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Hazard Analysis and Critical Control
Point (HACCP) System and
Guidelines For Its Application
What is HACCP ?
What is HACCP Stand for ?
A systematic approachapproach in identifying, evaluatingidentifying, evaluating
and controlcontrol food safety hazardsfood safety hazards
IdentifiesIdentifies and monitorsmonitors specific food borne hazards
that can adversely affect the safety of food productthat can adversely affect the safety of food product
Chronology of HACCP Development
• Develop from P-D-C-A
• 1959 Pillsbury & NASA Food safety
program for astronaut
• 1971 USA distribute HACCP concept
• 1985 Codex added HACCP to
General Principles of Food Hygiene
(Codex-GMP)
Chronology of HACCP Development
ProcessInput Out put
GMPs
HACCP
Food
Safety
Production process
Raw material
Premise & environment
Machine & equipment
Food Handler
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
Critical Control Point
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
5 Preliminary Step
5 Preliminary Step
•Genba: Real Place
•Genbutsu: real thing
•Genjitsu: actual Situatuin
•Genba: Real Place
•Genbutsu: real thing
•Genjitsu: actual Situatuin
HACCP Principles
6.6. Conduct a Hazard Analysis :Conduct a Hazard Analysis :
6.1 Hazard Identification & Analysis :
Raw material,
Ingredient,
packaging
Production
processes
FG Storage,
Delivery
HACCP Principles
Material/ process
step
Potential
Hazard(s)
No. Process
“Step title”
ID Step No.
Step title
6.1 Hazard Identification & Analysis :
Table for Hazard AnalysisTable for Hazard Analysis
HACCP Principles
Identify the cause of this hazard:
contamination, increase number,
survival
ID Step No.
Step title
Material/ process
step
Potential
Hazard(s)
No. Process
HACCP Principles
Source(s) of Potential HazardSource(s) of Potential Hazard
Man : Lack of knowledge & awareness
Material : Type / sources of Raw materials
Machine : Maintenance, installation
Measurement: Efficiency, technique
Method : Work Instruction
Environment : Management of work environment
(Glass Control, etc.)
HACCP Principles
Sources of information:Sources of information:
1. Record
2. Customer complaint
3. Scientific knowledge
4. In house experiment
5. Standard, Regulation
HACCP Principles
Fresh Egg
Mix with ingredients
(vegetable mixes)
Fried in Pan
Vegetable oil
Serve
#1
#2
#3
#4
#5Production of Omlet
HACCP Principles
Table for Hazard AnalysisTable for Hazard Analysis
Material/ process
step
Potential Hazard(s)
Type How to become
hazard
1. Fresh Egg B: Salmonella sp. Salmonella penetrate
into egg through “crack”
on egg shell
C: Alfatoxin Contamination from
feed production
P: Metal shard None
HACCP Principles
Any action and activity that can be used to
prevent or eliminate a food safety hazard
or reduce it to an acceptable level
6.2 Control Measure Identification :
6.6. Conduct a Hazard Analysis :Conduct a Hazard Analysis :
HACCP Principles
Control measure(s) sample :-
Biological H Chemical H Physical H
Temp,
time, pH
Control quantity of use
Pre requisite
program
Determine Maximum
Residue outlet
Control food sources
Use foreign
material detector
Pre requisite
program
Pre requisite
program
HACCP Principles
Table for Hazard AnalysisTable for Hazard Analysis
Material/
process
step
Potential Hazard(s) Control Measure(s)
Type How to become
hazard
1. Fresh Egg B:
Salmonella
sp.
Salmonella
penetrate into egg
through “crack” on
egg shell
1. Inspection before
receiving (WI)
2. Approved Supplier
3. At step #4, can
eliminate this hazard
C: Alfatoxin Contamination
from feed
production
1. Approved Supplier
2. COA from supplier
P: Metal
shard
None -
HACCP Principles
WorkshopWorkshop
Using Hazard Analysis form :-Using Hazard Analysis form :-
1. Identify potential hazard and
how it can cause diverse affect
2. Determine “Control Measure(s)”
HACCP Principles
6.3 Hazard Assessment :
6.6. Conduct a Hazard Analysis :Conduct a Hazard Analysis :
Evaluate the significant of hazard(s) by assessment from:-
The likely occurrences and severity of their adverse health effects
Likelihood/ severityLikelihood/ severity
HACCP Principles
Severity
Likelihood
• Adverse affect to health; death, etc
for example E.coli 0157:H7
•Toxin in high quantity, sudden effect
•Food Law / regulation
• Frequently occur
• Out break
HACCP Principles
6.3 Hazard Assessment :
Source of information
Technical knowledge
Experience
Results of controlResults of control
from pre-requisitefrom pre-requisite
programprogram Journal, text book,
Internet, etc.
HACCP Principles
Likeli
hood
1 =
Low
Rarely occur < 1 / 1 year
2 =
Mediu
m
Some ( 1 / month)
3 =
High
Usually occur > 12 / year
Severi
ty
1 =
Minim
Annoying (for example; hair)
Example: How to evaluate the likelihoodExample: How to evaluate the likelihood
HACCP Principles
Repeated failures may indicate that
decisions made in the Hazard Analysis
are not supported.
HACCP Principles
Likelihoo
d
Severity
1
Low
2
Medium
3
High
1 :
Minimal
1 2 3
2 : High 2 4 6
3 : Fatal 3 6 9Scores :
1-2 : use control measures – no specific a
3-9 : use decision tree
ant or Hazard Assessment = Likelihood x Severity
Example: How to evaluate the likelihoodExample: How to evaluate the likelihood
HACCP Principles
Materia
l/
proces
s step
Potential Hazard(s)
Control Measure(s) Evaluate the significant of
hazard(s)
Type How to
become
hazard
Note S L Co
1. Fresh
Egg
B:
Salmonel
la sp.
Salmonella
penetrate
into egg
through
“crack” on
egg shell
1. Inspection
before receiving
(WI)
2. Approved
Supplier
3. At step #4, can
eliminate this
hazard
Acceptance
level of salmo
in food = not
detect
3 1 3
C:
Alfatoxin
Contaminati
on from
feed
production
1. Approved
Supplier
2. COA from
supplier
No further
process can
eliminate
Frequently
3 3 9
HACCP Principles
WorkshopWorkshop
Using Hazard Analysis form :-Using Hazard Analysis form :-
Evaluate the significant of Hazard
HACCP Principles
WorkshopWorkshop
Using Hazard Analysis form :-Using Hazard Analysis form :-
1. Identify potential hazard and
how it can cause diverse affect
2. Determine “Control Measure(s)”
HACCP Principles
CCP Determination
• Determine if that process
step is CCP or not
• How to use “Decision Tree”
7. Determine Critical Control Point:7. Determine Critical Control Point:
HACCP Principles
Characteristic of CCP
• Adverse affect of hazard(s) at that step can be prevented
or
• Hazard(s) can be eliminate
or
•Hazard(s) can be reduced to acceptable level
7. Determine Critical Control Point:7. Determine Critical Control Point:
HACCP Principles
Significant of Hazard
Severity Likelihood R
Stop1
3
1 1
2 1 2
3
1
1
3
3
HACCP Principles
HACCP Principles
 Codex advise to use decision tree to determine
CCP
 But it does not mean that we have to use it in every
circumstance
 Individual shall be trained how to use it
Do preventive control measures exist?
Yes No
Is control at this step necessary for safety? Yes
Modify step, process or product
No Not a CCP Stop
Q1
CCPDecisionTree
7.2 CCP Decision Tree Determination
Do preventive control measures exist?
Yes No
Is control at this step necessary for safety? Yes
Modify step, process or product
No Not a CCP Stop
Is the step specifically designed to eliminate or reduce
The likely occurrence of hazard to an acceptable level?
Q1
Q2 Yes
CCP
No
Do preventive control measures exist?
Is control at this step necessary for safety?
Yes
Modify step, process or product
No
Not a CCP Stop
Is the step specifically designed to eliminate or reduce
The likely occurrence of hazard to an acceptable level?
Q1
Q2 Yes
CCP
No
Could contamination with identified hazard(s) occur in
Excess of acceptable level(s) or could these increase to
unacceptable level?
Q3
Yes No
Not a CCP Stop
•Delay time
•Cross con.
•Temp.
Do preventive control measures exist?
Yes No
Is control at this step necessary for safety?
Yes
Modify step, process or product
No
Not a CCP Stop
Is the step specifically designed to eliminate or reduce
The likely occurrence of hazard to an acceptable level?
Q1
Q2 Yes
CCP
No
Could contamination with identified hazard(s) occur in
Excess of acceptable level(s) or could these increase to
unacceptable level?Q3
Yes No
Not a CCP Stop
Will a subsequent step eliminate identified hazard(s) or
Reduce likely occurrence to acceptable level(s)?
Q4
Do preventive control measures exist?
Yes No
Is control at this step necessary for safety?
Yes
Modify step, process or product
No
Not a CCP Stop
Is the step specifically designed to eliminate or reduce
The likely occurrence of hazard to an acceptable level?
Q1
Q2 Yes
CCP
No
Could contamination with identified hazard(s) occur in
Excess of acceptable level(s) or could these increase to
unacceptable level?Q3
Yes No
Not a CCP Stop
Will a subsequent step eliminate identified hazard(s) or
Reduce likely occurrence to acceptable level(s)?
Q4
Yes
Not a CCP Stop
Do preventive control measures exist?
Yes No
Is control at this step necessary for safety?
Yes
Modify step, process or product
No
Not a CCP Stop
Is the step specifically designed to eliminate or reduce
The likely occurrence of hazard to an acceptable level?
Q1
Q2 Yes
CCP
No
Could contamination with identified hazard(s) occur in
Excess of acceptable level(s) or could these increase to
unacceptable level?Q3
Yes No Not a CCP Stop
Will a subsequent step eliminate identified hazard(s) or
Reduce likely occurrence to acceptable level(s)?
Q4
Yes
Not a CCP Stop
No
CCPDecisionTree
HACCP
HACCP
HACCP

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HACCP

  • 1. Hazard Analysis and Critical Control Point (HACCP) System and Guidelines For Its Application
  • 2. What is HACCP ? What is HACCP Stand for ? A systematic approachapproach in identifying, evaluatingidentifying, evaluating and controlcontrol food safety hazardsfood safety hazards IdentifiesIdentifies and monitorsmonitors specific food borne hazards that can adversely affect the safety of food productthat can adversely affect the safety of food product
  • 3.
  • 4. Chronology of HACCP Development • Develop from P-D-C-A • 1959 Pillsbury & NASA Food safety program for astronaut • 1971 USA distribute HACCP concept • 1985 Codex added HACCP to General Principles of Food Hygiene (Codex-GMP)
  • 5. Chronology of HACCP Development ProcessInput Out put GMPs HACCP Food Safety Production process Raw material Premise & environment Machine & equipment Food Handler
  • 6. 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 Critical Control Point 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
  • 8. 5 Preliminary Step •Genba: Real Place •Genbutsu: real thing •Genjitsu: actual Situatuin •Genba: Real Place •Genbutsu: real thing •Genjitsu: actual Situatuin
  • 9. HACCP Principles 6.6. Conduct a Hazard Analysis :Conduct a Hazard Analysis : 6.1 Hazard Identification & Analysis : Raw material, Ingredient, packaging Production processes FG Storage, Delivery
  • 10. HACCP Principles Material/ process step Potential Hazard(s) No. Process “Step title” ID Step No. Step title 6.1 Hazard Identification & Analysis : Table for Hazard AnalysisTable for Hazard Analysis
  • 11. HACCP Principles Identify the cause of this hazard: contamination, increase number, survival ID Step No. Step title Material/ process step Potential Hazard(s) No. Process
  • 12. HACCP Principles Source(s) of Potential HazardSource(s) of Potential Hazard Man : Lack of knowledge & awareness Material : Type / sources of Raw materials Machine : Maintenance, installation Measurement: Efficiency, technique Method : Work Instruction Environment : Management of work environment (Glass Control, etc.)
  • 13. HACCP Principles Sources of information:Sources of information: 1. Record 2. Customer complaint 3. Scientific knowledge 4. In house experiment 5. Standard, Regulation
  • 14. HACCP Principles Fresh Egg Mix with ingredients (vegetable mixes) Fried in Pan Vegetable oil Serve #1 #2 #3 #4 #5Production of Omlet
  • 15. HACCP Principles Table for Hazard AnalysisTable for Hazard Analysis Material/ process step Potential Hazard(s) Type How to become hazard 1. Fresh Egg B: Salmonella sp. Salmonella penetrate into egg through “crack” on egg shell C: Alfatoxin Contamination from feed production P: Metal shard None
  • 16. HACCP Principles Any action and activity that can be used to prevent or eliminate a food safety hazard or reduce it to an acceptable level 6.2 Control Measure Identification : 6.6. Conduct a Hazard Analysis :Conduct a Hazard Analysis :
  • 17. HACCP Principles Control measure(s) sample :- Biological H Chemical H Physical H Temp, time, pH Control quantity of use Pre requisite program Determine Maximum Residue outlet Control food sources Use foreign material detector Pre requisite program Pre requisite program
  • 18. HACCP Principles Table for Hazard AnalysisTable for Hazard Analysis Material/ process step Potential Hazard(s) Control Measure(s) Type How to become hazard 1. Fresh Egg B: Salmonella sp. Salmonella penetrate into egg through “crack” on egg shell 1. Inspection before receiving (WI) 2. Approved Supplier 3. At step #4, can eliminate this hazard C: Alfatoxin Contamination from feed production 1. Approved Supplier 2. COA from supplier P: Metal shard None -
  • 19. HACCP Principles WorkshopWorkshop Using Hazard Analysis form :-Using Hazard Analysis form :- 1. Identify potential hazard and how it can cause diverse affect 2. Determine “Control Measure(s)”
  • 20. HACCP Principles 6.3 Hazard Assessment : 6.6. Conduct a Hazard Analysis :Conduct a Hazard Analysis : Evaluate the significant of hazard(s) by assessment from:- The likely occurrences and severity of their adverse health effects Likelihood/ severityLikelihood/ severity
  • 21. HACCP Principles Severity Likelihood • Adverse affect to health; death, etc for example E.coli 0157:H7 •Toxin in high quantity, sudden effect •Food Law / regulation • Frequently occur • Out break
  • 22. HACCP Principles 6.3 Hazard Assessment : Source of information Technical knowledge Experience Results of controlResults of control from pre-requisitefrom pre-requisite programprogram Journal, text book, Internet, etc.
  • 23. HACCP Principles Likeli hood 1 = Low Rarely occur < 1 / 1 year 2 = Mediu m Some ( 1 / month) 3 = High Usually occur > 12 / year Severi ty 1 = Minim Annoying (for example; hair) Example: How to evaluate the likelihoodExample: How to evaluate the likelihood
  • 24. HACCP Principles Repeated failures may indicate that decisions made in the Hazard Analysis are not supported.
  • 25. HACCP Principles Likelihoo d Severity 1 Low 2 Medium 3 High 1 : Minimal 1 2 3 2 : High 2 4 6 3 : Fatal 3 6 9Scores : 1-2 : use control measures – no specific a 3-9 : use decision tree ant or Hazard Assessment = Likelihood x Severity Example: How to evaluate the likelihoodExample: How to evaluate the likelihood
  • 26. HACCP Principles Materia l/ proces s step Potential Hazard(s) Control Measure(s) Evaluate the significant of hazard(s) Type How to become hazard Note S L Co 1. Fresh Egg B: Salmonel la sp. Salmonella penetrate into egg through “crack” on egg shell 1. Inspection before receiving (WI) 2. Approved Supplier 3. At step #4, can eliminate this hazard Acceptance level of salmo in food = not detect 3 1 3 C: Alfatoxin Contaminati on from feed production 1. Approved Supplier 2. COA from supplier No further process can eliminate Frequently 3 3 9
  • 27. HACCP Principles WorkshopWorkshop Using Hazard Analysis form :-Using Hazard Analysis form :- Evaluate the significant of Hazard
  • 28. HACCP Principles WorkshopWorkshop Using Hazard Analysis form :-Using Hazard Analysis form :- 1. Identify potential hazard and how it can cause diverse affect 2. Determine “Control Measure(s)”
  • 29. HACCP Principles CCP Determination • Determine if that process step is CCP or not • How to use “Decision Tree” 7. Determine Critical Control Point:7. Determine Critical Control Point:
  • 30. HACCP Principles Characteristic of CCP • Adverse affect of hazard(s) at that step can be prevented or • Hazard(s) can be eliminate or •Hazard(s) can be reduced to acceptable level 7. Determine Critical Control Point:7. Determine Critical Control Point:
  • 31. HACCP Principles Significant of Hazard Severity Likelihood R Stop1 3 1 1 2 1 2 3 1 1 3 3
  • 33. HACCP Principles  Codex advise to use decision tree to determine CCP  But it does not mean that we have to use it in every circumstance  Individual shall be trained how to use it
  • 34. Do preventive control measures exist? Yes No Is control at this step necessary for safety? Yes Modify step, process or product No Not a CCP Stop Q1 CCPDecisionTree 7.2 CCP Decision Tree Determination
  • 35. Do preventive control measures exist? Yes No Is control at this step necessary for safety? Yes Modify step, process or product No Not a CCP Stop Is the step specifically designed to eliminate or reduce The likely occurrence of hazard to an acceptable level? Q1 Q2 Yes CCP No
  • 36. Do preventive control measures exist? Is control at this step necessary for safety? Yes Modify step, process or product No Not a CCP Stop Is the step specifically designed to eliminate or reduce The likely occurrence of hazard to an acceptable level? Q1 Q2 Yes CCP No Could contamination with identified hazard(s) occur in Excess of acceptable level(s) or could these increase to unacceptable level? Q3 Yes No Not a CCP Stop •Delay time •Cross con. •Temp.
  • 37. Do preventive control measures exist? Yes No Is control at this step necessary for safety? Yes Modify step, process or product No Not a CCP Stop Is the step specifically designed to eliminate or reduce The likely occurrence of hazard to an acceptable level? Q1 Q2 Yes CCP No Could contamination with identified hazard(s) occur in Excess of acceptable level(s) or could these increase to unacceptable level?Q3 Yes No Not a CCP Stop Will a subsequent step eliminate identified hazard(s) or Reduce likely occurrence to acceptable level(s)? Q4
  • 38. Do preventive control measures exist? Yes No Is control at this step necessary for safety? Yes Modify step, process or product No Not a CCP Stop Is the step specifically designed to eliminate or reduce The likely occurrence of hazard to an acceptable level? Q1 Q2 Yes CCP No Could contamination with identified hazard(s) occur in Excess of acceptable level(s) or could these increase to unacceptable level?Q3 Yes No Not a CCP Stop Will a subsequent step eliminate identified hazard(s) or Reduce likely occurrence to acceptable level(s)? Q4 Yes Not a CCP Stop
  • 39. Do preventive control measures exist? Yes No Is control at this step necessary for safety? Yes Modify step, process or product No Not a CCP Stop Is the step specifically designed to eliminate or reduce The likely occurrence of hazard to an acceptable level? Q1 Q2 Yes CCP No Could contamination with identified hazard(s) occur in Excess of acceptable level(s) or could these increase to unacceptable level?Q3 Yes No Not a CCP Stop Will a subsequent step eliminate identified hazard(s) or Reduce likely occurrence to acceptable level(s)? Q4 Yes Not a CCP Stop No CCPDecisionTree