implementation of aa hazard hazard analysis...
TRANSCRIPT
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IMPLEMENTATION OF AIMPLEMENTATION OF A HAZARD ANALYSIS HAZARD ANALYSIS CRITICAL CONTROL POINT (HACCP)CRITICAL CONTROL POINT (HACCP) SYSTEM SYSTEM IN FOOD INDUSTRIESIN FOOD INDUSTRIESIN FOOD INDUSTRIESIN FOOD INDUSTRIES
DepartmenDepartmentt of Food Science and Technologyof Food Science and TechnologyFaculty of Agricultural TechnologyFaculty of Agricultural Technology
Bogor Agricultural UniversityBogor Agricultural UniversityJulJulyy 20102010
Outline
• Introduction to HACCP system• Introduction to HACCP system
definition, why is it used, history, characteristics, where does it stand in a food safety management system, benefit and its implementation
• Preparing a HACCP plan
12 t f HACCP l d i t f t
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
12 steps of HACCP plan and assignments for step 1‐5, 6, 7‐8, 9‐12
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Introduction to a HACCP SystemIntroduction to a HACCP System
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
DEFINITION OF DEFINITION OF HACCPHACCP(Hazard Analysis Critical Control Point)(Hazard Analysis Critical Control Point)
HACCP is a preventive system designed to minimize
the risk of food safety hazards; however HACCP is
not a zero‐risk food safety assurance system
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WHY WHY IS IS HACCPHACCP USED IN A FOOD USED IN A FOOD SAFETY ASSURANCE SYSTEMSAFETY ASSURANCE SYSTEM
• Food safety is a non‐negotiable requirement for food quality and trade
• Failure in assuring food safety will result in :
• illnesses and death in consumers
• product recall detention or destruction
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
product recall, detention, or destruction
• loss in consumer trust
• government actions
HACCP HACCP CHARACTERISTICSCHARACTERISTICS
‐ Systematic approachy pp
‐ Proactive, not reactive
‐ Team effort, not individual’s
‐ Based on common sense technique
‐ Alive and dynamic system
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‐ Alive and dynamic system
‐ Not just a paperwork
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RELATIONSHIP BETWEENRELATIONSHIP BETWEEN GMPGMP, , SSOPSSOP, AND HACCP, AND HACCP ININFOOD QUALITYFOOD QUALITY--SAFETY MANAGEMENTSAFETY MANAGEMENT
SSOP
HACCP
Implementation and documentation of sanitationand hygiene program
Control of hazards in critical steps of process
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GMP
Basic and general recquirement for premises,equipment, workers, and process
FOOD SAFETY MANAGEMENT SYSTEM
• 1959 : Initially deceloped by Pillsbury Co. for astronaut’s food : bite‐size, edible wrapping, safe
HISTORY OF HACCP HISTORY OF HACCP
astronaut s food : bite size, edible wrapping, safe
• 1971 : HACCP concept was first explained to publicin the US in a National Food Safety Conference
• 1972 : Pillsbury obtained a contract in HACCP training for FDA inpectors
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• 1973 : A complete HACCP document was published for the first time, adopted for low acid can food industries
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HISTORY OF HACCP ........... (cont)HISTORY OF HACCP ........... (cont)
•1985 : US National Academy of Sciences) (NAS) recommended HACCP because it was concluded to give more assurance as compared to an end‐product quality control system
•1989 : NAS establish National Advisory Committee on Microbiological Criteria for Foods (NACMCF) and introduced 7 principles of HACCP
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
•1991 : Concept of Biological, Chemical, and Phyisical hazards was developed
•1997 : HACCP concept was adopted by Codex
Initial HACCP Concept
HISTORY OF HACCP ........... (cont)HISTORY OF HACCP ........... (cont)
1. Hazard analysis
2. Determination of critical control points needed for conrolling the identified hazards
3. Determination of procedures to monitor critical control points
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
p
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HACCP concept by NACMSF
HISTORY OF HACCP ........... (cont)HISTORY OF HACCP ........... (cont)
1. Hazard analysis2. Determination of critical control points (CCP) to control
the identified hazards3. Determination of critical limits for each CCP4. Determination of procedures to monitor CCP5. Determination of corrective actions when a deciation
occurs upon monitoring of a CCP
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
p g6. Detemination of effective recording system as a
documentation of a HACCP plan7. Determination of verification procedures to assure that
a HACCP system is implemented properly
Why is a conventional inspection not Why is a conventional inspection not adequate in assuring food safety?adequate in assuring food safety?
• The number of inspectors in any country is not• The number of inspectors in any country is not sufficient
• Inspection alone doesn not assure food safety• Inspection is anly a “snapshot” of food safety status in a certain period of time
• Contamination at low level is notdetected byconvensional testing
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convensional testing• Industries heavily rely on inspection, testing, consumer’s complaint to detect loss in control of their food quality‐safety management system
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WhyWhy is is HACCP HACCP becoming importantbecoming important??
N d t i th k t i kl• New products appear in the market quickly• Use of new methods, techniques and equipmentin food processing
• World market and changes in consumption patterns
• Emerging pathogens
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• Emerging pathogens• The need for international harmonization in world trade
BENEFIT OF IMPLEMENTATION OFBENEFIT OF IMPLEMENTATION OFHACCPHACCP SYSTEMSYSTEM
1. Prevent or detect unsafe raw materials and1. Prevent or detect unsafe raw materials and ingredients before entering production system
2. Prevent a problem to grow bigger since it is handled earlier with early warning in HACCP
3. Cautious of any hazard in a facility shared for production of various products
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4. Reduce internal product “holding” and or product destruction
5. Prevent dependence in end product testing that allow unsafe products relesed to the market
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Implementation of a HACCP System in Food Industries
• Specific for each type of product, process and factory
• Prerequisite : GMP and SSOP
• Requires strong commitment of management to
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provide safe food for the public
REFERENCES FOR HACCP IMPLEMENTATION
• Codex Alimentarius (CAC)• Codex Alimentarius (CAC)• SQF 2000: Safe Quality Food 2000• EQCI: European Quality Certification Institute• ISO 22000 : 2005 on Food Safety Management
System• Indonesia :
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
do es aSNI 01‐4852‐1998 on HACCPPedoman BSN 1004/1999
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STEPS FORSTEPS FOR HACCPHACCP IMPLEMENTATION IMPLEMENTATION (C(Codexodex))
7. Determine CCP Principle 2
Principle 1
6. Identify all potential hazards, analysis of risk and establish preventive measures
1. Establish HACCP team
2. Describe product
3. Identify product use
8. Determine CL for each CCP
9. Determine monitoring system for each CCP
10 . Determine corrective actionsf d i i
Principle 2
Principle 3
Principle 4
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4. Establish a flow chart
5. Verify flow chart on site
for deviation
11. Determine verification procedures
12. Determine recording system
Principle 5
Principle 6
Principle 7
Preparing a HACCP Plan
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Establish a HACCP TeamEstablish a HACCP TeamHACCP HACCP Step 1Step 1
• A HACCP team is established to develop a HACCP plan
• The team members is chosen from personnels who are
involved in daily activity of food production they are of
various education/academic/skill background
(multidiscipline) :may consists of personnels from
d i i i QA l b i i i
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production, sanitation, QA, lab, engineering sections
• The team ideally consists of no more than 6 people
• The HACCP team made the description of a product
Describe ProductDescribe ProductHACCP HACCP Step 2Step 2
whose HACCP plan is to be made
• When more than one product is produced, product can
be chosen based on various consideration such as
production number, degree of risk/hazard involved
• The descriptition includes raw materials ingredients
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• The descriptition includes raw materials, ingredients,
additives, processing technology, product characteritics
( pH, water content, aw etc), packaging (primary,
secondary, tertiary), and storage etc
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Product description includes :• Name
Describe ProductDescribe ProductHACCP HACCP Step 2Step 2
• Composition• Characteristics of end product• Processing methods• Preservation methods• Primary packaging• Packaging for distribution
Storage conditions
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• Storage conditions• Distribution methods• Shelf life• Special labelling• Instruction for use
Describe Product UseDescribe Product UseHACCP HACCP Step 3Step 3
• The HACCP team describe how the product is consumed by consumers, serving methods and consumer groups
• Consumer groups senstive to food safety hazard– Elderly – Infant
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– Pregnant Women– Ill people– Immunocompromised adults
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Flow Chart has to describe :
Establish Flow ChartEstablish Flow ChartHACCP HACCP Step 4Step 4
• Details of all process steps including inspection, transportation, storage and or delay :– Input to the process including raw materials, packaging, water and chemicals
– Output from the process including waste
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from packaging, raw materials, in‐progress products, rework and rejected products
• Validation of the established flow chart by :
Verify Flow ChartVerify Flow ChartHACCP HACCP Step 5Step 5
• Validation of the established flow chart by :
‐ observation of a flow process
‐ sampling
‐ interview
‐ observation of routine and non‐routine process
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• All HACCP team members must be invoved in flow chart verification process
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Assignments for Steps 1‐5
For each group consisting of 4‐6 students, • make a HACCP team, appoint the chair, describe each member’s skill or background
• describe the product your team has made• describe the product use, including the consumer
bli h h fl h
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
• establish theflow chart• verify flow chart in your group discussion• Use Form 1‐5 of the HACCP Work book
•The HACCP team evaluates specific hazard in each step and
Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
The HACCP team evaluates specific hazard in each step and or raw materials/ingredient associated to the step, and determine risk or significance of each hazard
•The HACCP team will use references, brainstorms, expert judgment and :
‐ the verified flow chart
raw materials ingredients additives and or processing
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‐ raw materials, ingredients, additives and or processing aids associated to the steps in the flow chart
‐ product description and use as well as user
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1. Hazard Identification :id tif h d( ) i th t ( ) d
Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
identify hazard(s) in the process step(s) and raw materials, ingredients, additives, processing associated to the steps
2. Determine Preventive MeasuresObtain the source of identified hazard(s) and design the preventive measures, i.e. any activity to eliminate and or minimize the hazard(s) to the acceptable level
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minimize the hazard(s) to the acceptable level3. Determine Risk or Significance
Classify risk or significance as H (high), M (medium) or L (low) using various approaches
• When identify hazard, a HACCP team must understand and
Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
consider :‐ types of hazard involved, probability (P=likeliness to occur), severity (S), probability of hazard being undetected (U)
‐ common hazard(s) associated to a food or raw material‐ whether quality will be incorporated in HACCP plan
• When determine risk, ONE of the following approaches can be d
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used :‐ risk as a function of P and S (applicable for process steps) or‐ risk as a function of P, S and U (applicable for process steps)‐ risk as a function of a risk category (applicable for raw material, product)
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Biological• Bacteria
VirusesProtozoa
Types of Food Safety Hazards
ProtozoaParasites
Physical Hazards• Glass • Wooden chips• Stone
Chemical Hazards• Mycotoxin• Mushroom, shellfish,
algae toxins• Pesticides, fungicides,
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• Metal pieces• Insect parts• Bone• Plastic• Personal accessories
, g ,fertilizer, hormines, antibiotics
• Heavy metals,dioxin• Adulterant : melamine, formaline• Excessive use of additives
Several questions that may arise during Hazard Identification of raw materials :
Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
‐ Can pathogens, toxins, chemical or physical hazards be present in raw mat? What kind?
‐ Is additive used? What’s the limit of use? Is there any possibility of using it at hazardous concentration
‐Will elimination of a certain ingredient support microbial growth?
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‐ Is acid use or pH of end product affecting microbial growth?
‐ Is aw of end product affecting microbial growth‐ Is cooling necessary to maintain quality during storage and or distribution?
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Several questions that may arise during Hazard Identification of process steps :
Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
Identification of process steps :
‐ Can contaminant(s) or hazard(s) enter the product during processing?
‐ Can personal hygiene, contaminated raw material or equipment, cause cause cross contamination?
‐ Can microorganisms grow and multiply during handling
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‐ Can microorganisms grow and multiply during handling, process and or storage?
‐ Is the combination of temperature and time adequate to prevent microbial growth?
Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
Identification of Hazard; conducted by :
• Observing list of raw materials, ingredient, additives, processing aids used to produce the food whose HACCP plan is prepared
• Observing flow chart including food handling, operations or processing techniques applied, storage etc
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• Making a list of hazards((biological, chemical and or physical) potentially occur/associated with materials, process step and identify where they might enter the process steps
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Determination of Risk/Significance of a Hazard
Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
Determination of Risk/Significance of a Hazard
• Is carried out to determine whether a specific hazard associated to a process step or material is significant or risky thus it is potential to be a CCP
• Approach to be used forsignificance determination in this class is : matrix of significance/risk based on P
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this class is : matrix of significance/risk based on P (probability) and S (severity)
Risk or Significance of A HazardRisk or Significance of A Hazard
Severity : y
Probability(likeliness to occur)
Ll Ml Hl
Lm Mm Hm*
l
m
L M H
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)Lh Mh* Hh*h
*significant hazard
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Raw material or ingredients sensitive to microbiological hazards
Beef and poultry, Egg, FishMilk and milk products, including cheeseNuts and ingredients containing nutsSpicesChocolateMushroomSoy flourGelatinPasta
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Frog legVegetablesCereals and their floursCultures for fermentationSeveral natural flavoring and colorants
Salt
S
Raw material or ingredients insensitive to microbiological hazards
Sugar
Chemical preservatives
Acidulant and food grade leavening agents
Gum and thickener (source‐dependent, some are sensitive such as tapioca and gum resulted from fermentation)
Synthetic coloran
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y
High sugar and or salt candy
Most oil and fat (except for butter)
Acid fruits
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Severity of PathogensSevere hazard on general population, life threatening or chronic sequelae or long term illness
Brucella melitensis, B.abortus, B. suis, botulin, EHEC, Salmonella typhi, S. paratyphi A,B,C, Shigella dysenteriae, Burkholderia cocovenenans, V.cholerae O1 dan O139, Mycobacterium bovis, aflatoksin, vCJD/BSE
Campylobacter jejuni serovar O:19, EPEC, ETEC, Clostridium perfringens C, C. botulinum A and B, Enterobacter sakazakii, Listeria monocytogenes, V. vulnificus, Hepatitis A virus, Cryptosporodium parvum
Severe hazard on limited population, life threatening or chronic sequelae or long term illness
S. enteritidis, S.typhimurium, other Salmonella, Yersinia enterocolitica, Y. pseudotuberculosis, Shigella flexneri, S.boydii, S.sonnei, L.
Serious hazard, decrease ion life capacity but not, life threatening, rare sequelae or medium term
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g f , y , ,monocytogenes, trichotecene, T2, zearalenon, fumonisin, okhratoksin
rare sequelae or medium term illness
Medium hazard, not life threatening, short term, self‐limiting symptoms, causes discomfort
B. cereus and its emetic toxin, C. perfringens A, EPEC, ETEC, enterotoksin Staph. aureus , V. cholerae non O1, dan non O139, SRSV (including Norovirus), histamin
Determination of Preventive MeasuresDetermination of Preventive Measures
Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
‐ Preventive measures are activities used to control the identified hazards
‐ Preventive measures shall be designed to eliminate or reduce the identified hazards to an acceptable level
‐ A hazard may require more than one preventive measures meanwhile one preventive measure may be
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measures, meanwhile one preventive measure may be used toward reduction and or elimination of more than none hazard
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Examples of Preventive Measures for Microbiological d
Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
Hazards :‐ heating (sterilization or pasteurization)‐ drying (aw reduction)‐ acidification‐ cooling (refrigeration)‐ freezingaddition of preservatives
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‐ addition of preservatives‐ fermentation‐modified atmosphere packaging (MAP)‐ control atmosphere storage (CAS)
Cl idi b li S ili i d i i ddi i
Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
Examples of Preventive Measures for A Specific Pathogen
Clostridium botulinum(botulism)
Sterilization during canning, addition of salt, nitrite, acidification to pH <4.6, aw reduction to 0.93
S. aureus Implementation of sanitation and SSOP, policy for infected personnels, cooling acidification heating
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cooling, acidification, heating, addituion of bacteriostatic agents
Salmonella Avoid contamination at the source of raw materials, control of raw mat, heating, cooling, pendinginan
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Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
Examples of Preventive Measures for Chemical Hazards
Natural toxicants Guarantee from supplier
Added chemicals Detail specification of raw materialsand or ingredient, supplier guarantee
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Chemical adulterant Identify all additives, check whetherthe additived are permitted for use
Identify Hazard and Determine RiskIdentify Hazard and Determine RiskHACCP HACCP Step 6 (1Step 6 (1stst principle)principle)
Examples of Preventive Measures for Physical Hazards
Foreign matters in rawmaterials
Implement a specification(s) for rawmaterial(s), supplier guarantee, inspectupon arrival
Foreign matters inpackaging materials,cleaning agents
Implement a specification(s) for rawmaterial(s), supplier guarantee, inspectupon arrival
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cleaning agents upon arrival
Foreign matters that mayenter to the productduring processing
Visual checking to end products, equipmentmaintenance, regular equipment inspection
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Team members discuss and study the flow chart and
Assignment for Step 6Assignment for Step 6
other references to • identify all possible hazards associated to raw
materials, formulation, process steps • determine the source of hazard• determine preventive measures for the indentified
hazards
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hazards• determine the risk or signifinace of the identified
hazards• Use form 6 of the HACCP Workbook
• The HACCP team will determine whether a processing
Determine CCPDetermine CCPHACCP HACCP Step 7 (2Step 7 (2ndnd principle)principle)
p gstep with significant hazard/risk is a CCP
• CCP (Critical Control Point) is a point or procedure in a food processing steps that will cause health risk to consumers when it is not controlled properly
• CCP can be :
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‐ a process step : heating, coolong‐ formulation : addition of acidraw materials
• A decision tree can be used to help determining CCPs
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General Question to be asked
Determine CCPDetermine CCPHACCP HACCP Step 7 (2Step 7 (2ndnd principle)principle)
General Question to be asked :
When control is not in place, will risk of health to the consumers occur ?
Answer :Yes Answer :No
CCP Not a CCP,
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May be a CP*
*Control point related to quality
Decision Tree for CCP DeterminationDecision Tree for CCP DeterminationFor each processing step in the flow chart :
Q1 : Does this step contain significant hazard?
Yes No
Q2: is there any preventive measure to prevent the identified hazards?
Modification of process step
Not CCP
to prevent the identified hazards?
Q4: Is there a possibility that hazards and or contamination that d i hi ill i bl l l?
Yes
Yes
Q3: is this step specifically designed to reduce/eliminate hazard to an acceptable level?
CCP
p p
Is control of this step necessary for food safety?
Yes
No
No
NoNot CCP
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occur during this step will increse to an unacceptable level?
Q5 : Is there any activity that will eliminate this hazard in the following steps?
Yes No CCP
Not CCP
Not CCP
NoYes
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• The HACCPteam will determine a critical limit for
Determine CLDetermine CLHACCP HACCP Step 8 (3Step 8 (3rdrd principle)principle)
each CCP• CL or Critical Limits
‐ are criteria to be fulfilled for each preventive measure implemented to a CCP‐ separate “accepted” from “rejected”‐mplemented to all CCPs
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mplemented to all CCPs‐must be justiviable‐must be measurable‐must be validated
Criteria commonly used for critical limits of CCPs
Determine CLDetermine CLHACCP HACCP Step 8 (3Step 8 (3rdrd principle)principle)
y
‐ Physical : time, temperature, humidity, Aw, viscosity, flow rate
‐ Chemical : pH, titratble acid, concentration of preservatives, salt concetration, free residual chlorine
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‐Microbiological :are usually not used, except when specific and sensitive rapid tests are available
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CCP Critical Component for CL
Determine CLDetermine CLHACCP HACCP Step 8 (3Step 8 (3rdrd principle)principle)
Retorting in a canning process Initial temperatatureCan weight after fillingCan volumePressure ofretortTime
Cooking of a hamburger Thickness of hamburgerTemperature of heating
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Temperature of heatingTime of heating
Addition of acid into acid drink pH of end productsMetal detection in cereal processing Callibration of detector
Sensitivity/capacity ofdetector
Examples of Critical Limits
Hazard CCP CL
Determine CLDetermine CLHACCP HACCP Step 8 (3Step 8 (3rdrd principle)principle)
Non spore former pathogen
Pasteurization 72 C minimal of 15 min
Metal Metal detector Chips of metal < 0.5 mm
Pathogen Oven drying Aw<0.85 to control growth
Excessive nitrite Beef curing max. 200 ppm of sodium nitrite in end product
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Pathogenic bacteria Acidification pH max 4.6 to control C. botulinum growth in acid food
Allergen Labelling Label must present and mention the allergen
Histamine Receiving of tuna Max. 25 ppm in tuna
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Sources of Information for CL Determination
Sources Example
Determine CLDetermine CLHACCP HACCP Step 8 (3Step 8 (3rdrd principle)principle)
Sources ExampleSurvey reference
supplier’s dataRegulation USDA codes
FDA regulationsPP PelabelanCodex, ICMSF
Research “Challenge test”“in house” training
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“in‐house” trainingExperts Thermal process certification
ConsultantMicrobiology ExpertManufacturing CompanySanitation experts
Operational Limit• In implementation, industry sets operational limits which are
stricter than critical limits• Operational limit is a point where an operator has to take
action when monitoring shows trends that a critical limit will likely be exceededlikely be exceeded
• When an operational limit is exceeded but critical limit is not, operator has to adjust the process without possibility of having unsafe food
• Examples of critical limits vs operational limits :Process Critical Limit Operational Limit
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Acidification pH 4.6 pH 4.3Drying Aw Aw 0.80Hot filling 80oC Aw 0.85Cutting 2.5 cm 2.0 cm
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Critical Limit dan Operational Limit
adjustment
Operational limit
Critical limit
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corrective actions
Assignments for Steps 7‐8
Team members discuss the results of the hazard analysis and :
• determine whether any of the significant hazard is a CCP, with the help of a decision tree
• Determine what limit is justifiable for
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• Determine what limit is justifiable for the identified CCPs
• use Form 7 and Form 8 of the HACCP Work book
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What to Monitor
Determine Monitoring ProceduresDetermine Monitoring ProceduresHACCP HACCP Step 9 (4Step 9 (4thth principle)principle)
b i i h h k li
At each CCP
Personnels who have access, skills, knowledge, not bias, need training and experience
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observation with check listMeasurement with data sheet
Per lot? How many sampels? How frequent?Risk, statistical analysis, literatures
Product name : . . . . . . . . . . .
SanitationS: satisfactoryR: needs repairW: warning
Date BeforeBreak I Break II Comment
Examples of Checklist
Time
Water change forspraying of equipment
Cleaning of processing tank
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Inspected bysupervisor QA Manager
Tank
Floor cleaning
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Example of Data sheet
Internal ProductsProduct Names : . . . . . . . . . . . . .
Line 1 Critical Limit : 180oF Date : ...............................
Time Temperatur
8.00 181
8.30 181
9.00 180
9 30 180
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9.30 180
10.00 179
10.30 179
Operator :.........................
Use of CL Monitoring
Determine Monitoring ProceduresDetermine Monitoring ProceduresHACCP HACCP Step 9 (4Step 9 (4thth principle)principle)
• obtain data (information) for decisions made• early warning when deviation occur• prevent/minimize product loss• pin point reasons for problems or deviations that occur• provide documents that a product has been processed in
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compliance with its HACCP plan
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Corrective actions :
Determine Corrective ActionsDetermine Corrective ActionsHACCP HACCP Step 10 (5Step 10 (5thth principle)principle)
Any actions taken when monitoring of CCPs
shows any deviation based on their CL; a
deviation of a CL suggests loss of control thus
product may not fulfil the requirements
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product may not fulfil the requirements
Immediate actions :
• adjustment for any process steps
Determine Corrective ActionsDetermine Corrective ActionsHACCP HACCP Step 10 (5Step 10 (5thth principle)principle)
adjustment for any process steps• actions upon processed product when loss of control occur
• investigation of reasons for control loss• appoint person in charge to make decisions of corrective action
`Deviation control
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Deviation control• identify reasons for control loss• isolate suspected products • evaluate suspected products
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Records of Corrective Actions contains :Code date of production
Determine Corrective ActionsDetermine Corrective ActionsHACCP HACCP Step 10 (5Step 10 (5thth principle)principle)
‐ Code, date of production‐ Reasons for proct holding‐ Amount (number) of products withold‐ Evaluation results, signature of person in charge of evaluation‐ Disposition, signature of person in charge of disposition‐ Reasons for deviation‐ Corrective actions taken
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
Corrective actions taken‐ Follow up actions to assess effectivity of corective actions ‐ Date‐ Signature of person in chargeRecords of Corrective Actions must be documented
V ifi ti i HACCP Pl
Determine Verification ProceduresDetermine Verification ProceduresHACCP HACCP Step 11 (6Step 11 (6thth principle)principle)
Verification in HACCP Plan:
• Application of any methods, procedures, testing or other
evaluations to determine whether a HACCP plan is valid
and comply with its requirement
• Include what to verify and who is responsible for the
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
verification process
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Determine Verification ProceduresDetermine Verification ProceduresHACCP HACCP Step 11 (6Step 11 (6thth principle)principle)
Verification of a HACCP plan
1. Verify whether a CCP is effectively controlledthrough testing, callibration, and review of monitoring results
2 Verify whether a HACCP system is in place through
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
2. Verify whether a HACCP system is in place through audit
Product testings and Periodical Spot Check‐ to support inspections to assure that all CCPs
Determine Verification ProceduresDetermine Verification ProceduresHACCP HACCP Step 11 (6Step 11 (6thth principle)principle)
‐ to support inspections to assure that all CCPs are in control
‐ Evaluation of personnels’ competence‐ Carried out at CCP, intermediate products, end products
‐ Survey of storage conditions, distributions, retail
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
and use of products‐ Callibrations of equipments used for monitoring and verification
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Determine Verification ProceduresDetermine Verification ProceduresHACCP HACCP Step 11 (6Step 11 (6thth principle)principle)
Review of Monitoring Results
• review of all daily records of CCPs
• review any other record related to food safety
• all review procedures are signed
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
• all review procedures are signed
• officer conducting reviews has to have skills
Periodical Reviews
Determine Verification ProceduresDetermine Verification ProceduresHACCP HACCP Step 11 (6Step 11 (6thth principle)principle)
• periodical reviews on all documented records • carried out when there is a change in procedures, raw materials, ingredients, additives, lay out, storage conditions,di t ib ti k i ti th d
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
distribution, , packaging, consumption methods• new hazard issues emerge
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Audit :
Determine Verification ProceduresDetermine Verification ProceduresHACCP HACCP Step 11 (6Step 11 (6thth principle)principle)
A systematic and independent evaluation to determine whether‐procedures have been implemented effectively‐activities and results comply with the procedure d t
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
documents
Team shall determine an effective recording
Establish Documentation SystemEstablish Documentation SystemHACCP HACCP Step 12 (7Step 12 (7thth principle)principle)
ea s a dete e a e ect e eco d gsystem for the HACCP Plan :
• Records of CCP monitoring, as log sheet/log book or check list
• The documented records are to be used for
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
inspection purposes and to study any damage that causes deviations and appropriate corrective actions
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HACCP documents include :
Establish Documentation SystemEstablish Documentation SystemHACCP HACCP Step 12 (7Step 12 (7thth principle)principle)
‐ HACCP plan and all of the supporting documents‐ Document of Monitoring ‐ Document of Corrective Actions‐ Document of Verification Procedures
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
CHANGES IN A HACCP PLAN
Changes in a HACCP plan can be done due to these f ll i hfollowing changes :
‐ raw materials
‐ lay out
‐ equipments
‐ cleaning or sanitation program
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
g p g
‐ implementation of new procedures
‐ new consumer groups
‐ new information on a hazard
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Assignments for steps 9‐12
Using information obtained from step 1‐8 and studies on the reference, team members discuss and determine :
• how a monitoring is designed for the CLs of theCCPs
• what kind of corrective actions are planned in the light of deviation during CL monitoring
• What kind of verification system is planned for the CLs/CCPs effectiveness
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010
CLs/CCPs effectiveness
• What kind of documents are to be made to be an effective HACCP system
• Complete the HACCP table
HACCP WorksheetHACCP Plan
Name of Product : ……………………………………………………………………Company :Company : …………………………………………………………………...
Process Principle 1 Principle 2 Principle 3 Principle 4 Principle 5 Principle 6 Principle 7step hazard CCP CL what how where who when corrective action verification documentation
what who
Bogor Agricultural UniversityRDH‐LN‐HACCP Training‐2010