Haccp training


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Haccp training

  1. 1. HACCP HACCP What is it?
  2. 2. What is HACCP? HACCP Hazard Analysis Critical Control Points• A powerful safety management technique• Structured preventative system• Promotes safety through hazard identification and control
  3. 3. The CRP Triangle
  4. 4. How HACCP works - the 12 Codex steps 12.Establish documentation & record keeping 11. Establish verification procedures 10. Establish corrective actions 9. Establish monitoring system for CCP’s 8. Establish critical limits for CCP’s 7. Determine Critical Control Points (CCP’s) 6.List hazards,conduct hazard analysis,consider control measures 5. On-site confirmation of flow diagram 4. Construct flow diagram 3. Identify intended use 2. Describe product1. Assemble HACCP Team
  5. 5. What is a Hazard?A HAZARD is...A property which may cause a product to be unsafe for consumption
  6. 6. Benefits of HACCP...5 Systematic approach5 Preventative system5 Resources are used effectively5 Documentary system builds and continually refreshes ‘due diligence’ in plant5 Internationally accepted system5 Strengthens Quality Management systems5 Demonstrates and reinforces management commitment and involvement
  7. 7. The HACCP team• Process line representative(s) (e.g. Specialist/ SET)• Packaging representative (e.g. Specialist/SET)• Support services• Production management representative (e.g. FLM)• CRP Project Leader (site Food Safety Manager or Food Safety SET)
  8. 8. HACCP project implementation
  9. 9. Sample Process Flowchart...
  10. 10. What is a Hazard?biologicalchemicalphysicalproperty or condition of food with the potential to cause an adverse health effect” (Codex 1997)
  11. 11. Step 1 What does Codex say about hazard analysis ?“The process of collecting and evaluating information on hazards and conditions leading to their presence to decide which are significant for food safety and therefore should be addressed in the HACCP plan”
  12. 12. Hazard determination Questions to be answered for each potential hazard at each process step : Presence of potential hazardPresence of potential in line or environmenthazard in raw material probable?probable? YES NO NO YES NO HAZARD *Unacceptable level, Unacceptablesurvival, persistence or YES contamination at this stepincrease at this step probable?probable? YES NO HAZARD YES ** *Reduction, if any, at a SIGNIFICAfurther step adequate? NT NO HAZARD* = Not a hazard at this step** = A CCP or an SCP at this step
  13. 13. Risk Assessment Model... FOOD SAFETY RISK ASSESSMENTSeverity Severity if Severity of affect if Hazard Occurs Multipliercontrols failLittle Damage Mild disappointment to the consumer. May lead to a complaint, no business interruption. Minor consequences. 1 Very minor medical treatment, (for example a broken tooth). Consumer disappointed and likely to lead to a complaint to the Damage Company. 2 Serious Illness at home. Medical treatment not necessary. A disappointed consumer very likely to lead to a complaint to a regulatory Damage authority. 3 Very Serious Damage Illness at home with medical treatment necessary. A very disappointed consumer. A significant risk of proscecution. 4 Disaster Hospitalization required. Significant risk of proscecution. Media coverage. Intervention by ‘Crisis management team’. Damage toSerious Illness ‘branded ‘ image. 5 Catastrophic Death. Top level ‘crisis management’ Certain risk of proscecution. Destruction of ‘brand’ 6Frequency Probability ofhazard occurring Frequency That Hazard Could Occur Multiplier if process fails Almost Impossible Less than once a year, no history of it occurring 1 Un-Likely Very occasional, has been known to occur 2 Small Risk Isolated event that result after manual operations 3 Likely Product or operational factors that can be expected to be present 4 Certain Product or operational factors that the process is expected to control 5
  14. 14. Risk Assessment Model... FOOD SAFETY RISK ASSESSMENT MATRIX FREQUENCY SEVERITY ALMOST UNLIKELY SMALL RISK LIKELY CERTAINIMPOSSIBLE (1) (2) (3) (4) (5) LITTLE 1 2 3 4 5 DAMAGE (1) 2 4 6 8 10 DAMAGE (2) SERIOUS 3 6 9 12 15 DAMAGE (3) 4 8 12 16 20 VERY SERIOUS DAMAGE (4) 5 10 15 20 25 DISASTER (5) 6 12 18 24 30 CATASTROPHIC (6)
  15. 15. Risk Assessment Model...GUIDELINE ACTIONS FROM RISK ASSESSMENT TO DETERMINE CONTROL MEASURES1–5 Probably controlled by a GMP. Check nature of problem against existing pre-requisite programmes Example might be an AIB ‘SERIOUS’ observation6–9 A consumer issue. With some risk to consumer safety. Certainly needs control by a GMP, could be a Specific Control Point Example might be an AIB ‘MAJOR’ observation10 – 16 Use Codex decision tree for microbiological hazards. Implications for corrective action procedures. Report/resolve and record at next HACCP review. Definitely either a GMP or an SCP Example might be an AIB ‘UNSATISFACTORY’ observation16 + Critical control point (CCP). Use Codex decision tree for microbiological hazards. Failure may result in food poisoning incidents. Initiates special HACCP review. External HACCP audit.(F x S = RISK)!!!! Make a note of limitations of seeing cost as a risk assessment factor.
  16. 16. What is a Control? Acontrol: is a preventative measure which• eliminates a hazard, or• prevents a hazard, or• reduces a hazard to an acceptable level
  17. 17. The next step... 7. Determine Critical Control Points (CCP’s) 6.List hazards,conduct hazard analysis,consider control measures 5. On-site confirmation of flow diagram 4. Construct flow diagram 3. Identify intended use 2. Describe product1. Assemble HACCP Team
  18. 18. Types of Control Points...Specific Control Points (SCP’s) - these arecontrol points which relate to line-specifichazardsCritical Control Points (CCP’s) - these arecommon to all of our products and processesand are established in our generic HACCPmodel : -Metal detection – Promotional inserts – Allergen Control
  19. 19. Next steps... 10. Establish corrective actions 9. Establish monitoring system for CCP’s 8. Establish critical limits for CCP’s 7. Determine Critical Control Points (CCP’s) 6.List hazards, conduct hazard analysis, consider control measures 5. On-site confirmation of flow diagram 4. Construct flow diagram 3. Identify intended use 2. Describe product1. Assemble HACCP Team
  20. 20. Critical limits• Maximum values should never be exceeded, so often target values are established• The limits must relate to the control measures identified• Decisions on what constitutes a harmful level requires technical food safety knowledge and sometimes may be a current legal requirement
  21. 21. Critical limits• Critical limits must be exact and monitorable• A numerical limit is not necessarily required in every case• Flexibility should not compromise food safety• It is often appropriate to set an ‘acceptable range’ rather than a fixed limit• Sometimes a green (acceptable), yellow (caution), red (unacceptable) rating system
  22. 22. Monitoring controls - specify...• How is the control monitored? - method• When is the control monitored ? - frequency• How is it recorded? - documentation
  23. 23. Monitoring controls - specify...All monitoring and corrective action must besigned off by a trained person.The resulting records must be retained and beavailable for inspection : – during verification – during HACCP audits – during AIB audits – during regulatory visits
  24. 24. The formal HACCP documentation...Documentation to be produced :• Completed Process Flowchart for each product line on site• Site HACCP Plan• Record sheets for the monitoring programmes specified
  25. 25. Recent revisions to CCPs• The removal of the requirement for Certificates of Analysis (CoAs) from seasoning companies• VA programme became a HACCP pre-requisite programme• Metal Detectors became a CCP by definition• The growth and development of promotions within the business has brought additional and significant new consumer and business risk• Scientific advances in relating to food allergens have led to Pepsico to develop allergen control practices in plant• Forthcoming legislative requirements for labelling of allergens prompted Pepsico to enlarge its allergen programme and broaden its scope of allergen CCP
  26. 26. Checking the HACCP ProgrammeValidation Verification Review
  27. 27. Validation• The assessment of the HACCP plan before implementation to provide confirmation that it is : – valid – accurate – and complete• Codex says : “obtaining evidence that the elements of the HACCP Plan are effective”• Ask yourself these questions : – “is it true? is it right?” – “will it deliver safe food?”
  28. 28. Validation - summaryRemember - validation is the process for checking : HACCP plan is complete and accurate - a true reflection of the site, its products and processes and the hazards associated with them HACCP system, if operated correctly, will deliver safe food - that it would work that it is a VALID system" It is not a process for checking whether it is being correctly carried out" Is the system at fault and in need of amendment, or would the system work if correctly operated and communicated?
  29. 29. Verification• To make sure that what is laid down in the HACCP plan accurately operated in reality• More ‘hands-on’• Confirms that everything is OK
  30. 30. Verification informationHACCP team should consider two key sets of data :• Feedback from the AIB audit• Food safety monitoring data : ~ Data on the monitoring of pre-requisite programmes, e.g. Pest Control records, Foreign Object trawls, glass and hard plastic audits, etc. ~ Data from HACCP monitoring sheets which record the checks on CCPs and SCPs
  31. 31. HACCP Annual Review• Conducted by the HACCP team• Comprises : – Re-validation of the HACCP system ~ Check the HACCP plan ~ Update the plan in response to changes – HACCP audit ~ Ideally, this audit should include an SET from another site! – Verification of the HACCP system as previously described – Review training needs for HACCP team and other plant personnel (possibly utilising a skills needs assessment) and relay outcome to HR personnel – Recommendations to improve food safety on site – Recommendations to improve AIB audit performance