SBP3073: Food Quality Assurance
Hazard Analysis Critical Control
Point (HACCP)
• Science based
• Step wise process:
– Identifies hazards
– Installs preventative
measures to eliminate or
reduce hazards in foods
• Proactive rather than reactive
• Risk based
Systematic approach to the identification, evaluation, and
control of food safety hazards to ensure and make food safe
• Emphasizes process control
• Concentrates on the points in the process that
are critical to the safety of the product
CCP
Capstone of HACCP in food safety management
• 1959 - developed by the Pillsbury Company in
USA, for NASA space programs
• Failure Modes and Effect Analysis was used as
basis for HACCP system development
• In the 1980’s - HACCP was used for food
inspection programs
• By 1992 - system has been improved and its
benefits recognized worldwide
Origin and Development of HACCP
• Eliminate or significantly reduce hazards
• Prevent or minimize microbial growth and
toxin production
• Control contamination
Objectives of HACCP
Unhygienic ice-water and dirty cloth
Objectives of HACCP
Improper storage of foods
Objectives of HACCP
Absence of personal hygiene
Objectives of HACCP
Why HACCP?
• Provides many benefits
Benefits
• Legislation recommendation
Legislation
• Many customers require it as one
Business of the conditions of doing
business
Insurance • It is an insurance against
foodborne incidents and diseases
• Good Manufacturing
Practices (GMP)
• Sanitation Standard
Operation Procedures
(SSOP)
Sanitation program
Pest control program
HACCP in Malaysia
• HACCP is certified by SIRIM QAS International
• Collaboration with Ministry of Health Malaysia
• SIRIM QAS International also offers a
combined HACCP/ ISO 9001:2000 certification
scheme
Reference: http://www.sirim-qas.com.my/business-sector/food-consumer-product-
manufacturing, Accessed on 9 May 2019
Terminology of HACCP
continue…
Terminology of HACCP
Answers 3 questions
H azard
• WHAT hazards can
enter the product?
A nalysis
•
C ritical Where do these hazards
occur?
C ontrol • How can we control or
P oint eliminate these
hazards?
Development of HACCP Plan
Food Safety Hazards
Transportation
Raw material
Process and
（Environment )
Distribution
Hazards
Biological Chemical Physical
Pathogens Toxins Metal
Virus Compound Glass
Parasite Residue Stone
Spoilage
Development of HACCP Plan
HACCP Plan
The written document which is based upon the
principal activities of HACCP and which
delineates the procedures to be followed to
assure the control of a specific process or
procedure
Development of HACCP Plan
Reference: http://fsq.moh.gov.my/v5/ms/garis-panduan-skim-pensijilan-haccp-malaysia/
How to Implement HACCP Plan
• Based on the application of 7 key
principles
• Key elements
- common sense
- knowledge of product and process
- understanding of HACCP
Development of HACCP Plan
Documentation
Understanding
Product Description
Process Flow
Diagram
7 Principles
Development of HACCP Plan
Assemble HACCP Team
Development of HACCP Plan
Describe Product and Identify
Intended Use
• Product Name(s)
• Important Product Characteristics
• How it is to be used
• Packaging
• Shelf Life
• Where it will be sold
• Labelling Instructions
• Special Distribution Control
• Specific Ingredients
Example
Construct
Flow Diagram
Development of HACCP Plan
Define the processing steps
Storage Packaging
Receiving and Preparation and Storage Distribution
Holding Labelling
Development of HACCP Plan
On-Site
Confirmation
of Flow
Diagram
Development of HACCP Plan
1 Conduct a Hazard Analysis (HA)
2 Determine Critical Control Point (CCP)
3 Establish Critical Limit (CL)
4 Establish Monitoring CCP (MCCP)
5 Establish Corrective Action (CA)
6 Verification (V)
7 Record / Documentation (R)
Principles of HACCP Plan
PRINCIPLE 1 – Conduct a hazard analysis
Conduct and identify the hazards
• The hazard analysis process accomplishes three
purposes:
1. Identify the hazards
2. Assess the risk for these hazards and where
significant hazards occur
3. Identified hazards can be used to develop
preventive measures for a process or product to
ensure or improve food safety Principles of HACCP
1. Identify the hazards
Biological Hazards Chemical
• pathogenic • histamine
bacteria • heavy metals
• viruses • pesticides
• worms • antibiotics
• protozoa • dyes
• mycotoxin
Physical
• bolts and nuts
• metal fragments
• sand, glass,
plastic
Principles of HACCP
2. Assess the risk for these hazards
Evaluate the risk of identified hazards based on:
Severity Probability
- The - Product history
consequence
(mild or
severe)
- Potential
duration
Principles of HACCP
3. Identified hazards that can be used to
develop preventive measurement
• Construct flow diagram:
– The flow diagram should cover all steps in the
operation
• List:
– all potential hazards associated with each
step
– conduct a hazard analysis
– consider any preventive measures to
minimize the identified hazards
Principles of HACCP
Example of Hazard Analysis Worksheet
Any potential hazards in each step? Any preventive
measures to minimize the identified hazards?
（1） （2） （3） （4） （5）
Ingredient/ Identify Are any Justify your What preventative
processing potential potential decision for measure(s) can be
step hazards food-safety column 3 applied to prevent HA?
introduced hazards
controlled or significant?
enhanced
（Yes/No）
Raw material:
a) Flour P - No None Additive Not Applicable
C - Benzoyl approved by
peroxide Food Act in
B - No certain ppm
a) Yeast B - Spoilage Yes Spoilage or Certified analysis from
pathogenic supplier
microbe
Principles of HACCP
PRINCIPLE 2 – Identify critical control points
Identify or determine critical control points (CCPs)
• Processing (food plants)
• Purchasing (vulnerable foods)
• Preparation (thawing, cross-contamination,
heating, holding, serving, and cooling/reheating)
– Cross-contamination: The transfer of
bacteria or other microorganisms from one
food to another
• Sanitation (cleanup, equipment, facilities, pest
control, and water)
• Storage
• Personnel Principles of HACCP
Continue…
Point, step, OR procedure in a food
process at which control can be
What ? applied and, where it is essential to
prevent OR eliminate a food safety
hazard OR to reduce it to an
acceptable level
Located at any step where hazards can
Where ? be either prevented, eliminated or
reduced to acceptable levels
Identify through decision tree based
How ?
on Codex Allimentarius
• Answer the questions in sequence
Principles of HACCP
Continue…
Principles of HACCP
CCP
Not CCP
Decision tree is just a tool,
you have to consider the
property of the product and the
process, as well as relevant
data and information when
determining CCPs
Principles of HACCP
Example of Hazard Analysis Worksheet
(after identify CCPs using decision tree)
（1） （2） （3） （4） （5） （6）
Ingredient/ Identify Are any Justify your What Is this step a
processing potential potential decision for preventative CCP?
step hazards food-safety column 3 measure(s)
introduced hazards can be (Yes/No）
controlled significant? applied to
or prevent HA?
enhanced （Yes/No）
Raw
material: P - No None Additive Not Applicable No
a) Flour C - Benzoyl approved by
peroxide Food Act in
B – No certain ppm
Principles of HACCP
Continue…
PRINCIPLE 3 – Establish critical limit
Establish critical limits at each CCPs
• Each critical limit should be something that can
be immediately monitored by measurement or
observation
– Temperature
– Time
– Water and humidity
– Thickness
– pH
Principles of HACCP
A criterion, which specifies the
What ? acceptable limits in CCP
Serve as boundaries of safety for each
Why ?
CCP
Information of critical limit
• Science Publication • Food scientist
• Foodstuff journal • Expert/Consultant
• Book Tech-criterion • Contrast Experiment
• Related Guideline • Consultation
• Code Guideline • Experiment Research
Principles of HACCP
Continue…
• Critical limits should NOT be confused with
operational limits which are established for
reasons other than food safety
• Each CCP may have more than one preventive
measures
• Example:
– critical limits to destroy / prevent pathogens for
thermal process
# time and temperature requirements for
thermal processes such as
pasteurization, cooking
Principles of HACCP
Example of Critical Limit of
Temperature for Food Storage
• Danger zone temperatures:
Range from 40° to 140°F (4° to
60°C), which is ideal for bacterial
growth
• Storage temperatures: Perishable
foods should be stored in the
refrigerator, freezer, or dry
conditions according to the
following temperatures:
– Refrigerator : > 40°F (4°C)
– Freezer : below 0°F (-18°C)
– Dry storage : 65°F (18°C)
Principles of HACCP
PRINCIPLE 4 – Establish Monitoring CCP
Monitor CCPs
• There are three main purposes for monitoring:
1. Facilitates tracking of the operation
- Action can be taken immediately before a
deviation occurs
2. Indicates or determine when there is loss of
control and a deviation have actually occurred
at CCP, and corrective action must be taken
(NOT meet a critical limit)
3. Provides written documentation for use in
verification of the HACCP plan
Principles of HACCP
Continue…
Monitoring CCP Process
Measure or When? can be • Physical or
observation to continuous OR chemical
evaluate if the non-continuous measurements
CCP is OR
operating within observations
the critical limits • Should be
taken and
Someone recorded in
trained for the real time
Areas or places activity
that CCP will be which will be
monitored monitored
Principles of HACCP
What will be monitored?
• Measurement of the time and temperature of a
thermal process
• Measurement of cold or frozen storage
temperature
• Measurement of pH
• Measurement of Aw
• Measurement of color
• Speed of production line
• Certificate of origin of raw material
• Harvest area of mollusk and shellfish
Principles of HACCP
How will critical limits be measured
and monitored?
• Thermometers
• Clocks
• Scales
• pH meters
• Water activity meters
• Analytical equipment
Principles of HACCP
Where is the monitoring area?
• Receiving area
• Cold room
• Packaging area
• Production area
Principles of HACCP
Who is responsible for monitoring?
• Production personnel
• Equipment operators
• Supervisors
• Maintenance personnel
• Quality control personnel
• Quality assurance personnel
Principles of HACCP
Monitoring frequency?
• Continuous monitoring (if posible)
– Thermographs
– Metal detectors
• Discontinuous monitoring
– Internal temperature of cooked products
– Evaluation of seam measures of canned food
– Sensory evaluation
Principles of HACCP
Example of Hazard Analysis Worksheet
(for monitoring CCPs)
Monitoring
Critical Corrective
CCP Hazards How Records Verification
Limits What How Who Action(s)
Often
CCP 1
CCP 2
Principles of HACCP
PRINCIPLE 5 – Take corrective action
Deviation: a failure to meet a required
critical limit for a critical control point
Principles of HACCP
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Corrective action
• Objective: to prevent foods which may be
hazardous from reaching consumers
• Corrective action should include:
1. Determine and correct the cause of non-
compliance
2. Determine the disposition of non-
compliance product
3. Records of any corrective actions taken
Principles of HACCP
Corrective actions
Monitoring CCPs Specify
Results: • What is done when
Yes or No deviation occurs?
• Who is responsible for
implementing the
If NO, then the corrective actions?
corrective action • Will a record be
procedure must be developed and
implemented maintained of the
actions taken?
Principles of HACCP
PRINCIPLE 6 – Verification
Objectives: to ensure that the HACCP plan is
based on scientific principles, and to establish
procedures that HACCP plan is working correctly
Includes:
• HACCP plan validation
• CCP verification:
- Calibration of monitoring equipment
- Targeted sample collection and testing
- Review of monitoring records
• HACCP plan verification:
- Audits
- Microbiological analysis of the final product
Principles of HACCP
Examples of Verification Activities
Activity Frequency Responsibility Reviewer
Verification Yearly or upon HACCP Plant
activities HACCP system coordinator Manager
scheduling change
Initial Prior to and Independent HACCP
validation of during initial expert (s) team
HACCP implementation
plan of plan
Principles of HACCP
Who performs verification?
HACCP team
Persons qualified by training and experience
verification
• Internal Verification Procedures
– Internal verification that the HACCP system
is working occurs in three phases
• External Verification Procedures
– Health Department Inspection
• National Surveillance
Principles of HACCP
PRINCIPLE 7 – Documentation
Objective: to establish effective record keeping
procedure that document the HACCP system
Record review must be conducted periodically
by qualified staff members of HACCP plan to
ensure it’s working properly
Principles of HACCP
Recording systems
• Background of • Deviation and
HACCP plan associated corrective
• Description of HACCP actions
system • Training
• Hazards analysis • Verification (internal
including modification and external
• CCP determination • Modifications to the
• Critical Limit HACCP system
determination • SSOP monitoring
• CCP monitoring record
activity and results • Complaint and recall
• External audit
• Other activities
