The document provides background information on HACCP (Hazard Analysis and Critical Control Points) and guidelines for its application. It describes how HACCP was developed in the 1960s to ensure food safety for NASA's space program. The document defines key HACCP terms and outlines the 7 principles of HACCP for identifying hazards and establishing control systems. It also discusses prerequisites, performing a hazard analysis to identify critical control points, establishing monitoring and corrective actions, and documentation requirements. The goal of HACCP is to prevent food safety hazards through implementation of control measures at critical steps.

1. The HACCP system and
application
Dr Nik Nor Ronaidi bin Nik Mahdi

2. Content
• Background
• Definitions
• Pros & Cons
• Principles
• Steps
• Guidelines for applications

3. Background

4. Background
• 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 → which is
inappropriate for highly perishable foods.

5. *Organoleptic refers to any sensory properties of a product, involving taste, colour, odour
and feel.

7. Background
• HACCP was developed in the 60s by the Pillsbury
Company, the U.S. military and NASA have
collaborated to develop a system for producing safe
food for the space program.
• NASA wanted a "zero defects" program to
guarantee safety in the foods that astronauts would
be consuming in space.

8. Background
• “Pillsbury” therefore, introduced and adopted
HACCP as a system that could provide the greatest
safety while reducing dependence on finished
product sampling 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.

9. Background
• In 1971, Pillsbury presented HACCP system to the
public for the first time
• In 1973, it was applied to low - acid canned foods
by USFDA
• In 1985, The United States National Academy of
Science recommended that the HACCP approach be
adopted in food processing establishments to
ensure food safety.
• Since then, HACCP has been recognized
internationally as a logical tool towards a more
modern, scientifically based inspection system.

10. Background
• HACCP programs are currently mandatory for
juice, seafood and meat production in US.
• The system is used at all stages of food production
and preparation processes including
packaging, distribution, etc.

12. Background

13. Background

14. Definitions

15. Definitions
• HACCP: A systematic approach to the
identification, evaluation, and control of food safety
hazards.
• Hazard: A biological, chemical, or physical agent
that is reasonably likely to cause illness or injury in
the absence of its control.
• Hazard Analysis: The process of collecting and
evaluating information on hazards associated with
the food under consideration to decide which are
significant and must be addressed in the HACCP
plan.

16. Definitions
• Control:
– (a) To manage the conditions of an operation to
maintain compliance with established criteria.
– (b) The state where correct procedures are being
followed and criteria are being met.
• Critical Control Point: 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.

17. Definitions
• HACCP overview:
– HACCP is an internationally recognised methodology for
preventing food safety hazards.
– HACCP uses a system of monitoring Critical Control Points (CCPs)
at steps in a food production process where a potential critical
hazard to food safety has been identified.
– If the monitoring result is outside the critical limit (a warning
sign), a pre-determined corrective action is implemented to
prevent the hazard from occurring.
– The goal for HACCP is to develop a system which is built on
preventing problems before they occur.
– The safety of the food product is built into the process of
producing the product rather than relying on inspection only after
food has been prepared.
– This system well and truly puts the responsibility for producing
safe food in the hands of industry, including not only management
but also individuals who handle food products.

18. Pros & Cons

19. Pros
• HACCP focuses heavily on problem prevention and
problem solving, through proper monitoring and
record-keeping by the industry.
– It is more proactive than reactive, when compared to
traditional end product sampling quality control methods.
– It has the potential to identify all conceivable, reasonably
expected hazards, even where failures have not previously
been experienced → particularly useful for new operations
– Reduce or eliminate food safety hazards
• One of the primary economic benefits of HACCP is that
it provides for reduced destructive sampling of the
finished product, as compared to the end-product
sampling required under traditional inspection systems

20. Pros
• Internationally recognised
• Less end of production tests.
• Provides the business with a marketing tool and
competitive advantage
• Provides improved supplier status with customers
Import Requirement by Develop Countries :
• –EU : all food import (since November 1996)
• –USA : fish and meat product (1997)
• –Japan, Australia and New Zealand : certain domestic
products and high risk products.

21. Cons
• Cost of development and implementation
• Cost of monitoring
• Impact on employee wages and workload
• Need to train supervisors managerial and
production staff
• Reduced Staff time available for other tasks

22. Principles

23. Principles
• Principle 1: Conduct a hazard analysis.
• Principle 2: Determine the critical control points
(CCPs)
• Principle 3: Establish critical control limits and
preventive measures.
• Principle 4: Establish monitoring procedures for
these critical control points.
• Principle 5: Establish corrective actions.
• Principle 6: Establish verification procedures.
• Principle 7: Establish record-keeping and
documentation procedures

24. Steps for the application of HACCP

26. Guidelines for the application of HACCP

27. Guidelines for the application of HACCP
Prerequisite Programs
• The production of safe food products requires that
the HACCP system be built upon a solid foundation
of prerequisite programs.
• These conditions and practices are now considered
to be prerequisite to the development and
implementation of effective HACCP plans.

28. • Common prerequisite programs may include, but
are not limited to:
– Facilities.
• The establishment should be located, constructed and
maintained according to sanitary design principles.
– Supplier Control.
• Each facility should assure that its suppliers have in
place effective GMP and food safety programs.
– Specifications.
• There should be written specifications for all
ingredients, products, and packaging materials.
– Production Equipment.
• All equipment should be constructed and installed
according to sanitary design principles.

29. – Cleaning and Sanitation.
– Personal Hygiene.
– Training.
– Chemical Control.
• Documented procedures must be in place to assure
the segregation and proper use of non-food chemicals
in the plant
– Receiving, Storage and Shipping.
• All raw materials and products should be stored
under sanitary conditions and the proper
environmental conditions
– Traceability and Recall.
• All raw materials and products should be lot-coded
and a recall system in place so that rapid and
complete traces and recalls can be done when a
product retrieval is necessary.
– Pest Control.

30. Guidelines for the application of HACCP
1. Assemble HACCP team
– should assure that the appropriate product specific
knowledge and expertise is available
– multidisciplinary team (engineering, production, sanitation,
quality assurance, and food microbiology) → may need
assistance from outside experts
– Need knowledgeable and experienced personnel to:
a) conduct a hazard analysis;
b) identify potential hazards;
c) identify hazards which must be controlled;
d) recommend controls, critical limits, and procedures for monitoring
and verification;
e) recommend appropriate corrective actions when a deviation
occurs;
f) recommend research related to the HACCP plan if important
information is not known; and
g) validate the HACCP plan

31. Guidelines for the application of HACCP
2.Describe product
– A full description of the product should be drawn up,
– includes relevant safety information such as:
• composition,
• physical/chemical structure,
• microcidal/static treatments (e.g. heat-
treatment, freezing, brining, smoking, etc.),
• packaging,
• Durability,
• storage conditions and
• Method of distribution.

32. Guidelines for the application of HACCP
3. Identify intended use and consumers of
the food
– Describe the normal expected use of the food.
– The intended consumers may be the general
public or a particular segment of the population
(e.g., infants, immunocompromised individuals,
the elderly, etc.) → vulnerable groups of the
population, (e.g. institutional feeding), may have
to be considered.

34. Guidelines for the application of HACCP
4.Construct flow diagram
– The purpose of a flow diagram is to provide a clear,
simple outline of the steps involved in the process.
– The scope of the flow diagram must cover all the steps in
the process which are directly under the control of the
establishment.
5.On-site confirmation of flow diagram
– The HACCP team should perform an on-site review of
the operation to verify the accuracy and completeness
of the flow diagram.
– Modifications should be made to the flow diagram as
necessary and documented.

36. Guidelines for the application of HACCP
6.Conduct a hazard analysis (Principle 1)
– The purpose of the hazard analysis is to develop a list of
significant hazards that are likely to cause injury or
illness if not effectively controlled
– Areas to be considered:
• Raw materials and ingredients
• Product formulation
• Processing conditions
• Packaging
• Storage and distribution
• Preparation and use
• Target groups

37. Guidelines for the application of HACCP
– Hazard analysis:
• Stage 1:
– hazard identification, can be regarded as a brain storming
session
– the team develops a list of potential biological, chemical or
physical hazards which may be introduced, increased, or
controlled at each step in the production process
• Stage 2:
– the hazard evaluation (based on the severity of the potential
hazard and its likely occurrence)
– the significant hazards associated with each step in the
production of the food should be listed along with any
measure(s) that are used to control the hazard(s)
– 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.

38. Guidelines for the application of HACCP
7. Determine Critical Control Points (Principle 2)
– CCP = a step at which control can be applied and is
essential to prevent, eliminate or reduce a hazard
– The information from hazard analysis is essential to
identify which steps in the process are CCPs
– CCP decision tree:
• Used after hazard analysis
• Used at the steps with identified significant hazards
• A subsequent step may be more effective in controlling a hazard and
may be the preferred CCP
• More than one steps in the process may be involved in controlling a
hazard
• More than one hazard may be controlled by a specific control
measure.

40. Guidelines for the application of HACCP
8. Establish Critical Limits for each CCP (Principle 3)
– Critical limit = a maximum and/or minimum value to which a biological,
chemical or physical parameter must be controlled at a CCP to prevent,
eliminate or reduce a hazard to an acceptable level
– A critical limit is used to distinguish between safe and unsafe operating
conditions at a CCP.
– Critical limits may be based upon factors such as:
• temperature,
• time,
• physical dimensions,
• humidity,
• moisture level,
• water activity (aw),
• pH,
• titratable acidity,
• salt concentration,
• available chlorine,
• viscosity,
• preservatives,
• sensory information such as aroma and visual appearance.

41. Guidelines for the application of HACCP
9.Establish a Monitoring System for Each CCP
(Principle 4)
– Monitoring = a planned sequence of observations or
measurements to assess whether a CCP is under control
and to produce an accurate record for future use in
verification
– Purposes of monitoring:
• To facilitate tracking of the operation. If monitoring indicates
that there is a trend towards loss of control, then action can be
taken to bring the process back into control before a deviation
from a critical limit occurs.
• To determine when there is loss of control and a deviation
occurs at a CCP, i.e., exceeding or not meeting a critical limit.
• To provide written documentation for use in verification

42. Guidelines for the application of HACCP
10. Establish corrective actions (Principle 5)
– Corrective actions are necessary when there is a
deviation from established critical limits.
– An important purpose of corrective actions is to prevent
foods which may be hazardous from reaching
consumers.
– Corrective actions should include the following
elements:
a) determine and correct the cause of non-compliance;
b) determine the disposition of non-compliant product
c) record the corrective actions that have been taken.

45. Guidelines for the application of HACCP
11. Establish Verification Procedures (Principle 6)
– Verification = activities other than monitoring, to
determine if the HACCP system is working correctly
– 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
– Verification activities are carried out by individuals
within a company, third party experts, and regulatory
agencies.

47. Guidelines for the application of HACCP
12.Establish Documentation and Record Keeping (Principle 7)
– Generally, the records maintained for the HACCP System should
include the following:
• A summary of the hazard analysis, including the rationale for determining
hazards and control measures.
• The HACCP Plan
– Listing of the HACCP team and assigned responsibilities.
– Description of the food, its distribution, intended use, and consumer.
– Verified flow diagram.
– HACCP Plan Summary Table that includes information for:
» Steps in the process that are CCPs
» The hazard(s) of concern.
» Critical limits
» Monitoring
» Corrective actions
» Verification procedures and schedule
» Record-keeping procedures
– Support documentation such as validation records.
– Records that are generated during the operation of the plan.

48. THaNK YoU