Professional Documents
Culture Documents
TQM
ISO 9000
QACP
HACCP
GMP/GHP
Traditional control
Surprise – swoop
Unrepeatability
Irregularity
Inaccurate scope and evaluation
Revealing faults not in all production steps
Rating on the base of final product
General plans
for:
Testing plant water
Removing waste and sewage
Pests control
Cleaning and disinfections
Control for health status
HACCP history
’50 NASA demand to safety food for astronauts
1959 Pilsbury Company + NASA + Natic Laboratory (US Army) + US Air Force Space +
Laboratory Project Group
1975 WHO System acceptance
1980 General basics and definitions International Commision on Microbiological
Specification (ICMSF FAO/WHO)
1987 Committee for Food Hygiene FAO/WHO (Codex Alimentarius) recommendation to
apply in food plants
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HACCP
Hazard Analysis and Critical Control Point
It allows to:
Monitor whole production of food and its distribution
Determine hazards on each step of production and distribution of food
Risk analysis
Eliminate or minimalize particular hazards on individual step of production – it is prevention
HACCP – tools to provide food safety – mainly sanitary aspects of food
HACCP
Specific for individual process, product, plant
Is not transferable to other plant
Is applied to provide food safety and quality
The HACCP principals are universal (common in variety food plant, applied to prevent hazards
Quality control
Raw and
Machines Good -
supporting Staff Technology
and tools food item
materials
Lack of food safety assurance
HACCP
Raw and
Machines Good -
supporting Staff Technology
and tools food item
materials
Food safety assurance
Principle 2: Identify critical control points. A critical control point (CCP) is a point, step, or procedure in a
food process at which control can be applied and, as a result, a food safety hazard can be prevented,
eliminated, or reduced to an acceptable level.
Principle 3: Establish critical limits for each critical control point. A critical limit is the maximum or
minimum value to which a physical, biological, or chemical hazard must be controlled at a critical control
point to prevent, eliminate, or reduce to an acceptable level.
Principle 4: Establish critical control point monitoring requirements. Monitoring activities are necessary
to ensure that the process is under control at each critical control point.
Principle 5: Establish corrective actions. These are actions to be taken when monitoring indicates a
deviation from an established critical limit. The final rule requires a plant's HACCP plan to identify the
corrective actions to be taken if a critical limit is not met. Corrective actions are intended to ensure that no
product injurious to health or otherwise adulterated as a result of the deviation enters commerce.
Principle 6: Establish procedures for ensuring the HACCP system is working as intended. Validation
ensures that the plants do what they were designed to do; that is, they are successful in ensuring the
production of safe product. Plants will be required to validate their own HACCP plans.
Principle 7: Establish record keeping procedures. The HACCP regulation requires that all plants maintain
certain documents, including its hazard analysis and written HACCP plan, and records documenting the
monitoring of critical control points, critical limits, verification activities, and the handling of processing
deviations.
HACCP advantages
HACCP enables to demonstrate to all interested parties, plant has done everything to produce safety
food according to food law requirements, good manufacturing practice and consumers needs
DUE DILIGENCE
HACCP scope
HACCP
Animals
Raw materials Processing Food market
purchasing
Non obligatory Obligatory Non obligatory
Food safety Food quality
HACCP definitions
HACCP: A system which identifies, evaluates, and controls hazards which are significant for food
safety.
HACCP plan: A document prepared in accordance with the principles of HACCP to ensure control
of hazards which are significant for food safety in the segment of the food chain under
consideration.
CORRECTIVE ACTION: Any action to be taken when the results of monitoring at the CCP
indicate a loss of control.
CRITICAL CONTROL POINT (CCP): A step in a food process at which control can be applied
in order to prevent a food safety hazard or to reduce its occurrence to an acceptable level.
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FOOD HANDLER: Any person who handles packaged or unpackaged food, food equipment and
utensils or surfaces in contact with food and is therefore expected to comply with food hygiene
requirements. (Codex)
FOOD HYGIENE: All conditions and measures necessary to ensure the safety and suitability of
food at all stages of the food chain. (Codex)
FOODBORNE DISEASE (FBD): A disease, usually either infectious or toxic in nature, caused by
agents that enter the body through the ingestion of food. The term "food" includes drinking-water.
Sometimes this is incorrectly referred to as food poisoning.
FOOD POISONING: This is a term that is often used to refer to foodborne illness/disease but
WHO does not recommend it.
FOOD SAFETY: Assurance that food will not cause harm to the consumer when it is prepared
and/or eaten according to its intended use. (Codex)
FOOD SPOILAGE: Food becomes unfit to eat as a result of: growth and activities of
microorganisms, insect infestation, action of enzymes, chemical reactions, and physical changes
(e.g. freezing, burning, drying, pressure, and humidity).
HIGH-RISK FOOD: These include foods that have been linked epidemiologically to foodborne
disease or that, due to their nature, preparation or storage, present a greater risk of foodborne
disease than other foods.
INFECTION: Entry and colonisation of an infectious microorganism in a living macroorganism
(host). Disease does not always develop but the host becomes a “carrier”.
INTOXICATION: Bacteria such as Clostridium botulinum or Staphylococcus aureus grow and
produce toxin in the food. When the food is eaten the person becomes ill. In contrast to an infection,
the person becomes ill without eating the live bacteria.
MALABSORPTION: Failure to absorb various nutrients.
PRESERVATION: Various methods to extend the shelf life of food (e.g. dehydration, heat
sterilisation, freezing, radiation, addition of preservatives) by inhibiting the multiplication and/or
growth of microorganisms and by minimising chemical and sensory changes.
PRESERVATIVES: Antimicrobial substances that prevent multiplication of microorganisms and
sometimes also used for preventing other types of undesirable activities.
RISK: A function of the probability of an adverse health effect and the severity of that effect,
consequential to (a) hazard(s) in food.
TARGET Value: A value or characteristic of a physical, chemical or biological nature, used to
assure that critical limits are not exceeded.
VECTOR: Also known as a vehicle. Method of transport for microorganisms to hosts or habitats
(e.g. wind, water, insects, rodents, pets, man, utensils).
VERIFICATION: The application of methods, procedures, tests and other evaluations, in addition
to monitoring to determine compliance with the HACCP plan. (Codex)
ADDITIVES AND INGREDIENTS: Substances added to foods to influence their condition or to
bring about specific characteristics or effects (help manufacture, preserve, improve palatability, eye
appeal, convenience - e.g. emulsifiers, flavours, thickeners, curing agents, humectants, colours,
vitamins, minerals, moulds, yeasts, and bacterial inhibitors).
Aw (WATER ACTIVITY) VALUE: The ratio of the water vapour pressure over a food to the
saturation pressure of pure distilled water at a given temperature, expressed on a scale of 1.0 to 0.0.
Pure water is 1.0 on this scale (WHO). It refers to the amount of water available for growth and
multiplication of microorganisms.
Product description
Name
Characteristic
Package
Sensory features
Weight
Components
Chemical contents
- proteins
- water
- fat
- carbohydrates
- water activity
- pH
Food additives (preservatives, colorants, antioxidants, residues, vitamins, flavorings, emulsifying salts,
emulsifiers)
Microbiological features
- total counts
- E. coli
- Salmonella,
- Staphyloccocus
- Listeria
Enterococcaceae
Storing conditions
Durability
Consumers assignment
Label
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Symbols
Process step
Product, byproduct, raw material, additive, side product, drop off, supporting material
Measurement
Decision
Bond
Follow-up treatment
Physical hazards
Cleaning tools foam particles, mops, plastic, fabric
Machine and devices metal particles – fillings, rubber, paints,
Air dust,
Packaging materials paper, plastic, wood, wires,
Staff cigarette ends, chewing gum, jewelry, ball pens,
Animals, Fur, pests and insects, feces, eggs,
Water, sludge,
Surroundings plaster, stones, sand, glass, rust,
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Chemical hazards
Residues of veterinary treatments hormones, antibiotics
Industrial and agricultural contaminants nitrates, heave metals, radioactive elements,
Toxins bacterial, fungi,
Result analysis
Establishing preventive actions and means
Do its exist?
Are its enough to prevent?
In case of lack preventive means for hazard it should be consider process changing
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Establishing CCPs
CCP – the most trouble spots in production process (considering food safety)
ATTENTION
Not each CP is CCP
Not each Control Point is Critical Control Point
Ways:
- using decision tree
- using own experience and nous
All sideway processes must be considered
Not all steps should be controlled
ATTENTION
Hazard ≠ CCP
CCP Monitoring
Recording monitoring results
Recording made up revising operations
Signature responsible person
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CCP Monitoring
Basic requirements
When?
What?
Who?
How?
How often?
What record?
Measures:
- physical
- chemical
- sensory
Applied methods have to deliver objective information
Process verification
Special tests
Microbiology tests
Market research
Consumers opinions
Internal audits
Verification processes records
- testing
- checking up
- evaluation
o with established frequency
o regularly
o according to instruction
HACCP Book
example
Content:
11
Title
Distributor
List of content
Preface
HACCP policy
Definitions and abbreviations
Structure of documents
Scope of HACCP system
Plan of plan – division
Characteristics of products
Flow charts
HACCP data sheets – hazards and CCP identifications
HACCP data sheets – monitor and correction actions
Documentation structure
HACCP documents:
Basic
HACCP book
Systemic Procedure Book
Company GMP/GHP Codex
Records
Supplementary
Technique-technology documentation
Cleaning and Disinfection Book
Pest and Rat Control Book
Specifications and Certifications Book
Stand instructions
Records
Preparing
Step Action record instruction
Establishing
actions
Standards,
Step Measure OK ? tolerances
(control point)
Record
Instruction of results
Follow up
Next step
Process in control
Process in control
Loss of control