Hazard Analysis and Critical Control Point, HACCP protocol used in various industries

1. HHazardazard AAnalysis &nalysis &
CCriticalritical CControlontrol
PPointoint
Dr. Vikram Gupta
Assistant Professor,
Department of Community Medicine,
Dayanand Medical College & Hospital,
Ludhiana
dr_vikramgupta@yahoo.co.in

2. HACCP ?
 H = Hazard
 A = Analysis
 C = Critical
 C = Control
 P = Point

4. HACCPHACCP::
A systematicA systematic
approach to theapproach to the
identification,identification,
evaluation, andevaluation, and
control of foodcontrol of food
safety hazards.safety hazards.
DefinitionsDefinitions

5. DefinitionsDefinitions
HHazardazard AAnalysisnalysis::
The process ofThe process of
collecting andcollecting and
evaluating informationevaluating information
on hazards associatedon hazards associated
with the food underwith the food under
consideration toconsideration to
decide which aredecide which are
significant and mustsignificant and must
be addressed in thebe addressed in the
HACCP plan.HACCP plan.

6. CCriticalritical CControlontrol
PPoint:oint:
A step at whichA step at which
control can becontrol can be
applied and isapplied and is
essential to preventessential to prevent
or eliminate a foodor eliminate a food
safety hazard orsafety hazard or
reduce it to anreduce it to an
acceptable level.acceptable level.
DefinitionsDefinitions

7. HACCP
 It is a systematic preventive approach to food
safety and pharmaceutical safety that
addresses physical, chemical,
and biological hazards as a means of
prevention rather than finished product
inspection.
 HACCP is used in the food industry to identify
potential food safety hazards, so that key
actions, known as Critical Control
Points (CCPs) can be taken to reduce or
eliminate the risk of the hazards being realized.

8. HISTORY

9. ++ =>=>
19591959

10. Method Development
1.Sampling for Pathogenic
microorganisms.
2. The Zero Defect Concept
3. Modes of Failure

11. 33 PrinciplesPrinciples
1. Identification and
assessment of
hazards associated
from growing to
consumption
2. Determination
of the critical
control points
to control any
identified
hazards
3.Establishmend
of systems to
monitor the
critical control
points
19711971

12. 19721972 Outbreak of botulismOutbreak of botulism!!!!!!
Canned Potato Soup Botulism
FDA promoted regulation of canned foods
FDA inspectors were trained for HACCP

13. 19881988:: 4th volume “HACCP in Food
Safety and Quality”
19891989: HACCP Principles for Food
Production
1991:1991:Guidelines for the Application
of the HACCP System
19921992 : “Hazard Analysis and
Critical Control Point

14. Feb,1995Feb,1995
“There is wide agreement
that ensuring food safety requires
taking steps throughout the
continuum of production, slaughter,
processing, distribution, and sale
of livestock and poultry carcasses
and meat and poultry products to
prevent hazards and reduce the risk
of food-borne illness.

15. HACCP
 Its introduction signaled a shift in emphasis
from end product testing to preventive control
at all stages of food production.

16. NEED For HACCP
 The establishment of the WTO paved the way for several
multilateral agreements on trade which include
agreements on the Application of Sanitary and
Phytosanitary (SPS) measures and on Technical Barriers to
Trade (TBT).
 These agreements encouraged countries to adopt
international standards.
 Within the context of the TBT agreement, the Codex
Alimentarius Commission (165 member countries) has
been recognized as an international standardizing body.
 It has recommended a Hazard Analysis Critical Control
Point (HACCP) based approach as a means to enhance
food safety

17. HACCP PLAN

18. Assemble the
HACCP Team
Preliminary Steps:Preliminary Steps:
Developing a
HACCP Plan

19. Assemble the
HACCP Team
PreliminaryPreliminary
Steps:Steps:
Developing a
HACCP Plan
Describe the Food

20. Assemble the
HACCP Team
PreliminaryPreliminary
Steps:Steps:
Developing a
HACCP Plan
Describe the Food
Describe the Food and its
Distribution

21. Assemble the
HACCP Team
PreliminaryPreliminary
Steps:Steps:
Developing a
HACCP Plan
Describe the Food
Describe the Food and its
Distribution
Describe the Intended Use and
Consumers of the Food

22. Assemble the
HACCP Team
PreliminaryPreliminary
Steps:Steps:
Developing a
HACCP Plan
Describe the Food
Describe the Food and its
Distribution
Describe the Intended Use and
Consumers of the Food
Develop a Flow Diagram Which
Describes the Process

23. Verify the Flow Diagram
Developing a
HACCP Plan
PreliminaryPreliminary
Steps:Steps:

24. 7 HACCP
Principles

25. 77 HACCPHACCP PrinciplesPrinciples

26. 1.Conduct
a hazard
analysis
Identify
hazards

27. 1.Conduct a
hazard
analysis
Identify
hazards
2.Determine
the critical
control
points(CCP)
in the food
preparation.

28. 1.Conduct a
hazard
analysis
Identify
hazards
2.Determine the
critical
control
points(CCP) in
the food
preparation.
3.Establish
critical
limits for
preventive
measures.

29. 1.Conduct a
hazard
analysis
Identify
hazards
2.Determine
the critical
control
points(CCP) in
the food
preparation.
3.Establish
critical
limits for
preventive
measures.
4.Establish
procedures to
monitor CCP’s

30. 5.Establish
corrective
action to be
taken when
monitoring shows
that a critical
limit has been
exceeded.

31. 5.Establish
corrective action to
be taken when
monitoring shows
that a critical
limit has been
exceeded.
6.Written HACCP
Plan

32. 5.Establish
corrective action to
be taken when
monitoring shows
that a critical
limit has been
exceeded.
6.Written HACCP
Plan
7.Establish
procedures to
verify that the
HACCP plan is
working.

33. 5.Establish
corrective action to
be taken when
monitoring shows
that a critical
limit has been
exceeded.
6.Written HACCP
Plan
7.Establish
procedures to verify
that the HACCP plan
is working.
1.Conduct a
hazard
analysis
Identify
hazards
2.Determine the
critical
control
points(CCP) in
the food
preparation.
3.Establish
critical
limits for
preventive
measures.
4.Establish
procedures to
monitor CCP’s

34. Validation
Who validates the HACCP plan?
 HACCP team
 Individual qualified by training or experience
What does validation involve?
 A scientific and technical review of the
rationale behind each part of the HACCP
plan from hazard analysis through each CCP
verification strategy

35. Validation Frequency
 Initially
 When factors warrant, e.g.,
 Changes in raw materials
 Changes in product or process
 Adverse review findings
 Recurring deviations
 New information on hazards or control measures
 On-line observations
 New distribution or consumer handling practices

36. Examples of Validation
Activities:
 Cooked hamburgers
 Collect data to establish that critical limits for
maximum patty thickness, maximum belt speed, and
minimum oven temperature will ensure that the
internal temperature of every patty reaches the
minimum requirement

37. Verification of CCPs
 Calibration
 Calibration record review
 Targeted sampling and testing
 CCP record review

38. Examples of Calibration
Activities
 A MIG thermometer used to monitor temperature at
a cook CCP may be checked for accuracy by
comparing it against a certified thermometer in a
hot-water bath
 The continuous temperature chart recorder on a
pasteurizer may be compared during each batch
against a certified accurate thermometer
 A pH meter is calibrated against pH buffer standards
of 7.0 and 4.0 when it is used to test products with a
final pH of 3.8 to 4.2

39. HACCP System Verification
Frequency
Annually
Occurrence of a system failure or
significant change in product or process

40. HACCP Plan Form:
Verification
1.
CCP
2.
Hazard
3.
Critical
Limits
What How Frequency Who
Monitoring
4. 5. 6. 9.
Verification
8.
Correctiv
e
Action(s)
10.
Record
s
7
.

41. 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

44. Why Implement a Food Safety
Program using HACCP Principles?
 To ensure that the food served to children is as safe as
possible

45.  HACCP is a food safety system that helps
identify foods and procedures that are most
likely to cause foodborne illness

46. Consequences of a foodborne
outbreak…
 Medical/legal claims
 Lost wages
 Cleaning and sanitizing costs
 Food loss-costs associated
 Bad publicity
 Embarrassment-loss of reputation
 Child Nutrition Program closes = hungry children

47. Causes of foodborne illness:

52. NO COOK PROCESS

53. Food passes through the temperature danger zone only
once before it is served….. (Cooking or Cooling)

54. Food passes through the danger zone more than
one time…..

64. Application of HACCP methodology
to pharmaceuticals
 The present guidelines are aimed at assisting industry to
develop and implement effective HACCP plans covering
activities such as research and development, sourcing of
materials, manufacturing, packaging, testing and
distribution.
 In the manufacture of pharmaceuticals, these may include
the manufacture of certain antibiotics, hormones,
cytotoxic substances or other highly active
pharmaceuticals, together with operations such as
fluidbed drying, granulation is an example of hazard
unit operations.The use of inflammable solvents
(solutions) and certain laboratory operations may also
constitute hazards.

65. HACCP Study- weaning foods
 Hazard analysis and critical control points of weaning
foods
 Mini Sheth, Jigisha Patel, Shikha Sharma and
Subadra Seshadri in Indian J of Paediatrics.
 Hazards and critical control points were identified during
the preparation, feeding and storage of weaning foods fed
to the children (6–24 months) belonging to low income
group (LIG) families using survey methods, spot and
indepth observations and microbial analysis.
 High microbial counts were obtained for the weaning
food samples procured from the families that were rated
as poor for both personal hygiene and environmental
sanitation

66.  Food samples that were held at ambient temperature
(25–35°C) showed high counts of coliforms, yeast
and Staphylococcus aureus and Bacillus cereus.
 Spice mixtures and mop samples also revealed high
counts for all these organisms.
 The hazards and critical control points identified
were high initial contamination of raw foods, poor
environmental sanitation and personal hygiene,
feeding of overmight moist foods stored at ambient
temperature and insufficient steaming of these foods.

67. HACCP Training in India
 3 -5 day training
 Course fee is around Rs 10,000
 Mumbai,Thiruvananthapuram

68. ICMR STUDY

73.  The major reported microbial hazards from
mushrooms are Clostridium, Salmonella, Bacillus and
Coliforms.
 The food handlers who grade the fresh mushrooms
were carrying Coliforms and were introducing the
Coliforms into fresh mushrooms.
 Critical Control Point for fresh mushrooms had been
identified as the food handler’s personal hygiene and
they were informed about the importance of
personal hygiene.

74.  In khoa it was the airtight packaging that was
responsible for microbial proliferation while the food
handlers were responsible in introducing Coliforms in
mushroom and paneer.
 Simple and economical solutions like muslin cloth
packing for khoa and thorough hand washing by food
handlers before touching the paneer or mushrooms
had totally eliminated the problem of microbial
contamination.

75. HACCP application (USA)
 Fish and fishery products
 Fresh-cut produces
 Juice and nectary products
 Food outlets
 Meat and poultry products
 School food and services

76. Food Regulation in India and HACCP
 In India, quality control with regard to food products is
being enforced through various regulatory mechanisms
like the
 Prevention of Food Adulteration Act (PFA),
 Agriculture Grading and Marketing (AGMARK),
 Fruit Products Order (FPO), etc.
 The Bureau of Indian Standards (BIS) has recently launched
a HACCP certification programme for the food industry.
 The Mother Dairy of Delhi and the Punjab Cooperative
Milk Federation have received HACCP certificates.
 The Agriculture and Processed Food Export
Development Agency (APEDA) has helped mango
processing units in Andhra Pradesh in HACCP.

77. HCCP Application to Animal
Production
“ The voluntary application of
HACCP principles can be useful
in establishing the CCPs within
the farm management and live
animal transportation arenas
where pathogenic organisms can
enter the food chain”
----USDA/FSIS

79. THANX…………….