(SAS) HACCP Lesson

HACCP

image of hazard symbol

Hazard Analysis and Critical Control Point or HACCP is a system for reducing the risk of safety hazards in food. This system requires that potential hazards are identified and controlled at specific points in the process. This includes biological, chemical or physical hazards. Any company involved in the manufacturing, processing or handling of food products can use HACCP to minimize or eliminate food safety hazards in their products.

HACCP is important because it prioritizes and controls potential hazards in food production. By controlling major food risks, such as microbiological, chemical and physical contaminants, the industry can better assure consumers that its products are as safe as good science and technology allows.

Awareness of food-borne illness is increasing, and concern throughout the industry is driving the use of the HACCP system.  HACCP systems are based on seven principles. Explore each section below to learn more about each.

     Conduct A Hazard Analysis     
        

Plans determine the food safety hazards and identify the preventive measures the plan can apply to control these hazards. The hazard identification is done in two steps, first the identification of hazards, then an evaluation of the hazard. The hazard evaluation is a determination of the degree of risk to the user from the identified hazard.

    
     Critical Control Point Identification     
        

At what steps in your process can controls be applied to prevent or eliminate the hazards that have been identified? These are your critical control points. For each critical control point you will identify the preventive measure. How will you prevent the hazard? Use of specific temperature, pH, time, procedures?

    
     Establishment of Critical Limits     
        

A critical limit is 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 that hazard to an acceptable level. What criteria must be met to control the hazard at that point? Is it a minimum temperature?

    
     Monitoring Procedures     
        

What will you measure and how will you measure it? You need to monitor the process at the critical control point and keep records to show that the critical limits have been met. Monitoring activities are necessary to ensure that the process is under control at each critical control point. In the US, the FSIS requires that each monitoring procedure and its frequency be listed in the HACCP plan.

    
     Corrective Actions     
        

You will establish what actions need to be taken if a critical limit is not met. This will be identified ahead of time for each CCP. The action must make sure that no unsafe product is released.

    
     Record Keeping     
        

You will determine what records are needed to show that the critical limits have been met, and the system is in control. HACCP regulation requires that all plants maintain certain documents, including hazard analysis, written HACCP plan and records documenting the monitoring of critical control points, critical limits, verification activities and the handling of processing deviations.

    
     Verification Procedures     
        

Verification ensures that the HACCP plan is adequate, that is, working as intended. The HACCP plan must be validated. Once the plan is in place, make sure it is effective in preventing the hazards identified. Test the end product, verify that the controls are working as planned. Perform ongoing verification of the system.

    

Sanitation is the key element in the quality control and/or HACCP plan of a successful food packing or processing facility. Sanitation is something many of us don't like to think about and we often take for granted. Various government agencies have set up regulations for minimum standards of sanitation but without desire and commitment on the part of individuals designated to carry out sanitation program, achievement of these standards will not be ensured. Self-inspection and the development of a HACCP plan specific to your facility are the most effective ways to maintain a sanitary facility that is in compliance with federal regulations.

One of the first steps towards a successful sanitation program is to walk through your facility and develop both a flow chart and a checklist to investigate major areas of concern.  Some sanitation requirements are:

  • Sanitation Inspection: incorporating sanitation inspections into your quality control program will facilitate discovery of anything that might cause or permit contamination.
  • Facility Surroundings: surroundings should be kept free from trash, weeds, spilled raw products, broken baskets or crates and any other accumulated waste or unsightly material; there should be no standing water inside or outside the facility.
  • Construction and Building Layout: the layout should be water tight to prevent rain and wind entry; doors should be closed tightly so rats and mice are prohibited from entry. Floors should be constructed of concrete or another easily cleaned material and should be smooth.
  • Storage and Warehousing: this should be provided separately for raw and finished goods. All materials should be stored in tightly closed containers and aisles should be left open for inspection.   Storage areas should have insect control and hazardous materials should be stored in areas only accessible to authorized persons.
  • Water Supply: water supply must be from a known source from which data on purity can be obtained; water should be checked for means of sanitary treatment. Pressure in water lines should be maintained to prevent back siphonage which can draw contaminated material into the water lines.
  • Sewer Systems: must be maintained separately from other waste disposal systems in order to prevent the possibility of toilet sewage backing up into the plant. A thorough check should be made to see that there is no danger of overflow or leakage from drains or toilets.
  • Toilet Facilities: facilities for employees should be well ventilated, well lighted and kept clean and dry. Odors are not only indicators of poor sanitary conditions but they are attractive to insects. Handwashing facilities must include hot and cold water, soap and individual towels.
  • Personal Habits of Employees: employees must be aware that they are handling food products for consumption. They must wear clean uniforms and proper hair covering.  Open sores, cuts or dermatitis on the hands are not permissible.
  • Pest Control: maintain a pest control checklist; check to see what the operator is doing and what poisons he/she is using.

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