records — SSOPs and others with the regulations developed to assure that these laws required in 9 CFR 416. are obeyed. These regulations are maintained in the • Prerequisite program records — USDA-FSIS Code of Federal Regulations in Title 9. Requirements will view prerequisite program records that are for a sanitation program are contained in 9 CFR 416. identified in HACCP plan. Regulations mandating a written HACCP plan are • Hazard analysis and decision-making contained in 9 CFR 417. At least one employee or their information — these records should include the representative at a meat or poultry slaughter or rationale for identifying hazards and selecting processing plant must meet minimum HACCP critical control points. training requirements (9 CFR 417.7). HACCP training • HACCP records — monitoring, pre-shipment is offered through many university Extension programs, review, corrective actions, verification, annual private food consulting firms, the Food Products HACCP reassessment. Association, and numerous trade organizations. 6
  • 7. Overview of HACCP (FS-20-W) PuRDuE ExTEnSiOn 6. Action steps for the processor Additional resources Look up, print, and read the sanitation regulation  Purdue Department of Food Science, for meat and poultry processing in the Code of } www.foodsci.purdue.edu/outreach Federal Regulations Title 9, Part 416. Food Safety and Inspection Service of the USDA, } www.access.gpo.gov/nara/cfr/waisidx_ } www.fsis.usda.gov 02/9cfr416_02.html FSIS food safety resources for the small and Select the person(s) who will make up the HACCP  very small plants, team. Look up, print, and read the HACCP } www.fsis.usda.gov/science/HACCP_Resources_ regulations for meat and poultry processing in Brochure/index.asp the Code of Federal Regulations Title 9, Part 417. } www.access.gpo.gov/nara/cfr/waisidx_ Acknowledgement 02/9cfr417_02.html The author would like to acknowledge the financial Enroll in an introductory HACCP course through  support of the United States Department of the Purdue Department of Food Science Agriculture/Food Safety Inspection Service/Strategic (www.foodsci.purdue.edu) or another provider. Initiatives, Partnerships, and Outreach Office in developing this fact sheet. This fact sheet was developed Other publications in this series with a portion of the funds provided from cooperative FS-21-W, Small Meat Processing Plants: SSOP and agreement FSIS-C-30-2003. GMP Practices and Programs (Sanitation Standard Operating Procedures and Good Manufacturing For additional information Practices) Kevin Keener } www.ces.purdue.edu/extmedia/FS/FS-21-W.pdf Associate professor, food process engineer, and Extension specialist FS-22-W, Small Meat Processing Plants: A Pest Director, Food Technology Development Laboratory Control Program Purdue Department of Food Science } www.ces.purdue.edu/extmedia/FS/FS-22-W.pdf West Lafayette, IN 47907-2009 FS-23-W, Small Meat Processing Plants: A Recall Phone: (765) 494-6648 and Traceability Program kkeener@purdue.edu } www.ces.purdue.edu/extmedia/FS/FS-23-W.pdf FS-24-W, Small Meat Processing Plants: Verification Programs } www.ces.purdue.edu/extmedia/FS/FS-24-W.pdf FS-25-W, Small Meat Processing Plants: Selection and Maintenance of Temperature Measurement Devices } www.ces.purdue.edu/extmedia/FS/FS-25-W.pdf New 9/07 In accordance with Purdue policies, all persons have equal opportunity and access to Purdue University’s educational programs, services, activities, and facilities without regard to race, religion, color, sex, age, national origin or ancestry, marital You can order or download materials on this and other status, parental status, sexual orientation, disability or status as topics at the Purdue Extension Education Store. a veteran. Purdue University is an Affirmative Action institution. This material may be available in alternative formats. www.ces.purdue.edu/new