1. HACCP
HACCP
What is it?

2. What is HACCP?
HACCP
Hazard Analysis Critical Control
Points
• A powerful safety management technique
• Structured preventative system
• Promotes safety through hazard identification and
control

3. The CRP Triangle

4. How HACCP works - the 12 Codex steps
12.Establish documentation & record keeping
11. Establish verification procedures
10. Establish corrective actions
9. Establish monitoring system for CCP’s
8. Establish critical limits for CCP’s
7. Determine Critical Control Points (CCP’s)
6.List hazards,conduct hazard analysis,consider control measures
5. On-site confirmation of flow diagram
4. Construct flow diagram
3. Identify intended use
2. Describe product
1. Assemble HACCP Team

5. What is a Hazard?
A HAZARD is...
A property which may cause a
product to be unsafe for
consumption

6. Benefits of HACCP...
5 Systematic approach
5 Preventative system
5 Resources are used effectively
5 Documentary system builds and continually
refreshes ‘due diligence’ in plant
5 Internationally accepted system
5 Strengthens Quality Management systems
5 Demonstrates and reinforces management
commitment and involvement

7. The HACCP team
• Process line representative(s) (e.g. Specialist/
SET)
• Packaging representative (e.g. Specialist/SET)
• Support services
• Production management representative (e.g.
FLM)
• CRP Project Leader
(site Food Safety Manager or Food Safety
SET)

8. HACCP project implementation

9. Sample Process Flowchart...

10. What is a Hazard?
biological
chemical
physical
property or condition of food with the potential
to cause an adverse health effect” (Codex
1997)

11. Step 1
What does Codex say
about 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”

12. Hazard determination
Questions to be answered for each potential hazard at each process
step :
Presence of potential hazard
Presence of potential in line or environment
hazard in raw material probable?
probable?
YES NO NO YES
NO HAZARD
*
Unacceptable level, Unacceptable
survival, persistence or YES contamination at this step
increase at this step probable?
probable?
YES NO HAZARD
YES ** *
Reduction, if any, at a SIGNIFICA
further step adequate? NT
NO
HAZARD
* = Not a hazard at this step
** = A CCP or an SCP at this step

13. Risk Assessment Model...
FOOD SAFETY RISK ASSESSMENT
Severity
Severity if
Severity of affect if Hazard Occurs Multiplier
controls fail
Little Damage Mild disappointment to the consumer. May lead to a complaint, no business interruption. Minor consequences. 1
Very minor medical treatment, (for example a broken tooth). Consumer disappointed and likely to lead to a complaint to the
Damage
Company. 2
Serious Illness at home. Medical treatment not necessary. A disappointed consumer very likely to lead to a complaint to a regulatory
Damage authority. 3
Very Serious
Damage
Illness at home with medical treatment necessary. A very disappointed consumer. A significant risk of proscecution. 4
Disaster Hospitalization required. Significant risk of proscecution. Media coverage. Intervention by ‘Crisis management team’. Damage to
Serious Illness ‘branded ‘ image. 5
Catastrophic Death. Top level ‘crisis management’ Certain risk of proscecution. Destruction of ‘brand’ 6
Frequency
Probability of
hazard occurring Frequency That Hazard Could Occur Multiplier
if process fails
Almost Impossible Less than once a year, no history of it occurring 1
Un-Likely Very occasional, has been known to occur 2
Small Risk Isolated event that result after manual operations 3
Likely Product or operational factors that can be expected to be present 4
Certain Product or operational factors that the process is expected to control 5

14. Risk Assessment Model...
FOOD SAFETY RISK ASSESSMENT MATRIX
FREQUENCY SEVERITY
ALMOST UNLIKELY SMALL RISK LIKELY CERTAIN
IMPOSSIBLE
(1) (2) (3) (4) (5)
LITTLE
1 2 3 4 5 DAMAGE
(1)
2 4 6 8 10 DAMAGE
(2)
SERIOUS
3 6 9 12 15 DAMAGE
(3)
4 8 12 16 20 VERY SERIOUS
DAMAGE
(4)
5 10 15 20 25 DISASTER
(5)
6 12 18 24 30 CATASTROPHIC
(6)

15. Risk Assessment Model...
GUIDELINE ACTIONS FROM RISK ASSESSMENT TO DETERMINE CONTROL MEASURES
1–5 Probably controlled by a GMP.
Check nature of problem against existing pre-requisite programmes
Example might be an AIB
‘SERIOUS’ observation
6–9 A consumer issue. With some risk to consumer safety.
Certainly needs control by a GMP, could be a Specific Control Point
Example might be an AIB
‘MAJOR’ observation
10 – 16 Use Codex decision tree for microbiological hazards.
Implications for corrective action procedures. Report/resolve and record at
next HACCP review. Definitely either a GMP or an SCP
Example might be an AIB
‘UNSATISFACTORY’
observation
16 + Critical control point (CCP). Use Codex decision tree for microbiological hazards.
Failure may result in food poisoning incidents.
Initiates special HACCP review. External HACCP audit.
(F x S = RISK)
!!!! Make a note of limitations of seeing cost as a risk assessment factor.

16. What is a Control?
Acontrol: is a preventative measure which
• eliminates a hazard, or
• prevents a hazard, or
• reduces a hazard to an acceptable level

17. The next step...
7. Determine Critical Control Points (CCP’s)
6.List hazards,conduct hazard analysis,consider control measures
5. On-site confirmation of flow diagram
4. Construct flow diagram
3. Identify intended use
2. Describe product
1. Assemble HACCP Team

18. Types of Control Points...
Specific Control Points (SCP’s) - these are
control points which relate to line-specific
hazards
Critical Control Points (CCP’s) - these are
common to all of our products and processes
and are established in our generic HACCP
model :
-Metal detection
– Promotional inserts
– Allergen Control

19. Next steps...
10. Establish corrective actions
9. Establish monitoring system for CCP’s
8. Establish critical limits for CCP’s
7. Determine Critical Control Points (CCP’s)
6.List hazards, conduct hazard analysis, consider control measures
5. On-site confirmation of flow diagram
4. Construct flow diagram
3. Identify intended use
2. Describe product
1. Assemble HACCP Team

20. Critical limits
• Maximum values should never be exceeded, so
often target values are established
• The limits must relate to the control measures
identified
• Decisions on what constitutes a harmful level
requires technical food safety knowledge and
sometimes may be a current legal requirement

21. Critical limits
• Critical limits must be exact and monitorable
• A numerical limit is not necessarily required in
every case
• Flexibility should not compromise food safety
• It is often appropriate to set an ‘acceptable range’
rather than a fixed limit
• Sometimes a green (acceptable), yellow (caution),
red (unacceptable) rating system

22. Monitoring controls - specify...
• How is the control monitored? - method
• When is the control monitored ? - frequency
• How is it recorded? - documentation

23. Monitoring controls - specify...
All monitoring and corrective action must be
signed off by a trained person.
The resulting records must be retained and be
available for inspection :
– during verification
– during HACCP audits
– during AIB audits
– during regulatory visits

24. The formal HACCP documentation...
Documentation to be produced :
• Completed Process Flowchart for each
product line on site
• Site HACCP Plan
• Record sheets for the monitoring
programmes specified

25. Recent revisions to CCPs
• The removal of the requirement for Certificates of
Analysis (CoAs) from seasoning companies
• VA programme became a HACCP pre-requisite
programme
• Metal Detectors became a CCP by definition
• The growth and development of promotions within the
business has brought additional and significant new
consumer and business risk
• Scientific advances in relating to food allergens have
led to Pepsico to develop allergen control practices in
plant
• Forthcoming legislative requirements for labelling of
allergens prompted Pepsico to enlarge its allergen
programme and broaden its scope of allergen CCP

26. Checking the HACCP Programme
Validation
Verification
Review

27. Validation
• The assessment of the HACCP plan before
implementation to provide confirmation that it is :
– valid
– accurate
– and complete
• Codex says : “obtaining evidence that the elements of
the HACCP Plan are effective”
• Ask yourself these questions :
– “is it true? is it right?”
– “will it deliver safe food?”

28. Validation - summary
Remember - validation is the process for checking :
HACCP plan is complete and accurate - a true reflection
of the site, its products and processes and the hazards
associated with them
HACCP system, if operated correctly, will deliver safe
food - that it would work
that it is a VALID system
" It is not a process for checking whether it is being
correctly carried out
" Is the system at fault and in need of amendment, or
would the system work if correctly operated and
communicated?

29. Verification
• To make sure that what is laid down in the
HACCP plan accurately operated in reality
• More ‘hands-on’
• Confirms that everything is OK

30. Verification information
HACCP team should consider two key sets of data :
• Feedback from the AIB audit
• Food safety monitoring data :
~ Data on the monitoring of pre-requisite programmes, e.g.
Pest Control records, Foreign Object trawls, glass and hard
plastic audits, etc.
~ Data from HACCP monitoring sheets which record the
checks on CCPs and SCP's

31. HACCP Annual Review
• Conducted by the HACCP team
• Comprises :
– Re-validation of the HACCP system
~ Check the HACCP plan
~ Update the plan in response to changes
– HACCP audit
~ Ideally, this audit should include an SET from another
site!
– Verification of the HACCP system as previously described
– Review training needs for HACCP team and other plant
personnel (possibly utilising a skills needs assessment)
and relay outcome to HR personnel
– Recommendations to improve food safety on site
– Recommendations to improve AIB audit performance