.

General Aim of the course To be able to understand, implement and improve

the Food Safety System in your area

By the end of this course you will be able to: Have a deep overall understanding of HACCP.

Know how to plan an effective system.

Be able to implement an effective HACCP system

Know how to design verification and maintenance systems.

Have a clear understanding of planning and implementing HACCP systems and leading teams

Be qualified to the highest level of HACCP certification

Key Message If you want to love a mermaid you must be

prepared to swim

African Proverb

Food Safety contents:

•What is Food Safety –definitions

•Why Food Safety.

•Food Contaminants and contamination.

•We are the leaders in Food Safety.

•Types of Food Safety Systems.

•The Pre Requisites Programs (PRPs).

•Good Manufacturing Practices.

•Good Hygiene Practices.

WHAT IS FOOD SAFETY

Assurance that food will not cause harm to the consumer when it is prepared and/or eaten according to its intended use

Food suitability

Assurance that food is acceptable for human consumption according to its intended use.

Food Safety and Food Quality •Food Safety: making a food safe to eat; free of

disease causing agents

•Food Quality: making a food desirable to eat; good taste, color, texture…

Why Food Safety? •Ensure that the consumers will not be harm by eating

food.

•Give a customer trust on your products.

•Reduce the number of tests done and that reducing the cost.

•Constancy of the business.

•Work with legal requirement

•opportunities to enter the international market.

Why it is required?

Intense farming and processing of food

Increase in meals consumed outside home

Increase in ready to eat foods

More traveling across the world

Increase amount of imported foods

Increase in number of susceptible people

Food Contaminants •There is three types of Food contaminants

•Physical

•Chemical

•Microbiological

Contaminants Any biological or chemical agent, foreign matter,

or substances not intentionally added to food which may compromise food safety or suitability

Types of Hazards Exercise •Every group write one type of hazards in

details-(e.g. if physical write the most types you could)

•If English write in the left side and leave the right space free-we need it later! The Arabic is opposite.

•Group formation

Physical •Woods

•Stones

•Glasses

•Pins and metals

•Insects and animals

Chemicals •Cleaning chemicals

•Greece

•Pesticides

•hormones

Microbiological

•Bacteria(E Coli, salmonella, listeria … etc).

•Yeast and Molds (Aspergillus … etc).

•Viruses(Hepatitis A, Human Rotavirus …etc).

Contamination

The introduction or occurrence of a contaminant in a food or food environment

E. coli O157:H7 Outbreak with packaged Spinach –September 2006 -USA

•204 confirmed illnesses

•104 hospitalizations

•31 cases of hemolytic uremic syndrome ةمزالتم

انحالل الدم ال ور م

•3 deaths

•Illnesses confirmed in 26 US states

•1 illness in Canada

Cross contamination

•Cross contamination occurs when harmful bacteria are transferred from contaminated food to uncontaminated food.

Cross contamination

•Direct cross contamination:

contact between raw food and ready-to-eat food during transport, storage or preparation

•Indirect cross contamination

spread of bacteria from raw food to ready-to-eat food via food handlers, equipment or surfaces.

E. coli O157 cross contamination E. coli O157 is a particularly dangerous organism

because:

• it can lead to serious untreatable illness and even death

• it is reported to have a very low infective dose (less than 100 bacteria can cause illness)

• it has the ability to survive refrigeration, freezing and environments which have a low pH or reduced water activity.

Common Symptoms

•Escherichia coli ‐diarrhea, vomiting القئ , mild fever

•Salmonella enteriditis (and other Salmonella spp.) ‐abdominal cramps, headache, fever, nausea, diarrhea

تشنجات البطن ،الداع والحمى،الغث ان واالسهال•

•Listeriamonocytogenes‐flu‐like, meningitis, encephalitis, abortion التهاب السحا ا، التهاب الدماغ، واإلجهاض

•Campylobacterjejuni‐diarrhea, vomiting, headache, fever, muscle pain

•Norwalk virus (nor virus) ‐nausea, diarrhea, headache, mild fever

How to avoid cross contamination -Separate raw Foods from the ready to eat Foods and

cocked Foods.

-Well cleaning to the food before preparing and sanitize it if needs.

-Authorized personnel only shall inter the preparing (manufacturing) area.

-Ware cleaned protection clothes.

-Washing hands before interring the Food preparing (manufacturing) areas.

-Cleaning the equipment well after use and use sanitation if needed.

We are the leaders in Food Safety نها ة الرتبة ف طلب(عام ف كتابه 1000كتب الطبري قبل

جب على العجان ان ضع قطعة على راسه حتى ال): الحسبه

قع شئ من عرقه على العج ن وان حلق شعر د ه حتى ال

سقط منه شئ كذلك.

• م لاد ه كتب 800وف كتاب معالم القربة ف طلب الحسبه سنة

المسلمون انه جب تغط ة االكل حتى ال قع ف ه الذباب وال تخلط

اللحوم المختلفه كالبقر والماعز والضأن مع لحم االبل حتى ال

أكلها من به مرض فتضره.

•http://www.youtube.com/watch?v=Du_vxFRadKY

Food safety program (System) A food safety program is a set of practices and

procedures that your business will need in order to manage food safety while it is in your care.

Food Safety Programs

•Pre Requisite Programs(GMPs, GHPs, SSOP).

•Hazard Analysis Critical Control Points (HACCP)

•ISO 22000: 2005 Food Safety Management System (FSMS).

Pre Requisite Programs (PRPs) •CODEXD efinition:

•A program that Is required prior to the application of the HACCP system to ensure that facility is operating according to the Codex Principles of Food Hyiene, the appropriate Code of Practice and appropriate food safety legislation.

Types of PRPs GAPs, Good Agriculture Practices

GMPs, Good Manufacturing Practices

GHPs, Good Hygiene Practices

SOPs,Standard Operation Procedures

Pre Requisite Programs (PRPs) Effective implementation of prerequisite programs

(PRPs) is essential to establish a sound foundation prior to application of HACCP or other food safety management systems

Pre Requisite Programs (PRPs)

Ineffective implementation of PRPs will likely lead to ineffective implementation of HACCP.

Prerequisite Programs are the Foundation of an Effective Food Safety System

1/HACCP

2/SANITATION STANDARD OPERATION PROCEDURE

3/ Pre Requisite Programs

What is the GMPs? Good Manufacturing Practices GMPs

That combination of manufacturing and quality control procedures aimed at ensuring that products are consistently manufactured to their specifications. (GMPs) are minimum sanitary and processing requirements necessary to ensure the production of wholesome food.

GMPs are for

•Personnel

•Buildings and facilities

•Equipment and utensils

•Production and process controls

•Warehousing and distribution

GMPs guide the development of SOPs

Primary Production Avoiding the use of are as where the environment

poses a threat to the safety of food

Controlling contaminants ,pests and diseases of animal sand plant sin such away as not to pose a threat to food safety

•a dopting practices and measures to ensure food is produced under appropriately hygienic conditions.

Primary Considerations at Primary Production:

•Environmental Hygiene

•Hygienic Production of Food Sources

•Handling, Storage and Transport

•Cleaning, Maintenance and Personnel Hygiene at Primary Production

Establishment: Design and Facilities Good housekeeping” applies to the surroundings and

the roof of the establishment

•Pest control starts at the boundaries of the premises

•Water management deals with incoming and used

•Ceilings and ducts are accessible for cleaning

Windows are closed or screened

•Internal surfaces are smooth and easy to clean

•Floors have rounded corners

•Dry zones are designed to remain dry

•Drains can be cleaned

Cable trays carry cables, not dirt or dust

•Insect killers are effective

•Only potable water is in contact with food

•Air handling systems deliver the required air

•quality (and not contaminants)

•Doors are closed when not used

Establishment : maintenance Objective

to control possible sources of food contamination through the supporting programs:

•Maintenance and cleaning

•Pest control systems

•Waste management

•Monitoring

Maintenance

•Establishments and equipment should be kept in condition to

•facilitate sanitation procedures

•function as intended, particularly at Critical Control Points (CCPs)

•prevent contamination of food e.g. metal shards, flaking plaster, debris, chemicals, pests, dust

Control of Operation formulating design requirements with respect to raw

materials, composition, processing, distribution and consumer use to be met.

•manufacture and handling of specific food items; and

•Designing, implementing, monitoring and reviewing effective control systems

Control of Operation:

•Control of food hazards through HACCP

•Hygiene control:

-Time & temperature humidity

-Cross contamination

-Microbiological specifications

•Incoming materials (incl. packaging materials)

•Water, air, steam

•Management, documentation, recall procedures

Standard Operating Procedure 1. Purpose Describe the process for <official name of

SOP>. Describe relevant background information.

2. Scope Identify the intended audience and /or activities where the SOP may be relevant.

3. Prerequisites Outline information required before proceeding with the listed procedure; for example, worksheets, documents, IFAS reports, etc.

4. Responsibilities Identify the personnel that have a primary role in the SOP and describe how their responsibilities relate to this SOP. If necessary, include contact information.

5. Procedure Provide the steps required to perform this procedure (who, what, when, where, why, how). Include a process flowchart.

6. References List resources that may be useful when performing the procedure; for example, Admin policies, Municipal Code, government standards and other SOPs.

7. Definitions Identify and define frequently used terms or acronyms. Provide additional and/or relevant information needed to understand this SOP.

Equipment

Equipment should be located so that it:

•permits adequate maintenance and cleaning;

•Functions in accordance with its intended use; and

•facilitates good hygiene practices, including monitoring.

Key Message Good Manufacturing Practices are the basis of safe

foodproductionandpreparation

•GoodHygienicPracticesdealwithsafetyandsuitabilityrequirementstobefollowedworld-wide

•Eachfoodoperationshouldadaptexistingcodestotheirparticularconditions

•Theyshoulddeterminewhichpracticesarecriticalto

productsafetyandthusmustbeincludedinthe

HACCPplan

Cleaning & sanitation Cleaningis the chemical or physical process of

removing dirt or soil from surfaces.

Cleaning removes 90-99% of the bacteria, but thousands of bacteria may still be present.

Sanitizingis the process that results in reduction/destruction of microbes.

Different sanitizers will be used for different food products.

Cleaning procedures involve

1. Removing debris from surfaces

2. Applying a detergent solution

3. Rinsing with water

4. Disinfection where necessary

5. Dry cleaning

Cleaning & Sanitation 1. Remove debris by wiping and scraping

2. Rinse with water

3. Clean with detergents

4. Rinse with water

5. Sanitize with hot water or chemical sanitizers (instructions for use and safety precautions on

the labels should always be followed when using chemical sanitizers)

6. Air dry

Why cleaning is important?

Why cleaning is important? In Addition to Food Safety

•Pleasant and safe work environment (removes dirt and grease)

•Auditor/ customer confidence (promotes favourable image)

•Removes bacteria and food on which bacteria grow

•Aids pest control (removes food and pests easier to see)

•Enables disinfection

Increased product shelf life and equipment performance

•Reduction in:

–Food wastage -Surface deterioration

–Customer complaints -Wear and tear

–Physical contamination

Cleaning Plan

•In order to ensure that cleaning and sanitation is carried out effectively in your premises, you

Should develop a well-planned cleaning and sanitation program and maintain relevant record s for evaluation.

Awell-planned cleaning and sanitation program should include the following elements:

•areas, utensils and equipment tobe cleaned

•frequency of cleaning required for each item

•cleaning procedure specified fore ach item

•equipment and methods to be used

•chemicals or systems to be used

•the staff responsible for each task

How much critical •Environmental surface sampling recognised as

important.

One study suggests if an organism is found in the environment there is a 70% chance of it getting into the food.

Item

Frequency

Equipment and chemicals

Method

ResponsiblePerson

Personal hygiene Good personal hygiene is essential to ensure food

safety. Food poisoning bacteria may be

Present on the skin and in the nose of healthy people.

•All food handlers must therefore maintain a high standard of personal hygiene and cleanliness in order to avoid transferring food poisoning micro-organisms to food.

Waste Management

•Waste can be regarded as any item of foods, ingredients, packaging materials, etc. which is

not suitable for further use and intended to be disposed of.

•Waste should be controlled carefully since it presents a risk of contamination of food.

When food waste is removed from food preparation area pending disposal, it must be placed in a tightly covered waste storage bin.

•Plastic liners should be used in waste disposal and storage bins.

•Waste disposal and storage bins should be emptied when full or on a regular basis.

•Waste disposal bins should be cleaned and sanitized daily and placed upside down and off the floor to drain overnight.

Personal hygiene Importance Personal hygiene of lies in the fact

that:

•Man is a reservoir for infectious disease agents

(e.g. V. cholerae, S. typhi, Shigella sp.)

•Man is a reservoir for enterotoxin-producing

S. aureus

•Some pathogens (e.g. Shigella sp, viruses) can

cause infection at low levels of contamination

•Food handlers’ hands can be a route of cross contamination.

Pest Control Good hygienic practices should

• prevent pests from entering the premises

• protect food from pests

• eradicate infestations immediately

• include regular inspections

Health status People known, or suspected, to be suffering from, or to

be a carrier of, a disease or illness likely to be transmitted through food should not be allowed to enter any food handling area if there is a likelihood of their contaminating food

Illness and injuries Conditions that should be reported to management so that

any need for medical examination and/or possible exclusion from food handling can be considered include:

• jaundice;

• diarrhea;

• vomiting;

• fever;

• sore throat with fever;

• visibly infected skin lesions (boils, cuts, etc.);

• discharges from the ear, eye or nose.

Personal cleanliness

Food handlers should maintain a high degree of personal cleanliness and, where appropriate, wear suitable protective clothing.

Personal Hygiene: Hand washing Personnel should always wash their hands when

personal cleanliness may affect food safety, for example:

•At the start of food handling activities

•Immediately after using the toilet

•After handling raw food or any contaminated material, where this could result in contamination of other food items; they should avoid handling ready‐to‐eat food, where appropriate

Personal Hygiene: Hand washing Use Sanitizer

•Typically use alcohol to kill microorganisms without water

• Usually contain a moisturizing component to counteract drying effect

• Most effective when used following hand washing with soap

• Are not substitute for proper hand washing.

What’s Wrong with this Picture?

What’s Wrong with this Picture?

Personal Behavior People engaged in food handling activities should

refrain from behavior which could result in contamination of food, for example: Smoking

Spitting

Chewing or eating

Sneezing or coughing over unprotected food

Storage As soon as supplies are received they should be placed

in the appropriate storage area(freezer, cool room or dry storage area).

•Packaging materials must be stored in a manner that prevents contamination by dust, insects and chemicals.

•All stock should be rotated to ensure the oldest stock issued first.

Raw food is stored separately to ready-to-eat food–if separate storage are as are not available, ready-to-eat food is stored above raw.

•All dry products are stored in a manner to prevent contamination from moisture, dust, dirt, pests and rodents.

•All perishable/ refrigerated/ frozen foods must be stored under temperature control.

SAFEstands for

Staff

Areas

Food and

Equipment

HISTORY OF HACCP HACCP has become synonymous with food safety.

It is a worldwide-recognized systematic and preventive approach that addresses biological, chemical and physical hazards through anticipation and prevention, rather than through end-product inspection and testing

The HACCP system for managing food safety concerns grew from two major developments.

The first breakthrough was associated with W.E. Deming, whose theories of quality management are widely regarded as a major factor in turning around the quality of Japanese products in the 1950s.

Dr Deming and others developed total quality management (TQM) systems which emphasized a total systems approach to manufacturing that could improve quality while lowering costs.

Deming Cycle: The Wheel of Continuous Improvement The essence of continuous improvement lies in

employees involvement. This happens when they improve their process, product or services by applying their creative faculties on their work related problems and routine jobs. Kaizen (Japanese word meaning continuous improvement) provides these employees a platform to unleash their creativity.

Dr. J.Edward Deming, the famous quality guru, provided a simple yet highly effective technique that serves as a practical tool to carry out continuous improvement in the workplace. This technique is called PDCA Cycle or simply Deming Cycle. PDCA is acronym of Plan, Do, Check and Action. Deming Cycle provides conceptual as well as practical framework while carrying out Kaizen activities by the employees. Let’s understand the concept with following illustration:

The four steps Plan, Do, Check and Action should be repeated over time to ensure continuous learning and improvements in a function, product or process.

For example if employees want to improve either of the above areas, they should ask themselves about following question during the PLANNING phase of this cycle:

What are we trying to accomplish?

What changes can we make that will result in improvement?

How will we know that a change is an improvement?

PLAN stage involves analyzing the current situation, gathering data, and developing ways to make improvements.

The DO stage involves testing alternatives experimentally in a laboratory establishing a pilot process, or trying it out with small number of customers.

The CHECK stage requires determining whether the trial or process is working as intended, whether any revisions are needed, or whether is should be scrapped.

The ACT stage focuses on implementing the process within the organization or with its customers and suppliers.

Once all this stages are completed to the fullest satisfaction, the improvement is standardized. The standardized work or product is the result of improvement initiative but it is not stopped here. With the changing circumstances or new techniques this standardized work, process, product or service is again subjected to further improvement thus repeating the Deming Cycle again and again.

The second major breakthrough was the development of the HACCP concept itself. The HACCP concept was pioneered in the 1960s by the Pillsbury Company, the United States Army and the United States National Aeronautics and Space Administration (NASA) as a collaborative development for the production of safe foods for the United States space programme. NASA wanted a "zero defects" programme to guarantee the safety of the foods that astronauts would consume in space.

Pillsbury therefore introduced and adopted HACCP as the system that could provide the greatest safety while reducing dependence on end-product inspection and testing.

HACCP emphasized control of the process as far upstream in the processing system as possible by utilizing operator control and/or continuous monitoring techniques at critical control points.

Pillsbury presented the HACCP concept publicly at a conference for food protection in 1971.

The use of HACCP principles in the promulgation of regulations for low-acid canned food was completed in 1974 by the United States Food and Drug Administration (FDA).

In the early 1980s, the HACCP approach was adopted by other major food companies

The United States National Academy of Science recommended in 1985 that the HACCP approach be adopted in food processing establishments to ensure food safety.

More recently, numerous groups, including for example the International Commission on Microbiological Specifications for Foods (ICMSF) and the International Association of Milk, Food and Environmental Sanitarians (IAMFES), have recommended the broad application of HACCP to food safety

THE CODEX ALIMENTARIUS The Codex General Principles of Food Hygiene lay a

firm foundation for ensuring food hygiene.

They follow the food chain from primary production through to the consumer, highlighting the key hygiene controls at each stage and recommending a HACCP approach wherever possible to enhance food safety.

These controls are internationally recognized as essential to ensuring the safety and suitability of food for human consumption and international trade

ADVANTAGES OF HACCP The HACCP system, as it applies to food safety

management, uses the approach of controlling critical points in food handling to prevent food safety problems.

The system, which is science based and systematic, identifies specific hazards and measures for their control to ensure the safety of food.

HACCP is based on prevention and reduces the reliance on end-product inspection and testing.

The HACCP system can be applied throughout the food chain from the primary producer to the consumer.

Besides enhancing food safety, other benefits of applying HACCP include more effective use of resources, savings to the food industry and more timely response to food safety problems.

HACCP enhances the responsibility and degree of control at the level of the food industry.

A properly implemented HACCP system leads to greater involvement of food handlers in understanding and ensuring food safety, thus providing them with renewed motivation in their work.

Implementing HACCP does not mean undoing quality assurance procedures or good manufacturing practices already established by a company; it does, however, require a revision of these procedures as part of the systematic approach and for their appropriate integration into the HACCP plan.

The application of the HACCP system can aid inspection by food control regulatory authorities and promote international trade by increasing buyers' confidence.

Any HACCP system should be capable of accommodating change, such as advances in equipment design, changes in processing procedures or technological developments.

APPLICATION OF HACCP While the application of HACCP to all segments and

sectors of the food chain is possible, it is assumed that all sectors should be operating according to good manufacturing practices (GMPs) and the Codex General Principles of Food Hygiene.

The ability of an industry segment or sector to support or implement the HACCP system depends on the degree of its adherence to these practices.

The successful application of HACCP requires the full commitment and involvement of management and the workforce.

It requires a multidisciplinary approach which should include, as appropriate, expertise in agronomy, veterinary health, microbiology, public health, food technology, environmental health, chemistry, engineering, etc. according to the particular situation.

The application of the HACCP system is compatible with the implementation of TQM systems such as the ISO 9000 series.

However, HACCP is the system of choice in the management of food safety within such systems.

THE HACCP SYSTEM The HACCP system, which is science based and

systematic, identifies specific hazards and measures for their control to ensure the safety of food.

HACCP is a tool to assess hazards and establish control systems that focus on prevention rather than relying mainly on end-product testing and inspection.

Any HACCP system is capable of accommodating change, such as advances in equipment design, processing procedures or technological developments

DEFINITIONS

Control (verb): To take all necessary actions to ensure and maintain compliance with criteria established in the HACCP plan.

Control (noun): To state wherein correct procedures are being followed and criteria are being met.

. Control measure: Any action and activity that can be used to prevent or eliminate a food safety hazard or reduce it to an acceptable level.

Corrective action: Any action to be taken when the results of monitoring at the CCP indicate a loss of control.

Critical Control Point (CCP): A step at which control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level.

Critical limit: A criterion which separates acceptability from unacceptability.

Deviation: Failure to meet a critical limit.

Plow diagram: A systematic representation of the sequence of steps or operations used in the production or manufacture of a particular food item

HACCP: A system which identifies, evaluates, and controls hazards which are significant for food safety.

HACCP plan: A document prepared in accordance with the principles of HACCP to ensure control of hazards which are significant for food safety in the segment of the food chain under consideration.

Hazard: A biological, chemical or physical agent in, or condition of, food with the potential to cause an averse health effect.

Hazard analysis: The process of collecting and evaluating information on hazards and conditions loading to their presence to decide which are significant for food safety and therefore should be addressed in the HACCP plan.

Monitor: The act of conducting a planned sequence of observations or measurements of control parameters to assess whether a CCP is under control.

Step: A point, procedure, operation or stage in the food chain including raw materials, from primary production to final consumption.

Validation: Obtaining evidence that the elements of the HACCP plan are effective.

Verification: The application of methods, procedures, tests and other evaluations, in addition to monitoring to determine compliance with the HACCP plan

PRINCIPLES OF THE HACCP SYSTEM

The HACCP system consists of the following seven principles:

Principle 1 Conduct a hazard analysis.

Identify the potential hazard(s) associated with food production at all stages, from primary production, processing, manufacture and distribution until the point of consumption.

Assess the likelihood of occurrence of the hazard(s) and identify the measures for their control

Principle 2 Determine the Critical Control Points (CCPs)

Determine the points, procedures or operational steps that can be controlled to eliminate the hazard(s) or minimize its (their) likelihood of occurrence.

A "step" means any stage in food production and/or manufacture including the receipt and/or production of raw materials, harvesting, transport, formulation, processing, storage, etc.

Principle 3 Establish critical limit(s).

Establish critical limit(s) which must be met to ensure the CCP is under control.

Principle 4 Establish a system to monitor control of the CCP

Establish a system to monitor control of the CCP by scheduled testing or observations.

Principle 5

Establish the corrective action to be taken when monitoring indicates that a particular CCP is not under control

Principle 6

Establish procedures for verification to confirm that the HACCP system is working effectively.

Principle 7 Establish documentation concerning all procedures

and records appropriate to these principles and their application.

GUIDELINES FOR THE APPLICATION OF THE HACCP SYSTEM Prior to application of HACCP to any sector of the food

chain, that sector should be operating according to the Codex General Principles of Food Hygiene, the appropriate Codex Codes of Practice, and appropriate food safety legislation.

Management commitment is necessary for implementation of an effective HACCP system.

During hazard identification, evaluation, and subsequent operations in designing and applying HACCP systems, consideration must be given to the impact of raw materials, ingredients, food manufacturing practices, role of manufacturing processes to control hazards, likely end-use of the product, categories of consumers of concern, and epidemiological evidence relative to food safety.

The intent of the HACCP system is to focus control at CCPs.

Redesign of the operation should be considered if a hazard which must be controlled is identified but no CCPs are found.

HACCP should be applied to each specific operation separately.

CCPs identified in any given example in any Codex Code of Hygienic Practice might not be the only ones identified for a specific application or might be of a different nature.

The HACCP application should be reviewed and necessary changes made when any modification is made in the product, process, or any step.

It is important when applying HACCP to be flexible where appropriate, given the context of the application taking into account the nature and the size of the operation.

APPLICATION The application of HACCP principles consists of the

following tasks as identified in the Logic Sequence for Application of HACCP .

1. Assemble HACCP team

The food operation should assure that the appropriate product specific knowledge and expertise is available for the development of an effective HACCP plan.

Optimally, this may be accomplished by assembling a multidisciplinary team.

Where such expertise is not available on site, expert advice should be obtained from other sources.

The scope of the HACCP plan should be identified.

The scope should describe which segment of the food chain is involved and the general classes of hazards to be addressed (e.g. does it cover all classes of hazards or only selected classes).

2. Describe product

A full description of the product should be drawn up, including relevant safety information such as: composition, physical/chemical structure (including Aw, pH, etc.), microbial/static treatments (heat-treatment, freezing, smoking, etc.), packaging, durability and storage conditions and method of distribution.

3. Identify intended use The intended use should be based on the expected

uses of the product by the end user or consumer.

In specific cases, vulnerable groups of the population, e.g. institutional feeding, may have to be considered

4. Construct flow diagram The flow diagram should be constructed by the

HACCP team.

The flow diagram should cover all steps in the operation.

When applying HACCP to a given operation, consideration should be given to steps preceding and following the specified operation.

5. On-site confirmation of flow diagram The HACCP team should confirm the processing

operation against the flow diagram during all stages and hours of operation and amend the flow diagram where appropriate.

6. List all potential hazards associated with each step, conduct a

hazard analysis, and consider any measures to control identified hazards

(SEE PRINCIPLE 1)

The HACCP team should list all of the hazards that may be reasonably expected to occur at each step from primary production, processing, manufacture, and distribution until the point of consumption.

The HACCP team should next conduct a hazard analysis to identify for the HACCP plan which hazards are of such a nature that their elimination or reduction to acceptable levels is essential to the production of a safe food

In conducting the hazard analysis, wherever possible the following should be included:

the likely occurrence of hazards and severity of their adverse health effects;

the qualitative and/or quantitative evaluation of the presence of hazards;

survival or multiplication of microorganisms of concern;

production or persistence in foods of toxins, chemicals or physical agents; and,

conditions leading to the above

The HACCP team must then consider what control measures, if any, exist which can be applied for each hazard.

More than one control measure may be required to control a specific hazard(s) and more than one hazard may be controlled by a specified control measure.

7. Determine Critical Control Points (SEE PRINCIPLE 2)

There may be more than one CCP at which control is applied to address the same hazard.

The determination of a CCP in the HACCP system can be facilitated by the application of a decision tree, which indicates a logic reasoning approach.

Application of a decision tree should be flexible, given whether the operation is for production, slaughter, processing, storage, distribution or other.

It should be used for guidance when determining CCPs. This example of a decision tree may not be applicable to all situations.

Other approaches may be used.

If a hazard has been identified at a step where control is necessary for safety, and no control measure exists at that step, or any other, then the product or process should be modified at that step, or at any earlier or later stage, to include a control measure.

8. Establish critical limits for each CCP (SEE PRINCIPLE 3)

Critical limits must be specified and validated if possible for each Critical Control Point.

In some cases more than one critical limit will be elaborated at a particular step.

Criteria often used include measurements of temperature, time, moisture level, pH, Aw, available chlorine, and sensory parameters such as visual appearance and texture.

9. Establish a monitoring system for each CCP

(SEE PRINCIPLE 4)

Monitoring is the scheduled measurement or observation of a CCP relative to its critical limits.

The monitoring procedures must be able to detect loss of control at the CCP.

Further, monitoring should ideally provide this information in time to make adjustments to ensure control of the process to prevent violating the critical limits.

Where possible, process adjustments should be made when monitoring results indicate a trend towards loss of control at a CCP.

The adjustments should be taken before a deviation occurs.

Data derived from monitoring must be evaluated by a designated person with knowledge and authority to carry out corrective actions when indicated.

If monitoring is not continuous, then the amount or frequency of monitoring must be sufficient to guarantee the CCP is in control.

Most monitoring procedures for CCPs will need to be done rapidly because they relate to on-line processes and there will not be time for lengthy analytical testing.

Physical and chemical measurements are often preferred to microbiological testing because they may be done rapidly and can often indicate the microbiological control of the product.

All records and documents associated with monitoring CCPs must be signed by the person(s) doing the monitoring and by a responsible reviewing official(s) of the company.

10. Establish corrective actions (SEE PRINCIPLE 5)

Specific corrective actions must be developed for each CCP in the HACCP system in order to deal with deviations when they occur.

The actions must ensure that the CCP has been brought under control.

Actions taken must also include proper disposition of the affected product.

Deviation and product disposition procedures must be documented in the HACCP record keeping.

11. Establish verification procedures (SEE PRINCIPLE 6)

Establish procedures for verification.

Verification and auditing methods, procedures and tests, including random sampling and analysis, can be used to determine if the HACCP system is working correctly.

The frequency of verification should be sufficient to confirm that the HACCP system is working effectively.

Examples of verification activities include:

Review of the HACCP system and its records;

Review of deviations and product dispositions;

Confirmation that CCPs are kept under control.

Where possible, validation activities should include actions to confirm the efficacy of all elements of the HACCP plan.

12. Establish Documentation and Record Keeping (SEE PRINCIPLE 7)

Efficient and accurate record keeping is essential to the application of a HACCP system.

HACCP procedures should be documented. Documentation and record keeping should be appropriate to the nature and size of the operation.

Documentation examples are:

Hazard analysis;

CCP determination;

Critical limit determination

Record examples are:

CCP monitoring activities;

Deviations and associated corrective actions;

Modifications to the HACCP system.