HACCP

1. HACCP Hazard Analysis Critical Control Points

2. Background • Farm to table mentality – everyone is responsible • Producers and distributors (e.g. grocery stores) • Size does not matter • Goal is to provide consumer with safe product • Preventative vs. fix it when it breaks

3. History • 1971: National Conference on Food Safety combines risk assessment with critical point concept • Mid 1970’s: Pillsbury uses HACCP for space program • 1973: HACCP adopted for Low-Acid Canned Food Regulations • 1985: National Academy of Science recommends HACCP for other food products

4. History • 1990’s: HACCP is internationally accepted • 1997: Mandatory Seafood HACCP • 1998-2000: Mandatory for all meat and poultry • 1999: Mandatory frozen desserts HACCP in Ohio • 2002: Mandatory Juice HACCP

5. Effects of the HACCP Plan • Improve your operation from the regulatory standpoint and provide for the safety of your food products • Reduce the chance for food-borne illness • Identify and document where corrections need to be made • Have you thoroughly review your operation specifically for food safety and place controls on those areas of concern

6. Five Required Forms • Process Flow Diagram • Hazard Analysis and CCP • Critical Limits, Monitoring, and Corrective Actions • Verification and Record Keeping • HACCP Plan Summary

7. Prerequisites 1) Workers must know how organisms multiply, survive and are killed and what they can do • Effects of physical/chemical contamination 2) Identify hazards to control (what are the risks?) 3) Identify limits needed to control hazards

8. Prerequisite Programs • Adequate facilities and equipment • Supplier control and product specification • Cleaning and sanitation • Employee hygiene and training • Chemical control • Receiving, storage, and shipping • Traceability and recall • Pest Control

9. Sanitation SOPs (SSOPs) • Basics for maintaining a food facility that has a clean, sanitary environment that is free from food hazards • How things are to be done • When they are to be done • Who will do them • What levels of operation a procedure is out of control and needs to be properly adjusted

10. SSOPs • Describe daily procedures to prevent direct contamination or adulteration of the product • Preoperational (cleaning) procedures are identified • Frequency is specified for each procedure. • Identifies responsible employee(s) • Daily records are kept to document implementation and monitoring of SSOP and any corrective action taken. • The individual with overall authority on-site signs and dates the SSOP upon initial implementation and any new modification

11. Pathogens Yersinia enterocolitica Bacillus cereus Salmonella Shigella Listeria Enteropathogenic Escherichia coli Spoilage Erwinia carotovora Pseudomonas Bacillus Molds (Alternaria, Botrytis, Penicillium, Phytophthora) Fresh Produce

12. Pathogens Staphylococcus aureus Shigella species Clostridium perfringens Listeria monocytogenes Spoilage Enterococci Pseudomonas Lactic acid bacteria Coliforms Yeast Hot/Cold Delicatessen

13. Pathogens Norwalk virus Norwalk-like viruses Otherwise rarely associated withfood-borne illness Spoilage Molds Bacillus subtilis Bakery

14. Pathogens Salmonella Campylobacter jejuni Clostridium perfringens Enteropathogenic Escherichia coli Listeria monocytogenes Staphylococcus aureus Spoilage Pseudomonas Acinetobacter Moraxella Lactobacillus Butcher Shop

15. Pathogens Vibrio cholerae Vibrio parahaemolyticus Clostridium botulinum type E Norwalk virus Spoilage Pseudomonas Seafood

16. Pathogens Salmonella Campylobacter jejuni Bacillus cereus Yersinia enterocolitica Listeria monocytogenes Spoilage Pseudomonas Flavobacterium Alcaligenes Diary/Egg

17. Chemical/Physical Hazards • Staples, wire, twist-ties • Glass, plastic film • Wood, tooth-picks • Sand, stones, bone pieces • Pesticides, insecticides, improperly prepared or improperly applied sanitizers and cleaners

18. Seven HACCP Principles • Conduct a Hazard Analysis • Determine the CCP • Establish Critical Limits • Establish Monitoring Procedures • Establish Corrective Actions • Establish Verification Procedures • Establish Record Keeping and Documentation

19. Conduct Hazard Analysis • Prepare a list of steps in the process where significant hazards occur • Describe the preventive measures • Only hazards to food safety • Hazard: any biological, chemical, or physical property that may cause a food to be unsafe for human consumption

20. Determine CCP • The last 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 • For every significant hazard identified, there must be at least one corresponding CCP to control the hazard, although more than one hazard may be controlled at a CCP • May be at hazard point or at a later step

21. Establish Critical Limits • Maximum or minimum value to which a physical, biological, or chemical hazard must be controlled at a CCP to prevent, eliminate, or reduce to an acceptable level the occurrence of the identified food safety hazard • Numbers or parameters based on visual observations (i.e. time or temperature)

22. Establish Monitoring Procedures • Observations or measurements to assess whether a CCP is under control and to produce an accurate record for future use in verification • Establish procedures for using the results of monitoring to adjust the process and maintain control

23. Est. Monitoring Program (cont) • Monitor Critical Limits values for What, How, Frequency, and Who • Identify the employee positions responsible for monitoring • Train employees monitoring the CCP in the testing procedures, the critical limits established, the methods of recording test results, and the actions to be taken when critical limits are exceeded. • Ensures that the employees understand the purpose and the importance of monitoring

24. Establish Corrective Action • Procedures to be followed when a deviation (failure to meet critical limit) occurs • Corrective actions ensure: • The cause of the deviation is identified and eliminated • The CCP will be under control after the corrective action is taken • Measures to prevent recurrence are established • No product that is injurious to health or otherwise adulterated as a result of the deviation is distributed for human consumption

25. Establish Verification Procedures • HACCP team to verifies that the HACCP system is working the way it is expected to work • Initially evaluate the operation of the HACCP system and then maintain an updated and effective HACCP system • Verification may be broken down into three categories: • Validation • Verification • Reassessment

26. Verification Categories • Validation: Test that the process with the Critical Limits prevent, eliminate, or reduce the hazard to an acceptable level • Verification: Assure that all required information is written down and documented • Do what you say and say what you do • Verify the written statements

27. Verification Categories (cont) • Reassement: • At least annually • Consider potential new hazards • Examine changes in the preparation, raw materials or raw ingredients, personnel, packaging of the finished product, or any other changes that could affect the hazard analysis

28. Establish Record Keeping and Documentation • Written documentation of the establishment’s compliance with its HACCP plan • Allow the retail facility to trace the history of an ingredient, in-process operations, or a finished product should problems arise • Help identify trends in a particular operation that could result in a deviation if not corrected • Help identify and narrow the scope of a recall • Good evidence in potential legal actions against an establishment. • There may be new HACCP team members and the rationale for certain decisions is forgotten

29. Records • In the Hazard Analysis, records of practices that keep hazards from likely occurring, i.e.: • Cleaning procedures • Employee training • HACCP plan and reassessments: • Validations • Verifications • Operating records (such as): • Operating Records of Critical Limits • Calibrations

30. Creating the HACCP Plan • Step 1: Create process flow diagram • Verify flow diagram • Step 2: Add each process step from flow diagram onto Hazard Analysis and CCP form

31. Creating the HACCP Plan • Step 3: For each process step and hazard: • Potential Hazards introduced, controlled, or enhanced at this step. • Does this potential hazard need to be addressed in the HACCP plan? • Why? (Justification for the decision made in the previous column.) • What measures can be applied to prevent, eliminate, or reduce the hazards being addressed in the HACCP plan?

32. Creating the HACCP Plan • Step 4: Deterimine CCPs • Is the identified hazard likely to occur? • Are there preventive measures for each hazard? • Is this the last point in which control can be applied to prevent, reduce or eliminate hazards • Step 5: Establish Critical Limits • Enter the process step/CCP on the Critical Limits, Monitoring, and Corrective Actions form

33. Creating a HACCP Plan • Step 6: Establish Monitoring • What: Identifying the Critical Limit(s) to be monitored • How: The monitoring instrument(s) to be used • Frequency: When creating the frequency between non-continuous readings, remember that if a Critical Limit Value does not meet specification, all product from the last acceptable reading to the next acceptable reading must be considered for Corrective Action • Who: Identify the position responsible for recording the Critical Limit Value(s)

34. Creating a HACCP Plan • Step 7: Corrective Actions • CCP under control • Disposition of noncomplying product determined • Cause corrected to prevent recurrence • Maintain records • Step 8: Verification • For each Process Step, enter all the Validation and Verification activities • Whenever a Reassessment occurs, fully document the reason for the reassessment and the results

35. Creating a HACCP Plan • Step 9: Record keeping • On each Process Step/CCP, enter all the Record-Keeping Procedures on the Verification and Record Keeping form • Step 10: HACCP Plan Summary • Hazard • Critical Limit • Monitoring Instrument • Corrective Action • Verification • Record Keeping • Step 11: All forms are to be reviewed for correctness, signed, and dated

36. Final HACCP Plan Manual • Cover Page (plant name, date, etc.) • HACCP Team • Products covered • Description of each process (hazards, CCP, etc.) • Employee training records • Recall procedure

37. Lot Identification/Coding • Necessary for recall procedure • Required items • The establishment where the food was prepared and/or processed • The food product • The year prepared and/or processed • The day prepared and/or processed • The period or shift during which the food product was prepared and/or processed (q4-5 hours, batch, shift changes)