HACCP is a risk-based food safety system used by the food industry to prevent foodborne hazards. It involves identifying potential hazards at specific points in the food production process and establishing controls to prevent, eliminate, or reduce hazards to safe levels. The key principles of HACCP include conducting a hazard analysis, determining critical control points, establishing critical limits, monitoring procedures, corrective actions, verification, and documentation. The document provides details on each step of implementing a HACCP system from assembling a HACCP team to establishing record keeping procedures.

1. HACCP
AWARENESS

2. HACCP/HARA
HACCP is the risk-management system used by the
food industry. HACCP provides a systematic
preventive approach to food safety from various types
of hazards in production processes that can cause the
finished product to be unsafe.
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HACCP – Hazard Analysis and Critical Control Point.
HARA – Hazard Analysis and Risk Assessment.

3. HACCP Philosophy
The HACCP philosophy simply states that biological,
chemical, or physical hazards, at certain points in the flow
of food, can be
• Prevented
• Removed
• Reduced to safe levels.
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4. Origin of HACCP
The concept was developed in the 1960s by the Pillsbury Company, while working with
NASA and the US Army Laboratories to provide safe food for space expeditions. The
limitations of end product testing became evident to those who were trying to provide
the safest possible food products. In order to ensure that food used for space missions
would be safe, almost all the product manufactured would need to be tested, leaving very
little for actual use. A new approach was needed. The practical and proactive system of
HACCP evolved from these efforts to understand and control food safety failures.
HACCP has been widely used by industry since the late 1970s, and is now internationally
recognized as the best system for ensuring food safety. It is endorsed by the Food and
Agricultural Organization (FAO) and the World Health Organization (WHO) of the United
Nations, and, in the United States.
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5. Reason for HACCP
implementation
1. The proportion of the population who have increased susceptibility to foodborne
illness is increasing, for example, the elderly community in many parts of the
world (including Japan and many western countries), the number of
immunocompromised Consumers are increasing.
2. Changing lifestyles have resulted in a number of changes to our eating habits:
(a) More people now regularly eat out or snack on the move, which has led to an
increased demand for food service establishments of varying standards.
(b) Many people work outside the home and rely on processed foods for fast meal
preparation; this has meant that knowledge of how to handle and prepare foods
has decreased in recent years.
(c) Increased mass production of foods has increased the potential for larger numbers of
consumers to be affected in the event of an outbreak of foodborne disease.
(d) Increased tourism has meant that people are exposed to foodborne hazards from
other areas.
3. Global sourcing of finished products
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6. HACCP
Principles
• 1. Conduct a Hazard Analysis
• 2. Determine the Critical Control
points (CCPs)
• 3. Establish Target Levels and Critical
Limits
• 4. Establish System(s) to monitoring
CCPs
• 5. Establish an appropriate
Corrective Action Plan for each CCP.
• 6. Establish Procedures to verify that
the HACCP system is working effectively
• 7. Establish Documentation
concerning all procedures and keep
their records application.
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7. Steps for
Implementing
HACCP
Institute of Good Manufacturing Practices India
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Step 1 Assemble
HACCP team
Step 2 Describe
Product
Step 3 Identify
Intended Use
Step 4 Construct
Flow Diagram
Step 5 On-site
Confirmation of
Flow Diagram
Step 6 List all
Potential Hazards,
Conduct a Hazard
Analysis, and Consider
Control Measures
Step 7 Determine
CCPs
Step 8 Establish
Critical Limits for
each CCP
Step 9 Establish a
Monitoring System
for each CCP
Step 10 Establish
Corrective Actions
Step 11 Establish
Verification
Procedures
Step 12 Establish
Documentation
and Record
Keeping

8. Institute of Good Manufacturing Practices India www.ffsqindia.org 8
Assemble HACCP team
Describe product
Identify intended use
Construct flow diagram
On-site confirmation of
flow diagram
List all potential hazards,
conduct hazard analysis
 Ensure availability of all
required expertise -
multidisciplinary team
 Scope of HACCP plan
decided
Assemble HACCP team

9. HACCP
Team
Example

10. Assemble HACCP team
Describe product
Identify intended use
Construct flow diagram
On-site confirmation of
flow diagram
List all potential hazards,
conduct hazard analysis
 A full description of the
product should be prepared
 All relevant safety
information should be
reported including:
composition, physical/
chemical characteristics,
packaging, storage
conditions, etc.
Desirable Product

11. Describe Product
• Key parameters would include:
• • Composition (e.g. recipe, raw materials/ingredients and their
origin)
• • Chemical and physical structure/properties (e.g. Aw, pH, emulsion)
• • Processing (e.g. has product been heated and to what extent)
and/or other preservation methods (e.g. brining, smoking)
• • Packaging system/materials (e.g. aseptic packaging, glass bottles,
vacuum)
• • Storage and distribution conditions (e.g. product to be kept frozen
or chilled)
• • Required shelf life under prescribed conditions (e.g. stated “use
by” date or “best-before”date)
• • Instructions for product use (e.g. storage, handling and cooking
instructions).
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12. Product Description
Example
• Product description
• Cook-in sauces of neutral pH.
• Ingredients: water, modified maize starch, skimmed milk powder, whey powder,
flour, butter, salt, sugar, white pepper, colour.
• Specific recipes will include potential allergens, e.g. celery and mustard
• Processing: The sauces are in-pack retorted to be commercially sterile using rotary
steam-heated water immersion batch retorts.
• Packaging: 450 ml Food grade glass jar with metal twist open closure.
• Wrap around paper label.
• Ink jet coded lot identification and date/time of production.
• Six jars packed per shrink-wrapped cardboard tray.
• Stacked ten high per pallet.
• No stacking of pallets.
• Storage/shelf life: Stated 12 month best-before shelf-life from date of production.
• Ambient shelf stable.
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13. Assemble HACCP team
Describe product
Identify intended use
Construct flow diagram
On-site confirmation of
flow diagram
List all potential hazards,
conduct hazard analysis
 Specify expected use of the
product
 Where appropriate consider
vulnerable groups of the
population
Identify Intended Use

14. Intended Use Example
• Cook-in sauces for use with poultry, meat and fish
as relevant. Meals to be cooked in the oven by the
customer/consumer.
• Intended for the general population, use of
potential allergens in the recipe clearly identified on
the label.
• Corrugation- Used in secondary packaging of pillow
packing of chips, Biscuit.
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15. Slide 15
Construct Flow Diagram
Assemble HACCP team
Describe product
Identify intended use
Construct flow diagram
On-site confirmation of
flow diagram
List all potential hazards,
conduct hazard analysis
 Flow diagram for process
should be constructed by
HACCP team
 The flow diagram should
cover all steps in the
operation
 HACCP team should confirm
the processing operation
against the flow chart
Include important data such
as time and temperature.

16. Flow
Diagram
Example
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17.  To Check the correctness of
information.
 To check whether important
information was not
overlooked.
 To check during all periods of
operation and cleaning , but
also during idle hours.
 Discuss practices with
operators.
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On site Confirmation of Flow
Diagram
Assemble HACCP team
Describe product
Identify intended use
Construct flow diagram
On-site confirmation of
flow diagram
List all potential
hazards, conduct
hazard analysis

18. PLANT
SCHEMATIC
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• Construct a plant schematic or floor plan of the
facility, identifying all equipment and rooms.
• Indicate on the floor plan the flow of product and
people through the facility.
• On the floor plan, identify all potential cross-
contamination points, whether biological, chemical or
physical. Some examples include:
- raw and cooked crossover
- allergen products versus non-allergens
- inedible materials and finished product crossover
- crossover of personnel from incompatible areas

19. Plant
Schematic
Example
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20. Slide 20
Module 4.2 – Codex Guidelines for the
Application of HACCP
List All Potential Hazards and Conduct
Hazard Analysis
Assemble HACCP team
Describe product
Identify intended use
Construct flow diagram
On-site confirmation of
flow diagram
List all potential hazards,
conduct hazard analysis
 HACCP team to list all
hazards reasonably
expected to occur at
each step in the food
chain
 Assess hazards to
determine which should
be included in HACCP
plan
 Consider what control
measures could be
applied for each hazard

21. Listing of Hazards
List all hazards associated with each step,
conduct Hazard analysis, consider any
measures to control identified hazards.
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22. Physical Hazards

23. Physical Hazards and
Common Sources
Material Sources
• Glass Bottles, jars, light
fixtures, thermometers,
gauge covers
• Metal Machinery,
agricultural fields ,staples,
buildings, employees

24. Types of
Chemical
Hazards
I. Naturally
Occuring Chemicals
II. Intentionally
Added Chemicals
III. Unintentionally
Added Chemicals

25. Intentionally Added

26. Unintentionally Added

27. Allergens
1. Milk
2. Eggs
3. Peanuts
4. Tree nuts, like walnuts, almonds etc.
5. Soy
6. Wheat and other grains with gluten,
including barley, rye, and oats
7. Fish
8. Shellfish

28. Biological Hazards
Biological Hazards
I. Bacteria
A. Sporeformers
Clostridium botulinum
II. Viruses
Hepatitis A and E
Rotavirus
III. Parasitic Protozoa and
Worms

29. Hazard Analysis
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30. Scoring System
Severity of hazard
1 = Minor injury to consumer
2 = Consumer in hospital/Serious short-term injury
3 = Death of consumer/Long-term illness leading to death
Likelihood of hazard
1 = Possibly could occur (unlikely to occur, but might)
2 = Probably could occur (likely to occur at some time but no history of
it occurring)
3 = Definitely will occur (at some time it is going to happen or has
occurred in the past)
Significance of hazards -
In this example any hazard with a total score of three or more is
deemed to be a significant hazard.
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31. Qualitative :Risk analysis - probability
• A simple qualitative tool:
P – Probability of Occurrence
Likely to occur
High
May occur
Medium
Unlikely to occur
Low
Very unlikely to occur
Remote

32. Risk analysis - severity
• A simple qualitative tool:
S – severity level if event occurs
Serious GMP non-compliance
Patient injury possible
Critical
Significant GMP non-compliance
Impact on patient possible
Moderate
Minor GMP non-compliance
No patient impact
Minor

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34. CCP Decision Tree
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35. Determining Critical Control Points
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36. Control Measure
Control measures are those actions and/or activities
that are required to prevent, eliminate or reduce the
occurrence of hazards to acceptable levels.
• More than one control measure may be required to effectively
manage a specific hazard. For example, introduction of metal
from damaged equipment could be managed by planned
preventative maintenance, cleaning procedures, and training of
staff in relevant procedures, together with well designed
equipment and correct set up.
• One control measure may manage more than one hazard. For
example, pasteurisation can be an effective control for reducing
the numbers of both Salmonella and Listeria to an acceptable
level.
• Control measures are not necessarily carried out at the same
process step at which the hazard arises. For example, the
presence of pathogens in a raw material or introduction during
subsequent preparation may be controlled by effective cooking
at a later step in the process.
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37. Critical
limit
• A criterion that
separates acceptability
from unacceptability
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38. Examples of
Critical Limits
Critical Limits can be :
 pH
 Water Activity
 Maximum Residue Limits
 Level of Cleanliness
 Levels of Chlorine
 Limits in microbiological Criteria
 Temperature
 Time
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39. Critical Limit, Target Limit ,
Tolerance
In addition to a critical limit
some businesses may set target levels.
Critical Limit A criterion which separates
acceptability (safe) from unacceptability
(potentially unsafe).
Target Level A predetermined value for
the control measure which has been shown
to eliminate a hazard at a CCP.
Tolerance The values between the
target level and the critical limit.
Deviation Failure to meet a critical
limit.
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40. Establish Monitoring System
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Monitoring serves three main purposes:
First,it tells you when there’s a problem at a CCP, and control
has been temporarily lost. (This allows you to take
corrective actions right away.)
Second,it tracks the system’s operation and can help identify
dangerous trends that could lead to a loss of control. (This
allows you to take preventive action to bring the process
back into control before it goes beyond the critical limits.)
Third,it provides written documentation of your compliance
with the HACCP regulation. (This information can be used
to confirm that your HACCP plan is in place and working
right.)
Specify in your monitoring procedures, every important
detail about...
• Who will do the monitoring
• What is being monitored
• When it is done, and
• How it is done

41. Corrective action
Any action to be taken
when the results of
monitoring at the CCP
indicate a loss of control
Corrective Actions
should ensure that
only safe products
reach the consumer.
Establish the corrective action
Establish the corrective action to be taken when
monitoring indicates that a particular CCP is not
under control

42. Establish Verification
Procedures
• Verification Procedures are
intended to check the
effectiveness of the HACCP
system
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43. Verification The following verification
procedures are undertaken:
• Audits of the HACCP system
- Internal: Carried out by the manufacturer on its own operations, e.g.
of PRPS, Operational PRPs and CCPs at least annually
- External: Review of suppliers as part of Approved Supplier
procedures
- Third party: Review the results of audits by Certification Bodies
• Investigate and trend :
- Customer complaints,
- Monitoring results
- Corrective actions
- Process deviations
- Product disposals
• Raw material and finished product testing,
• Incubation testing
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• Servicing and calibration of
significant equipment and
instrumentation
(e.g.:
- Fillers
- Retorts,
- Metal detectors,
- X-ray machines
• Review of the HACCP system

44. HACCP Plan
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45. Establish
Record Keeping
and
Documentation
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Minutes of HACCP study meetings,
decisions made and their reasons.
Records of monitoring
Records of Verification
Records of Deviations and
Corrective Actions
Records of modifications to HACCP
Plan