View
228
Download
0
Category
Preview:
Citation preview
8/4/2019 HACCP Introduction-Refresher Training
1/66
Page 1
HACCP Introduction - 7 Principles VERSION 2, June 2008
HACCP Introduction7 Principles
8/4/2019 HACCP Introduction-Refresher Training
2/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
2
The most common template (tool) for afood safety plan follows principles laid outunder a program called HACCP
Back in 1959, the US space agency NASAfaced a simple but mundane problem whenplanning its first manned space flights:How and what was it going to feedastronauts ?
The American food company Pillsbury
(now part of General Mills) was called intohelp.
HACCP stands for Hazard Analysis & Critical Control Points
The History of HACCP
8/4/2019 HACCP Introduction-Refresher Training
3/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
3
US Space Agency - NASA
8/4/2019 HACCP Introduction-Refresher Training
4/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
4
NASA concluded..
With standard QC..No way we could be sure that there
would not be a problem
Our present QC system is testing Raw Material andFinished Product
Sampling and testing of each batch of food is impractical
How did they know that the Foodis Safe?
Is End Product Testing Sufficient? How Many Samples to Test?
US Space Agency - NASA
http://www.nasa.gov/home/index.html8/4/2019 HACCP Introduction-Refresher Training
5/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
5
!
Finished ProductProcessingRaw Material
Example
If 1 of 1000 batches was defective (0.1%)..If test 60 batches..If we say Yes for release.>94% chance for releaseThen still would miss defective batches!
How many finished batches do you test?
QC ? QC
?
Storage & Transport
QC?QC?
8/4/2019 HACCP Introduction-Refresher Training
6/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
6
HACCP was developed by Pillsbury Company (USA) in 1959 The HACCP concept was pioneered in the 1960s by the Pillsbury Company,
the US Army and NASA as a collaborative development for the production ofsafe foods for the United States space program.
1973 Pillsbury published comprehensive document on Hazard Analysis
1974 - FDA used HACCP principles in development of low-acid regulations.
1980s major food companies began to utilize HACCP Principles
1993 the Codex Alimentarius Commission adopted Guidelines for theapplication of the Hazard Analysis Critical Control Point(HACCP) systemto include 7 Principles. Further updates were provided in 1997.
The HACCP system for food safety is now adopted as national guidelines or
required regulations in many countries.
This PepsiCo International HACCP Training is based on
1997 Codex and NACMCSF HACCP 1997 Guidelines
National Advisor Committee on Microbiolo ical Criteria for FoodsCAC FAO + WHO
HACCP Introduction
8/4/2019 HACCP Introduction-Refresher Training
7/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
7
Systematic Approach for:
Identification and assessment of Hazards associated withManufacturing, Distribution, and use of Food Products aswell as the definition of Preventative Measures for their
Control
HACCP focuses solely on Significant Hazards that areReasonably Likely to result in unacceptable health
risk to consumers
HACCP
8/4/2019 HACCP Introduction-Refresher Training
8/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
8
HACCP is a Tool
Hazard Analysis Critical Control Points (HACCP) is a tool andis not designed to be a stand alone program.
To be effective, other tools must include: adherence to goodmanufacturing practices, sanitation standard operatingprocedures, and a personal hygiene program.
8/4/2019 HACCP Introduction-Refresher Training
9/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
9
Why is Food Safety so Important ?
More countries will incorporate Food Safety principlesinto their food legislations
Food Safety Plans will be made mandatory for more
categories of products
In the long run, food business operations not basedon Food Safety will not be acceptable by the industry,consumers, government and other stakeholders
8/4/2019 HACCP Introduction-Refresher Training
10/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
10
Roles & Responsibilities
Management commitment
A clear understanding of the principles ofFood Safety system
Provide for sufficient resources for
training Allocate resources for implementation
Take ownership of the Food Safetysystem
The need to share experiences with othersectors to ensure that adequate provisionis made for food safety.
8/4/2019 HACCP Introduction-Refresher Training
11/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
11
1. Introduction to HACCP
2. Pre-requisite Programmes
3. Developing a HACCP System4. What are the Hazards
5. Assessing the Risk
6. Critical Control Points (CCPs)
7. Validation, Verification and Review
8. Implementation, Communications and Maintenance
Module 2
IPS
8/4/2019 HACCP Introduction-Refresher Training
12/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
12
Steps or procedures that control theoperational conditions within the foodestablishment, allowing for environmental
conditions that are favorable for safe andwholesome food manufacturing
Prerequisite programs are the foundation
for establishment of HACCP and guidelinesfor production of safe products.
Prerequisite Programs
8/4/2019 HACCP Introduction-Refresher Training
13/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
13
How Do These Programs Fit Together ?
The Umbrella shows theprograms and how they
link together -now we willlook at some of theseprograms in more detail
A common diagram of a quality /food safety system: the Umbrella.
8/4/2019 HACCP Introduction-Refresher Training
14/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
14
Prerequisite Programs address operationalconditions providing a foundation of a HACCPSystem
Manufacturing Facility Design
Receiving and Storage
Equipment Performance and Maintenance
Sanitation and Pest Control
Recall and TraceabilityPersonnel Training
Prerequisite Programs
8/4/2019 HACCP Introduction-Refresher Training
15/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
15
Prerequisite Programs
There are five (5) basic requirements :-
1. Documented all aspects written down(what, how, where, when, who)
2. Effectively implemented - monitored andsupervised
3. Assessed for effectiveness
4. Corrective action must be taken when
problems are identified5. Records kept of monitoring & corrective action
8/4/2019 HACCP Introduction-Refresher Training
16/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
16
Codex General Principlesof Food Hygiene
Relevant Codes of Practice
Relevant Food SafetyLegislation
Pre-requisite Programmes
Systems that are normally in place before the HACCPplan is developed to ensure the business is operating
according to:
8/4/2019 HACCP Introduction-Refresher Training
17/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
17
Also called Good Manufacturing Practices
Provides a sound foundation of HACCP
Covers Low Risk hazards
Allows the HACCP plan to be focused &specific
Give a formal support network for HACCPteam
Enables stream-lined HACCP plans
Food Safety Pre-requisite Programmes
8/4/2019 HACCP Introduction-Refresher Training
18/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
18
CROP to CONSUMER
Food Safety Programmes
What programmes do we have?
8/4/2019 HACCP Introduction-Refresher Training
19/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
19
AIB andInternalAudits
8/4/2019 HACCP Introduction-Refresher Training
20/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
20
Other Pre-requisites
People Programmes
Hygiene Training
Site Experts and Trainers
Quality Management
QA systems QAS
Vendor Assurance All raw materials
8/4/2019 HACCP Introduction-Refresher Training
21/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
21
Quality Managementensures the level ofQUALITY is consistentlymet
Plant
Quality
Systems
(IPS)
Traceability
Calibration
Document control
Record keeping
HACCP and Quality Management
Plant FoodSafety
Systems(CRP)
HACCP & CRPensures themanufacture ofSAFE products
8/4/2019 HACCP Introduction-Refresher Training
22/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
22
Document Control
Many documents in aHACCP system
Need to keep updated and
current Methods for withdrawal and
destruction of obsolete/out ofdate documents
Vital to ensure correctrecords kept
8/4/2019 HACCP Introduction-Refresher Training
23/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
23
Record-keeping
All monitoring forms forCCPs or SCPs need to bemaintained in retrievable
format for 3 years (see localrequirements)
Some records need only be
kept for shelf life + 6months
8/4/2019 HACCP Introduction-Refresher Training
24/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
24
Traceability
Ability to track where materials havecome from, and go to
One step up and one step down
All materials labelled by batch andlot
Segregate each batch and lot fromsimilar materials
Trail to link raw material batches andfinal product codes
8/4/2019 HACCP Introduction-Refresher Training
25/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
25
Calibration
Not all technical equipmentelectronically controlled
Other equipment needs to becalibrated by trained staff, e.g. :
Laboratory analytical equipment
On-line moisture meters
Metal detectors
Hand-held engineering test apparatus
Without calibration, informationgiven may be inaccurate and ourrecords are worthless!
8/4/2019 HACCP Introduction-Refresher Training
26/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
26
Pre-requisite Programmes
HACCP will work well if supported by other sound practices
Need to evaluate these practices and activities
Deficiencies and gaps in existing systems need to beidentified
Gap Analysis will help to identify these so that a completeframework exists on which to build the HACCP system
Evaluation of Pre-requisites in place
Completed pre-requisite programmes need to be validated inthe same way as HACCP to confirm their effectiveness
Procedures for verification will include audit, inspections,testing and analysis
Documentation and records are required
Effectiveness of Pre-requisites
8/4/2019 HACCP Introduction-Refresher Training
27/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
27
Role of Quality Pre-requisites
Key quality systems need to be in place toensure an effective HACCP system
HACCP plans should only cover food safety
not quality There is an essential relationship between
quality and food safety programmes, but..
A HACCP plan must stick to its scope:
FOOD SAFETY
8/4/2019 HACCP Introduction-Refresher Training
28/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
28
What is HACCP?
Structured, preventative system Achieves Food Safety through:
Hazard Identification
Control of Hazards
Hazard Analysis & Critical Control Point
8/4/2019 HACCP Introduction-Refresher Training
29/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
29
Why do we need HACCP?
To protect the consumers of our products Eliminate Food Safety Risk to the business
Legal Requirement in many countries (EU foodlegislation applied from 1 January 2006)
PepsiCo chosensystem for Food Safety and RiskAssessment: Simple
Effective
Understandable
8/4/2019 HACCP Introduction-Refresher Training
30/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
30
Seven Principles of HACCP
Principle 1 Hazard Analysis
Principle 2 Identified CCPs
Principle 3 Establish Critical Limits
Principle 4 Monitor CCPs
Principle 5 Establish Corrective Action
Principle 6 Verification
Principle 7 Record Keeping
8/4/2019 HACCP Introduction-Refresher Training
31/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
31
Principle 1 - Hazard Analysis
Identify the potential hazard(s) associated withfood production at all stages, from primaryproduction, processing, manufacture anddistribution until the point of consumption.
A flow diagram of the complete process isimportant in conducting the hazard analysis. Thesignificant hazards associated with eachspecific step of the manufacturing process arelisted.
If you dont know what the
hazards are, then find out !
8/4/2019 HACCP Introduction-Refresher Training
32/66
8/4/2019 HACCP Introduction-Refresher Training
33/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
33
Principle 3 - Establish Critical Limits
Establish critical limit(s) which must be met toensure the CCP is under control.
Critical limits are the operational boundariesof the CCPs which control the food safetyhazard(s).
All CCP's must have preventive measureswhich are measurable!
The criteria for the critical limits aredetermined ahead of time in consultation withcompetent authorities.
Unless you can MEASURE,you cant control!
8/4/2019 HACCP Introduction-Refresher Training
34/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
34
Principle - 4 Monitor CCPs
Establish a system to monitor control of theCCP by scheduled testing or observations.
It allows processors to assess trends beforea loss of control occurs. Adjustments can bemade while continuing the process.
The monitoring interval must be adequate toensure reliable control of the process.
Monitoring is effective datacollection to enable decision making!
8/4/2019 HACCP Introduction-Refresher Training
35/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
35
Principle - 5 Establish Corrective Action
Establish the corrective action to be takenwhen monitoring indicates that a particularCCP is not under control.
HACCP is intended to prevent product orprocess deviations. However, should loss of
control occur, there must be definite steps inplace for disposition of the product and forcorrection of the process.
These must be pre-planned and written
Failure requires: stopping the process,
hold the products, correcting the problemand recording the action!
8/4/2019 HACCP Introduction-Refresher Training
36/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
36
Principle - 6 Verification
Establish procedures for verification toconfirm that the HACCP system is workingeffectively
The system should be subject to periodicrevalidation using independent audits orother verification procedures.
Proving the system is effectiveand product is safe!
8/4/2019 HACCP Introduction-Refresher Training
37/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
37
Principle - 7 Record Keeping
The HACCP system requires the preparationand maintenance of a written HACCP plantogether with other documentation.
Usually, the simplest record keeping systempossible to ensure effectiveness is the mostdesirable.
Not documented, it did not happenNot documented -it did not happen!
8/4/2019 HACCP Introduction-Refresher Training
38/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
38
RawMaterial
Processing Heat Treatment FillingProcessing Transportation
and StorageShelf life/Consumption
Farm Fork
Prevention rather than Inspection Systematic Approach Identifies Hazards in the Process Identifies Critical Points for Control and Monitoring
Focus is on Safety and not Quality
7 Principles Summary
8/4/2019 HACCP Introduction-Refresher Training
39/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
39
12. Establish documentation & record keeping
11. Establish verification procedures
10. Establish corrective actions
9. Establish monitoring systemfor CCPs
8. Establish critical limitsfor CCPs
7. Determine Critical Control Points(CCPs)
6. List hazards, conduct hazard analysis, consider control measures
5. On-site confirmation of flow diagram
4. Construct flow diagram
3. Identify intended use
2. Describe product
1. Assemble HACCP Team
1
2
3
4
5
6
7
12 Codex steps & 7 principles
8/4/2019 HACCP Introduction-Refresher Training
40/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
40
1. Assemble HACCP Team
Codex step 1
Multi-disciplined Individual Expertise HACCP-Trained
Familiar with Process
8/4/2019 HACCP Introduction-Refresher Training
41/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
41
Who needs to be part of the HACCP team?
Process line representative(s)
Packaging representative
Support services (Engineers)
Production management representative (e.g. FLM)
HACCP Project Leader
Subject Specialist (Microbiologist, Regulatory affairs)
The HACCP team
8/4/2019 HACCP Introduction-Refresher Training
42/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
42
1. Assemble HACCP Team
Codex steps 2 to 4
4. Construct flow diagram
Process Flow
3. Identify intended use
Intended Use
2. Describe product
Describe Product
Specification
Ingredients (incl. Allergens)
Processing requirements
Labelling requirements
8/4/2019 HACCP Introduction-Refresher Training
43/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
43
Process Flow Charts
8/4/2019 HACCP Introduction-Refresher Training
44/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
44
Flow Charts Simple
All inputs All outputs All process steps Numbered steps Describe process
Not equipment
Process Flow Charts
Peeling
Slicing
Frying
Seasoning
Peel
Waste oilOil
1.
3.
4.
7.
2.
6.5.
8/4/2019 HACCP Introduction-Refresher Training
45/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
45
Hazard Analysis
What does Codex say about Hazard Analysis ?
The process ofcollecting andevaluating information on
hazards and conditions leadingto their presence to decide
which are significant for foodsafety and therefore should be
addressed in the HACCP plan
8/4/2019 HACCP Introduction-Refresher Training
46/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
46
Collecting and evaluating information
Brainstorming (use the HACCP team) Research (R&D and scientific and trade literature,public health statistics)
Analysis of available data (AIB reports , internal SOSaudits)
Consumer complaints data
Consumer surveys and reports
Talking to people on the line
Practical observation
Shelf life and challenge studies
Consider users and abusers
8/4/2019 HACCP Introduction-Refresher Training
47/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
47
What is a Hazard?
A HAZARD is...
A property which may cause a productto be unsafe for consumption
8/4/2019 HACCP Introduction-Refresher Training
48/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
48
What are the three types of Hazard?
Chemical
Physical
Biological
There are 3 main types of Hazard
8/4/2019 HACCP Introduction-Refresher Training
49/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
49
Identify the Hazards at each step in the process
Peeling
Slicing
Frying
Seasoning
Peel
Waste oilOil
1.
3.
4.
7.
2.
6.5.
8/4/2019 HACCP Introduction-Refresher Training
50/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
50
3.
CC
8/4/2019 HACCP Introduction-Refresher Training
51/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
51
The process of hazard analysis is the result of:
collecting information on hazards
evaluating their significance
Hazard Analysis
Using a Risk AssessmentModel to
determine what goes into the HACCPplan
HACCP I d i
8/4/2019 HACCP Introduction-Refresher Training
52/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
52
A Risk Assessment Model should be used
so that the risk assessment can be as objective
as possible and to enable the ranking of
hazards as to their importance
Risk assessment
RISK = Severity x Frequency
HACCP I d i
8/4/2019 HACCP Introduction-Refresher Training
53/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
53
These two together = Significance or RISK
Is the Hazard significant?
2. Ask yourself:
How often does it happen, what is the frequency?
1. Ask yourself:
What will be the severity of the outcome?
HACCP I t d ti
8/4/2019 HACCP Introduction-Refresher Training
54/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
54
Risk Assessment Model - Severity
RISK = Severity x Frequency
Severityif
controlsfail
Severity of affect if Hazard OccursMultipl
ier
LittleDamage
Mild disappointment to the consumer. May lead to a complaint, no business
interruption. Minor consequences.1
DamageVery minor medical treatment, (for example a broken tooth). Consumer
disappointed and likely to lead to a complaint to the Company.2
SeriousDamage
Illness at home. Medical treatment not necessary. A disappointed consumer
very likely to lead to a complaint to a regulatory authority.3
Very
SeriousDamage
Illness at home with medical treatment necessary. A very disappointed
consumer. A significant risk of proscecution. 4
DisasterSeriousIllness
Hospitalization required. Significant risk of proscecution. Media coverage.
Intervention by Crisis management team. Damage to branded image.5
Catast-rophic
Death. Top level crisis management Certain risk of proscecution.
Destruction of brand6
Severity
HACCP I t d ti
8/4/2019 HACCP Introduction-Refresher Training
55/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
55
Probability ofhazard
occurring ifprocess fails
Frequency That Hazard Could OccurMultipl
ier
AlmostImpossible
Less than once a year, no history of it occurring 1
Un-Likely Very occasional, has been known to occur 2
Small Risk Isolated event that result after manual operations 3
Likely Product or operational factors that can be expected to be present 4
Certain Product or operational factors that the process is expected to control 5
Frequency RISK = Severity x Frequency
Risk Assessment Model - Frequency
HACCP I t d ti
8/4/2019 HACCP Introduction-Refresher Training
56/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
56
6 9
A consumer issue. With some risk to consumer safety.
Certainly needs control by a GMP, could be aSpecific Control Point (SCP)
10 16Use Codex decision tree for hazards. Implications for correctiveaction procedures. Report/resolve and record at next HACCP review.Definitely either a GMP or an SCP,may be a CCP
15Probably controlled by a Good Manufacturing Practice (GMP).Check nature of problem against existing pre-requisiteprogrammes
16 +Likely to be a Critical control point (CCP). Use Codex decision treefor hazards. Failure may result in food poisoning incidents orProduct Recall. Initiates special HACCP review.
Guideline Actions from the Risk Assessment
HACCP I t d ti
8/4/2019 HACCP Introduction-Refresher Training
57/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
57
GMPs, SCPs and CCPs
A step in the food production process wherea control measure can be applied
Must control the hazard to a safe level, oreliminate it completely.
CCP
Critical Control Point
MagnetsSpecific Control Point
May occur at several points in theprocess
Do not give complete control of a Hazard
Will need a high level of checking.
SCP
Good ManufacturingPractice
METAL
METAL
Contact
Also called Pre-Requisites
Provide a sound foundation for HACCP
Control Low Risk hazards
GMP
HACCP Introduction
8/4/2019 HACCP Introduction-Refresher Training
58/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
58
Engineering out hazards - examples...
Making alterations to equipment to prevent metal-to-metal contact
Modifying equipment to prevent Allergen cross-contamination
Re-designing equipment to make it easier to clean
HACCP Introduction
8/4/2019 HACCP Introduction-Refresher Training
59/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
59
Preventing or reducing hazards - key questions
Is this controlled by a pre-requisite GMPprogramme?
Is there equipment or processing whichprevents the hazards being present at later
stages? If we cannot prevent the hazard occurring, is
our only option to monitor potentialcontamination to ensure that unsafe productcannot leave our factory?
HACCP Introduction
8/4/2019 HACCP Introduction-Refresher Training
60/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
60
CCPs should be identified with the aid of a
Decision Tree and/or Risk Assessment Matrix
Critical Control Points CODEXdefinition
A step where control can beapplied and is essential to
prevent, eliminate or reduce afood safety hazard to acceptable
levels
What is a CCP?
HACCP Introduction
8/4/2019 HACCP Introduction-Refresher Training
61/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
61
CRITICALCONTROL
POINT
*= Proceed to next hazard or step in the describedrocess
Q1. Are the controlmeasures in place for thehazard?
Q2. Is the process stepspecifically designed toeliminate or reduce the hazardto an acceptable level?
YES
Q3. Could contamination withthe hazard occur atunacceptable level(s) or increaseto unacceptable level(s)?
NO
Questions to be answered for each potential hazard at each process step. Do not proceed where
the hazard is managed by a pre-requisite or GMP programme:
YES
NO Is the control at this stepnecessary for food safety?
Modify process or product
YES
Not aCCP Stop
*
NO
Not aCCP
Stop
*
NO
YES Q4. Will a subsequent processstep eliminate or reduce thehazard to an acceptable level?
Not aCCP
Stop
*
YES
NO
CCP Decision Tree
HACCP Introduction
8/4/2019 HACCP Introduction-Refresher Training
62/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
62
What CCPs could we expect at suppliers?
Are the Metal Check Records completed fully?
Are the correct Test Pieces used by a trained person?
Is Corrective action taken if the test fails?
Is action taken for reject product?
HACCP Introduction
8/4/2019 HACCP Introduction-Refresher Training
63/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
63
CCP: Filtration
Process Step:Inline filtration at closest
point prior to filling.
Hazard:
Foreign objects > 7mm*
Critical Control Limit:
Present and intact filters/screens that preventpassage of objects >7mm.
PepsiCo Operational Target:Gatorade Clear: 15 m
Gatorade Cloudy: 25-40
m
Juices without added pulp: 2.4 mm
Juices with added pulp: 6.4
mm
Monitoring:Filters/Screens are inspected (i) present and (ii) intact, at a defined
frequency. Abnormal extraneous material with potential risks found on
intact screens are noted for root cause and investigative proposes (i.e.
gaskets, plastic, glass, or metal fragments)
Corrective Action: If filter/screen is not (i) present or (ii) intact during verification, put the
product produced since the last acceptable check on hold, stop the
process, and replace with functional filter/screen.
Notify designated quality employee to determine disposition of the
product. Establish statistical sampling plan to evaluate likelihood of
hazard in product and for the disposition of product. Corrective action
and disposition records must be documented.
Documentation: Filter/Screen Inspection Log
Extraneous Material Log
Hold and Release Records
Corrective Action Records Verification Records
*FDA Compliance Policy Guide#555.425 (FDA, 2001a).
HACCP Introduction
8/4/2019 HACCP Introduction-Refresher Training
64/66
HACCP Introduction VERSION 1 : November 2010
HACCP Introduction
64
The HACCP team will check that the HACCP study is valid and that ifcorrectly followed will deliver safe food.
The aims of this audit are: To ensure the scope of the HACCP is correct and still valid.
To ensure the HACCP study has been completed correctlyaccording to the seven Codex principles.
To ensure that any changes to the process, product or equipmenthave been reflected in the HACCP study
verb; to validate, ratify; valid, sound, defensible of reasonable objection(Oxford English Dictionary)
Which means..
Obtaining evidence that the elements of theHACCP plan are effective
Validation:
HACCP Introduction
8/4/2019 HACCP Introduction-Refresher Training
65/66
HACCP IntroductionVERSION 1 : November 2010
HACCP Introduction
65
verb; to establish truth or correctness by examination or demonstration(Oxford English Dictionary)
Which means..
Monitoring and Evaluating compliance
with the HACCP plan
This is focussed on how well the CCPs are being controlled.
The aims of this audit are:
To check that monitoring records are complete for each CCP.
To check that the person completing the CCP checks and recordshas been trained.
To check that any equipment used for monitoring CCPs has beencalibrated.
To check that appropriate corrective action has been taken whereany of the CCP checks have failed.
Verification:
HACCP Introduction
8/4/2019 HACCP Introduction-Refresher Training
66/66
HACCP Introduction
Ten point Checklist for HACCP
1. Was a multi-disciplined team used for theHACCP study? 2. Are Product descriptions and intendeduse details available for all products? 3. Is the Process Flow Diagram up to dateand signed off as correct?
4. Are all hazards listed including:Biological, Physical and Chemical (includingAllergens)? 5. Have Hazards been risk assessed? 6. Have CCPs been identified using adecision tree or expert panel? 7. Are all CCPs controlled to within theCritical limits and monitored frequently?
8. Have corrective actions been taken forany CCP failures? 9. Are verification/validation procedurescompleted frequently (at last annually)? 10. Is the HACCP plan up to date (reviewedannually?)?
HACCP Control Plan
Recommended