HACCP & ITS

IMPLEMENTATION IN FOOD
INDUSTRY

DR. H. K. SHARMA

Sant longowal institute of engineering & technology (sliet), longowal

 What is HACCP?
• HACCP stands for:
azard nalysis ritical ontrol oints

• A properly functioning HACCP system will result in

the production of a safer food product.

• Since April 1998, food businesses have been required

by law to have a food safety management system
based on the principles of HACCP.
 HACCP HISTORY
1969 The Pillsbury Company and NASA

Food safety requirements for foods

produced for manned space flight.

Control of food particles and water.

Need for absolute assurance for freedom

from pathogens.
• NASA Zero Defects Policy.
– 100 % testing of all components.

US Army Natick “Modes of Failure” concept.

Gather knowledge and experience about a food
product/process.
Predict what can go wrong, how and where in the
process problems can occur.
 HACCP & Food Regulation in India

• Prevention of Food Adulteration Act (PFA)

• Agriculture Grading and Marketing (AGMARK)

• Fruit Products Order (FPO)

• The Bureau of Indian Standards (BIS) launched

HACCP Certification
 WHEN TO DO A HACCP STUDY ?
ANY NEW LINE

DIFFERENCES IN RAW MATERIAL

SOURCES, EQUIPMENT, CAPACITIES,
ENVIRONMENT, CHANGE IN RECIPE

ANY CHANGE MEANS HACCP

 Main benefits of HACCP are
• Saves your business money in the long run

• Avoids you poisoning your customers

• Food safety standards increase

• Ensures you are compliant with the law

• Food quality standards increase

• Organises your process to produce safe food

• Organises your staff promoting teamwork and efficiency

• Due diligence defence in court.

 HAZARDS

MICROBIOLOGICAL

CHEMICAL PHYSICAL

ALLERGENS
 PHYSICAL HAZARDS
POTENTIAL HAZARDS
Glass
Visual
Metals Inspection
Stones Filters and
Screens
Plastic CONTROL
MEASURES Magnets trap /
Capsule
Metal detectors
Shell / Pit
Separation by
Wood density
Paper Personnel
precautions
 CHEMICAL HAZARDS
SOURCE
a) Industrial & Envt Chemical -Mercury, Lead, Cadmium

b) Contamination- Biological
origin Oxalates, Cyanides, Mycotoxins

c) Permitted Chemicals Pesticide residues, Fumigants, Fertilizers

d) During Processing Lead, Oxidised Fats, Tin, Urethanes

 MICROBIOLOGICAL HAZARDS
CONTROL

Temperature Time pH
Heating / Cooling Low or High

WaterActivity Preservatives
As low as possible

Apply 100% barrier for shoe change - Critical

area
 ALLERGENS

Ten common food allergens Symptoms

Milk Wheat Gastrointestinal tract

Nuts Citrus Skin

Strawberries Fish Ear and eye

Egg Peanuts Muscle and joint

Melons Soy Nervous system

Cardiovascular system
 HACCP Principle #1
Conduct a Hazard Analysis
The first Stage: HACCP team reviews the,
• Ingredients used in the product
• The Process & Equipment used
• The final Product Storage & Distribution
• The intended use & Consumers of the product

The Second Stage: The team decides which potential

hazards must be addressed in the HACCP plan
• The hazard is evaluated based on severity of the
potential hazard
 HACCP Principle #2
Determine Critical Control Points
• Critical Control Points (CCPs) are:
– A point, step, or procedure at which a control
measure is essential to prevent, eliminate, or
reduce a food safety hazard

Critical Control Points may include:

– Thermal Processing
– Chilling
– Testing Ingredients for chemical residues
– Product formulation control
– Testing product for metal contaminants
 HACCP Principle #3
Establish Critical Limits
• A critical limit:
– Is the maximum and/or minimum value to which a
parameter must be controlled at a CCP
– Separates acceptability from unacceptability
– Must be clearly defined and measurable

A Critical limit may be based on factor:

– Temperature
– Time
– Physical dimensions
– Moisture level etc.
 HACCP Principle #4
Establish Monitoring Procedures

• Monitoring:
– Is the process of conducting a planned
sequence of measurements to
determine if a CCP is under control
– Results must be recorded

• If monitoring shows that Critical Limits are not met,

then the process is out of control and the food may
be unsafe.
 HACCP Principle #5
Establish Corrective Actions
• Corrective Actions
– Are pre-determined activities that must occur when
monitoring indicates that a deviation has occurred.

– Must:
• Regain control of the process
• Locate and hold affected product
• Determine disposition of affected product
• Prevent a recurrence
 HACCP Principle #6
Establish Verification Procedures

• Verification
– Ensures the HACCP plan is being properly followed
– Confirms the plan is operating according to written
procedures

• Validation
– Ensures the HACCP plan is complete and valid
– Ensures the plan is effective in achieving expected food
safety outcomes
 HACCP Principle #7
Establish Record Keeping Procedures

• Record keeping must be complete and accurate and include:

– Documentation pertaining to all steps, including the
HACCP principles
– Appropriate record storage procedures
– A log book to keep track of changes
Prerequisite Programs (GMP)

• A few examples
– Plant premises and layout
– Water quality
– Transportation and storage
– Equipment
– Plant sanitation
– Employee training
 Assemble the HACCP Team

Describe the product

12 STEPS OF
Identify intended use
HACCP
Construct flow diagram

On-site verification of flow diagram

List all potential hazards conduct a hazard analysis. Determine control measures

Determine CCPs and describe the measures to control the hazards

Establish critical limit for the control measure at each C C P

Establish a monitoring system for each C C P

Establish corrective action for deviations that may occur

Establish verification procedures

Establish record keeping and documentation

A CASE STUDY OF FROZEN PEAS
PEAS
Product Name: Peas
Veg. Logo:
F.P.O No.: 122455
M.R.P.:
Shelf Life: 18 months at – 180C.
Manufacturer: Frozen Foods Limited.
Manufacturing date: / /
Nutritional fact:
Expiry date:
Name: Frozen Green Peas
Brand name: Food techno
Bar code:
Cooking instruction:
To boil: place the required quantity in a saucepan of boiling
water add salt to taste bring back to boil, cover and simmer for
2-3
General instruction: Never refreeze thawed product
Customer care no.: 0176-56786
HACCP Worksheet Forms Form 1.0

Worksheets: Hazard Analysis and Critical Control Point System

For Development of the HACCP Plan
HACCP Plan Identification page
Product : FROZEN VEGETABLES
Company : FROZEN FOODS LIMITED
Company Location : …..PB
Company contacts:-
Name : MR. A
Title : (MANAGING DIRECTOR)
Name : MR. S
Title : (DIRECTOR OPERATIONS)
Manufacturing Location: WORKS …. (PB)
Manufacturing Contact:-
Name : MR. B
Title : (DIRECTOR OPERATION)
Name : MR. P
Title : (PRODUCTION MANAGER)

Date HACCP Plan Prepared :

Date HACCP Plan Validated :
Date HACCP Plan Approved :
PREPARATION OF THE HACCP
TEAM
• Assemble the HACCP team

• Define the scope of the study

• Prepare a process flow diagram

• Develop employee awareness

• Verify the process flow diagram

PRELIMINARY STEPS
(A) QUALITY MANAGEMENT

(B) PRODUCTION MANAGEMENT

(C ) OPERATION MANAGEMENT

(D) PLANT MANEGEMENT

(E) PACKAGING MANAGEMENT

HACCP Worksheet Forms Form 1.1
PRELIMINARY STEP 1.

Product : FROZEN PEAS

Product code : ARM
Date : 10/10/2007

TEAM Name Title

HACCP Team Leader/ MR. A (DIRECTOR OPERATIONS)
Coordinator:
HACCP Team Members: MR. L (PLANT MANAGER)
MR. P (PROD. MANAGER)
MR. M (PACKING MANAGER)
MR. N (QUALITY MANAGER)
 HACCP Worksheet Forms Form 2.0
PRELIMINARY STEP 2.
Responsibility: Describe Food and its Distribution

* Common or Usual Name? (Please Attach Recipe/Formulation)

* Raw, Ready-to-Eat or must it be cooked before consumption?
* Preservation Method?
* Type of package?
* Method of Distribution?
* Is product distributed frozen, Refrigerated, or is it shelf
stable?
* Length of shelf-life? Temperature?
* Label instructions?
* Are special distribution controls needed?
 HACCP Worksheet Forms Form 2.1
PRELIMINARY STEP 2
PRODUCT : DATE :

Spec. Form: Preservation Packaging: Size Other

Number Powder, method: Dry, Bag, drum, Package or info
Diced, Refrig,. bulk, etc lots
etc. Frozen etc.
A Whole Frozen Bulk, bag. Lot wise
grains packing.
1 kg, 250
kg, 30 kg
J diced Frozen Bulk, bag 30 kg

B Diced Frozen Bulk , bag 30 kg

C pieces Frozen Bag 500 gm

D Pieces Frozen Bulk Bag 30 kg

E Diced Frozen Bulk bag 30 kg

 HACCP Worksheet Forms Form 3.0
PRELIMINARY STEP 3
Responsibility: Identify the Intended Use and Consumer of the
Food

•What is the normal use of the food by intended consumers?

•Who will consume the food?

• Is the food intended for High-Risk populations (Infants, Elderly,

Immune- compromised?)

•Is food intended for retail or food service?

•Is food held refrigerated, frozen or hot before consumption?

HACCP Worksheet Forms Form 4.0
PRELIMINARY STEP 4
• Preliminary Step 4.Develop Flow Diagram for the Specific
Product or Group of Products, Possible Parts of Sequence:

* Raw materials and ingredients

* Receiving
* In-Process steps
* Combination of In-Process streams
* Fabrication and further processing
* Product
* Packaging
* Storage
* Distribution
* Point of sale display
* Consumer use
PEAS PROCESSING FLOW
DIAGRAM
Receiving of raw Peas

Depoding Wastage Animal Feeding

Recovery of grains

A
 PRELIMINARY STEP 5

• Verification of the flow diagram to ensure accuracy and

completeness.
• Did the HACCP Team inspect the operation to verify the
accuracy and completeness of the flow diagram?
• Yes
• HACCP team coordinator: Mr. A
• * Is a plant layout attached?
Yes:
No:
 HACCP Worksheet Forms Form 5.0

• Listing of hazards associated with each step in the flow diagram,

determination of significant hazards and identification of preventive
measures to control the hazards.

• Instructions: To conduct the Hazard Analysis

• List all potential hazards associated with each Raw Material ingredient,
process operation and post production step. Label the hazard as B
(Biological), C (Chemical), or P (Physical).

• List preventive measures to control hazards.

• Determine the (Probability) of occurrence.

• Determine the severity of each hazard.

• Determine the Significant Risk Hazards though group consensus. Pick a Risk
and Severity Classification that together equal a significant Hazard-
 HACCP Worksheet Forms Form 6.

(A) Raw material/ (B) Identified (C)Preventive

Processing / Hazards Measures (S)
Post
Processing
Raw material P Hygiene storage/
(Storage & Transportation Temp.
Transportation)
Raw material P Good handling practice
(Handling)
Raw material P Good handling practice
Supply & distribution
Raw material P/B Personal hygiene
(Personal hygiene)
Raw material P/B Cutting tools/Air
(Cutting & coring tools)
Raw material P/B Vessel/sticking/rust/
(Washing stage-1) water
(A)Raw material/ (B) Identified (C)Preventive
Processing / Post Hazards Measures (S)
Processing

Processing (Washing stage- P/B Vessel sticking/rusting

2) &..
Processing (Blanching) P/C Machine part/Machine
oils/
Processing B WATER
(De-hydro cooling)
Processing B/P Water air/ Foreign
(Dewatering & Sorting) matter
Processing B AIR
(Freezing)
Post Processing P Sorting/Packing/Foreign
(Packing) matter
Post Processing P Handling
(Storage)
DECISION TREE
Occurrence Scale Severity scale Detection scale RPN CCPs

Factor Scale Factor Scale Factor scale Scale Y/N

Very high
Daily 5 Death 5 125 Y
5

Operational
Weekly 4 4 High 4 64 Y
disease
Food
Monthly 3 3 Moderate 3 27 Y
poisoning

Quarterly 2 Illness 2 Easy 2 08 N

Yearly 1 Minor 1 Very easy 1 01 N

Decades 0.1 Negligible 0.1 Detected 0.1 .001 N

 Likelihood
• Frequency
• Chance that the hazards will occur in normal
practices
Severity
• The Impact of that hazards on the consumer
health
• Either high (significant) or low
Technique used to identify Significant Hazards

Severity Likelihood

1) Fatality A) Common Repeat

2) Serious Thickness B) Known to occur

3) Product recall C) Could occur

(Published)
4) Customer Complaint D) Not expected to
occur
5) Not significant E) Practically Impossible
Technique used to identify Significant Hazards

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
 CRITICAL CONTROL POINT ?
Range factor RPN: S X O X D S’ = significant
S: 1-5 S’: if RPN ≥ 27 O = occurrence
D: 1-5 if RPN <27 D = detect ability
O: 1-5 but S = 5 S = severity
Significant hazard is one ≥ 27

• RISK = OCCURRENCE x SEVERITY

SIGNIFICANT HAZARD IS ONE

WITH RISK ABOVE 27
 WORKSHEET FOR CCPs
(A) Raw material/ (B) Identified (C) CONTROL POINT
Processing / Hazards
Post Processing MONITORING PT
CCP
Raw material P/B Hygiene storage/
(Storage & Stones/Soil/Shigella Transportation Temp.
Transportation) NO

Raw material P (Mechanical Good handling practice

(Handling)
damage)
NO
Raw material P Good handling practice
Supply & distribution
Raw material B (Shigella) Personal hygiene
(Personal hygiene)
Raw material P/B Cutting tools/Air
(Cutting & coring tools)
Raw material P/B (M/C Vessel/sticking
(Washing stage-1) /rust/water
Parts/E.coli)
(A) Processing / Post (B) Identified (C)CONTROL
Processing Hazards CCP
POINT
Processing (Washing stage- P/B (M/c parts, water supply NO
2) E.coli)

C/B (Machine/Oil
Processing (Blanching)
Salmonella Temp-Time YES

B (E.coli)
Processing (De-cooling) WATER NO

Processing P/B Water/air NO

(Dewatering & Sorting) (E.Coli/FM)

Processing B (Listeria)
AIR NO
(Freezing)
Post Processing P ( FE/N-FE)
TEMP. YES
(METAL DETECTOR)

B (Listeria) TEMP. YES

Post Processing
 Receiving of raw Peas
▼
Depoding to remove
grain from peas pods
▼
Transferring to even feed
hopper
▼
Washing (2 PPM Chlorine)
▼
Blanching
(90- 94 degree for 3.5-4.5 min)
(C.C.P)

▼
Hydro cooling (product
temp min 15 degree)
▼
 ▼
Inspection
▼
Dewatering
▼
Freezing
(3.8 min. at -180 C) (C.C.P)
▼
Final inspection and sorting

▼
Passing through metal
detector (C.C.P)
▼
Storage (-180 C) (C.C.P)

▼
Dispatch
(Under refrigeration condition)
 Establish Corrective Actions
• Using the cooked/blanched PEAS example:
– If the internal temperature of the peas piece
does not reach 74°C, then the product may
contain viable pathogenic bacteria
– The product in question must be properly re-
cooked
– The reason why the product did not achieve
74°C must be determined and corrected
PEAS BLANCHING CRITICAL TIME TEMP.
LIMITS FOR SALMONELLA
PARAMETER LIMITS
TARGET 90*c
TEMPERATURE

MIN TEMPERATURE 88*c

MAX.TEMPERATURE 92*c

COLD POINT TEMPER. . 74*c

TIME DURATION 2.5 MIN.

 MONITORING
• Monitoring Process:- BLANCHING

• What TEMP.

• How TIME-TEMP COMBINATION.

• When <88*c & >92*c

• Where BLANCHER

• Why INACTIVATION OF ENZYMES/MICROBES

• FREQUENCY PER HR.

• RESPONSIBILITY SUPERVISOR
 Establish Verification & Corrective
action Procedures
• Using the cooked peas example:
– At the end of each day, the HACCP Coordinator will
review the “processing report” to confirm that specified
temperatures were achieved for each batch

– Once per month, the coordinator will perform an on-

site verification to confirm that the temperatures of
every batch are being taken as specified using a
calibrated thermometer

– Once every 6 months, a random sample of 2 peas in no.

will be taken and sent to a laboratory for outside
analysis
 Documentation
• Stage Blanching

• CCP? yes
• Target Temp 92*C
• Critical limit <90*C
• Monitoring frequency Hourly
• Responsibility 1 supervisor
• Corrective action OK
• Responsibility 2 Plant Manager
• Documentation QA
 VALIDATION
Sr. HAZA CORRETI UNDERST COM RESPO
CCP VE ACT ANDING
No. RD MITT NCIBILI
EFFECTIV (EVERY ED TY
NESS ONE)

1 ENZ. BLANCH YES YES YES SUPER

(TEMP/ VISOR
TIME.)
2 FE METAL YES YES YES SUPER
DETECTOR VISOR

3
4
5
How to Audit
HACCP
For
CCP’S
(Mandatory Element )
 How to Audit HACCP
• Review HACCP Plan • Check for SOPs for
• Review process flow Release System,
diagram for CCP Deviation Process,
identification Disposition Process, etc
• Review QMS to ensure • Review any deviation
CCP’s identified documentation
• Follow QMS to the floor – Look for corrective
and review CCP documents actions & follow-up
– Line check sheets
– Operator signatures
Continued…

Examples of some records looked at to

verify HACCP Plan

• Supplier Audit Records (RM & PKG.)

• Equipment Calibration monitoring records
• Thermal Process Data
• Micro Test Results, shelf studies etc.
• Internal Sanitation, Housekeeping & Pest
Control Audits
 REMEMBER
• Do regular checks of CP/CCP ‘s.

• Do not bypass them

• Take corrective action during any abnormalities.

• Hold the product since last check in such cases.

• Inform your superior if malfunctioning ex- metal

detector in wrapping.
THANK YOU…