H.A.C.C.
P
capstone of a food safety program
Dr. Hany Khalil
USDA
Professor of Food Science
California Polytechnic State University
San Luis Obispo, California
History of HACCP
The HACCP concept had its origin in the USA and stands for "Hazard
"Hazard
Analysis Critical Control Point".
Chronology of its development:
1958-
1958- Concept discussions at NASA (National Aeronautics and Space
Administration)
1959-
1959- Development of the HACCP concept to assure one hundred percent
safety of food to be used in space
1971-
1971- The HACCP system was published and documented in the USA
1985-
1985- The National Academy of Science (NAS) recommended the use of the
the
system. Worldwide the system became used and the FAO/WHO Codex
Alimentarius cited the system in the Codex
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The HACCP Approach
The idea is to develop a plan that anticipates
and identifies places in the production process –
known as critical control points (CCP’s) where
contaminants might be introduced or other food
safety concerns can be identified
When critical limits are exceeded, corrective
action must be taken and documented
An independent third party should be used to
verify or validate the effectiveness of a HACCP
plan
The HACCP Approach, Cont.
A HACCP program is unique and specific
to each product in each processing facility
and requires a thorough analysis of each
phase of processing at that facility
The use of an individual trained in
developing HACCP programs is
recommended
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HACCP
Component of a Food Safety System
Overview
After prerequisite programs ( GAP’s, SSOP’s, and
GMP’s) have been established, you now have a
frame work for HACCP
HACCP provides a systematic approach to
identify, assess and control the risk of biological,
chemical, and physical hazards
HACCP is a living, evolving system
Example of a HACCP Program for
Almonds
At the moment, almond handlers in the
U.S.A. are not required under US law to
implement HACCP procedures in their
operations
However, handlers recognize the benefits
of HACCP practices to their customers and
integrate them into their production
routines
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Developing a HACCP Plan
in an Almond Processing Facility
A series of steps must be completed before a
HACCP plan can be developed:
1- Assemble a HACCP team
2- Provide a general description of the food
product, its processing, distribution, and storage
methods (flow chart is very helpful for this step)
3- Compile information on the customer
4- Identify the intended use by the typical
consumer
The Seven Principles of HACCP
1. Conduct a Hazard Analysis
2. Determine Critical Control Points
3. Establish Critical Limits
4. Establish Monitoring Procedures
5. Establish Corrective Actions
6. Establish Verification Procedures
7. Establish Record Keeping and
Documentation Procedures
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1. Conduct a Hazard Analysis
Assess the food safety hazards that are reasonably likely to occur
and that must be controlled for almonds or almond products based
upon experience, illness data, scientific reports, or other information
Hazards can be biological, chemical, or physical
Use the process flow chart
Summarize the information in a Hazard Analysis Worksheet
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2. Determine Critical Control
Points
All hazards identified in step #1 (Hazard
Analysis) must be controlled at some point in the
process
Identify the Critical Control Points (CCP’s) in
the process that will help you eliminated or
minimize the hazards (Decision Tree Flowchart
can help in this step)
The number of CCP’s identified depends on the
product being produced, the ingredients (if any)
used, and the processing methods employed
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3. Establish Critical Limits
Critical limits are tolerances beyond which the related
CCP is out of control and a potential hazard can exist
A critical limit is a maximum and/or minimum value at
which control must be maintained for the CCP
CCP limits cannot be average values or ranges of values
Critical limits must be validated by the processor or be
supported by scientific data or literature
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4. Establish Monitoring
Procedures
Monitoring is a scheduled observation of a CCP
and its limits
The procedure must be reliable enough and
performed often enough to ensure that the
hazard is under control
Determine what will be monitored, how it will
be monitored, when it will be monitored, and
who will perform the monitoring
HACCP Plan Form is needed for this step
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5. Establish Corrective Actions
When there is deviation from an established
CCP, corrective actions must be taken to prevent
a product that may be unsafe from reaching
consumers
Corrective action must include correcting the
problem and putting the process back in control,
and placing the product on hold pending
evaluation of safety
Corrective action steps taken must be
documented
6. Establish Verification
Procedures
Every HACCP plan should be examined to
validate its ability to control food safety
hazards that are reasonably likely to
occur, and that the plan is being
effectively implemented
Verification should include, at a minimum:
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6. Establish Verification Procedures, Cont.
a. Reassessment of the HACCP plan - Reassess the
adequacy of the HACCP plan whenever any
changes occur that could affect the hazard analysis or
alter the HACCP plan in any way, or at least annually
Changes may include: raw materials or sourcing of raw
materials, handling methods or systems, finished product
distribution systems, or the intended use or consumers
of the finished product
The HACCP plan must be modified whenever a
reassessment reveals that the plan is no longer adequate
6. Establish Verification Procedures,
Cont. 1
b. Ongoing verification activities - Ongoing
verification activities include a review of
any consumer complaints to determine
whether they relate to the performance of
CCP’s or reveal the existence of
unidentified CCP’s, the calibration of
process-monitoring instruments, or in-
process testing
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6. Establish Verification Procedures,
Cont. 2
c. Records review - A review, including signing
and dating, by an individual who has been
trained in accordance with appropriate HAACP
practices, including:
i. The monitoring of critical control points
ii. Ensuring that the records are complete and
that documented values are within the
critical limits
iii. The taking of corrective actions
7. Establish Record Keeping and
Documentation Procedures
The HACCP plan must be on file at the
facility
It must include documentation relating to
CCP’s and any action on deviations and/or
disposition of product
Types of records could include:
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7. Establish Record Keeping and
Documentation Procedures, Cont.
a. Processing - Records of all monitored CCP’s
b. Deviation - Records of any deviations from
the HACCP plan
c. Ingredients - Supplier qualification, ingredient
certification, audit records
d. Product safety - Records on safe shelf-life,
microbiological testing, microbiological challenge
studies
e. Storage and distribution - Traceability data
f. Validation studies
CONCLUSION
Ensuring food safety in your industry is not
difficult
Rather it takes consistent, steady, and diligent
effort to constantly think about your
process/product and be ready to implement
changes to enhance food safety
When should you begin implement a food safety
program?
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It Takes Time
The best time to implement
a food safety program is 20
years ago!
The next best time is NOW!!
TOGETHER WE CAN DO IT
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Q&A
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