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1. HACCP

2. •What is HACCP?
•Why do we need it?
•How can we learn about HACCP?

3. 2
PRP-Pre-Requisite Programme
OPRP - Operational PreRequisite Programme
CCP - Critical Control Point
HACCP -Hazard Analysis & Critical Control Point
DÉFINITION OF FEW TERMES IN HACCP
Before knowing HACCP you should know
about………..

4. DEFINITION OF “ HAZARD “
“ the potential to cause harm”
In HACCP we are
looking at 5
classes of Hazards
Microbiological (pathogens, toxins)
Physical (foreign bodies)
Chemical (pesticides, cleaning agents)
Allergenic
Nutritional (Over- or Underdosing)

5. • CCP = ELIMINATES
• OPRP = CONTROLS
likeli-hood of introducing contamination &
prolifération
• PRP = ENSURES
hygienic production environment
PRP – OPRP – CCP RELATION TO PROCESS
- Upgraded GMPs
- Downgraded CCPs
- linked to control measure of safety- relevant CP in QMS

6. WHAT DIFFERENTIATES
PRPs OPRPs
 may contribute to reduction
of the hazard but may not
be essential for control
 apply to a specific
identified hazard
 apply to a specific product
or process
 are essential to reduce the
level of the hazard
Validation:
are we doing the right things?
(example: right past temp? Can metal detector achieve targets?)
Verification:
are we doing things right?
(example: requested temperature in pasteurization achieved over whole run, metal
detector functioning)
Verification and Validation
an OPRP from a PRP?

7. HACCP is a self-contained system that allows us to deal with
important food safety issues.
• It answers to key questions about the safety of the food that we
produce or handle:
What type of business am I involved in?
What are the food safety hazards associated with my business?
What causes those hazards?
How can i control or remove those hazards?
How can i show that i have controlled or removed those hazards?
What will i do if things go wrong?
WHAT IS HACCP?

8. • Hazard assessment of critical control points (HACCP) aims
the Identification, evaluation and control of steps that are
critical to product safety in the food technological chain.
HACCP enables the management of a cost-effective, Ongoing
food safety program.
HACCP is a tool to assess hazards and establish control systems that focus on
Prevention rather then end product testing

9. • Assemble HACCP team
• Describe product(s) and processes
• Identify intended use
• Construct flow diagram
• Onsite verification of flow diagram
5 preliminary steps
HOW IT WILL WORK ?????

10. 1.Assemble HACCP team
The HACCP team should be multidisciplinary in nature. It
includes supply chain department, production, engineering,
electrical, quality all departments to have a better ideas.

11. 2.PRODUCT DESCRIPTION
Full description of the food product. Include information
on what it contains,
How it is made or prepared, stored and distributed
The ‘intended use’ of the food product is the expected use
of the product by the end user or consumer..
e.g. IN NEXT SLIDE

13. 3. IDENTIFY INTENDED USE:
The intended use should be based on the expected uses of the product by the end user or consumer.
In specific cases, vulnerable groups of the population, e.g. institutional feeding, may have to be
considered.
Table 6: examples for intended use
Intended Use Examples Applicable for plant Y/N
Frozen Snacks  Ready-to-Cook (RTC) –
including Retail & Food Service

Further Processing  Food for further processing
(customer or consumer)


14. 4. PROCESS FLOW CHART
The flow diagram describes the process and shows the raw materials, processing steps,
packaging, storage and distribution stages.
Include the information needed for hazard analysis – such as information on micro–
organisms that may be associated with the product. Do they form spores or toxins? What is
their potential for survival and growth?
Other information includes: process times and temperatures, chemical usage, premises
conditions and hygienic design, cleaning, equipment characteristics, storage conditions, and
instructions for consumer use.

15. OK
Not Ok
1) Receipt, Weighing and Unloading ofherbs
a) QA
Rejection (Defects:
Yellowleaves,
damage, shrinked,
foreign particle
(plastic, mud, dead
insect, stone,metal
piece,thread)
10) Final Inspection
9) IQF Freezing at -18 C
7) Slicing as per
Specification/Customer Requirement
2) Grading/Cutting/Sorting
14) Storage in Freezer
room at -18 Deg Cen
13) Metal Detector (2mm Fe,
2.5mm Non Fe & 3mm SS )
11) Weighing & Packing
15) Dispatch in refrigerated
truck to customer.
Return to
vendor
Online Reject
Waste
Scrap
b) QA
6) Washing with 0.03% of Per acetic acid
g) QA
Rejection / Return
to the Supplier
Material
i) QA
Sorted Waste
Scrap
f) QA
4) Receipt ofUV
treated water
through UG Sump.
3) Receipt & Storage of
Per acetic acid.
5) Addition of per acetic
acid in UV treated water
in the washing tub.
OPRP-1
OPRP-2
Metal detector
rejected sent for
Scrap
CCP-1
CCP-2
Waste water /
rejected pieces
ETP
12) Receipt,
Inspection
and Storage
of Packing
d) QA
8) Feeding to IQF
If temp is not
meeting -15 to
-18 C
Not OkOK
e) QA
Not Ok
c) QA
h) QA
9a) Refreezing
Flow Chart for Herbs
EXAMPLE : PROCESS FLOW FOR FREEZING OF HERBS

16. • Check the flow diagram
• Compare the actual processes being carried out with the flow
diagram.
5. ON SITE VERIFICATION

17. 1. Conduct a hazard analysis
2. Determine critical control points
3. Establish critical limits
4. Establish monitoring procedures
5. Establish corrective actions
6. Establish recordkeeping and documentation procedures
7. Establish verification procedures
HOW HACCP WORKS – THE PRINCIPLES

19. CONDUCT HAZZARD ANALYSIS (PRINCIPLE 1)
Check that all potential microbiological, chemical and physical hazards have
been considered for each stage in the business – from raw materials to finished
product.
Physical
hazard
Chemical
hazard
Allergen

20. Hazard Assessment
Likely Hood of occurrence
Improbable 1 once a Year
Unlikely 4 Once a Month
Occasional 7 Once a Week
Frequently
1
0 Once a Day
Consequences/Severity
Minor/No Injuries 1 No Injuries
Medium 4 Small Injuries
High 7 Illness
Very High
1
0 Catastrophic
Control Measure scoring
No controls
1
0 Not documented /No Validation
Medium Controls 7 Documented but Not validated
High controls 4 Manual control and validated
Bench Mark 1
Auto/Robust control with
validated
For assessing significance of a
hazard score accordingly as
mentioned below
RISK MATRIX
SEVIERITY/
CONSEQUENCES
10 100 400 790 1000 10
CONTROL
7 49 196 343 490 7
4 16 64 112 160 4
1 1 4 7 10 1
1 4 7 10
FREQUENCY/LIKELYHOOD
Non Significant 1 - 160
Significant 161 - 490
Unacceptable Above 491
A multidisciplinary HACCP team
identifiers All the hazards that may
be reasonable expected to occur at
each step from Primary production,
processing, manufacture, and
distribution up to Consumption;
should identify which hazards are
such nature that their Elimination or
reduction to acceptable levels is
essential to the production Of safe
food; should evaluated likely
occurrence of hazards and severity
of Their adverse effects.

21. 2. DETERMINE CRITICAL CONTROL POINTS
After risk assessment the significant hazard was taken for the decision tree to make
correct decision whether it is OPRP or CCP. There may be more than one CCP at
which control is applied to address the same hazard. The determination of a CCP in
the HACCP system can be facilitated by the application of a decision tree) which
indicates a logic reasoning approach. Application of a decision tree should be
flexible, given whether the operation is for production, slaughter, processing,
storage, distribution or other. It should be used for guidance when determining
CCPs. Training in the application of the decision tree is recommended. If a hazard
has been identified at a step where control is necessary for safety, and no control
measure exists at that step, or any other, then the product or process should be
modified at that step, or at any earlier or later stage, to include a control measure.

22. DECISION TREE
1. Is control measure available for identified hazard
NO
YES
1.A is a control measure neccessary ??
not a CCP
STOP
modify the process
YES NO
2. Is the step specifically designed to eliminate the
hazard ??
YES
CCP stopNO
3. can contamination with identified hazard occur at
this stage ?
4. will the hazard be removed in subsequent stage ?
not a CCP
STOP
NO
YES
not a CCP
STOP
CCP
NO
YES

23. • Establish critical limits for each critical control point (where possible), how the
critical limits can be monitored, and decide on the action to take if these limits are
exceeded.
• Critical limits must be specified and validated for each Critical Control Point. In
some cases more than one critical limit will be elaborated at a particular step. Criteria
often used include measurements of temperature, time, moisture level, pH, Aw,
available chlorine, and sensory parameters such as visual appearance and texture.
Where HACCP guidance developed by experts has been used to establish the critical
limits, care should be taken to ensure that these limits fully apply to the specific
operation, product or groups of products under consideration. These critical limits
should be measurable.
3.ESTABLISH CRITICAL LIMITS STEPS

24. 4. ESTABLISH A MONITORING SYSTEM FOR EACH CCP, OPRP,
Monitoring is the scheduled measurement or observation of a CCP relative to its critical limits. The
monitoring procedures must be able to detect loss of control at the CCP. Further, monitoring should
ideally provide this information in time to make adjustments to ensure control of the process to prevent
violating the critical limits. Where possible, process adjustments should be made when monitoring
results indicate a trend towards loss of control at a CCP. The adjustments should be taken before a
deviation occurs. Data derived from monitoring must be evaluated by a designated person with
knowledge and authority to carry out corrective actions when indicated. If monitoring is not
continuous, then the amount or frequency of monitoring must be sufficient to guarantee the CCP is in
since the publication of the decision tree by Codex, its use has been implemented many times for
training purposes. E.g.
Process Step
& Critical
Control Point
Significant
Hazards
Critical Limits
for each
preventive
measure
Monitoring
Critical
What How
Frequenc
y
W
h
o

25. 5. ESTABLISH CORRECTIVE ACTIONS
The actions must ensure that the CCP has been brought under control. Actions taken must also
include proper disposition of the affected product. Deviation and product disposition procedures
must be documented in the HACCP record keeping. Establish procedures for verification.
Verification and auditing methods, procedures and tests, including random sampling and
analysis, can be used to determine if the HACCP system is working correctly. The
frequency of verification should be sufficient to confirm that the HACCP system is
working effectively. Verification should be carried out by someone other than the person
who is responsible for performing the monitoring and corrective actions. Where certain
verification activities cannot be performed in house, verification should be performed on
behalf of the business by external experts or qualified third parties. E.g.

26. 6. ESTABLISH VERIFICATION P OCEDURE
CONTROL MEASURE
CORRECTIVE ACTION RECORDS
VERIFICATI
ON
Product Temperature every
30 minutes between -15
degree cen to -18 deg cen
(IQF OPRP 2)
Product: Keep the product
Under hold and
immediately product to be
refreeze.
Process: Check for the
calibration of the
thermometer.
Check for the IQF and
back end process.
In process Record.
HOLD record.
Reprocess record.
Verification of
Log sheet & Re
process
Quantity.
Example:

27. • Decide the level of documentation and record keeping needed that will meet the needs of
the business to demonstrate the effectiveness of the food safety programme.
• Documentation may include:
• A plan of the layout of the food business
• Hazard worksheets
• Action plan worksheets
• Procedural documentation
• Checklists
• RM /in process /production log sheets or diaries
• Training programmes
• Maintenance
• Control points.
7.ESTABLISH RECORD KEEPING AND
DOCUMENTATION (PRINCIPLES 6 & 7)

28. TRAINING
Training of personnel in industry, government and academia in HACCP principles
and applications and increasing awareness of consumers are essential elements for
the effective implementation of HACCP. As an aid in developing specific training to
support a HACCP plan, working instructions and procedures should be developed
which define the tasks of the operating personnel to be stationed at each Critical
Control Point. Cooperation between primary producer, industry, trade groups,
consumer organizations, and responsible authorities is of vital important.
Opportunities should be provided for the joint training of industry and control
authorities to encourage and maintain a continuous dialogue and create a climate of
understanding in the practical application of HACCP.

29. • Establish a regular internal audit of the system, or parts of it
and review or modify it to accommodate new information or
problems as they are identified.
• The frequency of internal audits will depend on the complexity
of the operation and whether there are any changes or problems
experienced in the Process.
REVIEW AND AUDIT

30. 12 February 2019 NCE 30
Control measure
Clamp
Critical Limits
Opening 60cm +/- 5
GMP
Clamp Maintenance
Lion Feeding
Monitoring
Frequency of
Tail Wagging
Corrective Actions
Change clamp
Replace operator
Verification
Incidence
of "Headless bodies"
HACCP is so easy !

31. QUESTIONS ??