THE IMPLEMENTATION OF

HAZARD ANALYSIS CRITICAL

CONTROL POINTS

DEPARTMENT Of FOOD SAFETY And QUALITY

Sarawak State Health Office
 HACCP
• APA ITU HACCP?
• SEJARAH BERKENAAN HACCP
• KEBAIKAN DI SEBALIK SISTEM HACCP
• PRINSIP-PRINSIP HACCP
• CABARAN
• KESIMPULAN
 What is HACCP

• A systematic approach specifically designed for food safety

that helps to prevent food contamination from biological,
physical, chemical, and allergen means using scientific
analysis and principles

• HACCP is a tool to assess hazards and establish control

systems that focus on prevention rather than relying mainly
on end-product testing

• HACCP is recognized as a benchmark system worldwide in

ensuring food safety and serves as a legal requirement for
food industry in a lot of developed countries

3
 Definisi HACCP
• Merupakan satu bentuk program yang
menyediakan pendekatan yang bersistematik
untuk mengenalpasti dan memantau sebarang
punca pencemaran mikrobiologi, fizikal dan
kimia kepada pihak yang berkepentingan
menyediakan makanan

4
 plier Selection Criteria.
• Do technical, environmental, aquacultural and social accountability standards
meet or exceed requirements?

• What level of certification is held?

• Does the product quality meet specification, and can it do so consistently?

• Do available volumes meet forecast requirements?

• Can intellectual property be protected?

• Is exclusivity available?

5
 History of HACCP
1960s’(late)
q Developed jointly by the Pillsbury Co., US Army Laboratories at Natick, USAF Space Lab
Project and NASA
q production of safe foods for US manned space program

1971
q HACCP concept presented to the US public for the first time at the National Conference on
Food Protection
q originally, only three principles
1973
q FDA mandated HACCP-based regulations for low- acid canned foods

1980
q HACCP adopted by WHO as part of Codex Alimentarius

1985
q US National Academy of Sciences (NAS) recommended that HACCP be adopted by all
regulatory agencies and that it be mandatory for all food processors as it was the most
effective and efficient means of assuring food safety
6
1989 – 1992
q US National Advisory Committee on Microbiological Criteria for Foods (NACMCF)
developed and standardized the HACCP system with its seven HACCP principles

1991
q EU (former EEC) legislated the use of HACCP-based “own-checks” system for fish and
fishery products
q FDA/NMFS Voluntary Seafood Inspection Program based on HACCP initiated

1993
q Codex Guidelines for the Application of the HACCP System were issued and adopted by
the 20th Session of the Joint FAO/WHO Codex Alimentarius Commission
q HACCP-based QMP for seafood industry made mandatory in Canada

1995
q With the establishment of WTO and the SPS and TBT Agreements, HACCP became the
international reference system for food safety as it has been adopted by Codex
1997
q New US Seafood HACCP Regulation effective from 18 Dec 97

2003
q The draft revised Codex Guidelines for the Application of the HACCP System were
adopted by the 26th Session of the Joint FAO/WHO Codex Alimentarius Commission 7
 Establish records and
documentation
Establish procedures for
verification

7
Conduct a Hazard 6
Analysis
1

5 Establish the
corrective action

2
Determine the
critical control
points
4
3
Establish a system to
monitor and control of
Establish Critical
CCP
limit(s)
8
PRINCIPLES OF THE HACCP SYSTEM
• Analyze Hazards
Potential hazards associated with a food and
measure to control those hazards
Hazard – eg, a microbe; a toxin; ground glass or
metal fragments
• Identify Critical Control Points – CCP
These are points in a food’s production from its raw
state through processing and shipping to
consumption by the consumer at which the
potential hazard can be controlled or eliminated eg,
cooking, cooling, packaging and distribution
• Establish preventive measure with Critical Limit CL for each control
point
eg. A cooked food – setting the min. cooking temperature – time
required to ensure the elimination of any harmful microbes

• Establish procedures to monitor CCP such as determine how and by

whom cooking time and temperature should be monitored

• Establish corrective action CA to be taken when monitoring shows

that a CL has nit been met, eg. Reprocessing or disposing of food if
the minimum cooking temperature is nit met.

• Establish procedures to verify that the system is working properly

eg. Testing time -and- temperature recording devices to verify that
a cooking unit is working properly
• Establish effective recordkeeping to document
the HACCP system
• Include records of hazards and their control
methods the monitoring od safety requirement
and action taken to correct potential problems
• Must be backed by sound scientific knowledge,
• eg. Published microbiologicalstudies on time and
temperature factors for controlling foodborne
patho
 HACCP does not stand alone
• Prerequisite programs are the building blocks
to HACCP HACCP

GHPs

GMPs SSOPs

Practice maintenance

Training Plant Design

QC Program QA Program
The Elements of
• Design and Facilities – premises • Personal hygiene – health status ;
and rooms; equipments; water illness and injuries ; personal
supply; toilet facilities; hand cleanliness ; visitors
washing facilities; lighting; • Transportation and distribution
storage • Recalls and traceability
• Control of Operation –time and • Product information – batch
temperature control ; incoming identification ; labelling
raw materials ; packaging ; ice
• Training – training programs ;
and steam ; microb
training schedules ;
contamination
• Maintenance , cleaning and • Internal inspection – internal audit;
sanitasition – maintenance self inspection
program ; pest control ; waste • Management review
management ;
 PRELIMINARY STEPS IN
DEVELOPING HACCP PLAN
 Preliminary Steps
Komitmen pengurusan

Pembentukan team HACCP

Deskripsi produk

Kenalpasti cara
penggunaan & pengguna
Menyediakan carta alir
proses

Pengesahan
SEQUENCE FOR HACCP IMPLEMENTATION
Now on to the construction of
HACCP plan ….
 HACCP TEAM
A multi-disciplinary HACCP team shall be set up to develop,
maintain and review the HACCP system.

People chosen that have expertise in different areas:

o Production
o Shipping
o Quality Assurance
o Sanitation
o Maintenance
o Sales
 PRODUCT DESCRIPTION
o Product Name(s)
o Materials used
o Sensitive materials identified
o Potential material known to cause hypersensitivity
(allergy) identified
o Reworked material
o Important products characteristics
o Process type
o Packaging and labelling
o Shelf-life and storage conditions
o Handling and distributions
o Intended consumers
PRODUCT DESCRIPTION

1. Product Name Frozen Squids / Cuttlefish Meat. [Squids(Loligo sp), Cuttlefish

(Sepia sp) and Octopus(Octopus sp)] Sea catch.
2. Raw Material Squids, cuttlefish, octopus, sodium chloride, MSG

3. Sensitive Ingredient and Allergen Seafood

4. Reworked material (to be taken as None
ingredient)
5. Important product characteristics Highly perishable, raw, frozen.

6. Process Type Freezing

7. Packing Type Block frozen, packed in Polyethylene (PE) Food Grade
Plastic Bag and then into master carton
8. Labelling Brand ABC
9. Labelling instruction for consumer Keep frozen at or below -18ºC.
Do not refreeze if thawed and uncooked
10. Storage Keep frozen at or below – 18°C

11. Shelf life 18 months if stored at or below temperature – 18°C

12. Special distribution control Transport in refrigerated container/trucks maintained at or

below -18ºC.

13. Intended use & consumer For genaral public.

Product shall be cooked before consumption.
14. Sensitive consumer Those who are allergic to seafood shall not consume
15. Where product will be sold Retail, wholesale, food service and hypermarket (local) and
export to Singapore, Indonesia, China and Brunei.

16. Traceability code Date of Manufacturing DD/MM/YYYY and production code

 Define the processing steps

Packaging
Storage and
Receiving Preparation and Storage Distribution
Holding Labelling
Construct a process flow diagram for Value Added Seafood Processing Factory

Process Steps:

1.Receiving of raw material

2.Quality Check
3.Storage
4.Weighing
5.Packing
6.Freezing
7.Cartoning and Strapping
8.Final Storage
9.Loading and Dispatch
 Packaging Receiving of Raw Material
Material

Not OK Not OK
QC
QC Reject
Reject Check
Check OK
OK
Storage
Storage

Weighing

Packing

Freezing

Cartoning & Strapping

Final Storage

Loading And Dispatch

PRINCIPLE 1: Identification of Hazards and
Determination of Control Measures
• To conduct a hazard analysis and identify
appropriate control measures
• Purpose of hazard analysis is to identify which
hazards are of such nature that their
elimination or reduction to acceptable levels is
essential to the production of a safe food
In conducting the hazard analysis, wherever possible the
following should be included:

• the likely occurrence of hazards and severity of their

adverse health effects;
• the qualitative and/or quantitative evaluation of the
presence of hazards;
• survival or multiplication of microorganisms of
concern;
• production or persistence in foods of toxins, chemicals
or physical agents; and,
• conditions leading to the above.
TYPE OF HAZARDS
• Physical
• Biological
• Chemical
 Prinsip Nombor 1
Menjalankan Analisis Hazard (Bahaya
Analisis Hazard (Bahaya):)

Proses pengumpulan dan penilaian maklumat

mengenai bahaya yang berkaitan dengan

makanan di bawah pertimbangan. Ia

menentukan bahaya yang penting dan perlu

ditangani di dalam pelan HACCP

 Jenis-jenis Bahaya
Bagi sistem pemprosesan makanan, tiga jenis bahaya

telah dikenalpasti:

• Biologi (patogen dan toksin mikrob)

• Kimia (racun perosak, antibiotik, bahan pengawet,

dan lain-lain.)

• Fizikal (kaca, logam, plastik keras, dan lain-lain.)

Determination of Hazards

o Look at each input- ingredients

o Determine possible hazards
-reference (books, journal, case study, guidelines)
o How are they controlled?
Raw Material/ Potential Rational for inclusion Is this a Significant Hazard? What Measures can be Is this raw
Packaging Hazard state or exclusion as a applied to control this material/packaging material
Material whether biological, Hazard significant hazard? a sensitive material
chemical or physical (Yes/No)
Severity Likelihood Significant Yes/No Q1 Q2 Q3 Yes/
No
Process Step Potential Rational for Is this a Significant Hazard? What Measures can be Is this process steps a
Hazard state inclusion or applied to control this Critical Control Point?
whether biological, exclusion as a significant hazard? (Yes/No)
chemical or Hazard
physical Severity Likelihoo Significant Yes/No Q1 Q2 Q3 Q4 Yes/
d No
 FOOD SAFETY HAZARDS

1. BIOLOGICAL HAZARD
• pathogenic bacteria
• virus
• biogenic amines
• aquatic biotoxin
• parasites
2. CHEMICAL HAZARDS
3. PHYSICAL HAZARDS

35
 Common Causative Agents

q Bacteria q Viruses
§ Bacillus cereus
§ Campylobacter § Norovirus
§ Clostridium botulinum § Astrovirus
§ Clostridium perfringens § Hepatitis A virus
§ Escherichia coli
Ø Shiga toxin-producing E. coli q Parasites
Ø Enterotoxin producing E. coli
Ø Enteroinvasive E. coli § Cryptosporidium
Ø Enteropathogenic E. coli § Cyclospora cayetanensis
§ Listeria monocytogenes § Entamoeba histolytica
§ Salmonella, non-typhoid § Giardia intestinalis
§ Salmonella Typhi § Trichinella
§ Shigella
§ Staphylococcus aureus
§ Vibrio q Chemicals/other
§ Yersinia enterocolitica § Heavy metals
§ Pesticides
§ Fungal toxins
§ Fish toxins
 Pathogenic Bacteria Indigenous to the Aquatic
Environment
• Clostridium botulinum
Ø non-proteolytic types B, E and F
• Pathogenic Vibrio spp.
Ø V. cholera, V. parahaemolyticus and V. vulnificus
Ø Other vibrios
• Aeromonas hydrophila
• Plesiomonas shigelloides

37
 Pathogenic Bacteria Indigenous to the General
Environment

• Listeria monocytogenes
• Clostridium botulinum
Ø proteolytic types A and B
• Clostridium perfringens
• Bacillus spp

38
 Pathogenic bacteria in the animal/human
reservoir
• Salmonella spp.
• Shigella spp.
• Escherichia coli
• Campylobacter jejuni
mesophilic campylobacter
• Staphylococcus aureus

39
GROUPS OF VIRUS CAUSING GASTROINTESTINAL
DISEASE

40
BIOGENIC AMINES

41
 BIOGENIC AMINES
Amino acid precursor Biogenic amine

Histidine Histamine
Ornithine Putrescine
Putrescine1 Spermidine
Lysine Cadaverine
Tyrosine Tyramine
Arginine Agmatine
1 Not an amino acid

42
MARINE BIOTOXINS AND THE ASSOCIATED POISONINGS

43
PARASITES

44
Raw Material/ Potential Rational for inclusion Is this a Significant Hazard? What Measures can be Is this raw
Packaging Hazard state or exclusion as a applied to control this material/packaging material
Material whether biological, Hazard significant hazard? a sensitive material
chemical or physical (Yes/No)
Seve Likeli Signi Yes/No Q1 Q2 Q3 Yes/N
rity hood fican o
t
Semi IQF Biological:
Prawn/Shrimp Pathogenic bacteria
(Aquaculture) such as Vibrio
parahaemolyticus,
Vibrio cholera, Vibrio
valnificus.

Chemical:
Heavy metals (As,
Pb and Hg),
Antibiotic and Drugs
Residues (Nitrofuran
and Chlorophenicol)

Physical:
Wood and Insect and
Metal Fragment
Raw Material/ Potential Rational for inclusion Is this a Significant Hazard? What Measures can be Is this raw
Packaging Hazard state or exclusion as a applied to control this material/packaging material
Material whether biological, Hazard significant hazard? a sensitive material
chemical or physical (Yes/No)
Severity Likelihood Significant Yes/No Q1 Q2 Q3 Yes/
No
Semi IQF Biological:
Prawn/Shrimp Pathogenic bacteria Raw material may
(Aquaculture) such as Vibrio contain pathogenic
parahaemolyticus, bacteria originating
Vibrio cholera, Vibrio from natural
valnificus. environment and
temperature abuse
during transportation
may cause
multiplication of
pathogenic bacteria.
No history of prawn
carry any parasites
Chemical:
Heavy metals (As, No possibility of
Pb and Hg), heavy metal
Antibiotic and Drugs contamination
Residues (Nitrofuran because
and Chlorophenicol) prawn/shrimp
harvested less than
4 months.
Unregulated and
uncontrolled use of
Antibiotics and drugs
may cause residues
carry over in raw
material
Physical:
Wood and Insect and Carryover and
Metal Fragment contamination during
harvesting
Process Step Potential Rational for Is this a Significant Hazard? What Measures can be Is this process steps a
Hazard state inclusion or applied to control this Critical Control Point?
whether biological, exclusion as a significant hazard? (Yes/No)
chemical or Hazard
physical Severity Likelihood Significant Yes/No Q1 Q2 Q3 Q4 Yes/
No
Receiving Biological:
Pathogenic bacteria
such as Salmonella
spp., Escherichia
coli and
Staphylococcus
aureus

Chemical:
Nil
Physical:
Wood and Insect

Storage Biological:
Pathogenic bacteria
such as Salmonella
spp., Escherichia
coli and
Staphylococcus
aureus
Process Step Potential Rational for Is this a Significant Hazard? What Measures can be Is this process steps a
Hazard state inclusion or applied to control this Critical Control Point?
whether biological, exclusion as a significant hazard? (Yes/No)
chemical or Hazard
physical Severity Likelihood Significant Yes/No Q1 Q2 Q3 Q4 Yes/
No
Receiving Biological:
Pathogenic bacteria Temperature abuse
such as Salmonella during
spp., Escherichia transportation may
coli and cause growth and
Staphylococcus multiplication of
aureus pathogenic bacteria
and unhygienic
handling during
receiving may
cause more
contamination
Chemical:
Nil -
Physical:
Wood and Insect Unlikely to occur
because raw
material is
protected by
primary packaging
material and
receiving is carried
out in enclosed and
clean area. Pest
control carried out
regularly to
minimized pest
infestation
Storage Biological:
Pathogenic bacteria Unlikely to occur
such as Salmonella because raw
spp., Escherichia material placed
coli and immediately into
Staphylococcus cold room after
aureus visual inspection to
maintained cold
chain and prevent
multiplication of
pathogenic bacteria
How to determine hazard is a significant hazard

o Conduct a risk analysis

o How to conduct a risk analysis?
HAZARD RISK ANALYSIS
1.Hazard identification is carried out for all raw material, ingredient, packaging material and process step.
2.Potential hazard are classified as biological, chemical and physical hazards.
3.Rational of inclusion and exclusion for each potential hazard is considered based on logic and scientific evidence.
4.Risk analysis is conducted on all potential hazard identified and it is based on its severity and likelihood of occurrence.
5.Potential hazard will be then determined as whether it is significant or not based on a matrix system as below:

Severity of occurrence is classified as:

•Can be fatal 1
•Can cause serious illness 2
•Can result in product recall 3
•Can generate a customer complaint 4
•Insignificant 5

Likelihood of occurrence is classified as:

•Common occurrence A
•Known to occur(it has happened at our premises) B
•Could occur (I’ve heard of it happening) C
•Not expected to occur D
•Practically impossible to occur E

Severity Likelihood
A B C D E
1 1 2 4 7 11
2 3 5 8 12 16
3 6 9 13 17 20
4 10 14 18 21 23
5 15 19 22 24 25

50
Raw Material/ Potential Rational for inclusion Is this a Significant Hazard? What Measures can be Is this raw
Packaging Hazard state or exclusion as a applied to control this material/packaging material
Material whether biological, Hazard significant hazard? a sensitive material
chemical or physical (Yes/No)
Severity Likelihood Significant Yes/No Q1 Q2 Q3 Yes/No

Semi IQF Biological:

Prawn/Shrimp Pathogenic bacteria Raw material may 2 A 3 Yes
(Aquaculture) such as Vibrio contain pathogenic
parahaemolyticus, bacteria originating
Vibrio cholera, Vibrio from natural
valnificus. environment and
temperature abuse
during transportation
may cause
multiplication of
pathogenic bacteria.
No history of prawn
carry any parasites
Chemical:
Heavy metals (As, No possibility of 3 C 13 No
Pb and Hg), heavy metal
Antibiotic and Drugs contamination
Residues (Nitrofuran because
and Chlorophenicol) prawn/shrimp
harvested less than
4 months.
Unregulated and
uncontrolled use of
Antibiotics and drugs
may cause residues
carry over in raw
material
Physical:
Wood and Insect and Carryover and 3 C 13 No
Metal Fragment contamination during
harvesting
Process Step Potential Rational for Is this a Significant Hazard? What Measures can be Is this process steps a
Hazard state inclusion or applied to control this Critical Control Point?
whether biological, exclusion as a significant hazard? (Yes/No)
chemical or Hazard
physical Severity Likelihood Significant Yes/No Q1 Q2 Q3 Q4 Yes/
No
Receiving Biological:
Pathogenic bacteria Temperature abuse 2 A 3 Yes
such as Salmonella during
spp., Escherichia transportation may
coli and cause growth and
Staphylococcus multiplication of
aureus pathogenic bacteria
and unhygienic
handling during
receiving may
cause more
contamination
Chemical:
Nil - - - - -
Physical:
Wood and Insect Unlikely to occur 4 C 18 No
because raw
material is
protected by
primary packaging
material and
receiving is carried
out in enclosed and
clean area. Pest
control carried out
regularly to
minimized pest
infestation
Storage Biological:
Pathogenic bacteria Unlikely to occur 2 A 3 Yes
such as Salmonella because raw
spp., Escherichia material placed
coli and immediately into
Staphylococcus cold room after
aureus visual inspection to
maintained cold
chain and prevent
multiplication of
pathogenic bacteria
 PRINCIPLE 2: Determination of Critical
Control Points (CCPs)
• A critical control point is defined as 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

• The determination of a CCP in the HACCP

system can be facilitated by the application of
a decision tree
 Prinsip nombor 2
Menentukan titik kawalan kritikal
Titik kawalan kritikal (CCP):

Titik Kawalan Kritikal adalah satu langkah di mana

kawalan boleh digunakan, dan yang mana kawalan
adalah penting, untuk mencegah atau
menghapuskan bahaya keselamatan makanan atau
mengurangkan ke tahap yang boleh diterima
Raw Material/ Potential Rational for inclusion Is this a Significant Hazard? What Measures can be Is this raw
Packaging Hazard state or exclusion as a applied to control this material/packaging material
Material whether biological, Hazard significant hazard? a sensitive material
chemical or physical (Yes/No)
Severity Likelihood Significant Yes/No Q1 Q2 Q3 Yes/ No

Semi IQF Biological:

Prawn/Shrimp Pathogenic bacteria Raw material may 2 A 3 Yes Yes Yes No No
(Aquaculture) such as Vibrio contain pathogenic
parahaemolyticus, bacteria originating
Vibrio cholera, Vibrio from natural
valnificus. environment and
temperature abuse
during transportation
may cause
multiplication of
pathogenic bacteria.
No history of prawn
carry any parasites
Chemical:
Heavy metals (As, No possibility of 3 C 13 No No - - No
Pb and Hg), heavy metal
Antibiotic and Drugs contamination
Residues (Nitrofuran because
and Chlorophenicol) prawn/shrimp
harvested less than
4 months.
Unregulated and
uncontrolled use of
Antibiotics and drugs
may cause residues
carry over in raw
material
Physical:
Wood and Insect and Carryover and 3 C 13 No No - - No
Metal Fragment contamination during
harvesting
Raw Material/ Potential Rational for inclusion Is this a Significant Hazard? What Measures can be Is this raw
Packaging Hazard state or exclusion as a applied to control this material/packaging material
Material whether biological, Hazard significant hazard? a sensitive material
chemical or physical (Yes/No)
Severity Likelihood Significant Yes/No Q1 Q2 Q3 Yes/No

Semi IQF Biological:

Prawn/Shrimp Pathogenic bacteria Raw material may 2 A 3 Yes Temperature and visual Yes Yes No No
(Aquaculture) such as Vibrio contain pathogenic checked carried out during
parahaemolyticus, bacteria originating receiving to ensure cold
Vibrio cholera, Vibrio from natural chain maintained
valnificus. environment and Raw material obtain from
temperature abuse reliable supplier and
during transportation analysis carried out on
may cause randomly selected finished
multiplication of product
pathogenic bacteria.
No history of prawn
carry any parasites
Chemical:
Heavy metals (As, No possibility of 3 C 13 No Raw materials obtain from No - - No
Pb and Hg), heavy metal reliable supplier.
Antibiotic and Drugs contamination Legislations are regulated
Residues (Nitrofuran because and enforced by competent
and Chlorophenicol) prawn/shrimp authority to control the use
harvested less than of antibiotic and drugs
4 months. residues in aquaculture
Unregulated and farming.
uncontrolled use of Letter of guarantee for
Antibiotics and drugs antibiotic and drugs may be
may cause residues obtained from supplier if
carry over in raw necessary
material
Physical:
Wood and Insect and Carryover and 3 C 13 No Physical hazard reduced to No - - No
Metal Fragment contamination during acceptable level during QC
harvesting inspection upon receiving
and packing process step
Process Step Potential Rational for Is this a Significant Hazard? What Measures can be Is this process steps a
Hazard state inclusion or applied to control this Critical Control Point?
whether biological, exclusion as a significant hazard? (Yes/No)
chemical or Hazard
physical Severity Likelihood Significant Yes/No Q1 Q2 Q3 Q4 Yes/
No
Receiving Biological:
Pathogenic bacteria Temperature abuse 2 A 3 Yes Yes No Yes No Yes
such as Salmonella during
spp., Escherichia transportation may
coli and cause growth and
Staphylococcus multiplication of
aureus pathogenic bacteria
and unhygienic
handling during
receiving may
cause more
contamination
Chemical:
Nil - - - - - - - - - - -
Physical:
Wood and Insect Unlikely to occur 4 C 18 No Yes No No - No
because raw
material is
protected by
primary packaging
material and
receiving is carried
out in enclosed and
clean area. Pest
control carried out
regularly to
minimized pest
infestation
Storage Biological:
Pathogenic bacteria Unlikely to occur 2 A 3 Yes Yes No No - No
such as Salmonella because raw
spp., Escherichia material placed
coli and immediately into
Staphylococcus cold room after
aureus visual inspection to
maintained cold
chain and prevent
multiplication of
pathogenic bacteria
Process Step Potential Rational for Is this a Significant Hazard? What Measures can be Is this process steps a
Hazard state inclusion or applied to control this Critical Control Point?
whether biological, exclusion as a significant hazard? (Yes/No)
chemical or Hazard
physical Severity Likelihood Significant Yes/No Q1 Q2 Q3 Q4 Yes/
No
Receiving Biological:
Pathogenic bacteria Temperature abuse 2 A 3 Yes Temperature check and Yes No Yes No Yes
such as Salmonella during visual examination carried
spp., Escherichia transportation may out on raw material.
coli and cause growth and Worker practices good
Staphylococcus multiplication of hygiene and GMP
aureus pathogenic bacteria Program in place to
and unhygienic prevent contamination.
handling during
receiving may
cause more
contamination
Chemical:
Nil - - - - - - - - - - -
Physical:
Wood and Insect Unlikely to occur 4 C 18 No Worker practices good Yes No No - No
because raw hygiene and GMP
material is Program in place to
protected by prevent contamination.
primary packaging Physical hazard reduced
material and to acceptable level during
receiving is carried QC inspection during
out in enclosed and receiving
clean area. Pest
control carried out
regularly to
minimized pest
infestation
Storage Biological:
Pathogenic bacteria Unlikely to occur 2 A 3 Yes GMP Program in place to Yes No No - No
such as Salmonella because raw prevent contamination.
spp., Escherichia material placed Stock rotation First --In-
coli and immediately into First –Out
Staphylococcus cold room after Cold room temperature
aureus visual inspection to maintained at ≤-18°C
maintained cold
chain and prevent
multiplication of
pathogenic bacteria
Process Step Potential Rational for Is this a Significant Hazard? What Measures can be Is this process steps a
Hazard state inclusion or applied to control this Critical Control Point?
whether biological, exclusion as a significant hazard? (Yes/No)
chemical or physical Hazard

Severity Likelihood Significant Yes/No Q1 Q2 Q3 Q4 Yes/

No

Freezing Biological:
Pathogenic bacteria Inadequate freezing 2 A 3 Yes Freezer temperature Yes No Yes No Yes
such as Salmonella may cause monitored at fix interval and
spp., Escherichia multiplication of product core temperature
coli and pathogenic bacteria verified to ensure reach -
Staphylococcus 18°C.
aureus

Chemical:
Ammonium Not likely to occur 3 D 17 No Ammonium is not used as Yes No No - No
(NH3)and Ferrous because no direct coolant for freezing. Trays
(Fe) contact between used for freezing are
coolant and product. inspected for rust before
used.

Physical:
Nil - - - - - - - - - - -

Cartoning & Biological: Temperature abuse

Strapping Pathogenic bacteria during cartoning & 2 A 3 Yes GMP Program in place to Yes No No - No
such as Salmonella strapping may cause prevent contamination.
spp., Escherichia multiplication of Product fast moving during
coli and pathogenic bacteria cartooning & strapping to
Staphylococcus maintain cold chain.
aureus

Chemical:
Nil - - - - - - - - - - -

Physical:
Insect Not likely to occur 4 E 23 No - - - - - -
because product is
packed with
secondary
packaging material
 CCPS
qMetal detector
o Metal is a hazard in our facility
o Not fully controlled by any prerequisite
program
o Metal detectors specifically designed
identify product containing metal
o That product can be removed
o No other step will remove the metal
 CCPs
What is your role?
o Monitor
§ Look, smell, measure
o Record
o Corrective actions
o Verify
§ Monitor people doing activity
§ Take corrective actions when necessary
§ Complete records properly
 PRINCIPLE 3: Determination of Critical
Limits for Each CCP

• A critical limit is 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 to an
acceptable level the occurrence of a food
safety hazard.
• 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, or
sensory information such as aroma and visual
appearance.
Prinsip Nombor 3
Menentukan Had Kritikal
Had kritikal (CL):

Nilai maksimum dan/atau minimum di mana

parameter biologi, kimia atau fizikal mesti dikawal

pada CCP untuk mencegah, menghapuskan, atau

mengurangkan bahaya ke tahap yang boleh diterima

 Had Kritikal
Parameter Biasa Digunakan untuk menubuhkan Had Kritikal

Masa Suhu Berat/ukuran Kelembapan

Kandungan
Aktiviti air Pengawet pH
garam

Racun
Pembersihan Kelikatan Bahan Asing
Perosak

Hormon Antibiotik Lain-lain….

CCP No.& Potential Critical Limits Monitoring Corrective Action Verification Records
Process Step Hazard state whether (What/How/
biological, chemical Frequency/Who)
or physical

What How Frequency Who

CCP Potential Critical Limits Monitoring Corrective Action Verification Records
No.& Hazard state (What/How/
Process whether biological, Frequency/Who
Step chemical or physical )

What How Frequency Who

CCP 2b Biological:
Freezing Pathogenic bacteria Freezer
such as Salmonella Temperature ≤ -
spp., Escherichia 32°C
coli and
Staphylococcus
aureus
PRINCIPLE 4: Determination of Monitoring
System for Each CCP

• Monitoring is the scheduled measurement or

observation of a CCP relative to its critical
limits
• The monitoring procedures must be able to
detect loss of control at the CCP
• Monitoring should ideally provide this
information in time to make adjustments to
ensure control of the process to prevent
violating the critical limits.
Purpose of monitoring :
1) Essential to food safety management in that it
facilitates tracking of the operation
2) To determine when there is loss of control,
and a deviation occurs at a CCP
3) Provide written documentation for use in
verification
Prinsip Nombor 4
Menentukan Prosedur Pemantauan
Memantau:
• Menjalankan aktiviti pemantauan
(monitoring) yang dirancang supaya sesuatu
proses, titik atau prosedur yang dinilainya di
bawah kawalan

• Merekod dengan tepat data-data supaya untuk

kegunaan masa depan dalam pengesahan
 Prosedur Pemantauan
Tujuan pemantauan:
• Untuk mengesan operasi proses apabila
terdapat trend ke arah had kritikal yang boleh
dibetulkan/diselaraskan sebelum ia keluar dari
titik kawalan kritikal

• Untuk mengenalpasti jika terdapat

ketidakpatuhan pada titik kawalan kritikal

• Untuk menyediakan dokumentasi bertulis

daripada sistem kawalan proses
 Establish Monitoring Procedures
• Monitoring is critical
• Written documentation

Remember,
if it has not been written down,
It has not been done!
CCP Potential Critical Limits Monitoring Corrective Action Verification Records
No.& Hazard state (What/How/
Process whether biological, Frequency/Who
Step chemical or physical )

What How Frequency Who

CCP 2b Biological:
Freezing Pathogenic bacteria Freezer Freezer Visual End of Production
such as Salmonella Temperature ≤ - Temperature reading freezing Operator
spp., Escherichia 32°C Gauge cycle
coli and
Staphylococcus
aureus
 PRINCIPLE 5: Determination of Corrective
Actions for Each CCP

• Where there is a deviation from established

critical limits, corrective actions are necessary
• Therefore, corrective actions should include the
following elements:
• (a) determine and correct the cause of non-
compliance;
• (b) determine the disposition of non-compliant
product and
• (c) record the corrective actions that have been
taken
Prinsip Nombor 5
Menubuhkan Tindakan Pembetulan

Tindakan pembetulan:

Prosedur yang perlu diikuti apabila ketidakpatuhan

berlaku
 Tindakan Pembetulan
Komponen:
• Untuk membetulkan dan menghapuskan punca
ketidakpatuhan dan memulihkan kawalan proses

• Untuk mengenalpasti produk yang menghasilkan

semasa ketidakpatuhan proses dan menentukan
status penggunaannya atau pelupusannya
 Establish Corrective Actions

qPreplanned (written) Procedures

o What problems might occur

o What specific action should take place

o Who will be responsible for the action

o Who will document the corrective action steps

CCP Potential Critical Limits Monitoring Corrective Action Verification Records
No.& Hazard state (What/How/
Process whether biological, Frequency/Who
Step chemical or physical )

What How Frequency Who

CCP 2b Biological:
Freezing Pathogenic bacteria Freezer Freezer Visual End of Production When freezer temperature
such as Salmonella Temperature ≤ - Temperature reading freezing Operator gauge reading does not
spp., Escherichia 32°C Gauge cycle reach -32°C, check product
coli and core temperature.
Staphylococcus a. If product core temperature
aureus reaches more than 0°C,
transfer product to another
freezer and start freezing
process again.
b. If product core temperature
does not reach 5°C after
freezing time more than 5
hrs, reject and discard
product.

c. Whenever freezer
temperature does not reach -
32°C at end of freezing
cycle, request maintenance
worker to check fault on
freezer.
d. Ensure that all the freezer
is operating in optimal
condition before placing
product into freezer
PRINCIPLE 6: Determination of Verification
Procedures

• Verification is defined as those activities, other

than monitoring, that determine the validity
of the HACCP plan and that the system is
operating according to the plan
Prinsip Nombor 6
Menubuhkan Prosedur Pengesahan
Verifikasi:

• Aktiviti-aktiviti, selain daripada pemantauan,

yang diwujudkan untuk mengenalpasti
ketidakpatuhan pelan HACCP dan sistem
beroperasi mengikut perancangan

Validasi adalah sebahagian daripada verifikasi

 Prosedur Verifikasi
Proses Verifikasi
- bertanya sama ada sistem HACCP yang dilaksanakan
mengikut perancangan, iaitu adakah anda lakukan apa
yang anda katakan yang anda lakukan?

Proses Validasi
- bertanya sama ada analisis bahaya adalah lengkap
dan jika langkah-langkah kawalan berkesan, iaitu
adakah anda melakukan perkara yang betul?
 Establish Verification Procedures

qConfirmation that a food safety program is

working

qProvides the needed information to

ümaintain an effective program

üupdate the program as needed
CCP Potential Critical Limits Monitoring Corrective Action Verification Records
No.& Hazard state (What/How/
Process whether biological, Frequency/Who
Step chemical or physical )

What How Frequency Who

CCP 2b Biological:
Freezing Pathogenic bacteria Freezer Freezer Visual End of Production When freezer temperature Verification of
such as Salmonella Temperature ≤ - Temperature reading freezing Operator gauge reading does not monitoring
spp., Escherichia 32°C Gauge cycle reach -32°C, check product records daily by
coli and core temperature. production
Staphylococcus a. If product core temperature supervisor/
aureus reaches more than 0°C, HACCP Team
transfer product to another Member
freezer and start freezing External
process again. calibration of
b. If product core temperature cold room
does not reach 5°C after thermometer
freezing time more than 5 gauge yearly
hrs, reject and discard Yearly testing
product. (external
laboratory) on
c. Whenever freezer randomly
temperature does not reach - selected final
32°C at end of freezing product for
cycle, request maintenance pathogenic
worker to check fault on bacteria
freezer. Check product
d. Ensure that all the freezer core
is operating in optimal temperature
condition before placing reach ≤ -18°C
product into freezer Randomly when
needed
 PRINCIPLE 7: Documentation and Record
Keeping

• Efficient and accurate record keeping is

essential to the application of a HACCP system
• HACCP procedures should be documented
• Documentation and record keeping should be
appropriate to the nature and size of the
operation
Prinsip Nombor 7
Penyimpanan Rekod dan Prosedur
Dokumentasi
• Rekod-rekod yang terperinci adalah penting
untuk kejayaan mana-mana program kawalan
makanan

• Penyimpanan rekod yang sesuai juga

merupakan salah satu cabaran terbesar dalam
memenuhi kehendak program keselamatan
makanan
Establish Record Keeping Procedures

The record keeping system should be:

o Simple
o Part of the daily/weekly routine
o Accurate
o Comprehensive
o Kept for at least one year (some districts choose to
keep them for 3 years as they do other records)
 Freezing Time Freezer Temperature Product Core Corrective Action Taken Checked by
(°C) Temperature
Start Finished (°C)
CCP Potential Critical Limits Monitoring Corrective Action Verification Records
No.& Hazard state (What/How/
Process whether biological, Frequency/Who
Step chemical or physical )

What How Frequency Who

CCP 2b Biological:
Freezing Pathogenic bacteria Freezer Freezer Visual End of Production When freezer temperature Verification of CCP2
such as Salmonella Temperature ≤ - Temperature reading freezing Operator gauge reading does not monitoring COA
spp., Escherichia 32°C Gauge cycle reach -32°C, check product records daily by Cal
coli and core temperature. production
Staphylococcus a. If product core temperature supervisor/
aureus reaches more than 0°C, HACCP Team
transfer product to another Member
freezer and start freezing External
process again. calibration of
b. If product core temperature cold room
does not reach 5°C after thermometer
freezing time more than 5 gauge yearly
hrs, reject and discard Yearly testing
product. (external
laboratory) on
c. Whenever freezer randomly
temperature does not reach - selected final
32°C at end of freezing product for
cycle, request maintenance pathogenic
worker to check fault on bacteria
freezer. Check product
d. Ensure that all the freezer core
is operating in optimal temperature
condition before placing reach ≤ -18°C
product into freezer Randomly when
needed
 Receiving of Raw Material
Packaging CCP 1b
Material Critical Limit:
Product Temperature ≤ -15°C

Not OK Not OK
QC
QC Reject
Reject Check
Check OK
OK
Storage
Storage

Weighing

Packing

Freezing
CCP2b
Critical Limits:
Freezer Temperature ≤ -32°C

Cartoning & Strapping

Final Storage
CCP3b
Critical Limits: Cold Room Temperature ≤ -
18°C

Loading And Dispatch

Verified by: ………………………………….