Hazard Analysis Critical Control Point

System that will enable you

to consistently serve food by
identifying and controlling
possible hazards through
the flow of food
 History of HACCP
The HACCP concept had its origin in the USA and stands for
"Hazard Analysis Critical Control Point".

Chronology of its development:

1958- Concept discussions at NASA (National Aeronautics

and Space Administration)
1959- Development of the HACCP concept to assure one
hundred percent safety of food to be used in space
1971- The HACCP system was published and documented
in the USA
1985- The National Academy of Science (NAS)
recommended the use of the system. Worldwide the
system became used and the FAO/WHO Codex
Alimentarius cited the system in the Codex
HACCP System
Cont.
HACCP system is the
idea that if significant
biological, chemical, or
physical hazards are
identified at specific
points within the flow of
food, they can be
prevented, eliminated
or reduced to safe levels
Cont.
HACCP system is the idea that if significant
biological, chemical, or physical hazards are
identified at specific points within the flow of
food, they can be prevented, eliminated or
reduced to safe levels.
HACCP system will help to do
the following:
Identify the food & procedures that are likely to
cause food-borne illness

Develop procedures that’ll reduce the risk of a

food-borne illness outbreak

Monitor procedures to keep food safe

Verify the food you serve is consistently safe

 Prerequisite Programs
Standard Operating Procedures (SOPs)
supports the HACCP plan and are the basic
operating conditions for producing safe food

They protect the food from contamination,

minimise microbial growth

Ensure the proper functioning of equipment

Prerequisite Programs may include:

Proper personal hygiene practices

Cleaning and sanitation programs
Proper facility-design practices
Equipment- maintenance programs
Supplier selection and specification
programs
 The HACCP Approach
The idea is to develop a plan that anticipates and
identifies places in the production process –known
as critical control points (CCP’s) where
contaminants might be introduced or other food
safety concerns can be identified

When critical limits are exceeded, corrective action

must be taken and documented

An independent third party should be used to verify

or validate the effectiveness of a HACCP plan
Cont.

A HACCP program is unique and specific

to each product in each processing facility
and requires a thorough analysis of each
phase of processing at that facility

The use of an individual trained in

developing
HACCP programs is recommended
Component of a Food Safety System

• Overview
• After prerequisite programs ( GAP’s,
SOP’s, and GMP’s) have been established,
you now have a frame work for HACCP
• HACCP provides a systematic approach to
identify, assess and control the risk of
biological, chemical, and physical hazards
• HACCP is a living, evolving system
Example of a HACCP program for Almond Handlers
At the moment, almond handlers in the U.S.A.
are not required under US law to implement
HACCP procedures in their
operations

However, handlers recognise the benefits of

HACCP practices to their customers and
integrate them into their production routines
Developing a HACCP Plan in an
Almond Processing Facility
A series of steps must be completed before a
HACCP plan can be developed:
1- Assemble a HACCP team
2- Provide a general description of the food
product, its processing, distribution, and storage
methods (flow chart is very helpful for this step)
3- Compile information on the customer
4- Identify the intended use by the typical
consumer
The Seven Principles of HACCP
1. Conduct a Hazard Analysis

2. Determine Critical Control Points

3. Establish Critical Limits

4. Establish Monitoring Procedures

5. Establish Corrective Actions

6. Establish Verification Procedures

7. Establish Record Keeping and Documentation

Procedures
1. Conduct a Hazard Analysis
Assess the food safety hazards that are reasonably
likely to occur and that must be controlled for
almonds or almond products based upon
experience, illness data, scientific reports, or other
information
Hazards can be biological, chemical, or physical
Use the process flow chart
Summarize the information in a Hazard Analysis
Worksheet
To perform a hazard analysis, need to consider the
following:

Ingredients used in
menu’s

Equipment & process

Customers you serve

Key steps to follow when performing a hazard analysis

1. Identify potential food hazards

2. Determine where hazards can occur in the flow
of food
3. Group food by how it is processed in your
establishment
4. Identify your customers
 Identify potential food hazards

Identify any food that may

become contaminated if
handled incorrectly at any
step in its flow

Potentially hazardous food

on a menu may include
cheese, sour cream,
chicken, beef, scallops,
shrimps and pork
Determine where hazards can occur in the flow of
food
For each item on the list of hazardous food, identify the steps
in its flow through the establishment
For each step , identify any potentially adverse conditions the
food might be exposed to & consider how the equipment in
operation might affect the food

Eg: Steps in the chicken’s flow through the restaurant include

receiving, storage, preparation, cooking and service. There
are potentially adverse conditions at each step. During
preparation, those conditions include thawing the chicken at
room temp. and preparing the chicken on the same cutting
board used to prepare other food (cross-contamination)
Group food by how it is processed in your establishment
Food prepared & served without
cooking ( salads, raw oysters,cheese
& sandwich meats

Hazards' involve contamination by

employees, equipment, or other
food
Cont.
Food prepared and
cooked for immediate
Service like hamburgers,
scrambled eggs, and hot
sandwiches.
Hazards involve improper
cooking, which may not
eliminate the biological
hazard
Cont.

Food prepared, cooked,

Held, cooled, reheated
and served like soups,
sauces & gravies

Hazards may occur at

many points
Identify the customers
Particularly important if
the customers are very
young, elderly or people
who are ill or
immuno- compromised
2. Determine Critical Control Points
All hazards identified in step #1 (Hazard Analysis)
must be controlled at some point in the process

Identify the Critical Control Points (CCP’s) in the

process that will help you eliminate or minimize
the hazards (Decision Tree Flowchart can help in
this step)

The number of CCP’s identified depends on the

product being produced, the ingredients (if any)
used, and the processing methods employed
3. Establish Critical Limits
 Critical limits are tolerances beyond which the
related CCP is out of control and a potential hazard
can exist
 A critical limit is a maximum and/or minimum
value at which control must be maintained for the
CCP.
 CCP limits cannot be average values or ranges of
values
 Critical limits must be validated by the processor
or be supported by scientific data or literature
When establishing critical limits,
it must be:
Measurable ( time or temperature)
Based on scientific data, food regulation
( such as the FDA Food Code) and expert
advice
Appropriate for the food and equipment
when prepared under normal conditions and
specific to the establishment
Clear and easy to follow
4. Establish Monitoring Procedures
 Monitoring is a scheduled observation of a CCP
and its limits
 The procedure must be reliable enough and
performed often enough to ensure that the
hazard is under control
 Determine what will be monitored, how it will be
monitored, when it will be monitored, and who
will perform the monitoring
 HACCP Plan Form is needed for this step
To develop a successful monitoring program, need to focus on
each CCP & establish clear directions that specify the following:

1. How to monitor the CCP. This depends on the critical limits you have
established and might include measuring time, temperature, PH, oxygen, water
activity

2. When and how often to monitor the CCP. Continuous monitoring is

preferable, but not always possible. Regular monitoring intervals should be determined
based on the normal conditions and depend on volume, equipment and procedures

3. Who will monitor the CCP. Assign responsibility to a specific employee/ or

position and make sure that person is trained properly

4. Equipment, materials, or tools needed to monitor the CCP. Provide

employees with the proper tools to make the task easy
5. Establish Corrective Actions
 When there is deviation from an established CCP,
corrective actions must be taken to prevent a
product that may be unsafe from reaching
consumers

 Corrective action must include correcting the

problem and putting the process back in control,
and placing the product on hold pending
evaluation of safety

 Corrective action steps taken must be documented

6.Establish Verification Proceed
 Reassessment of the HACCP plan - Reassess the
adequacy of the HACCP plan whenever any changes
occur that could affect the hazard analysis or alter the
HACCP plan in any way, or at least annually

 Changes may include: raw materials or sourcing of raw

materials, handling methods or systems, finished product
distribution systems, or the intended use or consumers of
the finished product

 The HACCP plan must be modified whenever a

reassessment reveals that the plan is no longer adequate
Cont.
Ongoing verification activities – Ongoing
verification activities include a review of
any consumer complaints to determine
whether they relate to the performance of
CCP’s or reveal the existence of
unidentified CCP’s, the calibration of
process-monitoring instruments, or in
process testing.
6.Establish Verification Procedures
 Records review - A review, including signing
and dating, by an individual who has been trained
in accordance with appropriate HAACP practices,
including:
1. The monitoring of critical control points
2. Ensuring that the records are complete and that
documented values are within the critical limits
3.The taking of corrective actions
7.Establish Record Keeping and Documentation
Procedures

 The HACCP plan must be on file at the

facility
 It must include documentation relating to
CCP’s and any action on deviations and/or
disposition of product
Cont.
Types of records could include:
a. Processing - Records of all monitored CCP’s
b. Deviation - Records of any deviations from
the HACCP plan
c. Ingredients - Supplier qualification, ingredient
certification, audit records
d. Product safety - Records on safe shelf-life,
microbiological testing, microbiological challenge
studies
e. Storage and distribution - Traceability data
f. Validation studies
Potentially Hazardous Food
(a) "Potentially hazardous food" means a food that is
natural or synthetic and that requires temperature control
because it is in a form capable of supporting:

(i) The rapid and progressive growth of infectious or

toxigenic microorganisms;

(ii) The growth and toxin production of

Clostridium botulinum; or

(iii) In raw shell eggs, the growth of Salmonella

enteritidis.
(b) "Potentially hazardous food" includes an
animal food (a food of animal origin) that is
raw or heat-treated; a food of plant origin
that is heat-treated or consists of raw seed
sprouts; cut melons; and garlic and oil
mixtures that are not acidified or otherwise
modified at a food processing plant in a way
that results in mixtures that do not support
growth
(c) "Potentially hazardous food" does not include:
(i) An air-cooled hard-boiled egg with shell intact;
(ii) A food with an aw value of 0.85 or less;
(iii) A food with a pH level of 4.6 or below when measured at 24oC (75oF);
(iv) A food, in an unopened hermetically sealed container, that is commercially

 processed to achieve and maintain commercial sterility under conditions of

nonrefrigerated storage and distribution; and
 (v) A food for which laboratory evidence demonstrates that the rapid and
 progressive growth of infectious or toxigenic microorganisms or the growth of
 S. enteritidis in eggs or C. botulinum can not occur, such as a food that has an
A food that may contain an infectious or
toxigenic microorganism or chemical or
physical contaminant at a level sufficient to
cause illness, but that does not support the
growth of microorganisms
10 Rules of Safe Food Handling

1. Strict personal hygiene is required from all employees.

2. Clean & sanitize food contact surfaces and equipment before and
after every use, after any interruption in the preparation and service
process, and at least every four hours during continual use.

3. Identify all potentially hazardous foods (high in protein or

carbohydrates) and document your food handling procedures. Make
these written procedures part of employee training, everyday tasks
and regular self - inspections.

4. Purchase food and other supplies only from reputable, approved

suppliers.
Cont.
5. Store raw foods away from prepared and ready-to-eat foods. 6” above the floor and 2”
away from walls. Avoid cross-contamination from hands, equipment and utensils.

6. Prepare food, observing the rules for time and temperature control. Thaw frozen
foods in a refrigerated unit. Batch process all potentially hazardous food within one hour
at room temperature then re-refrigerate if necessary before cooking. (Maximum 4 hours
in total time between 4°C/40°F and 60°C/140°F).

7. Cook or heat process foods to above the recommended minimum internal

temperature. Use an industry approved, accurate thermometer to confirm internal
temperature.

8. Hold – keeping hot foods hot and cold foods cold. Prepare and hold hot foods at
60ºC/140ºF or hotter and hold cold foods at 4ºC/40ºF or colder.

9. Cool hot foods to 4ºC/40ºF or colder within four hours, then wrap, label, date and
store in a refrigerated unit after food is cooled.

10. Reheat food to a minimum internal temperature of 74ºC/165ºF for at least 15 seconds,
within 2 hours.