Hazard Analysis Critical Control

Point (HACCP)

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 Contents

 Introduction

 History

 Objective

 Hazards

 Principles

 Critical control point

 Application of HACCP

 Conclusion

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 Introduction (HACCP)

 Food safety in the early twenty-first century is an international

challenge requiring close cooperation between countries in agreeing

standards and in setting up transnational surveillance systems.
 Behavior of consumers has been gradually changing.

 Currently require not only much higher dietary quality, hygiene and

health standards in the products they purchase

 But they also look for certification and reassurance of products’

origins (national or geographical) and production methods.

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 HACCP Preamble

 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.

HACCP Objectives:

 Eliminate or significantly reduce the hazard

 Prevent or minimize microbial growth and toxin production.

 Control contamination

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 History and development of HAACP

S.No Year Particulars

1. 1959. The Pillsbury Company develops concept for NASA ( required a ‘zero
defect’ program to guarantee safety in the foods astronauts consumed in
space)

2. 1971 Pillsbury presented the HACCP system at a US national food protection

conference

3. 1973. An HACCP system was adopted for the Low-Acid Canned Food

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5. 1990 United Nations Codex Alimentarius Commission Food Hygiene
standard embraced HACCP as an internationally accepted method
for ensuring food safety by identifying hazards and monitoring their
Critical Control Points in the process.

6. 1997 • Codex Document on HACCP principes and application,

• FDA’s Seafood HAACP program becomes mandatory.
7. 2006 Legal requirements to apply HACCP in food businesses (other than
primary production)
8. 2006+ Increased worldwide use of HACCP in food safety legislation

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 HACCP?

 HACCP stands for ‘Hazard Analysis Critical Control Point’.

 HACCP is a system that identifies, assesses, and controls the biological,

chemical, and physical hazards that are associated with food production
or practice to prevent potential problems before they happen.

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 H A CCP

Hazard:
 Biological: harmful microorganisms

Ex. pathogenic bacteria, yeast molds, viruses,

insects, worms, rodents

 Chemical: those either naturally occurring, intentionally added or

unintentionally added.
Ex. antibiotic residues, metal ions, pesticide residues

 Physical: glass, stones, metal, nail, hair. plastic

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Critical Control Point (CCP):
 Identifiable point in the production chain where a hazard may occur.

 Action is taken to prevent the hazard from occurring.

 This can either be a point, step or procedure at which control can be

applied and is essential to prevent or eliminate a hazard or reduce it to an

acceptable level.

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 Guidelines for the application of HACCP system:

1. Assemble the HACCP team

2. Describe product

3. Identify intended use

4. Construct flow diagram

5. On-site verification of flow diagram

6. List all potential hazards, conduct a hazard analysis and determine control measures

7. Determine CCPs

8. Establish critical limits for each CCP

9. Establish a monitoring system for each CCP

10. Establish corrective actions

11. Establish verification procedures

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12. Establish record keeping and documentation
Assemble HACCP team:
 Accomplished by assembling a multidisciplinary team.

Describe product :
 Including information of composition, physical/chemical structure ( aw,

pH...), microbial composition, packaging durability and storage conditions

and delivery method.

Construct flow diagram:

 should cover all steps in the operation

List all potential hazards associated with each step:

 Possible physical, chemical, and biological hazards need to be understood

carefully
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Conduct a hazard analysis, and consider any preventive measures to minimize
the identified hazards:
 After understanding possible hazards, their sources, control steps need to be

introduced in flow chart for reducing the hazard

Establish monitoring systems for each CCP:

 Once CCP is established for controlling hazard, the step need to be monitored

( control of past. Temp. etc.)

Establish corrective actions to be taken when monitoring indicates deviation

from critical limits:
 If CCP monitoring is not done and if that step deviates

hazard may not be reduced, hence corrective action for monitoring of CCP is a must
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Verification:
 Process that is used to evaluate whether a product, service, or system

complies with regulations. Verification can be in development, scale-up,

or production. Analysis of a product – sensory, physical and chemical
quality

Validation
 The process of establishing documentary evidence demonstrating that a

procedure, process, or activity carried out in testing and then production

maintains the desired level of compliance at all stages.

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Establish effective record keeping procedures that document the
HACCP system:
 Maintenance of records at all the departments – SOPs, GMPs,

production flow chart, analytical results, shelf life etc.

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 Food safety standard

 ISO 22000:2005 (Food Safety Management System) is an International

standard, aligned with ISO 9001:2000 as well as HACCP

 Applicable to the entire food chain irrespective of the size and

complexity, such as
 Complete supply chain (production - processing -distribution)

 Agricultural producers (animal based-plant based food)

 Other suppliers of services and goods (packaging and

veterinary products); processors and retailers

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1.Hazard Analysis

 The first step involves identifying any hazards that must be

prevented, eliminated or reduced to acceptable levels.

 All potential hazards, from the receipt of raw materials to the

finished product, must be considered.

 A hazard must be controlled if it is likely to occur, and/or likely to

result in an unacceptable risk to consumers.

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 2.Determine the Critical Control Point (CCP)

 Identifying the Critical Control Point (CCP) at the steps to prevent

or eliminate a hazard or to reduce it to acceptable levels.

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 3. Establish Critical Limits

 A critical limit is a maximum or minimum value to which a

biological, chemical or physical limit must be controlled at a CCP.

 This is set in order to prevent, eliminate or reduce a hazard to an

acceptable level.

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 4. Critical Control Point (CCP) monitoring

 A planned series of observations need to be taken to determine whether a

CCP is within critical limits.

 This also helps to create an accurate record for future use in verification.

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 5. Corrective actions

 Corrective actions to be followed when a hazard is identified in the food

production.

 The aim is to correct and eliminate the cause of the hazard and bring
CCP back under control.

 The cause of problem must be identified to prevent future recurrence.

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 6.Verification Procedures

 Verification procedures are those activities, other than monitoring

CCPs, that verify the HACCP plan and show the system is operating
accordingly.
 This is usually completed yearly or when a system fails or there is a

major change in the product or process.

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 7. Record Keeping Procedures

 Documentation and record keeping help to show the effective application

of HACCP.

 These records could be included in the development of the HACCP plan,

CCP monitoring, corrective actions or verification activities.

 Four different types of HACCP records include:

1. HACCP plan and support documentation used in developing the plan.
2. Records of CCP monitoring.
3. Records of corrective actions.
4. Records of verification activities.

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 HACCP plan for paneer processing.

Critical
Hazard Ccp limit Monitoring Corrective action Verification
Microbial CCP 1 76°C Pasteurized milk Sent for re- Proper
pasteurization -80°C for & Pasteurization pasteurization, temperature of
of milk 15 sec temperature effective pasteurization
monitoring, study by Lab testing
thermographs & studying
thermographs
Physical CCP 2 Fe Metal pieces by Check the sliced Proper
(metal Cutting of material: Metal detector paneer for metal working of
pieces) paneer (metal 0.4mm x-ray scanning, contamination & Metal
detector) Non Fe Each time the use of certified detector Each
material: product is cut cutting machines time the
0.5mm into pieces product is cut
SS intopieces by
material: production
0.7mm manager

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 HACCP certified products

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 Conclusion

 Food safety is an important aspect & awareness is increasing

 Farm to fork-safety is quality assurance

 Hazard analysis, spotting CCP, applying control measures, verification

and recording are required to make any food safe for consumption
 GMP is a prerequisite for HACCP

 Increases consumer acceptability

 Should be made mandatory for all food industries

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 Seven principles of HACCP implementation

1. Conduct a hazard analysis

2. Determine the CCPs

3. Establish critical limit(s)

4. Establish a monitoring system

5. Establish corrective actions

6. Establish verification procedures

7. Establish documentation

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 Application of HACCP to Market Milk
Production
Cleaning & sanitation of Udder & teats of milch animal in milking parlour (to
reduce animal microflora – coliforms, salmonella, S.aureus)

Cleaning and sanitization of hands of milker ( to reduce human microflora

S.aureus, E.coli, Salmonella)

Milking into clean & sanitized pail (cleaning & sanitation of pail/ can reduce air
microflora – Bacillus spp., micrococci)

Transferring into can

Chilling in cold store(5ºC) - To inhibit growth of mesophiles

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 Pasteurization – 63ºC/30 min (batch method) or 72ºC/15 sec (continuous
method) & immediate cooling to 5ºC - CCP (to kill all pathogens –Coxiella
burnetii that causes Q fever and most of spoilage causing bacteria)

Packing in sachet & storing in clod store at 5ºC till distribution ( to inhibit the
growth of thermodurics and thermophilic bacteria as they survive pasteurization

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