The HACCP method in mineral water bottling

1. Lifelong Learning Programme
WP.5
Development of online and offline courses
The HACCP method in mineral water bottling
Partner P5 - CSEI Catania
Dr. Chiara COPAT – University of Catania
Dr. Caterina LEDDA – University of Catania

2. Hazard and risk: What is it?
Hazard analysis: Identify all possible
hazards potentially created by a product,
process or application SENSATION
Risk assessment: It is the next step after
the identification of potential hazards.
Risk in this context is the probability and
severity of the hazard becoming reality
MATHEMATICS / A NUMBER

3. Hazard analysis: What is it?
Objectives:
Tool for safety practitioners to:
• identify possible hazards,
• provide an evaluation of the risks,
• prompt alternative design solutions to
mitigate or control the risks to an
acceptable level

4. Hazard Management Process
• Identify the hazards: health, safety, and
environmental hazards
• Assess the risks: injury, illness, damage,
productivity loss…
• Evaluate risks: Likelihood x Consequence
(Severity).
• Hazards can be ranked from high to low risk
• Control the risks
• Monitor and Review

5. What to consider?
• The number of times tasks which could result in
an incident are undertaken
• The number of people performing the task(s)
• The likelihood of the incident occurring while
the task is being performed
• If it (the incident) occurs, what will happen?

6. Caution:
Any unidentified hazard will not be addressed
by safety measures and will not be detected
during testing
Hazards not identified during this analysis can
create substantial risk to users of the design

7. Hazard Analysis and
Critical Control Points
HACCP
• System for food safety management
(including bottled water)
• Internationally recognized and recommended

8. • A stepwise process which:
- Identifies hazards
- Installs preventive measures to eliminate or reduce
hazards
• A proactive (before) rather than reactive (after)
system
• A risk-related and based system
What is an HACCP system?

10. HACCP Importance
By reducing major food risks - microbiological, chemical
and physical - the industry can better guarantee that its
products are as safe as good science and technology allow
By reducing food/water borne risks, public health protection
is strengthened

11. How to perform a HACCP Study?
HACCP studies involves a logical
sequence of tasks ...

13. Assemble a HACCP Team
• By involving a team of people, a greater diversity of skills
and knowledge appropriate to the system will be available
• It is counselled to create a team with some external people
Define the Terms of Reference
• Identify the process (e.g. the production and supply of
water)
• Identify the limits of the study
• All hazards (microbiological, chemical and physical)
must be considered as a whole, or will each type of
hazard be considered individually?
• Each process stage is studied individually (e.g. ozonation,
filling, capping...)

14. Describe the Product and Identify the Intended Use
Draw up a full description of the production system, including
information on water composition and the method of distribution as
well as the materials used in the production:
• Raw materials: water, CO2 and added minerals (depending on the
type)
• Authorised water treatments
• Materials in contact with the product (filling line and containers:
bottles, cans...)
• Storage conditions and methods of distribution
• Theoretical/legal expiry date

15. Identify the consumer/s target group/s for the product
The intended use shall be based on the composition and
expected uses of the product
In specific cases, people that can be affected (e.g. infants,
special diets) should be considered

16. Flow Diagram
Draw a flow diagram of all aspects of the factory/procedure
considering:
• Source and its protection
• Water operation
• Raw materials
• Processing
• Packing (all steps)
• Storage
• Distribution
• Retailer
• Point of consumption (drinking)

18. 1. Step – process identified in the flow diagram; Hazard - potential source of harm
or adverse health effect/s on a person or persons; Risk - the likelihood that a
person may be harmed or suffer adverse health effects if exposed to a hazard;
Control Measures (CM)
2. Critical Control Point Yes/Not (CCP Y/N)
3. Control Limits (verification) (C Limits)
4. Monitoring:
5. Corrective Actions (CA)
6. Verification
7. Documentation

19. The HACCP team shall list all hazards reasonably expected to occur at
each step according to:
- Scope from primary production, processing, manufacture and
distribution until the point of consumption
- Each process step identified in the flow diagram shall be assessed
for the introduction or presence of a hazard
The HACCP team shall next conduct a hazard analysis to identify
which hazards are of such a nature that their elimination or
reduction to acceptable levels is essential to the production of safe
bottled / packaged water.
PRINCIPLE 1
List All Hazards Associated With Each Step And Consider Any
Control Measures To Control The Hazard

20. The identification of a Critical Control Point (CCP) in the HACCP
system is facilitated by the application of a Decision Tree (next).
Application of the Decision Tree determines if the step is a
"critical" control point for the identified hazard
If a hazard has been identified at a step where control is necessary for
safety and no control measure exists at that step, or at any other
step, then the product or process must be modified at that step, or
an earlier or later stage, to include a control measure
PRINCIPLE 2
Identify the Critical Control Points

22. Critical limits shall be specified and validated for each CCP. Details
of the establishment of critical limits shall be recorded
These critical limits shall be measurable
Criteria often used include: measurements of time, temperature,
concentration of disinfecting agent (not in the water), pH, absence
of metals, microbiological limits, sensory parameters e.g. visual
appearance and texture, etc.
In some cases more than one critical limit will be elaborated at a
particular step
PRINCIPLE 3
Establish Critical Limits for each CCP

23. Monitoring is a planned sequence of observations or measurements of a
CCP target level and tolerance
Typical monitoring methods include visual evaluations, physical
measurements (e.g. temperature), chemical analysis, and microbiological
assessment
Records and documents associated with monitoring CCPs must be
signed by the person(s) doing the monitoring and by a responsible
reviewing official of the company
If monitoring is not continuous, then the amount of frequency of
monitoring must be sufficient to guarantee the CCP is under control
PRINCIPLE 4 Establish a Monitoring System for each CCP

24. Specific corrective actions must be developed for each CCP in order to deal
with any deviation. The action must ensure the CCP is brought under
control and include details of what to do with the affected product
Monitoring and auditing should be carried out to determine if the system is
working correctly. Examples include a review of the HACCP system and
its records, review of deviations, checks to ensure CCPs are under
control, validation of established critical limits, etc.
PRINCIPLE 5 Establish Corrective Actions
PRINCIPLE 6 Validate the HACCP System

25. In order to be efficient and effective, keeping of records is essential
Each process step as documented in the flow diagram must be detailed in
the HACCP chart and the controls, monitoring, corrective actions, etc.
determined accordingly. This will ensure that the hazards at each
process step are duly considered and controlled
These records must be reviewed periodically e.g. annually or when there is
a significant change in operation
PRINCIPLE 7
Establish Record Keeping and Documentation

26. SAMPLE HACCP CHART