2. for the safety of
for the safety of
Livestock Products
Livestock Products
Presented by:
Irshad A.Irshad A.
PhD. Scholar
DPV (N) 14001 (LPT)
Department of Livestock Products Technology
(Meat Science)
4. HACCP SYSTEMHACCP SYSTEM
What is HACCP?
Hazard Analysis
Critical Control Point
Food Safety Management System
It Identifies, Evaluate and Controls
Hazards which are Significant for Food
Safety
Raghavendra Adiga
5. IntroductionIntroduction
• Hazard analysis critical control point (HACCP)
system leads to the production of microbiologically
safe foods by analysing the hazards of raw materials
that may appear at the processing and at the
consumer end.
• The HACCP system improves product safety by
anticipating and preventing health hazards before
they occur.
• This concept enhances consumer confidence in the
food industry while motivating developing countries
to build a firm food safety control system for export.
9. Brief HistoryBrief History
HACCP was 1st
developed in the 1960s to
ensure food safety for the first manned
National Aeronautics and Space
Administration (NASA) space missions.
NASA required a ‘zero defect’ program to
guarantee safety in the foods astronauts
consumed in space.
10. Brief HistoryBrief History
WHO Europe recommends HACCP.
1959 The Pillsbury Company develops concept for NASA.
1971
HACCP- presented at the US National Conference on
Food Protection.
1972
The Pillsbury Company in the United States began the
application of its HACCP concept to the manufacture of
its consumer food products.
1973 Pillsbury published the first comprehensive treatise on
HACCP
1973
HACCP system was adopted for the Low-Acid Canned
Food Regulations due to Bon Vivant Vichyssoise SoupBon Vivant Vichyssoise Soup
incidenceincidence
1980 WHO/ICMSF report on HACCP.
1983
11. Brief HistoryBrief History
FAO/WHO provide guidance for regulatory assessment
of HACCP
1985
The Food and Nutrition Board of the National Research
Council/National Academy of Science published two
books recommending the HACCP
1989
The U.S. National Advisory Committee on
Microbiological Criteria for Food (NACMCF)
developed and approved a standardized and updated
HACCP system for food safety
1990s
Codex Alimentarius Commission for Food Hygiene
standard embraced HACCP as an internationally
accepted method for ensuring food safety
1997 FDA’s Seafood HAACP program becomes
mandatory
1998
12. Brief HistoryBrief History
1998 HACCP becomes mandatory for large meat and
poultry manufacturers
1999 HACCP becomes mandatory for small meat and poultry
manufacturers
2003 FAO/WHO develop HACCP guidelines
2006
Increased worldwide use of HACCP in food safety
legislation
The HACCP system has grown to become the universally
accepted method for food safety assurance
WHY ???
13. The need for an effective food safetyThe need for an effective food safety
assurance methodassurance method
Food borne disease are a widespread public health
problem
Emergence of food borne disease
Increased knowledge and awareness of the serious
and chronic health effects
New food technologies and processing methods
Increased awareness of the economic consequences
of food borne disease
Assurance
throughout the food
chain
14. Terms and definitions used in HACCP planningTerms and definitions used in HACCP planning
and implementationand implementation
Term Definition
CCP Decision tree A sequence of questions to determine whether a control point is
a CCP.
Continuous
Monitoring
Uninterrupted collection and recording of data such as
temperature on a strip chart.
Control (a) To manage the conditions of an operation to maintain
compliance with established criteria. (b) The state wherein
correct procedures are being followed and criteria are being
met.
Control Point Any point, step, or procedure at which biological, physical, or
chemical factors can be controlled.
Corrective Action Procedures to be followed when a deviation occurs.
Criterion A requirement on which a judgment or decision can be based.
Critical Control Point
(CCP)
A point, step, or procedure at which control can be applied and
a food safety hazard can be prevented, eliminated, or reduced
to acceptable levels.
Critical Defect A deviation at a CCP which may result in a hazard.
15. Term Definition
Critical Limit A criterion that must be met for each preventive measure
associated with a critical control point.
Deviation Failure to meet a critical limit.
HACCP Plan The written document which is based upon the principles of
HACCP and which delineates the procedures to be followed
to assure the control of a specific process or procedure.
HACCP System The result of the implementation of the HACCP plan.
HACCP Team The group of people who are responsible for developing a
HACCP plan.
HACCP Plan
Reevaluation
One aspect of verification in which a documented periodic
review of the HACCP plan is done by the HACCP team with
the purpose of modifying the HACCP plan as necessary.
HACCP Plan
Validation
The initial review by the HACCP team to ensure that all
elements of the HACCP plan are accurate.
Hazard A biological, chemical, or physical property that may cause a
food to be unsafe for consumption.
16. Term Definition
Monitor To conduct a planned sequence of observations or
measurements to assess whether a CCP is under control and
to produce an accurate record for future use in verification.
Preventative Measure Physical, chemical, or other factors that can be used to
control an identified health hazard.
Random Checks Observations or measurements which are performed to
supplement the scheduled evaluations required by the
HACCP plan.
Risk An estimate of the likely occurrence of a hazard.
Sensitive Ingredient An ingredient known to have been associated with a hazard
and for which there is a reason for concern.
Severity The seriousness of a hazard.
Target Levels Criteria which are more stringent than critical limits and which
are used by an operator to reduce the risk of a deviation.
Verification The use of methods, procedures, or tests in addition to those
used in monitoring to determine if the HACCP system is in
compliance with the HACCP plan and/or whether the HACCP
plan needs modification and revalidation.
17. Who are all involved in HACCP??Who are all involved in HACCP??
18. The objectives of application of the HACCP systemThe objectives of application of the HACCP system
Reduction of
costs
of food analysis
More efficient
QA
system
19. Building and
Equipment design
Cleaning and Sanitization
Proper facilities
Storage (Cold, Dry, Chemical)
Service (Potable Water, ventilation)
Personal Hygiene
Hand Washing
Good Hygienic Habits
Prerequisite ProgrammesPrerequisite Programmes
21. Initial steps necessary to develop a HACCP planInitial steps necessary to develop a HACCP plan
(1) Assemble the HACCP Team
(2) Describe the food and its distribution
(3) Identify the intended use and consumers of the food
(4) Develop flow diagram
(5) Verify flow diagram
(6) Conduct hazard analysis:
(a) identify and list steps in the process where the hazards
of potential significance occur
(b) list all identified hazards associated with each step
(c) list preventative measures to control hazards
22. Seven Principles of HACCPSeven Principles of HACCP
1. Conduct a hazard analysishazard analysis
2.2. Identify the CCPsIdentify the CCPs in the process
3. Establish critical limitscritical limits for each CCPs
4. Establish CCP monitoringmonitoring requirements
5. Establish corrective actioncorrective action for deviation from the
critical limit
6. Establish procedures for verificationverification that the
HACCP system is working correctly
7. Establish recordkeeping procedures for
documentingdocumenting the HACCP system
23. Hazard analysisHazard analysis Critical limitsCritical limits Corrective actionCorrective action
Identify theIdentify the
CCPsCCPs
MonitoringMonitoring VerificationVerification
&&
DocumentingDocumenting
Principles of HACCPPrinciples of HACCP
25. Principle 1. Conduct a hazard analysisPrinciple 1. Conduct a hazard analysis
A list of steps in the process where significant hazards
occur should be prepared and their preventive measures
should be described.
Hazards are categorized into three general areas:
biological, chemical, and physical. For the most part,
biological, which includes pathogens, is the hazard that
most plans are used to prevent.
The challenge that faces the HACCP Team is to determine
what are truly significant versus insignificant hazards.
The team must weigh both risk and severity when
analyzing hazards.
(Stevenson and Bernard, 1995)
26. Principle 2. Identify the CCPs in the processPrinciple 2. Identify the CCPs in the process
A Critical Control Point is defined as a point, step or procedure
at which control can be applied and a food safety hazard can be
prevented, eliminated, or reduced to acceptable levels.
This differs from a Control Point, which is a less specific and
important step in the process.
The selection of CCPs is aided by the use of a CCP Decision
Tree.
This Decision Tree is designed to allow the Team to ask specific
and logical questions to help determine, what is truly a Critical
Control Point versus a Control Point or something that could be
handled under the GMPs (Good Manufacturing Practices) or
SOPs (Standard Operating Procedures).
27. Principle 3. Establish critical limitsPrinciple 3. Establish critical limits
Critical limits must be established for preventive measures
associated with each identified CCP.
Critical Limits serve as the boundaries for each CCP.
Examples of Critical Limits are preventative measures such
as temperature, pH, time, moisture level, etc.
28. Principle 4. Establish CCP monitoring proceduresPrinciple 4. Establish CCP monitoring procedures
Procedures must be established for using the results of
monitoring to adjust the process and maintain control.
CCP monitoring is a planned sequence of observations or
measurements to assess whether a CCP is under control and to
produce an accurate record for future use in verification.
Monitoring is focused on preventing deviations (those
occurrences outside the Critical Limits) from happening. If
deviations do occur, monitoring will provide the information as
to when problems occurred so that corrective action can be
taken.
Monitoring is performed best in real-time, i.e., measuring the
process as it occurs rather than taking samples and sending to a
laboratory.
29. Principle 5. Establish corrective actionPrinciple 5. Establish corrective action
Corrective action has to be taken when monitoring
indicates that there is a deviation from an established
critical limit.
There are three areas that corrective action plans address:
(a)to determine the disposition of non-compliance product,
(b)to fix or correct the cause of noncompliance to assure that
the CCP is under control, and
(c)to maintain records of the corrective actions that have been
taken where there has been a deviation from Critical
Limits.
30. Principle 6. Establish procedures for verification thatPrinciple 6. Establish procedures for verification that
the HACCP system is working correctlythe HACCP system is working correctly
Verification is an on-going process that helps in ensuring
that the HACCP Plan is doing what it is supposed to do:
prevent hazards from becoming a part of the food supply.
Outside experts play an important role in giving input to
the Team as to ways to improve the Plan.
31. Principle 7. Establish effective recordkeepingPrinciple 7. Establish effective recordkeeping
proceduresprocedures
The approved HACCP Plan and associated records must
be on file at the establishment for documenting the
HACCP system.
For the most part, this may be the only part of the
HACCP Plan that will be audited or reviewed by
customers or regulators.
1. Temperature Charts
2. Cleaning Schedules
3. Pest Control Records
4. Equipment Maintenance Records
5. Training Records
6. Delivery Checks
7. Non conformance Reports
32. 1. ASSEMBLE HACCP TEAM1. ASSEMBLE HACCP TEAM
2. DESCRIBE PRODUCT2. DESCRIBE PRODUCT
3. IDENTIFY INTENDED USE3. IDENTIFY INTENDED USE
Decision Tree/ Logic sequence in HACCPDecision Tree/ Logic sequence in HACCP
33. Decision Tree/ Logic sequence in HACCP
4. CONSTRUCT FLOW DIAGRAM4. CONSTRUCT FLOW DIAGRAM
6. HAZARD ANALYSIS6. HAZARD ANALYSIS
5. ON SITE VERIFICATION OF FLOW DIAGRAM5. ON SITE VERIFICATION OF FLOW DIAGRAM
34. HAZARD ANALYSISHAZARD ANALYSIS
LIST HAZARDSLIST HAZARDS
BIOLOGICAL
CHEMICAL
PHYSICAL
BIOLOGICAL
CHEMICAL
PHYSICAL
LIST PREVENTATIVE
MEASURES
LIST PREVENTATIVE
MEASURES
FOR EVERY STEP IN THE FLOW DIAGRAMFOR EVERY STEP IN THE FLOW DIAGRAM
35. DO PREVENTATIVE
MEASURES EXIST?
DO PREVENTATIVE
MEASURES EXIST? NO
SEE NEXT SLIDE
NO
SEE NEXT SLIDE
YES
GO TO
NEXT QUESTION
YES
GO TO
NEXT QUESTION
CCP DECISION TREE QUESTION 1CCP DECISION TREE QUESTION 1
36. DO PREVENTATIVE
MEASURES EXIST?
DO PREVENTATIVE
MEASURES EXIST?
NO
NOT A CCP
REPEAT FOR NEXT
HAZARD OR STEP
NO
NOT A CCP
REPEAT FOR NEXT
HAZARD OR STEP
CCP DECISION TREE QUESTION 1CCP DECISION TREE QUESTION 1
YES
MODIFY STEP
PROCESS OR
PRODUCT
YES
MODIFY STEP
PROCESS OR
PRODUCT
NO
IS CONTROL
AT THIS STEP
FOR SAFETY?
NO
IS CONTROL
AT THIS STEP
FOR SAFETY?
37. IS STEP DESIGNED
TO ELIMINATE
OR REDUCE HAZARD?
IS STEP DESIGNED
TO ELIMINATE
OR REDUCE HAZARD?
CCP DECISION TREE QUESTION 2CCP DECISION TREE QUESTION 2
CCP
YES
NO
GO TO
NEXT QUESTION
NO
GO TO
NEXT QUESTION
38. Decision Tree/ Logic sequence in HACCP
8. ESTABLISH CRITICAL LIMITS8. ESTABLISH CRITICAL LIMITS
9. MONITORING SYSTEM9. MONITORING SYSTEM
FOR EACH CCPFOR EACH CCP
39. IS STEP DESIGNED
TO ELIMINATE
OR REDUCE HAZARD?
IS STEP DESIGNED
TO ELIMINATE
OR REDUCE HAZARD?
CCP DECISION TREE QUESTION 2CCP DECISION TREE QUESTION 2
CCP
YES
NO
GO TO
NEXT QUESTION
NO
GO TO
NEXT QUESTION
40. COULD CONTAMINATION
HAZARD OCCUR
OR INCREASE ?
COULD CONTAMINATION
HAZARD OCCUR
OR INCREASE ?
NO
NOT A CCP
REPEAT FOR NEXT
HAZARD OR STEP
NO
NOT A CCP
REPEAT FOR NEXT
HAZARD OR STEP
CCP DECISION TREE QUESTION 3CCP DECISION TREE QUESTION 3
YES
GO TO
NEXT QUESTION
YES
GO TO
NEXT QUESTION
41. WILL SUBSEQUENT STEP
ELIMINATE OR REDUCE
HAZARD?
WILL SUBSEQUENT STEP
ELIMINATE OR REDUCE
HAZARD?
CCP DECISION TREE QUESTION 4CCP DECISION TREE QUESTION 4
CCP
NO
YES
NOT A CCP
REPEAT FOR NEXT
HAZARD OR STEP
YES
NOT A CCP
REPEAT FOR NEXT
HAZARD OR STEP
42. Decision Tree/ Logic sequence in HACCP
8. ESTABLISH CRITICAL LIMITS8. ESTABLISH CRITICAL LIMITS
9. MONITORING SYSTEM9. MONITORING SYSTEM
FOR EACH CCPFOR EACH CCP
43. Decision Tree/ Logic sequence in
HACCP
DEVIATIONDEVIATION
9. MONITORING SYSTEM9. MONITORING SYSTEM
12. RECORDS AND DOCUMENTATION12. RECORDS AND DOCUMENTATION
11. VERIFICATION11. VERIFICATION
IN CONTROLIN CONTROL
10. CORRECTIVE
ACTION
10. CORRECTIVE
ACTION
44. Decision Tree/ Logic sequence in
HACCP
9. MONITORING SYSTEM9. MONITORING SYSTEM
IN CONTROLIN CONTROL10. CORRECTIVE
ACTION
10. CORRECTIVE
ACTION
FOR EACH CCPFOR EACH CCP
DEVIATIONDEVIATION
45. Decision Tree/ Logic sequence in
HACCP
12. RECORDS AND DOCUMENTATION12. RECORDS AND DOCUMENTATION
11. VERIFICATION11. VERIFICATION
IN CONTROLIN CONTROL
REVIEWREVIEW
46. Designing a HACCP planDesigning a HACCP plan
The development of an HACCP plan for meat
processing begins with the construction of a flow
diagram for the entire process.
The diagram should begin with the acquisition of
raw materials and include all steps through
packaging and subsequent distribution.
A flow diagram for the production of frozen
cooked chicken patties is illustrated in Fig.
(Tompkin, 1990).
47. Fig.1.A flow diagram for the production of frozen cooked chickenFig.1.A flow diagram for the production of frozen cooked chicken
pattiespatties 1. Receiving (chicken)
↓
2. Mincing
↓
3. Mixing
↓
4. Forming
↓
5. Cooking (CCP1)
↓
6. Freezing (CCP2)
↓
7. Boxing (CCP2)
↓
8. Distributing (CCP2)
↓
9. Reheating
↓
10. Serving
48. To begin the HACCP process, a raw material control decision
tree has to be drawn in which a few questions should be
raised.
When this is done, the answer to all (yes) is mentioned as
below. It is likely to find that the raw material must be
managed as a CCP.
Q1. Is there a hazard? Raw ground chicken patties are known
to be vehicles for Escherichia coli O157:H7 and Salmonella.
Q2.Will the hazard be processed out? This will be achieved in
step 5 (cooking)
Q3. Is there a risk of cross contamination? This can occur in
steps 7, 8 and 10.
50. Application of HACCP principlesApplication of HACCP principles
Principle 1. Hazards and risks
Raw meat is a sensitive ingredient and the
cooked product is subject to recontamination
after processing and during distribution.
51. Principle 2. CCPs
Assuming the chicken meat has been
produced and handled under GMP; step 5 is
the undisputable CCP1, since it can
eliminate the hazards. CCP2s may be
assigned to steps 6, 7 and 8.
CCP1 is the most important and effective
CCP of the product. CCP2 is comparatively
less important not an absolute CCP.
52. Principle 3. Critical limits
Temperature is the critical parameter from steps 1
to 9
It consists of proper refrigeration temperature in
steps 1 to 4; proper cooking temperature in step 5;
freezing in steps 6 to 8; and heating in step 9.
The overall objective is to keep the fresh chicken
meat at or below 4o
C at all times, cook patties to
80o
C, freeze to -20O
C and store at the same
temperature.
53. Principle 4. Monitoring HACCP
Use chart recorders for steps 2 to 4, use
thermometers for steps 5 and 6, and
temperature recorders for step 8.
54. Principle 5. Corrective actions
These refer to deviations from critical
limits identified during monitoring of
CCPs.
Specific corrective actions to be taken
should be clearly spelled out.
For example, if the target temperature in
step 5 is not reached, will the batch be
discarded, reprocessed, or assigned to
another use?
55. Principle 6.Verification
Overall this is an assessment of how
effective the HACCP system is performing.
Typically some microbial analysis are done
in order, for example, were all relevant
pathogens destroyed in step 5? Have the
products in retail stores been
contaminated after being cooked?
56. Principle 7. Record Keeping
This should be done by product lot number
in such a way that records are available to
verify the events in steps 2 to 4.
Where room temperatures are involved,
chart recorder tracings should be kept.
57. HACCP CertificationHACCP Certification
BIS offers two Certification schemes to the food industry.
i) HACCP Stand-alone Certification against IS 15000:1998
ii) HACCP based Quality System Certification provides for
two Certification through one audit Certification of Quality
System against IS/ISO 9000 and Certification of HACCP
against IS 15000:1998
58. Limitations of HACCPLimitations of HACCP
HACCP requires the education of non professional food handlers,
especially in the food service industry and in homes.
The failure of the individuals to get a proper understanding of
HACCP could lead to its failure.
To be effective this concept must be accepted not only by food
processors but also by food inspectors and public.
It is anticipated that experts will differ as to whether a given step
is a CCP and how best to monitor such steps. This has the
potential of eroding the confidence of others in HACCP.
Even after the best application of HACCP principles at the
processor level, there is a need to exercise usual precautions
between the purchase and consumption of the product.
59. ConclusionsConclusions
HACCP program empowers people to focus their attention
on prevention rather than digging out the cause after a
food borne outbreak occurs.
HACCP is not a set of seven independent principles; each
must build on the other.
As with any other endeavour, all components must be
working for the total plan to be effective and successful.
This system must be implemented by everyone to better
assure a safer food/meat/milk/licestock product supply.