HACCP TRAINING PROGRAM PROJECT , PRACTIES & ACTIONS

Introduction , History & Definitions : Food is the most basic instinct in human life, Handling Or Processing & Serving food is one of the hardest job around the world as much as we can save others life , We can feel more proud like HEROES .

Try to think depth on words definition after asking lots of questions like WHY? WHEN? WHAT? & WHERE? After asking that much question you will know the right way then you can WALK-IN .

Food one of life Problem & Solve , sometimes food can kill others and sometimes can save them , imagine the connection of both to know how handling food is very Difficult & Serious it is one of

daily life habits from our Un-Consciousness & Consciousness .

What is the right definition of HACCP?The best way to prevent Harmful, Problems & Food illness Before happened Or some process can save people daily life needs. We can also say it is most

important methods can help people to feel satisfaction ,

Specialists in the biological science say that the definition of HACCP is a Systematic , Scientifically based approach to Food Safety.

It is a Method for identifying hazards in the production of food and implementing control measures to prevent eliminate Or reduce significant hazard to an acceptable level .

It is not a Standalone program but a part of a comprehensive food safety management system FSMS to ensure the production of safe food , the program is sticky the Prerequisite Program PRP’S & Good

Manufacturing Practices GMPS .

Why HACCP ? Hazard Analysis Critical Control Point . Repeatedly demonstrated that it is the most effective system to ensure food safety , is the disciplined application of scientific process to each specific food process , Ensure food safety lead to effective control of identified food safety hazards .

Become a key component of food safety regulation globally but the greatest growth can be attributed to customer demands for greater food safety .

International food chains fined that HACCP delivers additional benefits when properly implemented improvement in product Consistency & Inventory control as well as evidence of reeducation in food safety related Customer Complaints that could result in significant losses have been cited as an additional advantage to implementing a FSMS based on HACCP.

Identifying & Controlling hazard significant for food safety are heart of HACCP, seeking to control hazard significant for food safety the word significant is important since HACCP managers must judge which hazard are important for food safety . Requirements for a comprehensive based on food safety management system FSMS.

Reasons for HACCP , Disciplined application of science to each specific food process leads to effective control of identified food safety hazard. Guides & Encourages organizations to accept responsibility for food safety instead of relying upon compliance with official regulations and inspections by food safety regulation.

 

People responsible for food processes become involved in Planning & Implementing food protection controls and become aware of their roles and responsibilities for food safety .

Improves the design of food products and processes for achieving safe food , Prepares an organization for HACCP based food safety regulation trade specifications and customer requirements for a comprehensive based food safety management system FSMS .

Who Required The organizations who is requires in HACCP at US is FDA & USDA , also we can say all people who is handling food production Process or Progress

The world health organization defines safe food as Assurance that food will not case harm to the customer When it is prepared and or eaten according to its intended use .

 

USDA FDA

United States Department of Agriculture Food & Drug Administration Regulates

Responsible for Farm & Foreign Agriculture service ,

Food nutrition & Consumer service , food safety marketing and regulatory program.

Natural resources & Environment , Research m education & economics Or rural developments

Latest update from the USDA is Intensive Grazing Systems, It is a type of rotational grazing that uses higher per acre stocking rates in smaller grazing units, Can provide multiple benefits for farmers and the environment. Can help maintain & enhance farm profitability while reducing labor and input costs. Can result in improved soil health, increase in sequestered carbon and decreased emissions of other greenhouse gases .

Most of food except Meat , Poultry & Pasteurized egg products ,

Medical and Occupational products , Cosmetics & animal feeds

FDA requires processes involved in the production of the following food implement HACCP

Juices Processes , Seafood , Retail food service facilities utilizing special processes such as Smoking or Curing food , using food additives as a method of

preservation ,

Packaging of food using reduced oxygen packaging methods , sale of molluscan &

shellfish from a tank ,

Custom processing of animals for personal use , production of sprouted beans Or seeds for sale

HACCP History :As a food safety concept was developed in the 1960 . NACMCF was established in 1988 in the unite state , In 1985 the national academy of sciences released its report an evaluation of the role of microbiological criteria for food and made

recommendations that led to the formation and appointment of NACMCF ,NACMCF developed and released HACCP principle for food production in November of 1989 and has worked to standardized the principle of HACCP for all members of the food industry At 1992 the document was updated by NACMCF as the hazard analysis and critical control point systemIn 1997 it was revised to be consistent with the WHO's CODEX HACCP In 1988 the international commission on microbiological specifications for food ICMSF published microorganisms in food.The CODEX committee on food hygiene developed draft HACCP principle in June 1991 CPDEX officially adopted its HACCP guidelines in October 1993 , in 1993 NACMCF revised the guidance standard codifying the currently used five preliminary steps and seven principle of HACCP CODEX & NACMCF amended their standards in 1997

2003 NACMCF integrated the us definition of HACCP with successful implementation and sustenance of the HACCP process.

Types of hazards in food: Biological , Chemical Or PhysicalAs per the last data in USA from the Center for Disease Control CDC & local health departments it is estimated that each year US residents experience 48 million food borne illnesses , 128,000

hospitalizations 3000 death & 10 billions of dollars losses , Reducing food born illness by 1% can prevent about 500,000 from getting sick annually and by 10 % keep about 5 million from getting sick

5 risk factors that result in food borne illnesses

Food Improper holding Inadequate Cooking Poor Contaminated equipments unsafe from Time & Temperature Personal Hygiene

& resource Prevention of

contamination

Biological Hazard : Microbiological Hazards Contaminates cause illnesses as below

 

Below is the name of Bacteria's , Viruses & Parasites that can cause food borne illness for most of the food organization the microorganism of greatest concern are the following Clostridium botulinum can be fatal recovery by an infected person is slow and treatment can be expensive incidents from commercially canned foodsSalmonella is an common food born disease , it is spread through contamination of processed material with raw products , it is killed by right storage and cooking right temperaturestaphylococcus aurous cause of an intoxication the organism must be present and have proper growth condition and have a lack of competitive organismsClostridium Perfringensare frequently associated with food service operations , it may survive improper cooking temperature abuse particularly failure to hold large cooked cuts of meat or poultry at 140 or abovelisteriosis monocylogenes can be found in meat , poultry or dairy product and vegetables , a special concern with it the ability to grow at low temperature such as those found in refrigerated process area

toxin-mediated infection Intoxications Infections

An illness caused by the ingestion of a bacteria that while in the intestinal tract included Shigella species & Shiga toxin producing E-Coli

An illness caused by the ingestion of a bacterial toxin produced by a microorganism,

Staphylococcal poisoning & Botulinum intoxication

An illness caused by the ingestion of a sufficient number of pathogenic microorganisms cause to an adverse health affected by salmonella , listeriosis.We can say that it is the organism itself that causes illness we can’t see by eyes.

Enterovirulent Escherichia coli is a serious food borne hazard it is a commonly spread to food from water contaminated with human or animal feces , it can lead to dieShigella it is responsible for many food borne illnesses each year from poor personal hygiene and food handlingCampylobacter is a serious liver disease caused by the hepatitis , can easily pass the disease to others within the same householders it can cause deathHepatitis A is the most common bacterial cause of diarrheal illness , children and young adults are the most commonly affectedNoro Virus are a group of related viruses that case acute gastroenteritis in humans

Bacterial growth: It can be grow quickly and they have a district pattern of growth because they are single celled organisms bacteria split themselves in half to replicate phases of bacterial growth as following

Lag Phase which is the longest phase during it there is little cell growth , it can go on for several hours or many days depending on the environmental condition

Log Phase time for bacteria to become extremely active and being the process of dividing during it the size of the bacterial colony increases dramatically Stationary Phase involves a slow-down in the growth of cells and colony , it is stability phaseDecline phase the number of dead bacterial cells begin to outnumber the new ones

To much question come into mind storms When we see the phases such as : How long can food sit out at room temp? Potentially hazardous food that stays in the temperature "danger zone", 40-140 °F (4-60 °C), for more than 2 hours should be discarded. Potentially hazardous foods are those foods that spoil most easily, such as unshelled eggs, raw meats, fish, shell fish, dairy products, almost all cooked foods.How long does it take for bacteria to grow on food? Bacteria grow most rapidly in the range of temperatures between 40 ° & 140 °F, doubling in number in as little as 20 minutes. This range of temperatures is often called the “Danger Zone” That's why the Meat and Poultry advises consumers to never leave food out of refrigeration over 2 hours.What temperature does bacteria grow on food? The temperature range in which most bacteria grow is between 40 degrees F (5 degrees C) and 140 degrees F (60 degrees C). Raw and cooked foods should not be kept in this danger zone any longer than absolutely necessary.

Factors influencing bacterial growth One of the primary objectives of a HACCP program is to establish processes to inhibit microorganisms capable of causing food borne illness . The ability of an organism to pass a hazard can be destroyed by a number of factors including;

Nutrients Food PH - Acidity Or Alkalinity

Atmosphere Oxygen presence

Time - Time it takes to grow

Water Activity Moisture Temperature

Competition - Other bacteria &

Microbial interaction

Inhibitors - substances such as preservatives

Food Acidity Temperature Time Oxygen Moisture Food:The type of food you have will let you know How risky your food choices can be. Such fish, milk ,

Eggs & cooked grains are all have a high risk of contamination .Acid:The level of acidity will let you know if it's good environment for bacteria to grow Such Tomato & vinegar.Temperature:Cooking food to correct minimum temperature & maintaining it at or below 41f or at or above140f Most bacteria grow well between 40 & 140f ( 5 & 60 c ) Time: keeping potentially hazardous food in the danger zone to less than 4 hours or more in the temperature danger zone allows bacteria to multiply enough to cause illness. Bacteria reproduce every 15 to 30 minutes and can grow from a single cell to over 1000000 cell in 5 hours .

Oxygen: Just like you most of bacteria need oxygen to grow. That's why we wrap our food in plastic and seal containers tight. No air, No bacteriaMoisture: Bacteria also need certain amount of moisture to live and produce. Foods that are low in moisture like pasta, dried grains and nuts have less of a chance for bacteria to grow than meat, vegetables and cooked grainsPH is the measure acidity of food , the ph scale has a range of 1.0 to 14.0 with 7.0 being neutral , bacteria most commonly involved in food borne illness grow best on foods with ph between 4.6 and 7.0 highly acidic foods such as tomatoes , citrus fruit with ph values between 4.6 don’t usually support Bactria growth

Water Activity :The water activity of a food is not the same things as its moisture content although moist foods are likely to have greater water activity than are dry foodsWater Activity is a measure of microbial susceptibility accepted by the USDA and a key component when conducting a hazard analysis The USDA guidelines state a potentially hazardous food dose not include a food with a water activity value of 0.85 Or less The Amount of water activity in a food affects potential growth of harmful Bactria , foods with a high level of water activity may support bacteria growth Bactria growth best on foods with a water activity of 0.85 Or Higher on scale of 0 -1.0

Oxygen requirements for Bactria growth and survival Different type of Bactria have varying requirements for oxygen , these are variations in between;

Strict Aerobes Grow only in an environment where they get plenty of oxygenStrict Anaerobes Grow only in an environment where no air is present Facultative anaerobes Grow best in oxygen but can grow in the absence of oxygen by sealing oxygen from foods Microoerephilic require oxygen but grow best on an environment where little air is present , these type of Bactria are relatively uncommon , indifferent these bacteria are indifferent to the oxygen level as milk or milk products lactobacillus Or streptococcus.Other biological hazard like viruses are the smallest of all microorganism that must infect a living cell oflarger organism to reproduce . viruses are transmitted 3 ways:

Person to personPerson to food to person pass but does not growPerson to food contact surface to person

Good hygiene practice is the key to preventing viral food borne illness

Physical hazards :Is depending on How the food is handled Or prepared , proper handling may be sufficient to remove , prevent or reduce a microbiological hazard to an acceptable level

 

Now it is time to ask How we can Avoid this happened to our products & How we can carry out the hazard before happened that is the game as team worker or managers or much better leaders we are working to avoid problems before happen not to wait until happened and start to think of solve .

There are 5 sources of physical hazard

Inadvertent materials from the soil ( stones , metal , insects , thorns , wood or small animals )Inadvertent materials from Processing & Handling ( bone , glass , metal , wood , nuts, bolts , screening and wire , cloth, paint chips , rust )Materials entering the food during distribution ( insects, metal , soil , stones ) Materials intentionally placed in food ( employee sabotage Or tampering )Miscellaneous debris and other materials

 

To Prevention physical hazard you can fowling below 7 methods Effective systems for pest control ( Following , Evaluating & Reporting )

Implementing system for removing foreign objects such as Bones Or Stone , Glass from the productEnsure that the general condition of the facility shipping , receiving practices facility maintenance procedures , Product storage facilities & procedure

Review of packaging materials and handling procedures Review of agricultural practices to identify potential of physical hazard Review of personnel practices staff like jewelry , buttons and finger nails

Evaluation of packaging materials to identify physical contamination that may occur from tampering from packaging.

Chemical hazard : Generally it is associated with cleaning and sanitizing ( Equipments , Machines , Products, Utensils and Or Human )

Some statistic from the USA government of food allergens into human: 1 in 25 suffer from food allergies , 30000 visit hospital emergency annually ,150 die annually 190

food items may cause an adverse physical reaction when consumed Such as milk & milk production , Eggs and the products , Peanuts and products tree nuts and products , soybeans and

products , fish and products , shellfish and products , cereals containing gluten Discussed the prevention of Chemical Hazard through out MSDS as per concept approval Certificate Or follow manufacture procedures with right Handling , Shipping , Receiving & Storage.

Below is the sources of chemical hazards Agricultural chemicals include Pesticides , Antibiotics Or Fungicides Industrial chemical included Cleaners & Sanitizers Or Materials used to fabricate or operate manufacturing, storage , transport Or equipmentsNaturally occurring toxicants included products of Plant , Animal Or Microbial metabolites such as Alfa-toxins and Myo-toxins Food processing chemical included Preservatives , Stabilizers & Color enhancers Allergens chemical ( proteins ) that cause abnormal response triggered by the body

immune system , it is reactions to food can sometimes cause serious illness and death

The Prerequisites Program ( PRP’S )Definition of PRP’s it is a vital and essential piece of an effective comprehensive food safety management system , it is a foundation of effective HACCP program included the GMP’s & SSOP’s as well as additional environmental and operational systems that contribute to the sanitation and safety of food environment The additional programs included preventive maintenance, products information, consumer awareness , allergen control , waste management , food defense and bio security processes

GMP’s & SSOP’s can be described as the cornerstones of food safety and are two of the components on which prerequisite programs are based and required for successful implementation of HACCP What are the GMP’s is Good Manufacturing Practices contain both requirements and guidelines for the manufacture of food and drug products in a safe , sanitary environment What are SSOP’s Sanitation Standard Operating Procedures. it is program for food production facilities and required for certain sanitation conditions , It is procedures put in place to help

accomplish the overall goal of maintaining GMP’s / PRP’s in the production of food . The most important now in the PRP’s is to be documented & including :

Clear , distinct program description Defined personnel responsibilities for specific functions Description of all procedures which will impact food safetyCorrective actions Schedules of activity frequency Materials utilized for implementation Record maintenance daily , weekly & monthly Safety considerations for employeesExpected measurable outcomes of effective program implementation

The common of PRP’s program included but not limited into below mention points:

Employees health & hygiene: It is an individual general state of health, hygienic practices and habits.The personal cleanliness of person and clothing Clothing and any personal belongings must be stored away from food or food contact items as equipment’s , no jewelry or other objects that may fall into food , equipment’s or packing , hair must be restrained by hair nets , handling food with clean and specials gloves The proper washing hands very important to avoid that contaminated food process and if the employees have a gastrointestinal illness or an infected lesion , it is reducing the spread of microorganisms in food facility.

Employee Training: Training included the practicing can led to successful business it is the heart and soul of consistency , the training program should be documented and assessed for continued effectiveness considerations for employee training Should Include;Nature and composition of the food produced Processing , packaging and warehousing of products Facilities and equipment Method of delivery and transport Employees culture and experiences including language , beliefs level of comprehension Employee expectations

Facilities Design & Equipment Maintenance: The buildings in food is handled and processed must be designed and constructed in keeping with sanitary principles , it is necessary to adjust the existing environment to accommodate a variety of product or processing considerations including :Type of food Product flow Refrigeration , Processing , Sanitation , Ventilation requirements Dry storage & Warehousing Accessibility of hand washing facilities Storage of chemicalsLighting requirements Employees rest room , break and change room

To prevent harborage of pets or any other sources of contamination, the ultimate goal to protect food product include raw and finished product from contaminated the design of buildings who use to work on food production as following

Premises , surroundings and site of building include parking lots Exterior , interior and construction features

Operational flow and facility layout Example;

Food contact surfaces , food handling and inspection areas , Floor, Walls and Ceilings , Cold storage facilities Heating equipments , Dry storage , Floors , Drains & Waste traps , hand washing stations , sanitary facilities , toilet and change room , preventive maintenance program , chemicals and storage , potable and non-potable water , cross connections and backflow prevention

Sanitation: The most effective point which is can help us to avoid food from harmful as FDA & SSOP sanitation standard operating procedures require attention to the following: Safety of water source Food contact surface Prevention of cross-contamination Maintenance of hand washing and toilet facilities Protection from contamination Proper labeling , storage and use of toxic materials Control of employee health Exclusion of pests Effective cleaning & sanitation TO

Reduce the risk of cross contamination Increase the working life of equipments

Minimize attraction of insects and rodents Reduces the risk for a food borne illness outbreak

Chemical usage and safety Employees are the key of ensure that handling or storing and using it by proper way and proper labeling or storing , To further ensure safe use:

Employees must have access to chemical information included MSDS Chemical must be approved for use in food facility

Employees must be trained in emergency procedures

Pest control Most of pests is source of physical contamination and can be carry pathogenic microorganisms and contaminate food or food borne illness , should be doing it with more carefully and with specialized company as per agreements Receiving , storage and transport Items and products should be revived on the proper temperatures and must be Handel , Store & Transported to minimize the possibility of contamination , damage or other types of compromise to raw material , packaging and finished When constructing to receiving, and storage there is some key elements such as

Supplier approval Raw materials/ packing

Employee training Inspection protocol

Documentation Equipment’s Calibration To be measure Intrinsic & Extrinsic factors in food are accurate and reliable and to be ensure , this is can be achieve when implemented and documented and put in mind that there is some of the calibrated equipment for accuracy against a national standard or as per manufacture equipment .

To ensure that all the equipment's and machines provide accurate reliable results you should follow your effective calibration program contain:

Identify & Document all equipment requiring calibration As weights, scales , PH meters , Water activity meters , Thermometers , Hygrometers , Metal detection devices.Document calibration method & schedule Daily , Weekly & Monthly Or Annually Identify responsible employee to perform or manage calibration label all instruments as appropriate Identify record and frequency ( Accuracy Check vs. Calibration )

Supplier Approval Program ( APL )Most effective point is the source of our supple if it is from the right Or wrong source that is the big question mark can be effective if our ingredient sources is capable of consistently delivering safe , quality & on time supplies according the specific equipments and the receiving guidelines assures that:

Product safety & quality is protectedRaw materials meet agreed with specifications , consistency of raw material & finished productthat can be happened when supplier following below key elementsNew supplier approval protocol ( specifications , legal requirements , expectations , 3rd audit result letters of guarantee)

Required food safety and quality management system Ongoing supplier evaluation Data collection , microbiological , chemical and physical hazard assessments Quality , audit , defects , temperature on time delivery , product integrity Pre receipt of raw materials verification (certificate of analysis trailer seal integrity )

Product traceability & recall Ensure that compromised product can be rapidly removed from circulationprovides assurance that product is easily identifiable and traceable to the customer and to the raw material suppliers , Traceable -One forward-One backDocuments clear and concise instruction for alerting the appropriate regulatory agencies , customers and supplies.product withdrawal/recall Any time there is a need to withdraw or recall a product , it is inconvenient and disruptive . circumstances leading to this drastic action are always unexpected ,therefore , advance

5 preliminary steps to developing a HACCP plan: The only right way to implemented the 7 HACCP principle and to make it effective we will follow the steps to developing a HACCP plan is

Assemble HACCP team

Should be involvement of both Management & Subordinates the team will be responsible to implement the basics of HACCP system and PRP‘s program , Also they focusing to identify significant food safety hazards to be controlled by the system of HACCP in the place and they verify the effective implementation of the HACCP plan and they have continues responsibility for the Revision , Validation & Verifications of HACCP in order to accommodate changes to food

Products , Process Or Technologies . HACCP plan must have clear identify of what is the products and process will be covered clear tasks with range of each product such as some already we received RTE.

Describe the product

The most important part is to know the right definition of the products we use to start processing the production till we finished, here team will be responsible for the documentation such as day dots or a labeling system including Row Materials & Ingredients, recipes of production, physical and chemical characteristic packing and storages , distributed with full of documentation & evidence .

Identify the intended use

Identify the intended use the team will be responsible to consider the potential use of the product and the targeted consumer including who are Elderly , Infants & Malnourished , ill or immune-compromised such as cancer or kidney patients , they will be ensure that the consumer will be receiving fresh , clean and uncontaminated food item such as implementing the effective allergy system on the place who work and focusing with cooking procedures or handling frozen and fresh fish in house system and following up with crew members with guided , effected and

knowledgeable . Construct flow diagrams

Once the team has identified the scope of plan to be developed including the product , processes and targeted consumer , it is time to document the process steps included in the plan , an effective method to document is to constructing a flow diagram as below

Receive raw materials & Packing Load , Ship & Distribute

Warehouse / Storage Finishing the Product

Storage & Preparation Packaging

Processes

Frozen chicken breast

To frozen storage

Thawed in walk-in cooler move to prep area

Handel under right temperature and with PVC

Cooked over right procedure and temperature

Serve immediately hot and out of danger zone

The team must verify its accuracy by literally walking through the facility and observation, firsthand the processes to confirm that all steps are identified and accurately describes effective Daily checklists with comments, target and action

Perform an on-site verification of flow diagrams

The 7 principles of HACCP Will be divided into 2 category, The identification of significant hazards ( HA hazard analysis ) &

The control of those hazards ( CCP critical control point ) The 7 Principle of HACCP as below:Conduct a hazard analysis Determine the critical control point's CCPEstablish critical limits Establish a system to monitor critical limits Establish corrective actions for critical limit violations Establish procedures for verification of the HACCP plan Establish a record keeping system

Conduct a hazard analysis:The process of identifying a significant risk related to food product Or manufactures , Once a HACCP team will identify & document the hazard it will be able to reduce and prevent it to an acceptable level for consumers.

The team must be measure and control it as step that can prevent eliminate or reduce hazard Including Sanitation control , Receiving process &Temperature , PH Or Water Activity.The likelihood ( Refer to how probable it is that a hazard may become a problem ) of occurrence & potential severity ( Considers the significant impact if this hazard is not controlled ) To performing a hazard analysis, we are able to include below mention stepsThe occurrence & severity of each hazard The qualitative & evaluation of the presence of hazards The multiplication characteristic of the microorganism for biological hazards The conditions that contribute to each hazardPersistence of toxins, chemical or physical agents in foods

Identify The CCP:Here we should understand and know what is the different between CP & CCP CP is any step in your process where control can be applied to a potential hazard. There may be dozens of cp’s within a food preparation process, a CCP is a point during the preparation Or processing of food where steps must be taken to reduce or eliminate a significant food safety hazard CP are points where you can exercise control & CCP are points where you must exercise control to prevent , reduce significant hazard to acceptable level to be safety consumed from our customer. CCP may include , But are not limited to below points

Cook temperatureCook time

Freezing time Labile control for allergens

Wash/rinse step for ready to eat produce Metal detection

In-line screens or magnets x-ray detection

Experienced team of HACCP we should not mix between CCP & CP after we got it the HACCP plan will be able to only address CCP as per the different facilities that prepare the same food may identify different hazards , the points , steps or procedures may have different CCP due to differences in layout, equipment's ingredients or processes , it is essential that the unique condition within each facility be considered during the development of a HACCP plan

Tools to identifying CCP it is very important to use here to helping us for determine its CCP such as daily HACCP check list , monthly HOH audit with tracking results.

Establish Critical Limits:Is an measurement Or observation that separates what is acceptable from what is not acceptable , each CCP will have one or more control measures associated with each significant hazard a control must be applied with the preventing significant hazard to an acceptable level and when limit is violated a corrective action must be instituted

When we establish the limits it will be necessary to consider the capability of equipment and personnel to monitor the critical limit as well as the cost and the necessary monitoring frequency , it should not be confused with target level or tolerance , Targeted level is associated with goals of the facility wants to achieve while critical limits are mandatory. it is detected by regulation or government association such as minimum cooking or storage temperatures or holding time or cooking time critical limit can be quantitative – rely on a value that must be met Or not exceeded or qualitative rely on a descriptive value .

Establish Monitoring Procedures:is an action and planned sequences of observations and measurements to assess whether a CCP is under control , it is assuring that the HACCP is functioning properly.

The core purpose of monitoring is the confirmation of critical limits compliance , there is 2 way of monitoring procedure is Continuous Or Non-continues .

The right monitoring system and procedure will help us to prevent hazard before happened or can be warning alarm system for us to focusing with process or procedure on handling food items Below is the correct procedure of doing right monitoring What describe the critical limit How describe the monitoring procedure in details Where must be done at the appropriate location to accurately measure the critical limit Who access to the CCP. Skills & knowledge When continuous Or periodic may require sampling

Types of monitoringObservation usually applied to qualitative , descriptive critical limits , such as any foreign materials present it is includes sensory and visual observation for physical characteristics like appearance or metal , glass , bone & wood .

Measurement applies to quantitative , numerical critical limits such as time , temperature and ph will be recorded on daily sheet , use always calibrated utensils

Establish Corrective Action:Must be start and do when a critical limit is violated will be determine the disposition of the non conforming product , should be documented for each critical limit at each CCP Procedure should be conservative , taking into consideration the risk involved if the product were to be consumed. Who is Responsible Action taken in the process should the process be stopped Disposition of the suspect product ( segregated or disposed of )What is the root cause of the non-conformance Documentation & Reporting Example frozen MeatCritical limit finished product labels for product processed must contain a sulfating agent declaration Corrective action segregate and re-label improperly labeled product , segregate and return label stock that does not contain the proper declaration

Establish procedures for verificationThe function of verification is to provide a degree of confidence that the plan is based on solid process.

Below is type of verification activities include

Initial validation take place before the HACCP plan is implemented is the plan effective in producing a safe product. HACCP system verification contain the validation of HACCP plan focusing on collecting & evaluating scientific and technical data to determine whether the HACCP plan when properly implemented willeffectively control the identified hazards .

CCP verification Consists of regularly scheduled activities such as calibration of Monitoring Devices, Reviewing Records , Targeted Sampling & Testing

Regulatory Verification Depending on the industry and product or as per government requirements

The data assemble to validate a HACCP plan is 2 types Theoretical principle expert advice from processing authorities scientific data or other information demonstrating the particular process control measure can adequately address specified hazards such as studies establishing the temperature necessary to kill organisms of concern In-Plant Observations measurements , test results or other information demonstrating that the control measures as written into a HACCP plan , can be operated within a particular establishment to achieve the intended food safety objective .

Recordkeeping Once the HACCP team has completed the process, it should be documented and recorded as most of organization they records associated with their HACCP system and related to HACCP plan development to their daily operations and for verification activities as some of the records will be defined by regulatory requirements

Requirements Of Records must exist for the five preliminary steps and the six HACCP steps already Scope of the HACCP plan Products & Processes covered by the plan Use of the products Flow diagram produced Hazard analysis including the preventive measures identified CCP determinations Information & data collected to justify critical limits Schedule & types of monitoring Sampling plans Corrective action plans Sample records Schedule and types of verification procedures and Validation data

Most of the records associated with HACCP system are for monitoring and corrective actions can be simple a check list or data sheet , can do it manually or automatically collected , continually Or intermittently collect the choice of the record type depends on the data collected

The checklists can be designed to easily interpret results and demonstrate trends and highlight subtle changes , Data we need all records must be dated , signed by 2 persons in charge one for completed and one to reviewing or verifying .

Below is common errors we should be Avoided Entering information ahead of time Entering false information Failing to correlate time of day with the record Failing to record information that allows it to be tracked or followed through with other record Failing to record process deviations or corrective actions and Failing to record calibration of equipments.