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Module3 HACCP, GMP and SSOP
This document provides an overview of Hazard Analysis and Critical Control Point (HACCP) programs. It discusses the history and development of HACCP from the 1960s to its current use in various sectors of the food industry. The key aspects of HACCP covered are the 7 principles, with an emphasis on monitoring critical control points using time/temperature devices and separation methods, and maintaining thorough record keeping of monitoring data.
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Module3 HACCP, GMP and SSOP
- 1. 1 Module 3: The Heart of Hazard Analysis Critical Control Point (HACCP) Programs
- 2. 2 Food Safetyand HACCP • The purpose of HACCP is to help ensure the production of safe food • The goal of HACCP is to prevent and/or minimize risks associated with biological, chemical, and physical hazards... to acceptable levels • It is based on PREVENTION rather than detection of hazards
- 3. 3 History ofHACCP • Pioneered in the 1960’s • First used for the space program - Pillsbury and NASA • Adopted by many food processors and the U.S. government
- 4. 4 Uses ofHACCP? A “farm-to-the-fork approach” • On-farm agriculture • Transportation • Food preparation & handling • Food processing Meat and poultry regulations Seafood regulations • Food service • Consumer handling & use
- 5. 5 HACCP Regulations • USDA - HACCP regulations for meat and poultry slaughter and processing: “Pathogen Reduction Act” • FDA - HACCP regulations for inspection of seafood products • FDA requirements for fruit juice that is not heat-processed
- 6. 6 Steps ofHACCP 1. Organize a HACCP team 2. Describe the product, ingredients, and the process 3. Develop a HACCP flow diagram for each product 4. Perform the 7 principles of HACCP 5. Train employees how to implement HACCP properly
- 7. 7 HACCP Principles 1. Identify hazards 2. Determine Critical Control Points (CCPs) 3. Determine safety limits for CCPs 4. Monitor CCPs 5. Corrective action 6. Record data 7. Verify that the system is working
- 8. 8 The Heartof HACCP Monitoring CCPs: • Time/Temperature devices Thermometers • Separation devices filters, screens
- 9. 9 The Heartof HACCP Record Keeping: • Who records the data? • How often? • What do you do if the data is not what it should be? • Who checks the data?
- 10. 10 Examples ofHACCP Implementation Of HACCP
- 11.
Editor's Notes
- #2 Module 3 is intended to teach the participant the following objectives: Introduce the HACCP concept Identify HACCP regulations Show how HACCP programs are developed and implemented Focus on monitoring procedures and record-keeping procedures
- #3 HACCP is a program that the food industry uses to help ensure that the production and handling of foods (from the farm to the consumer’s plate) is safe to consume. HACCP works by preventing and eliminating biological, chemical, and physical hazards in finished food products. Two main questions are asked: What types of hazards are expected to be present? How can I control these hazards so the food is safe to consume? HACCP is based on controlling the processing and handling of food in order to control hazards. HACCP is not based on detection of food hazards.
- #4 HACCP began in the 1960’s. HACCP was developed primarily by the Pillsbury Food Company and NASA for foods that were sent into space with the astronauts. The goal of this project was to provide a program that could nearly guarantee that a food does not contain a biological, chemical, or physical hazard that could cause illness. Soon after people were sent into space, HACCP was implemented in the food industry because it made good sense. HACCP continues to be the most effective and manageable program that the food industry can use to control food safety hazards.
- #5 HACCP has been called a “farm-to-the-fork” approach and has been used to control hazards in the entire food production chain. In the past, HACCP has been used mainly by food processors for shelf-stable foods (canned foods) and other foods that do not require cooking (lunch meat). Today, the development and implementation of HACCP programs is mandatory in meat, poultry, and seafood slaughter and processing operations. In the future, HACCP is expected to be used on the farm, in retail food establishments, and in the homes of consumers.
- #6 Within the past few years, development and implementation of HACCP has been made mandatory for meat and poultry operations and in seafood processing operations. The USDA is responsible for overseeing the “Pathogen Reduction Act” for meat and poultry slaughter and processing plants. The FDA is responsible for overseeing the Seafood HACCP regulations. Mandatory HACCP is expected in the fruit and vegetable industry in the next couple of years. There are currently special requirements for fruit juices that are not heat-processed.
- #7 Development and implementation of HACCP is not an easy process. The first step in the process is to develop a HACCP team. A team may consist of quality assurance, quality control, maintenance, purchasers, line workers, plant management, etc. The next step is to describe the product that you make, including all ingredients and processes. Following the description of the product, a flow diagram picture of the process flow is generated. Start the long process of developing and implementing the seven principles of HACCP. This may take several weeks or months to complete. Lastly (and most importantly) is education and training. In order for HACCP to work, employees need to know how and why they need to do certain tasks to control food safety.
- #8 The HACCP team will address seven principles: 1. Identify hazards: biological, chemical and physical hazards in the product and from the process. 2. Determine Critical Control Points (CCPs). Where are the points in the process where we can control the hazards? 3. Determine safety limits for CCPs: Specifically, how can we assure that these hazards are under control? Control is usually done through time and temperature or through a separation process. 4. Monitor CCPs: You need to know what and how to monitor the CCP limits. 5. Corrective action: What should be done if you do not meet the safety limits? Discard the product? Re-process the food? 6. Record data: How should the data be recorded? Who should do it? How often should it be done? 7. Verify that the system is working. Someone on the HACCP team needs to periodically evaluate the whole system to be sure that it is working properly. The most important parts of HACCP that you will be involved with is monitoring, corrective action, and record keeping procedures. This is the “heart” of HACCP.
- #9 In nearly all situations, the safety limits for the CCPs will be temperature and time. For example, a CCP limit might be “cooking to at least 165°F for at least 1 minute.” Another CCP limit may be “cool the chicken to less than 40°F in less than two hours.” There are several different ways that temperature and time can be measured. Provide examples specific to your operation. Physical hazards are usually removed by a separation process. There are several different ways to separate hazards from food. Provide examples specific to your plant.
- #10 Records are important because they show that you have done all that you could to ensure safety of your food product. They are essentially your “receipt.” It is important to know who should record the data. Normally the data is recorded automatically by a computer or other instrument, but monitoring can also be done by food workers. Someone needs to be responsible for recording the data. WHO records the data, HOW OFTEN the data is recorded, and the CORRECTIVE ACTION to be taken will be outlined in the HACCP plan. At the end of the processing day, all the HACCP records will be reviewed by management to ensure that the records are complete.
- #11 Provide examples of HACCP implementation specific to your plant.
- #12 Provide examples of HACCP implementation specific to your plant.