HACCP

1. PREPARATION OF HACCP PLAN AND
ESTABLISHMENT OF CPP DECISION
TREE

2. Hazard Analysis Critical Control Point(HACCP)
• HACCP is a systematic approach to the identification,
evaluation, and control of food safety hazards. Preventing
problems from occurring is the paramount goal underlying
any HACCP system.
• The Hazard Analysis and Critical Control Points (HACCP)
System is a logical, scientific approach to controlling safety
problems in food production.
• While adopts HACCP, puts controls in place at each point in
the production system where safety problems could occur
from biological, chemical, or physical hazards.
• Write a HACCP plan to start a HACCP system
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
safety assurance program.

3. Definitions
Critical Control Point (CCP). A point, step, or procedure in a food process at
which control can be applied and as a result a food safety hazard can be
prevented, eliminated, or reduced to acceptable levels.
Critical limit. The maximum or minimum value to which a physical, biological,
or chemical hazard must be controlled at a critical control point to prevent,
eliminate, or reduce to an acceptable level the occurrence of the identified
food safety hazard.
Deviation. Failure to meet a critical limit.
HACCP. Hazard Analysis and Critical Control Points. A process that
identifies specific hazards and preventive and control measures to
ensure the safety of food.
HACCP Plan. The written document that is based upon the principles
of HACCP and that delineates the procedures to be followed to
ensure the control of a specific process or procedure.

4. • HACCP System. The HACCP plan in operation, including the HACCP Plan
itself.
• Hazard (Food Safety). Any biological, chemical, or physical property that
may cause a food to be unsafe for human consumption.
• Hazard Analysis. The identification of any hazardous biological, chemical,
or physical properties in raw materials and processing steps, and an
assessment of their likely occurrence and potential to cause food to be
unsafe for consumption.
• Monitor. To conduct 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.
• Preventive measure. Physical, chemical, or other means that can be used
to control an identified food health hazard.
• Process. A procedure consisting of any number of separate, distinct, and
ordered operations that are directly under the control of the establishment
employed in the manufacture of a specific product, or a group of two or
more products wherein all CCP’s, such as packaging, may be applied to
one or more of those products within the group.

5. Hazard Analysis and Critical Control Points
(HACCP)
• The Hazard Analysis and Critical Control Points (HACCP) System
is a logical, scientific approach to controlling safety problems
in food production.
• While adopts HACCP, puts controls in place at each point in the
production system where safety problems could occur from
biological, chemical, or physical hazards.
• Write a HACCP plan to start a HACCP system.

6. Principles of HACCP
The foundation of HACCP can be found in the seven principles that describe its
functions. These seven principles are:
• Principle No. 1: Conduct a Hazard Analysis. Prepare a list of steps in the process
where significant hazards occur, and describe the preventive measures.
• Principle No. 2: Identify the Critical Control Points (CCP’s) in the process.
• Principle No. 3: Establish critical limits for preventive measures associated with
each identified CCP.
• Principle No. 4: Establish CCP monitoring requirements. Establish procedures
for using the results of monitoring to adjust the process and maintain control.
• Principle No. 5: Establish corrective action to be taken when monitoring
indicates that there is a deviation from an established critical limit.
• Principle No. 6: Establish effective recordkeeping procedures that document
the HACCP system.
• Principle No. 7: Establish procedures to verify that the HACCP system is working
correctly.

7. Preliminary Steps
• Assemble the HACCP Team
• Identify Products/Foods/Processes that must be
covered by the HACCP plan
• Develop a List of Ingredients, materials, equipment
and recipes/formulations.
• Develop a Process Flow Diagram
• Verify the Process Flow Diagram

8. Common Approach for HACCP
Implementation
a. Assemble HACCP Team (multi-disciplinary)
b. Write Product Description (how is it made and what raw materials are
used?)
c. Identify Target Audience (include markets and customers)
d. Create Process Flow Diagram
e. Verify Process Flow Diagram
f. Identify Hazards
g. Perform Hazard Analysis
h. Determine Critical Control Points (CCP)
a. Use CCP Decision Tree
i. Establish Critical Control Point Limits (if applicable)
j. Establish Monitoring Procedures for Critical Control Points (if applicable)
k. Establish Corrective Actions for Critical Control Point Deviations (if
applicable)
l. Verify HACCP Plan

9. Preparing a HACCP Plan:
Step 1: Assemble the HACCP Team
• Cross Functional Team
• Management Sponsorship / Buy-In / Participation
• HACCP Training
• Documents: Team List / Charter with Management Sign-Off/ Facility
Training Log

10. Facility HACCP Team
Facility Name: Date:
Team Member Name Position HACCP Team Role Signature
Facility Manager Member
Corporate Quality
and CI
Advisor
Q.A./Product
Safety/Env
Team Leader
Converting Mgr. Member
Printing Supervisor Member
Converting –
Lead Operator
Member
Shipping/Receiving
Coordinator
Member
Printing Operator Member
Maintenance
Technician
Member
Facility Training Log
Subject: Date(s): Trainer’s Name &
Title:
Materials
Used:
Print Name: Signature Date:

11. Step 2: Write Product Description
a. What do you make?
b. How do you make it?
c. Intended usage (include time and temperature as
applicable)
d. What Raw Materials are used?
e. Intended markets / customers
f. Document: Written Descriptions of what is made and
production process

12. Product / Category Description
Facility Name Date
Product/ Product Category: Multiwall Packaging
Product description: Printed Multiwall packaging. Packaging constructed typically of multiple plies of paper,
sometimes with a film liner, and used to package food, ingredients, or pet food
Process Flow: Receipt of order, Graphics development and verification, Receipt of raw materials,
Printing, Tubing, Bottoming, Packaging, Shipping
Food Safety Characteristics: Based on risk assessment and end use. Direct/Indirect/Non-food contact. Applied
labeling (if any) must be accurate to prevent/eliminate mislabeling of finished products
that could lead to allergen and/or regulatory food safety labeling non-compliance.
Measures must also be instituted for the prevention of introduction of foreign objects
such as metal contamination or accumulated debris
Customer/ Consumer Use: Finished bags to be used for containing food, ingredients, or pet food.
Target Market: Food or Pet industry
General Raw Materials: Paper, film, inks, photopolymer plates, adhesives, string
Packaging/Palletization: Pallets, corrugated boxes, stretch wrap, cardboard/corrugated slip sheets, cardboard
corner boards, poly shrouds, banding
Shelf Life: Typically not specified but recommended to be no greater than one year dependent on
storage conditions
Storage & Distribution: Material stored at plant warehouse, distributed to food manufacturing plants/pet food
manufacturing plants at ambient temperature. -20°F - 120°F, protect from moisture
Other: No additional information

13. Step 3: Create Process Flow Diagram (PFD)
a. Block Diagram showing manufacturing steps
b. Include Receipt of Raw Materials and Shipping of Finished
Goods
c. Document: Process Flow Diagram
d. Note: Add CCPs to PFD

15. Step 4: Verify Accuracy of Process Flow Diagram
a. Team walks through plant with PFD
b. Confirm PFD with team and facility personnel
c. Make necessary changes before proceeding
d. Document: Edited Process Flow Diagram / Signed & Dated
showing approval
Step 5: Perform Hazard Analysis
a. Evaluate raw materials for Chemical, Physical, and Biological
Hazards
b. Evaluate processes for Chemical, Physical, and Biological
Hazards
c. Document: Hazard Analysis Sheet for Raw Materials
d. Document: Hazard Analysis Sheet for Processes

16. Raw Material/Process Hazard Analysis
List each raw
material/
ingredient in
the process
Does this
material /
ingredient
INTRODUCE a
potential food
safety hazard?
What is it?
C =Chemical
P = Physical
B = Biological
Is this hazard
CONTROLLED by a
Prerequisite
Program or process
step?
If YES, identify the
program or
process. If a pre-
requisite program
or process is
identified, do not
complete
Columns 4-6 and
go to next process
step. If NO, go to
column 4.
Is this hazard
ELIMINATED
By a subsequent
process step?
If YES, this step is
NOT a CCP. Identify
the subsequent
process step in
Column 5 and
proceed to the next
process step. If the
hazard is
eliminated at this
step, enter NO and
go to column 6 and
assign a CCP #.
Identify the
last process
step that will
eliminate the
potential
hazard.
(Example:
metal-
detector,
filter, etc…)
Assign a CCP
# when the
answer in
Column #4 is
NO.
(otherwise
leave blank)
Films (BOPP,
HDPE, LDPE &
LLDPE)
C-NO Yes – Receiving
InspectionsP-Yes–Foreign
Material
B-NO
Adhesives
(starch, hotmelt,
Lamination)
C-NO Yes – Receiving
InspectionsP-Yes–Foreign
Material
B-Yes-Infestation

17. Step 6: Determine Critical Control Points (CCPs)
• a. Use CCP Decision Tree
• b. Confirm CCPs Using CCP Definition
• c. Document: Raw Materials / Process Hazard Analysis Worksheets
• d. Document: CCPs on HACCP Master Plan
CCP Decision Tree Table
Product:
A critical control point is defined as a point, step or procedure at which control can be applied and a food
safety hazard can be prevented, eliminated or reduced. Steps presenting a significant potential food safety
risk (Hazard Analysis) are listed.
Process step
Hazard
Biological = B
Chemical = C
Physical = P
Q1. Does this
step involve a
hazard of
sufficient risk
and severity to
warrant its
control?
Q2. Does a
preventive
measure for
the hazard exist
at this step or
in a subsequent
step?
If Q2 is No..
Is control at
this step
necessary
for safety?
Q3. Is control at
this step
necessary to
prevent,
eliminate or
reduce the risk
of the hazard to
consumers?
CCP#

19. Step 7: Establish Critical Limits for CCPs (if applicable)
a. Critical Limits must be meaningful; should be measurable
b. Document: HACCP Master Plan
Step 8: Establish Monitoring Procedures for CCPs (if any)
a. Identify how Critical Limits will be monitored; by whom;
frequency; documentation requirements
b. Training for those performing the CCP monitoring
c. Documents: HACCP Master Plan
Step 9: Establish Corrective Actions for CCP Deviations (if
applicable)
a. Identify Corrective Action for CCP checks falling outside of
Critical Limits
b. Evaluation of products from previous CCP check
c. Document: HACCP Master Plan

20. HACCP Master Plan Summary
Product:
Process
Step
Hazard
Descri-
ption
CCP
Descri
ption
Critical
Limit
Monitoring
Procedures/
Frequency/
Person
Responsible
Corrective
Actions/
HACCP
Records
Verification
Procedures/
Person
Responsible
Who:
What:
When:
How:
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.

21. HACCP Master Plan

22. Step 10: HACCP Plan Validation
a. Are CCPs meaningful, measurable?
b. Have all risks been identified, evaluated?
c. Have raw materials changed?
d. Has process or equipment changed?
e. Documents: Reassessment Log / Change Log / History /
Meeting Minutes
Verification confirms that the HACCP plan is being
followed and Validation confirms that the HACCP plan properly
addresses the appropriate activities. Verification and
Validation activities must be documented.

23. HACCP Plan Verification and Validation
Verification:
Includes activities such as:
an annual internal (or external) audit to confirm the
HACCP plan is being followed as written;
confirmation of operator training;
confirmation of operator competence with respect to
monitoring CCPs and addressing out-of compliance
occurrences;
 HACCP record review;
previous HACCP plan audits; and,
spot-checking prerequisite program.
Verification assures that the HACCP plan is operating
effectively on a day-to-day basis.

24. Validation:
Includes activities such as:
critical review of the hazard analysis for depth and
accuracy (i.e. were all hazards considered? Were
the correct CCPs chosen?);
critical evaluation of the CCPs (i.e., are critical limits
meaningful and actionable?); and,
monitoring activities (i.e., are the correct
parameters monitored at the correct frequency?).
Validation provides evidence that the
techniques and methods adopted by the plant are
not just effective in theory, but will in fact work for
the specific plant

26. Record Keeping & Documentation
Records provide evidence that procedures are being
followed and CCPs are monitored as required. They
provide objective evidence to internal and external auditors.
As in ISO 9000, if something is not documented, it’s not
done.
• Types of documents plant will need: Examples are provided in
the Preparing a HACCP Plan section of this model. In short,
the plant documentation will include: the HACCP Plan; Hazard
Analysis; HACCP Procedures; HACCP Records; a list of
HACCP trained personnel and team members; and, supporting
documentation from the Prerequisite Programs.
• Completing HACCP Records: HACCP records should be
completed at the time of use. Information should be recorded
in permanent ink.

27. Record Keeping & Documentation
• Review of HACCP Records: CCP records should be reviewed
by a trained company representative prior to releasing an order
for shipment. The review must be documented.
• Proper documentation practices: The plant should follow
proper documentation practices such as prohibiting the use of
correction fluid (white-out) and pencil on permanent records.
Also, changes to entries should be made using a single line-out
along with initialing and dating the change. A documentation
practices procedure should be in place.
• HACCP Record Retention: The plant’s record retention policy
should include a retention time for HACCP records. In many
cases, this will be two years.

28. Record Keeping and Verification
Product:
Process Step/CCP Records Verification Procedures
1.
2.
3.
4.