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FOUNDATION COURSE
COURSE AGENDA
HACCP Principles
System Maintenance
Introduction of HACCP
Slid
e 3,
rev
1
Group activities
Brainstorming
Theoretical input
System Maintenance
Reflection
Slid
e 4,
rev
1
Illustration coming
Illustration coming
Active participation
Illustration coming
Slid
e 5,
No stupid questions
rev
1
Slid
e 6,
rev
1
Introduction to HACCP
Development of HACCP
Foodsafety
Consequences
Limitations of quality
inspection
More complex processes /
food operations
External pressure
10
2
HACCP Principles
1
Prerequisites
GMP, GHP, others
System Elements
ISO 9001 or general
principles on
management
system
requirements
e.g.: Management Review,
Internal Audits,
Corrective-Preventive
Actions, Document control
etc
11
Beginningofjourney
HACCPsystem
12
Origin
Pilsbury,
Milestones
NACMCF
HACCP
Implementation of EU Directive
USDA/FDA prescribe industry specific HACCP guidelines shellfish, meat, horticulture
White paper on Food Safety published in Jan 2000 - Farm13
To-Fork concept was introduced
DEVELOPMENT OF HACCP
14
BENEFITS
Preventative System
Systematic Approach
Effective use of Resources
Cost Effective Control System
Helps Demonstrate Due Diligence
Internationally Accepted
Complements Quality Management Systems
Facilitates regulatory inspection
Demonstrates Management Commitment
Product Quality Bonus
15
Legalrequirements
16
GROUP WORK
17
Pre-requisite Program
GAP, GMP, GHP, GLP
19
TheFoundationtoHACCP
prerequisiteprogram
20
Maintenance
Food Safety
Management System
Prerequisites
GMP
Basic
steps of
HACCP
7 HACCP
principle
s
Implement
ation
21
Slid
DEFINITION OF PRE-REQUISITES
universal steps or procedures that control the operational conditions
within a food establishment allowing for environmental conditions that
are favourable for the production of safe food
Codex Alimentarius Commission
3. Primary Production
8. Establishment: Transportation
5. Control of Operation
10. Training
As defined in CAC-Basic Code of Hygiene
24
CASE STUDY
Define a pre-requisite program for the company for your company
Group I : Production
Group II : Storage requirements
Group III : Packing area
Group IV
: Staff facilities
25
HACCP Implementation
Slid
HACCP SO FAR
GHP
7 HACCP
GMP preparation
Implementation Maintenance
principles
others
Prerequisites
HACCP Method
System Elements
28
Management Commitment
Step 1
Step 2
Step 3
Step 4
Step 5
29
Step 7
Step 8
Step 9
Step 10
Step 11
Step 12
PreparatorystepsofHACCP
31
Management Commitment
32
33
34
Step 3
Young
Old
Pregnant
Immuno-disordered
35
36
37
38
Step 5
39
40
HACCPPrinciples
41
42
DEFINITIONS
Hazard
A biological, chemical or physical agent in, or condition of, food
with potential to cause an adverse health effect.
Codex Alimentarius Commission
Biological
Chemical
Physical
E. Coli (0157:H7)
Glass
Salmonella
Clostridium perfringens
Pesticide residues
Paper
Listeria monocytogens
Antibiotic residues
Plastic
Staphylococcus aureus
Environmental
contaminants
Dead Insects
Camphylobacter
Chemical contaminants
from packaging
Allergens
Jewellery
43
SOME CONSIDERATIONS .
pH
best grow values : 6.6-7.5
Molds > Yeasts > Bacteria
Salmonella spp. 3.5 - 9.5
Clostridium botulinum : 4.5 - 8.5
Nutrient Content
water
source of energy
source of nitrogen
vitamins, minerals
Oxidation-Reduction Potential
The O/R potential of a substrate
the ease with which the
substrate loses or gains
electrons
anaerobic (e.g.: Clostridium
spp.) - Eh
aerobic (e.g.: Bacillus spp.) + Eh
44
Literature
Reg
ulat
ory
g
es in
c
i
t
c
a
r
p
Basic
ry
indust
uide
line
s
Epidemiological data
the
Customer Complaints
nal and
r
e
t
n
i
f
o
Results
udits
a
l
a
n
r
e
t
ex
45
DEFINITIONS
Hazard / Risk analysis:
The process of collecting and evaluating information on hazards and
conditions leading to their presence to decide which are significant for food
safety
RISK = PROBABILITY*SEVERITY
Likeli
hoo
d/
Pro Low
bab
ilit Medium
y High
Consequences / Severity
Low
Medium
High
Significant
Significant
Significant
Significant
Significant
Slid
DEFINITIONS
Control Measure
Control Measures are those systems in place at a process step that eliminate
hazards or reduce their impact or occurrence to acceptable levels.
Codex Alimentarius Commission
Slid
48
49
Temperature- time,
pH,
titratable acidity,
concentrations,
moisture level,
water activity,
available chlorine,
viscosity,
food additives quantity
sensory parameters (texture, smell) etc.
50
Target Level
all
CCPs
Safety Buffer Zone
lower
Critical Limit
all hazards
Control measure
51
Step 9
product.
53
Determine CCP
Slid
Step 11
Purpose;
Methods, standard operating procedures or tests applied;
Tasks and responsibilities;
Frequency;
Records.
55
DEFINITIONS
Validation :
Obtaining evidence that the elements of the HACCP plan are effective.
Codex Alimentarius Commission
Slid
DEFINITIONS
Verification :
The application of methods, procedures, tests and other evaluations, in
addition to monitoring to determine compliance with the HACCP plan.
Codex Alimentarius Commission
Examples
Review of the HACCP system documents and records;
Analysis of (near) recalls and product dispositions;
Verify control measures are effective
Analysis of customer and consumer complaints related to hygiene and food
safety;
Review of analytical outcome of random sampling and analysis of products;
Evaluation of conformity with applicable legislation and regulations
Review of gaps competency gaps staff with respect to hygiene and food
safety, resulting in effective (on-the-job) training sessions;
Slid
VALIDATION VS VERIFICATION
Are we doing the right things?
Validation
Literature
Our plans
Verification
Our plans
Our activities
58
Examples of Documents
Policy
Internal Audits
Product Recall
Examples of Records
Audit reports
Training records
59
MaintainingtheHACCP
system
60