HACCP-TRAINING-FOR-NIFST-APRIL-2015-1.ppt

HACCP-TRAINING-FOR-NIFST

1. Agenda
•Definitions
•Review of HACCP Principles
• Practical example ---Review of Typical
water treatment Plant
• Questions and Answers

2. •House Keeping is a process where in everyone in the in an organization Is committed and
involved in upkeep of the work place And Cleanliness of Machine, Material & Information
etc., such that Only needed material + information etc., is kept and it’s fastest Accessibility
is ensured.
WHAT IS HOUSE KEEPING ?
•Systematic approach to a better workplace.
•Involved arrangement, cleanliness, discipline and maintenance Standards.
•Assigns a place for everything and ensures everything is in it’s Place.
•Is everybody’s responsibility.
•Is the starting point of any improvement activity
•Means easy retrieval of information.
Hygiene Therefore is a practice of keeping oneself and one’s surrounding clean in order to
prevent disease.
While safety is a condition of being protected from danger or risk which could lead to harm
House Keeping and Hygiene
Defined

3. Implementation
Food Safety Management
System
Imple-
ment-
ation
Mainten-
ance
GHP
GMP
others
Prerequisites
7 HACCP
principles
HACCP Method System Elements
Implementing a Food Safety Management System
preparation

4. HACCP
Hazard Analysis and Critical
Control Point

5. HACCP - General
It is a method to assess
hazards and establish control
systems that focus on
prevention.
mandatory in most EU
countries
based on 7 principles
HACCP
Prerequisites
GMP, GHP, others

6. preparationStep 0. Management commitment
preparationStep 1. Assemble the HACCP team
preparationStep 2. Describe the product(s)
preparationStep 3. Identify intended use
preparationStep 4. Construct flow diagram
preparation Step 5. On-site confirmation of flow diagram
principle 1Step 6. a) List all potential hazards
b) conduct a hazard analysis
c) identify control measures
HACCP Implementation
Main steps in implementation

7. principle 2 Step 7. Determine CCPs.
principle 3 Step 8. Establish Critical Limits for
each CCP
principle 4 Step 9. Establish a monitoring system
for each CCP
principle 5 Step 10. Establish corrective actions
principle 6 Step 11. Validate
Step 12. Establish verification
procedures
principle 7 Step 13. Establish documentation and
record keeping procedures.
HACCP Implementation
Main steps in implementation

8. HACCP
•Is not a new concept
•Is preventive, not reactive
•A system for food and water safety control
•Is a management tool used to protect the
food and water supply against biological,
chemical and physical hazards
•Is not a zero-risk system
•Is designed to minimize the risk of food
safety hazards

9. Benefits
Changing a company approach
 from retrospective quality testing to
preventive way of thinking
Providing a systematic approach covering all
aspects of food and water chain from raw
materials final product consumption
Increasing customer - consumer confidence in
product safety, trade opportunities

10. Benefits
Can be used in evaluating existing processes
or new ones to be developed
Provides scientific bases and confidence for
inspection, for regulatory agencies
Cost effective way of assuring safety and
control of food-borne hazards

11. The opportunities
Gives opportunities for real team work
forms basis for training of the staff
valuable resource in continuous improvement
Useful technique for analysing hazards
Can be combined and supported by other
management systems

12. Step 0 : Management Commitment
Food and water safety is a responsibility of
producer and shall be included in the policies
of the organization
Top management has the final responsibility
for the policy of the organization and shall
document, support and communicate this
policy
Periodically the management shall verify the
implementation of policies

13. Step 1: assemble the HACCP
team
Depending on the size of the company
Small (4-6 persons) & multi-disciplinary:
engineering, maintenance
production, technology
QM, quality control
microbiology, hygiene
logistic
legal department
others (marketing & sales, purchasing,
R&D, finance, etc.)

14. Training of the HACCP team
Training of the team to ensure understanding of
Methodology
Terminology
Training to get familiar with
Defined scope and objective
Food Safety policy
Prerequisites
Legal requirements

15. The product description/technical data associated with the
product:
 composition
 ingredients
 processing conditions
 final product characteristics
 instruction for use
customer requirements
 legal prescriptions, regulations, technical literature
data, and specifications of raw materials.
The traceability of the raw materials up to and including
the final supply shall be described
Step 2: Describe product(s)

16. Step 3: Identify intended use
Identify potential users
Safe storage, preparation and serving
described
Unintended handling and use of product
taken into consideration
Specification for the final product based on
info from customers, internal experts

17. Construct a flow diagram
Step 4 : construct a flow diagram

18. Flow diagram – Example of (Water
Treatment)
Water source
Treatment
Sand filter
Water tank
Carbon purifier
Polishing filter
Treatment compounds

19. Lay out
In a lay out of the facility all production lines,
storage areas, personnel facilities shall be
depicted
Where applicable the following description shall
be available - the areas covered by hygiene and
pest control programs and facilities for
personnel

20. Step 5 : Control & verification of
flow charts.
The description of the process schemes, flow diagrams
and lay out plans shall be verified for compliance with the
actual situation
This verification shall be periodically repeated – at least
annually – in order to timely identify and document the
changes/modifications of the process installation and in
the lay out and to be able to assess the risks for safety in
time.
 The execution of the verification shall be documented in
a program

21. List all potential hazards in every process step
Step 6 : Hazard analysis & control
measures

22. Hazards
Hazard : a biological, chemical or
physical agent in, or condition of,
foodstuffs or water with the
potential to cause an adverse
health effect.

23. Chemical hazards
1. Naturally occurring
Mycotoxins (e.g. aflatoxin)
Mushroom toxins
Shellfish toxins (e.g. paralytic shellfish poisoning, diarrheic SP, neurotoxic SP)
Scombrotoxin (histamine)
Ciguatoxin
2. Added chemicals
Agricultural chemicals (e.g. pesticides, fungicides, fertilisers, hormones...)
Toxic elements and compounds (e.g. heavy metals, dioxins & PCBs…)
Food additives (e.g. preservatives, flavour enhancers, nutritional additives,
colorants…)
Plant chemicals (lubricants, detergents, sanitisers, coatings, paint…)
Chemicals intentionally added (sabotage)

24. Physical hazards
Material Injury potential Sources
Glass Cuts, bleeding
May require surgery
Bottles, glass, light
fixtures, utensils, gauge
covers
Wood Cuts, infection, choking
May require surgery
Fields, pallets, boxes,
buildings
Stones Choking, broken teeth Fields, buildings
Metal Cuts, infection Machinery, fields, wire,
employees

25. Hazard identification
Precise identification of each type of hazard
e.g. (micro)biological :
contamination with Staphylococcus aureus
growth of yeasts
survival of Cryptosporidium
e.g. chemical :
residue of detergent
contact with lubricant
contamination by cooling liquid

26. Conduct a risk analysis

27. Hazard Analysis
Hazard Analysis : the process of
collecting and evaluating information
on hazards and conditions leading to
their presence to decide their
significant for food safety and
therefore should be addressed in the
HACCP plan.

28. PROBABILITY of the HAZARD which may
occur
CONSEQUENCE (SEVERITY)
1 very smalle.g. every ten year
2 small e.g. yearly
3 possiblee.g. monthly
4 big e.g. weekly
1 very limited e.g. no significant health impact
2 moderate e.g. unease, nausea, mild
diarrhoea
3 severe e.g. sickness or injury requiring
medical intervention
4 very severe (catastrophe)e.g. serious health impact, could
be fatal
Hazard analysis

29. Risk analysis
4 5 6 7
3 4 5 6
2 3 4 5
1 2 3 4
Probability
Severity
Big
Possible
SevereModerateVery Limited
Very Small
Small
Very Severe

30. Hazard Analysis
Control measure: Any action and activity that
can be used to prevent or eliminate a food
safety hazard or reduce it to an acceptable level.
Control measure, general: A measure to
control a specific part of the PRP (see use of
decision tree)
Control measure, specific: A measure to
control a CCP (see use of decision tree)

31. Control measures
The HACCP team shall identify and document
the control measures that are to be applied and
– as a result of hazard analysis – are or will be
implemented to eliminate or reduce risks to an
acceptable level
Control measures shall, as far as applicable, be
documented in specifications, instructions,
procedures

32. Hazard Analysis worksheet - Example
Add the steps, potential hazards and their significance,
justification, and potential control measures in columns
1-5, respectively
(1)
Processing
step
(2)
Identify
potential
hazards
introduce
d or
enhanced
at this
step
(3)
Are any
potential
food
safety
hazards
significant
?
(Yes/No)
(4)
Justify
your
decision
for
column 3
(5)
What
measure(
s) can be
applied to
control
the
significant
hazard ?

33. Determine Critical Control Points
Step 7 : Determine CCPs

34. Critical Control Point (CCP)
Critical Control Point: a step at which control
can be applied and is essential to prevent or
to eliminate a food safety hazard or reduce it
to an acceptable level.

35. Critical Control Point (CCP)
•Points may be identified as CCP’s when
hazards can be prevented, for some
products and processes the following may
be true:
–Introduction of hazard can be prevented by control at
receiving step
–A chemical hazard can be prevented by control at the
raw water stage
–Pathogen growth in the finished product can be
prevented by control at treatment stage (e.g., pH
adjustment or addition of preservatives)

36. Critical Control Point (CCP)
•Points may be identified as CCP’s when
hazards can be eliminated, for some
products and processes the following may
be true:
–Pathogens and parasites can be killed during
heat treatment or UV light treatment
–Metal fragments can be detected by a metal
detector and eliminated by removing the
contaminated product.

37. Critical Control Point (CCP)
•Points may be identified as CCP’s when
hazards are reduced to acceptable levels,
for some products and processes the
following may be true:
–Occurrence of foreign objects can be
minimized manually.
–Some chemical hazards such as Chlorine can
be reduced by processes such as strict
checks on dosing pumps and calibration

38. Aided by use of a decision tree:
consider each step in the flow
diagram
must be applied on each
(significant) hazard
use common sense
Determine CCPs

39. CCP determination - Example
(1)
Processing
step
(2)
Identify
potential
hazards
introduce
d or
enhanced
at this
step
(3)
Are any
potential
water
safety
hazards
significant
?
(Yes/No)
(4)
Justify
your
decision
for
column 3
(5)
What
measure(
s) can be
applied to
control
the
significant
hazard ?
(6)
Is this
step a
PRP ?
(Yes/No
& Why)
Is this
step a
Critical
Control
Point ?
(Yes/No
& Why)
Add PRP’s & CCP’s in column 6

40. Step 8: Establish Critical Limit(s)
for each CCP

41. Critical Limits
Critical Limit: a criterion which separates
acceptability from unacceptability of a
product or parameter.

42. Critical limits
•Specify and validate, if possible, criteria that separate
acceptability from unacceptability. Measurements of
temperature, pH, a
w
, sensory parameters, etc.
•National regulations/standards and Company standards
need to be met (or exceeded).
•Target levels may also be determined (= action values).

43. HACCP Plan Form
1.
CCP
2.
Hazards
3.
Critical
limits
The CCP’s, hazards and critical limits should be recorded in
columns 1, 2 and 3 on the HACCP plan form

44. Step 9 : Establish a Monitoring
System for each CCP

45. Establish a monitoring system
Monitoring is an essential part of the study
The system must be able to detect loss of control
at the CCP (non-conformity) in time for the batch to
be isolated before it is used/consumed
Continuously or spot checks

46. The system must include:
monitoring method
monitoring frequency
personnel responsible for monitoring
personnel responsible for evaluating the
monitoring results
indication of where the monitoring result is
recorded/documented
Monitoring system

47. Monitoring of critical process
parameters
What : usually a measurement or observation to assess if
the CCP is operating within the critical limit
How: usually physical or chemical measurements (for
quantitative critical limits) or observations (for qualitative
critical limits) – Needs to be real-time and accurate
Frequency: continuous or periodic (non-continuous)
Who: responsible individual trained to perform the specific
monitoring activity or evaluate monitoring records

48. HACCP Plan Form
1.
CCP
2.
Hazards
3.
Critical
limits
Monitoring
4.
What
5.
How
6.
Freq.
7.
Who
Specify the monitoring procedures for each CCP

49. Step 10: Establish Corrective
Action for deviations that may occur

50. Actions in case of deviation at a CCP:
•Corrective action for the process
• Handle non-conforming products
–Place suspect products on hold
–Assess the situation and seek for advice
–Conduct further tests to assess safety
•When enough information is obtained, make a
decision.

51. Step 11: Validation

52. Validation
Validation : Obtaining evidence (in
advance) that the specific and general
control measures of the HACCP plan are
effective.
“Are we going to do the right things ?”

53. Validation
Initial phase, in which the HACCP plan is
tested and reviewed
Validation of Critical Limits:
Process to ensure, that critical limits are
properly designed
Evaluate, if the target value are
adequate to control identified hazard

54. Step 12 : Verification
The food or water business operator shall have a
program for confirming that the HACCP system is
working effectively (auditing, sampling and
analyzing…)
This verification shall be conducted periodically with
the purpose of examining whether the system is
applied as documented and whether the system is
still fit for purpose or needs to be revised/modified
The frequency shall be sufficient to ensure
continuing suitability and adequacy
A feedback loop to management needs to be
established for review

55. Verification
Verification : the application of methods,
procedures, tests and other evaluations, in
addition to monitoring to determine
compliance with specified requirements.
“Are we doing things right ?”

56. Types of verification
Internal audits
Analysis
Handling of customer complaints
The use of statistical analysis
External audits from authorities, customers or
third parties
...

57. Step 13: Establish Record Keeping
and Documentation

58. Document and Data Control
Manual with policy, scope, procedures etc.
Document control
to approve documents for adequacy prior to issue,
to review and update as necessary and re-approve
documents,
to ensure that changes and the current revision
status of documents are identified,
to ensure that relevant versions of applicable
documents are available at points of use,
to ensure that documents remain legible and readily
identifiable,

59. Document and Data Control
to ensure that documents of external origin are
identified and their distribution controlled,
to prevent the unintended use of obsolete documents,
and to suitably identify them if they are retained for
any purpose

60. Records
The documentation and data shall consist at least of:
Records to demonstrate that the members of the HACCP team
have adequate knowledge, expertise and different disciplines
available;
Records concerning management reviews and, if needed,
related actions;
Records of the hazard analysis and information sources
(legislation, standards, literature, hygiene- codes, GMP, Codex)
used by the HACCP teams to identify and evaluate the hazards
and risks;
Records of the assessment of every step in the process and the
reasons for establishing the Specific Control Measures (CCP
related) and General Control Measures;

61. Records
Monitoring reports (dated and signed) of the Specific Control
Measures to demonstrate the control of the related CCP’s;
Records of deviations occurred (exceeded action limits and critical
action limits) of the Specific Control Measures and the corrective
actions taken;
Records related to the verification program (including internal
audits) and their evaluation;
Records that are relevant to ensure traceability of food stuffs.

62. Key Next steps --- Awareness
The organisation should ensure that its
employees working at each relevant function
and level are aware of:
the importance of conformance to Food and
water Safety requirements
their roles and responsibilities in achieving
conformance to the requirements
the potential consequences of departure from
specified operating procedures

63. Typical Example of HACCP
Application in Water Production

64. Typical Water Treatment Plant

500m
3
Surface
(Raw H2O)
Tank


5


8


3


500m
3
Surface
(Iron Free H2O)
Tank
CO2
Plant
Bore Holes (Chlorinated with dosing pump)
To Chematron Treatment plant
Manual Washing Bay
Administrative Block
Ice Plant
Hydrant Points
Production Toilets
Compressors
Washer 2
Boiler
Washer 1
Washer 3
Washer 4 3 sand Filters
(30 m
3
each)
Cl2 NaOH
BORE HOLES
8. 60 m3/h - Beside ETP
2. 60 m3/h - Behind Iron removal plant
3. 60 m3/h – Behind ETP
1. 30m3/h – Beside CO2
5. 60 m3/h – Beside cullet bay

WATER TREATMENT FLOWCHART
(A)
45 m
3
FeCl3
NaOH
NaOH
Cl2
Cl2
45 m
3
45 m
3
48 m
3
50 m
3 FeCl3
4 CSD Lines
Canteen
Syrup Rooms
QA Laboratory
EVA Line
PET CSD LINE

H2O from 500m
3
Raw H2O Tank
Holding
Tank
2 Sand filters
(25m
3
/h each)
Intermediate
Tanks
2 Carbon Purifiers
(25 m
3
/h each)
Holding
Tank
38m
3
/h Sand
Filter
45m
3
/h Carbon
purifier
Intermediate
Tank
45m
3
/h CHEMATRON WATER TREATMENT PLANT 2
50m
3
/h CHEMATRON WATER TREATMENT PLANT 1
(B)
IRON REMOVAL PLANT

TM
TM
CM
CM
CM = Chlorine Monitor
TM = Turbidity meter
FM = Flow meter
FM FM
FM
FM
KEY
Polisher
Polisher


Effluent to ETP

65. Questions &Answers

66. Thank You