FOODSAFE Level 2 (Advanced)

Section 2
Introduction to HACCP

Revised 2001
Learning outcome
 to demonstrate a basic understanding of
the HACCP system

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Introduction to HACCP
Major points to be covered
 introduction to HACCP
 HACCP terms
 beginning a HACCP system
 HACCP steps
 how HACCP challenges an operator

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Introduction to HACCP
Origins of HACCP
 HACCP is a program developed by
Pillsbury and the US Army for NASA in
the 1960s

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Introduction to HACCP
HACCP Food Safety Assurance Pyramid

T o ta l
M anagem ent
C o m m itm e n t

HACCP

B i o l o g ic a l
C h e m ic a l E d u c a tio n a n d
P h y s ic a l T r a in i n g
H a z a rd s

C l e a n in g a n d T im e a n d P erso nal
S a n itiz in g P e s t C o n tro l
Te m p e ra tu r e H yg ie n e

Developed by Robert B. Gravani, Cornell University

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Introduction to HACCP
HACCP terms
 hazard
 risk
 control point
 critical control point (CCP)
 critical limits
 SOP/GMPs

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Introduction to HACCP
HACCP steps
1. Hazard analysis
2. Identify critical control points
3. Establish critical limits
4. Monitor critical control points
5. Establish corrective action
6. Establish a record keeping system
7. Verification
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Introduction to HACCP
Step 1: Hazard analysis
 potentially hazardous foods
 food flows
 identifying the hazards

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Introduction to HACCP
Food flow examples

Not Cooked

Receive Store Prepare Hold Serve

Cook and Serve

Receive Store Cook Serve

Cook and Chill

Receive Cook Cool Reheat Hold Serve

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Introduction to HACCP
Product flow charting
Chowder Soup Base Shrimp Clams Vegetables
(frozen) (frozen) (canned) (pre-cut, washed)

STORAGE

PREPARATION

Cooking

Heat all ingredients to 74ºC (165ºF)

Standard Operating
Procedures

Reheating

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Introduction to HACCP
Seafood chowder flow chart
Chowder Soup Base Shrimp Clams Vegetables
(frozen) (frozen) (canned) (pre-cut, washed)

Receiving

Storage

Store in freezer Store in dry storage Store in refrigerator

Preparation

Thaw soup base Rinse

in refrigerator shrimp

Cooking
Heat all ingredients to 74°C (165°F)

Serving and Holding

Hold chowder at 60°C (140°F) or higher

Standard Operating
Procedures

Cooling
Cool chowder to 21°C (70°F) within 2 hours and
then to 4°C (40°F) within an additional 4 hours

Reheating
Reheat chowder to 74°C (165°F) or higher within 2
hours ONLY ONCE

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Introduction to HACCP
Step 2: Identify critical control points

 control points
 critical control points (CCPs)

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Introduction to HACCP
CCP decision tree
Q 1 D o c o n t r o l m e a s u r e ( s ) e x is t f o r th e id e n tifie d h a z a r d ?

YES N O M o d if y s te p , p r o c e s s o r p r o d u c t .

I s c o n t r o l a t th is s te p n e c e s s a r y f o r s a fe t y ? YES

N O N ot a C C P STO P

Q 2 D o e s t h is s t e p e lim i n a te o r r e d u c e t h e lik e ly o c c u r r e n c e o f a h a z a r d t o a n a c c e p t h a b le le v e l?

N O YES

Q 3 C o u ld c o n t a m in a t io n w it h th e id e n t if ie d h a z a r d ( s ) o c c u r in e x c e s s o f
a c c e p t a b le le v e l( s ) o r c o u ld it in c r e a s e t o a n u n a c c e p t a b le le v e l( s ) ?

YES N O N ot a C C P STO P

Q 4 W ill a s u b s e q u e n t s t e p e lim in a t e t h e i d e n t if ie d h a z a r d ( s ) o r
r e d u c e it s lik e ly o c c u r r e n c e t o a n a c c e p ta b le le v e l?

YES N ot a C C P STO P N O

C R IT IC A L C O N T R O L P O IN T

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Introduction to HACCP
Seafood chowder flow chart
Chowder Soup Base Shrimp Clams Vegetables
(frozen) (frozen) (canned) (pre-cut, washed)

STORAGE

Store in freezer Store in dry storage Store in refrigerator

PREPARATION

Thaw soup base Rinse shrimp

in refrigerator

Cooking

Heat all ingredients to

Serving and Holding

Hold chowder at

Standard Operating
Procedures

Cooling
Cool chowder at

Reheating
Reheat chowder at

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Introduction to HACCP
Step 3: Establish critical limits
 establish critical limits for critical control
points and standard operating
procedures

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Introduction to HACCP
Seafood chowder flow chart
Chowder Soup Base Shrimp Clams Vegetables
(frozen) (frozen) (canned) (pre-cut, washed)

STORAGE

Store in freezer Store in dry storage Store in refrigerator

PREPARATION

Thaw soup base Rinse shrimp

in refrigerator

Cooking

CCP Heat all ingredients to

Serving and Holding

CCP Hold chowder at

Standard Operating
Procedures

Cooling
CCP Cool chowder at

Reheating
CCP Reheat chowder at

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Introduction to HACCP
Step 4: Monitor CCPs
 what critical limits are to be monitored
 who will be responsible for monitoring
 how the critical limits will be monitored
 how often the critical limits will be
monitored

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Introduction to HACCP
Seafood chowder flow chart
Chowder Soup Base Shrimp Clams Vegetables
(frozen) (frozen) (canned) (pre-cut, washed)

Receiving

Storage

Store in freezer Store in dry storage Store in refrigerator

Preparation

Thaw soup base Rinse

in refrigerator shrimp

Cooking
CCP Heat all ingredients to 74°C (165°F)

Serving and Holding

CCP Hold chowder at 60°C (140°F) or higher

Standard Operating
Procedures

Cooling
CCP Cool chowder to 21°C (70°F) within 2 hours and
then to 4°C (40°F) within an additional 4 hours

Reheating
CCP Reheat chowder to 74°C (165°F) or higher within 2
hours ONLY ONCE

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Introduction to HACCP
Seafood Chowder HACCP Plan

Procedure Hazards CCP Critical Types of Corrective Records Verification

(Y/N) Limits Monitoring Action if
Procedures Critical
Limits not
met

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Introduction to HACCP
Step 5: Establish corrective action
 Example:
– if it is below 74º C (165º F), continue
cooking; check the internal temperature
every 20 minutes until it is 74 º C (165 º F)

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Introduction to HACCP
Step 6: Establish a record keeping system

 to document efforts to protect food

 to provide a detailed history
 to pinpoint deviations

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Introduction to HACCP
Step 7: Verification
 to determine the validity of the HACCP
plan
 to ensure that the system is operating
according to plan

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Introduction to HACCP
How HACCP challenges operators
 developing SOP/GMPs
 training employees
 developing self-monitoring tools
 motivating staff and management
 developing standardized menus and
procedures

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Introduction to HACCP
Setting up a HACCP system
 obtain commitment to HACCP
 select menu items and procedures
 identify potentially hazardous ingredients
 analyze processing/preparation
procedures
 implement employee training program

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Introduction to HACCP
Where do we start?

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Introduction to HACCP