HACCP Training Program

TÜV
TÜVSÜD
SÜDSouth Asia 11/27/2020 HACCP Implementation Program Ed 2020 Rev 0 Slide 1
Why Food Safety?

 New products are coming on the market at a fast pace

 New processing methods and equipment
 World market and changing patterns of consumption
 World trade need for international harmonization
 Emerging pathogens
 More and more customers scrutinize food they eat due to food scares
 Customers are better educated and informed
 Regulators Active in safeguarding food
 CODEX
 Shareholders/Insurers (Litigations/Claims)
 Retailers/Private Labels (Brand Protection)

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Food Chain and Sources of Contamination

Vehicle
emission
Crops

Processing
Agricultural
practices
Livestock Cooking
Retail

Landfills
Storage

Seafood

Industrial emissions
and effluents Distribution
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Relevance of Food Safety

Besides direct health consequences, food borne illnesses can result

in:

 Loss of consumers’ confidence

 Reduce productivity,

 Impose substantial stress on health care system

 Reduce economic output

 Finally, Legal actions and closure of food business.

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Campylobacter: Undercooked Poultry
Hepatitis A: Improper Food Handling
E. coli: Fresh Produce
Salmonella: Processed Foods
Wrong practices followed neglecting food safety

Negligence / 1 mistake can cost millions

Wrong practices followed neglecting food safety
Wrong practices followed neglecting food safety
Attitude towards food – 101 uses for a bin
Food Safety Guidelines and Standards

 Guideline: It is an advisory document which gives explanatory information to

meet the requirements or conformity. For example: HACCP, GMP
 Standard: It is an agreed and authorized set of requirements which must be
followed in order to be compliant. For example:
• British Retail Consortium (BRC Standards)
• International Food Standards (IFS Standards)
• ISO 22000
About Codex

The Codex Alimentarius Commission is the body established to develop food

standards under the Joint FAO/WHO Food Standards Programme
Codex Alimentarius (in Latin) = Food Book / Food Code

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Codex Alimentarius

The collection of food standards and related texts adopted by the Codex
Alimentarius Commission is known as the Codex Alimentarius.

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About Codex

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Codex General Principles of Food Hygiene

Recommended International Code of Practice General Principles of Food Hygiene

CAC/RCP1-1969, Rev.4(2003)

Objectives
 Identify the essential principles of food hygiene applicable throughout the
food chain, to achieve the goal of ensuring that food is safe and suitable for
human consumption
 Provides a baseline structure for other, more specific, codes applicable to
particular sectors
 Such specific codes should be read in conjunction with this document and its
appendix on HACCP and Guidelines for its application

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Basic Principles of Codex Food Hygiene

1. Primary Production

2. Establishment: Design And Facilities

3. Control of Operation

4. Establishment: Maintenance And Sanitation

5. Establishment: Personal Hygiene

6. Transportation

7. Product Information And Consumer Awareness

8. Training

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Food Safety

Food Safety can be achieved by implementing HACCP.

GMP
GHP
PRP
GLP
HACCP (As per Codex Alimentarius eg;
GWP
CAC/RCP-01, ISO/TS 22002-1
GDP,
etc

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HACCP

The HACCP
(Hazard Analysis and Critical Control Point) System

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The HACCP System

It was developed to ensure safe foods for NASA and the Apollo and Gemini
program by controlling the environment and the processing parameters.

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The HACCP System

Dr. Howard E. Bauman- Father of HACCP

(1925 – 2001)

 Doctorate in Microbiology from

University of Wisconsin, USA
 Joined M/s. Pillsbury in 1953 as Head-
Research, Bacteriology Dept.

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History of HACCP System

YEAR ORGANISATION/ EVENT PRODUCT/COMMENT

1959 Pillsbury Company / NASA / US Army NATIK Laboratory / US Air Food for Astronauts (Apollo and
Force Space Laboratory Project Gemini)
1971 National Conference of Food Protection Introduction of HACCP to the world
(03 Principles)
1973 USFDA (United States Food and Drug Administration) Low Acid and Acidified Canned
Foods
1985 National Academy of Science (USA) Food Industries
International Commission for Microbiological Standards for (05 Principles)
Foods (ICMSF)
International Association of Milk, Food and Environmental
Sanitarians (IAMFES)
1989 US National Advisory Committee on Microbiological Criteria for 07 Principles
Food (NACMCF)
1993- Joint FAO/WHO Food Standards Programme (CODEX) Accepted the Principles
1997
NOW Recommended International Code of Practice General All over the world
Principles of Food Hygiene (CAC RCP 1-1969, Rev.4 2003)

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The HACCP is..

Rather
than

Preventive and Proactive approach to control food safety hazards.

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The HACCP System

Codex defines HACCP as “a system which identifies, evaluates and controls

hazards which are significant to food safety”.

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Organizations in the Food Chain

Crop Producers Producers of Pesticides, Fertilizers and Veterinary Drugs

Food Chain for the Production of Ingredients and

Feed Producers Additives
Regulatory Authorities

Transport and Storage Operators

Primary Food Producers
Producers of Equipment

Secondary Food Producers Producers of Cleaning Agents

Producers of Packaging Materials

Wholesalers
Service Providers

Retailers Other Supplying Food Chains

Consumers

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Key Elements of FSMS

 Interactive Communication (Prevention of unsafe food; Food

should be harmless to the consumers)

 Based on Prerequisites (GMP + GHP)

 Hazard Analysis and Critical Control Points (HACCP)

 Management System requirements

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Food borne illness

From 31 known food born pathogens –

 9.4 million illness
 55961 hospitalized
 1351 deaths

From Unspecified agents –

 38.4 million illness
 71878 hospitalized
 1686 deaths
www.cdc.gov/foodborneburden/2011-foodborne-estimates.html

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HACCP

Aims at preventing hazards at the earliest possible

point in the food chain.
 Contaminants
 Pathogenic micro-organisms
 Physical objects
 Chemicals
 Raw Materials
 A process
 Inadequate directions for use to the consumer
 Storage conditions

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HACCP

 Safe food is obtained by applying HACCP “from farm to fork”

 Hazards are all kinds of agents when present at unacceptable levels

 Control means “ having things under control”

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HACCP

 A system for food safety control

 Preventive not reactive

 A management tool used to protect the food supply

against “Hazards”

 Not a zero-risk system (it minimizes the risk but not

completely eliminates)

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Origin of HACCP

 Pioneered in 1960’s by Pillsbury company, US Army

and National Aeronautics and Space Administration
(NASA)

 First used when foods were developed for the space

program.

 Based on “Failure, Mode and effect Analysis”

 During 1970’s and early 1980’s HACCP was used to some

extent for non canned foods, but it was in 1985 that it was
applied seriously to various categories of food.

 Adopted by many food processors and the U.S.

Government.

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Why HACCP?

 Contaminated products: wide variety of potentially

harmful materials

 Occur worldwide

 Three types of hazards; biological, chemical and

physical.

 Human health implications

 Huge cost implication

 May result from tampering or shopper abuse.

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Why should food companies use HACCP?

 It is a proven system, which gives assurance of effectively managed food safety

 Enables co. to maintain top priority on food product safety

 Involvement of personnel from different disciplines ensures that all employees have the same
fundamental objective – food safety is a must

 Assures customers of the safety of its operations, indicating that it is a responsible and
professional company

 It is a legislative requirement in most of the countries

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Why should food companies use HACCP?

 HACCP is becoming popular as an industrial food safety system and as a tool to meet
regulatory requirements because:-

 Encourages prevention rather than correction

 It is a scientific approach

 It encourages people to take an active role in the planning and implementation of food
protection controls.

 It makes people aware of food safety hazards

 It makes it unnecessary to engage in random sampling and end product testing

 It results in a safe products and systems

 It encourages the application of uniform HACCP Specification at all levels of the food system

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 54
Advantages over traditional methods

 Emphasizes process control

 Concentrates on the points in the process that

are critical to the safety of the product

 Stresses communication between the regulator

and the industry.

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Standards of HACCP

 Joint FAO/WHO Codex Alimentarius committee (1993)

 Recommended International code of practice – General Principles of Food Hygiene CAC/RCP

1-1969 (Seven principles recognized internationally)

 FDA Sea Food HACCP Regulations

 Assured Safe Catering

 SQF 2000(Safe Quality Food 2000) based on HACCP

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Standards of HACCP

EC Directive 93/94/EEC, 14/6/93

The directive suggests the integration of

 The hygiene practices of the recommended international code of practice,

 General principles of food hygiene of the codex alimentarious and

 The principles of HACCP with the quality management practices of ISO 9001

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HACCP

 The basis of HACCP - GMP and SSOP

 No SSOP - No HACCP

 SSOP documented and implemented

HACCP
 Facility sanitation
SSOP
 Cleaning schedule
GMP
 P.H, GHPs, GMPs

 The entire system verified by QA personnel and Records kept

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Support programs for HACCP

 Management commitment

 Plant design as per GMP

 Insect and pest control

 Product identification and traceability

 Trained personnel

 Good warehousing practices

 Calibration

 Recall procedures

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Hazards

A Biological, Chemical or Physical property that may

cause a food to be unsafe for consumption.

In HACCP it refers to conditions or contaminants in

foods that can cause illness or injury

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Physical

Possible Sources of Hazards

Microbiological Hazards

Microbiological include

1. Harmful bacteria
Food Infection and Food Intoxication
Spore forming and Non spore forming Bacteria.

2. Viruses
Hepatitis A to E
Norwalk virus group

3. Parasitic Hazards
Worms and Protozoa

4. Fungi
Yeast and Mould

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Bacterial hazards

Micro-organism Why a hazard

Clostridium botulinum (spore forming) Causes intoxication that affects the central nervous
system and causes shortness of breath, blurred vision,
loss of motor capabilities and death.
Listeria monocytogenes (non spore forming) Causes an infection with mild flu-like symptoms.
Severe forms of listeriosis are possible in people with
weakened immune systems causing septicemia,
meningitis etc.
Salmonells spp (non spore forming) Causes an infection with the following symptoms:
nausea, vomiting, abdominal cramps, diarrhea, fever
and headache. Death is possible in people with
weakened immune system.

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Viral hazards

Micro-organism Why a hazard

Hepatitis A virus Causes fever and abdominal discomfort followed by jaundice

Norwalk virus Causes nausea, vomiting, diarrhea and abdominal pain (gastroenteritis).
Headache and low grade fever may also occur.

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Parasitic hazards

Organism Why a hazard

Giardia lamblica Causes diarrhea, abdominal cramps, fatigue, flatulence, and weight loss

Entamoeba histolitica Causes dysentery (severe diarrhea with presence of blood in stool)

Ascaris lumbricoides This roundworm causes intestinal and lung infection

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Fungi

A number of fungal sp. are capable of producing

metabolites that are toxic to humans and
domestic animals. These are called mycotoxins.
 Aspergillus spp. and Fusqrium spp
 Aspergillus: Cause aflatoxicosis.
 Symptoms: causes acute liver damage,
cirrhosis. Suppresses the immune system
and causes liver cancer e.g. nuts, seeds,
cereals etc.
 Mushrooms: poisonous and non-poisonous
look alike.
 Purchase from reputable suppliers..

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Chemical hazards

1. Naturally occurring
Like Mycotoxin, Scombrotoxin, Ciguatoxin and
Shellfish poisoning

2. Intentionally Added
Like food additives, preservatives, nutritional additives
and color additives

3. Unintentionally or incidentally added chemicals.

Like agricultural chemicals, toxic compounds,
lubricants etc.

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Naturally occurring chemical hazards

Source Why a hazard

Certain fish species (e.g., Tuna, Mahimahi) Spoilage of certain species of fish can result in
production of toxic levels of histamine
Mycotoxins E.g., Nuts, cereals, etc.

Shell fish toxins Oysters and other types of shell fishes

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Intentionally added chemical hazards

Source Why a hazard

FD & C Yellow 5 Can produce an allergic type reaction in (food colouring) sensitive
people.
Sodium Nitrite (preservative) Can be toxic in high concentrations

Vitamin A Can be toxic in high concentrations

Sulphating agents Can cause allergic type reaction in sensitive people

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Unintentionally added chemical hazards

Source Why a hazard

Agricultural chemicals (e.g. Can be acutely toxic if present in the food at high levels and may
pesticides, herbicides) cause health risks with long term exposure.
Cleaning chemicals (e.g. acids, Can cause chemical burns if present in the food at high levels
caustics)
Maintenance chemicals (e.g. Chemicals that are not approved for food use and may be toxic
lubricants, paint)

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Physical hazards

Source Why a hazard Source

Glass Cuts, bleeding; may require surgery to Bottles, jars, light fixtures, thermometers,
find or remove gauge covers
Wood Cuts, infection, choking Fields, pallets, boxes, buildings

Stone Choking, broken teeth, cuts, infection Fields, buildings, machinery, employees

Insulation Choking Building materials

Bone Choking, trauma Improper processing

Metal Cuts, broken teeth, may require surgery Machinery, agricultural fields, wire, staples,
to remove buildings, employees

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Logical sequence of application of HACCP

1. Assemble the HACCP Team

2. Describe the Product

3. Describe the Intended Use

4. Prepare Flow Chart

5. On-site Verification of Flow Chart

6. Conduct Hazard Analysis

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Logical sequence of application of HACCP

7. Determine the Critical Control Points (CCPs)

8. Establish critical limits for each CCP

9. Establish a monitoring system for each CCP

10. Establish corrective action when there is a loss control at CCP

11. Establish verification procedures

12. Establish Documentation and record keeping

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1. Assemble the HACCP Team

 The team should be multidisciplinary

 Include people who are familiar with the actual

operations.

 Have the required knowledge and authority to

implement changes.

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2. Describe the product

 Product description

 Composition

 Method of preservation

 Packaging

 Storage conditions

 Distribution

 Intended use and consumers

 Preparation

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3. Describe the Intended Use

 Who is the target group?

 How the end product is used?

e.g. for direct consumption or additive in
manufacture of a product

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4. Prepare Flow Chart

SHOW™ FLOW CHART

 Should include all steps Product Name : FRESH BEEF PROCESSING (SOUTH KIRKBY)

Step No :1.0 Step No :1.1

RECEIVE
INPUT PACKAGING

 Will be used in the hazard analysis Step No :2.0 Step No :1.2

process and HACCP Plans

TRANSFER & STORE
STORE IN INPUT PACKAGING
CHILL

Step No :3.0
BOX DECANT &
TRANSFER

Step No :4.0
BUTCHERY
PROCESS

Step No :5.0
WEIGHED

Step No :6.0 Step No :6.1

MACHINE MANUAL
FURTHER FURTHER
PROCESS PROCESS

Step No :7.0
PACKING

Step No :8.0
Q.A CHECKED

Step No :9.0
METAL DETECT

Step No :9.0.1 Step No :9.0

FREEZE STRAPPED &
STACKED IN
OUTPUT CHILL

Step No :10.0
OUTPUT

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Flow Chart

Preparation of the flow diagrams  Sequences of steps.

 Outsourced process
 Re-working
 Intermediate product
 By product
 Waste removal
 Addition of steam, air.
 Flow chart verification

8.5.1.5.2 On-site confirmation of

flow diagrams
8.5.1.5.3 Description of processes
and process environment
5. On-site Verification of Flow Chart

 Check for accuracy and completeness

 Develop traffic flow diagrams

 Identifies possible contamination points

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6. Conduct Hazard Analysis

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.

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Areas to consider for Hazard Analysis

Raw Materials:

 What hazards are likely to be present in each raw material

that may affect the process / product?

 Are any of the raw materials themselves hazardous if excess

amounts are added?

 Design and plant equipment (premises)

 Risks of cross - contamination during process holding stages -

microbiological, chemical, physical safety issues?

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ISO 22000:2018 – Clause 8.0

• 8.5.2 Hazard analysis

HAZARD ANALYSIS
PRODUCT TYPE: Frozen PUD Shrimp
WHAT CONTROL

SIGNIFICANT (RISK
FACTOR = A X B)
TYPE OF

OCCURANCE (B)
POTENTIAL

LIKELIHOOD OF

IS THE HAZARD
MEASURES CAN BE

SEVERITY (A)
HAZARD HAZARD
PROCESS / INTRODUCED, JUSTIFICATION FOR APPLIED TO
BIOLOGICAL CONTROLLED OR
STEP DECISION PREVENT THE
PHYSICAL ENHANCED AT
SIGNIFICANT
CHEMICAL THE STEP-CAUSE.
HAZARDS
Presence of
pathogenic
Biological
microorganis
m
Raw
material Presence of
receiving Chemical sulphite
(shrimp/ residue
lobster)
Glass pieces,
wood, stones,
Physical
and Metal
pieces
ISO 22000:2018 – Clause 8.0
Hazard – Likelihood and Severity

i) Likelihood (Probability):
The probability of such hazard occurring is measured using the following parameters:
Frequent (Daily) -5
Likely (Weekly) -4
Occasional (Monthly) -3
Unlikely (Yearly) -2
Very Unlikely (Not yet observed) -1

ii) Severity (Impact):

The severity or impact of such hazard on the human health is measured using the
following parameters:
Critical (Death) -5
High (Hospitalization/illness) -4
Medium (Absence from work) -3
Low (Complaint/economic loss) -2
Negligible (Almost no effect) -1
ISO 22000:2018 – Clause 8.0

Significance
Significance Rating:
Quantifying Hazards (Exposure)

Critical 5 5 10 15 20 25
Significant
Hazards
High 4 4 8 12 16 20 (controlled by
OPRP or
10 HACCP Plan)

Medium 3 3 6 9 12 15
Hazard
Impact / Non-Significant
Hazards
Severity Low 2 2 4 6 8 10 (controlled by
9 PRP)

Negligible 1 1 2 3 4 5

1 2 3 4 5

Never Unlikely Occasional Likely Frequent

Hazard Occurrence Probability

Hazard Analysis

HAZARD ANALYSIS
PRODUCT TYPE: Frozen PUD Shrimp
TYPE OF WHAT CONTROL

OCCURANCE (B)
POTENTIAL

(RISK FACTOR =
LIKELIHOOD OF

IS THE HAZARD
SEVERITY (A)

SIGNIFICANT
HAZARD HAZARD MEASURES CAN BE
PROCESS / JUSTIFICATION FOR

A X B)
INTRODUCED,
BIOLOGICAL CONTROLLED OR
APPLIED TO PREVENT
STEP DECISION
PHYSICAL ENHANCED AT THE THE SIGNIFICANT
CHEMICAL STEP-CAUSE. HAZARDS
1. Unhygienic conditions 1. Adherence to GMP.
Presence of followed at catchments area 2. Supplier declaration
Biological pathogenic 2. Unhygienic condition of 3. RM Inspection
4. Supplier evaluation

Likely
microorganism transport vehicle.
Low
3. Temperature abuse.
(2)

(4)

(8)
Raw 1.Adherence to GMP.
1. Improper supplier level 2. Approved supplier
material
Occasional
Presence of practices 3. Supplier’s declaration.
receiving Chemical
sulphite residue 2. Improper transportation & 4. RM inspection
High

(shrimp/ Storage practices

(12)
5.Rejection of the lot
(4)

(3)

lobster)
1.Adherence to GMP
Glass pieces, 1. Unhygienic conditions 2.Hygienic condition of
Occasional

wood, stones, followed at catchments area transport vehicle.

Physical
Medium

and Metal 2. Unhygienic condition of 3. Incoming material

pieces transport vehicle inspection.
(3)

(3)

(9)

4. Supplier evaluation
FSSC 22000 Ver 4.1 IA Ed 2018 Rev 1
 Raw material Receiving (1)
OPRP
Biological:- (2)
Pathogenic micro organisms may be Significant
present Hazards

Proper Chilling of the Raw Material with (3)

Ice and Keeping the temp within 4° C Control Measures

Temperature of the raw material during What

(4)

Receipt
Using calibrated thermometer How
(5)

For Every 500 kg of raw materials Frequency

(6)
Monitoring
OPRP PLAN FORM - Product: Raw Fish

(7)

Purchase supervisor Who

1.Reject lot if the material temp > 4° C (8)

2.Inform and Train the supplier on Correction and

FSSC 22000 Ver 4.1 IA Ed 2018 Rev 1

significance of RM Temp Corrective
3. Re evaluation of Supplier Action(s)

1. Raw materials Inspection Record (9)

2.Training Record Records
3.Supplier Evaluation n Record

1.Weekly verification of the process and (10)

records By QA Personnel Verification
2. Training Record Verification by QA Mgr
 Packing (Metal Detection Process) (1) CCP

Physical – Metal Fragments (2) Significant

Hazards

TÜV SÜD South Asia

Metal Detection (3) Control Measures

No metal pieces above 1.5 mm for Fe; 2.5 mm for (4) Critical Limits
non-Fe; 2.00 mm for SS
(5)

Presence of metal fragments in the finished What

product
HACCP PLAN – Raw Fish

Automatically by the machine- Metal Detector How

(6)

Continuous - For each and every final packet of Frequency

Monitoring
(7)

materials

Production Staff
(8)

Who

1) Separate the packet with metal contamination, (9) Correction and

segregate the metal pieces and attach with Corrective Action(s)
identification tags.
2) Check for the defective parts and proper
maintenance / replacement of all the food contact
surfaces.

FSSC 22000 Ver 4.1 IA Ed 2018 Rev 1

3) Training of the technical personnel and
their evaluation

1) Metal Detector Monitoring Record; (10) Records

2) Preventive Maintenance Record;
3) Calibration Record of Metal Detector;
Slide 87

4) Training Record;
5) Correction and Corrective Action Record

1) Daily verification of the sensitivity of metal (11) Verification

detector by QA Manager
2) Weekly Verification of the maintenance
process by the technical manager
3) Calibration Record
Hazard analysis

HAZARD ANALYSIS
PRODUCT TYPE: Whole Spices

Severity of Adverse
POTENTIAL

Health affects (B)

significant (risk
factor = a x b)
Occurrence (A)
TYPE OF

Likelihood of

Is the hazard
HAZARD WHAT CONTROL
HAZARD
INTRODUCED, JUSTIFICATION FOR MEASURES CAN BE
PROCESS / STEP BIOLOGICAL
CONTROLLED OR DECISION APPLIED TO PREVENT THE
PHYSICAL
ENHANCED AT SIGNIFICANT HAZARDS
CHEMICAL
THE STEP-CAUSE.

Likely (4)
Steam sterilization is subjected Monitoring time and

High (4)
to the reduction of microbial temperature gauges,
Biological Microbial Load load and ample inactivation of
(16) Sterilization at 100- 110 C
enzymes.

1.Adherence to GMP
Unlikely (2)

Steam Chances from 2. Hygienic condition of

Low (2)
Since the entity is controlled by
transport vehicle.
Sterilization Chemical machinery SOP, SSOP and GMP,
(4) contamination is not possible 3. Incoming material
lubricants inspection.
4. Supplier evaluation
Negligible

Not identified. Since the entity

Never (1)

Stones, is controlled by SOP, SSOP 1. Adherence to GMP.

Physical
(1)

and GMP, contamination is not 2. De-stoning, Sieving etc

Foreign body (1)
possible

TÜV SÜD South Asia Slide 88 17-Jul-14 FSMS AWR Ed 2014 Rev 0
Hazard analysis

HAZARD ANALYSIS
PRODUCT TYPE: Whole Spices

Severity of Adverse
POTENTIAL

Health affects (B)

significant (risk
factor = a x b)
Occurrence (A)
TYPE OF

Likelihood of

Is the hazard
HAZARD WHAT CONTROL
HAZARD
INTRODUCED, JUSTIFICATION FOR MEASURES CAN BE
PROCESS / STEP BIOLOGICAL
CONTROLLED OR DECISION APPLIED TO PREVENT THE
PHYSICAL
ENHANCED AT SIGNIFICANT HAZARDS
CHEMICAL
THE STEP-CAUSE.

Unlikely (2)
Moisture maintained Not likely to occur

Low (2)
Yeast and Mold
Biological through drying , heating controlled by GMP and
growth Occasionally (4) etc. SSOP

Low (2) As the unit is controlled by Not likely to occur

SOP, SSOP and GMPs controlled by GMP and
Chemical Grease or oil
(3)

Pulverizing (4) contamination is not SSOP

possible

Likely hood of occurrence

Likely (3)

Magnets are placed at

of discharge of metallic
High

Physical Metal Pieces

(4)

discharging outlet of
(12) parts during processing
gauze strength of 10000
due to breakage.

TÜV SÜD South Asia Slide 89 17-Jul-14 FSMS AWR Ed 2014 Rev 0
Hazard Assessment

 Conduct the hazard assessment to determine whether its elimination or

reduction to acceptable levels is essential,
 Its control is needed to meet the defined acceptable level
 Describe the methodology used and record

TÜV SÜD South Asia Slide 90 17-Jul-14 FSMS AWR Ed 2014 Rev 0
Selection and Assessment of Control Measures

 Select appropriate combination of control measures

 Categorized selected control measures whether manage through Operational PRP
or HACCP plan

TÜV SÜD South Asia Slide 91 17-Jul-14 FSMS AWR Ed 2014 Rev 0
7.5 Establishing the Operational Prerequisites Programme

Document operational PRP

 Food safety hazard(s) to be controlled
 Control measure
 Monitoring procedures
 Correction and corrective action to be taken
 Responsibilities and authorities
 Record of monitoring

TÜV SÜD South Asia Slide 92 17-Jul-14 FSMS AWR Ed 2014 Rev 0
 Pulverizing (1)
OPRP

Metallic contaminants (2)

Significant

TÜV SÜD South Asia

Hazards

RM Inspection/ Approved (3)

Control Measures
Supplier/Magnets are placed at

Slide 93
discharging outlet of gauze strength of
10000

Metal Pieces on Magnet What

(4)

17-Jul-14
Weighing metal pieces on Magnet How
(5)

Once in a shift Frequency

Monitoring
(6)
OPRP Plan Form – Product: Spice Powder

Operator Who
(7)

(8)

FSMS AWR Ed 2014 Rev 0

1.Reject the lot if the material contains > 5
Correction and
gm/kg
Corrective Action(s)
Preventive maintenance, Supplier evaluation
etc.
1. Magnet inspection record
(9)
Records

1.Weekly verification of the process and

records By QA Personnel
(10)

2. Training Record Verification by QA

Verification

Mgr
Potentially hazardous food

The most frequently implicated (contaminated)

foods include:
 Meat
 Poultry
 Seafood.

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 94
Food safety issues and contaminants

Dioxin Cola

Harmones Meat and banana

BSE (Mad Cow Disease) Meat from Europe

B.H.C. Cashew

Staph. Toxin Ice cream

Listeria Dairy products

Salmonella Chicken, egg, and spices

Sulphites and antibiotics Sea foods

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 95
Food safety issues and contaminants

Non-permitted coal tar colours

Industrial pollutants
Petroleum products
All these hazards could be controlled only through preventive strategy

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 96
Hazard Identification

Hazardous agents

Raw Material Environment Process

Finished Product

Testing - too late

Product wasted
May not detect

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 97
Establish Preventive Measures

For each identified hazard detail the preventive

measures to control the hazard. e.g.
1. Sanitation
2. Time control
3. Temperature control
4. Labels
5. Equipment maintenance
6. Training
7. GMP

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 98
7. Determination of Critical Control Points (CCP)

A point, step or procedure at which control can be applied and a food safety hazard can be
prevented, eliminated or reduced to acceptable limits.
CCPs are product and process specific.
e.g.
 Cooking,
 Metal detector,
 pH,
 Formulation control etc.

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 99
To determine CCP

» Focus on the Flow of Food

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 100
CCP Decision Tree

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 101
8. Establish Critical Limits

Critical limit:
A criterion that must be met for each preventive measure associated with a CCP.
It represents the boundaries that are used to ensure that an operation produces safe products.
 Time,
 Temperature,
 pH,
 Moisture level,
 Water activity

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 102
9. Monitor Critical Control Points

Monitor:

To conduct a planned sequence of observations or

measurements to assess whether a CCP is under
control and record the results for future verification.

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 103
Purpose of Monitoring

 To track the operation of the process and enable the

identification of trends towards a critical limit that may
trigger process adjustments.

 To identify when there is loss of control

 To provide written documentation of the process control

system.

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 104
Monitoring

 What ?

 How ?

 Who ?

 When ?

 Sampling

Continuous monitoring is preferred

 Attribute sampling

 Must be statistically sound

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 105
Monitoring methods

 Visual observation includes :

 Sensory and visual checks

 Visual observation for physical characteristics

 Checks of sanitary conditions

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 106
10. Establish Corrective Actions

Any action to be taken when the results

of monitoring at the CCP indicate a loss
of control.

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 107
Corrective Actions

 Identify, isolate and evaluate products when critical limits are exceeded.

 Control deviations such as

 Identification of deviation,

 Isolation of affected product,

 Evaluation of affected product

 Corrective actions : cause of the deviation, take action to prevent recurrence and follow up
with monitoring and reassessment to ensure that the action taken is effective.

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 108
11. Establish verification procedures

The Application of methods, procedures, tests

and audits in addition to verify and determine
compliance with the HACCP plan and/or
whether the HACCP plan needs modification.

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 109
Elements of verification

 HACCP Plan Validation

 HACCP system Audits

 Equipment calibration

 Targeted sampling and testing

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 110
Validation

 Obtaining evidence that the elements of the HACCP plan are effective.

 It involves a scientific and technical review of rationale behind each part of HACCP plan, from
hazard analysis through each verification strategy.

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 111
12. Establish Records

 Records provide evidence that the HACCP system is working

 Provide tracking system

 Help identify problems

 Evidence of compliance to critical limits

 Evidence of corrective action

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 112
Record Keeping

4 Kinds of records are needed:

 HACCP Plan and support documentation used in
developing the plan.
 Information and data collected in order to arrive at
critical limits
 Records of CCP monitoring
 Records of Corrective actions
 Records of verification activities
• Training records
• Time temperature logs

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 113
HACCP System Audits

 Confirmation: All hazards are identified.

 Preventive measures identified for all hazards.

 Critical limits are sufficient.

 Procedures and equipment are calibrated

adequately.

 Independent assessment: to enable client to

confirm that supplier conforms to safety and
Quality obligation

 To enable the quality system to be certified

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 114
HACCP System Audits

 Audits performed to compare the actual

practices and procedures written in the HACCP
plan

 Systematic and independent

 It includes
• On site observations
• Interviews and
• Review of records and documents

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 115
Calibration

 Checking instruments against a standard to

ensure reliability

 Frequency sufficient to assure continuous

assurance

 Calibration record review

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 116
Targeted Sampling and Testing

 Microbiological analysis of the sample

 Organoleptic analysis.

 Samples can be taken to ensure that the

equipment settings to control the CCP are
appropriate for product safety.

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 117
Verification of the HACCP Plan

The assessment of the HACCP Plan before

implementation to provide confirmation that it is valid,
accurate and complete.

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 118
Verification Procedures

 Procedures other than those used in Monitoring to

ensure that the HACCP Plan is implemented
correctly and remains effective.

 Audit Plan

 Data Analysis

 Review of Consumer Complaints

 Microbiological Analysis

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 119
How to verify the HACCP Plan

Use personnel with audit skills

 Assess all elements of the HACCP Plan

 Process Flow Diagram

 HACCP Control Chart

 Assess the Process area

 Control Measures

 Process Capability

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 120
What types of data?

 CCP log sheets

 Process control charts

 Audit reports

 Customer complaint data

 Pest control record

 Minutes of meetings

 HACCP

 Hygiene

 Quality

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 121
HACCP Manual

 Company Profile

 Introduction

 Organization Chart

 Hygiene Department organization Chart

 HACCP/GMP Committee

 HACCP Team

 HACCP Policy

 Definition and Terminology

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 122
HACCP Manual

 Training

 Prerequisite/Support Program includes GMP,

SSOP etc.

 Machinery/Equipment Layout

 Staff Flow and Machinery Flow

 Hazard analysis Worksheet

 HACCP Plan

 Verification procedure/Audit

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 123
HACCP Manual

 Additional Documentation:

 Specifications

 Operating Procedures

 Work Instructions

 Records

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 124
Maintenance of HACCP System

 Verification and Updating Procedures

 Ongoing Internal Audits

 Data Analysis

 Keeping abreast of emerging hazards

 Updating and amending the HACCP Plan

 Ongoing training requirements

 Maintenance documentation

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 125
Keeping abreast of the emerging hazards

 New Technologies

 New natural foods

 New combinations of foods

 Changing legislation

 New information on existing issues

 New ways of packaging food

 Changing eating habits

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 126
On-going training requirements

 HACCP/ Food Hygiene Refresher Training

 New Personnel

 HACCP Teams

 CCP Monitors

 Awareness Training

 Cleaning and Sanitizing

 Proper use of Equipment

 Personnel handling

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 127
Updating and amending HACCP Plan

 New raw materials/suppliers

 Changes to process

 Factory environment alterations

 New packaging

 HACCP audit

 Changes resulting from “improvements”

 HACCP review

 Essential for the HACCP Plan to remain valid –

changes need to be documented.

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 128
Responsibility for implementation

HACCP works best when it is part of an

employee’s routine and not

EXTRA DUTY

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 129
Who should be involved?

 Involve those most directly in that step of the flow of food.

 Move to “lowest” level possible.
 Line employees need to be trained so that corrective actions are automatically done when a
potential problem is found
 Managers should verify the log sheets regularly

 Management can not be in all CRITICAL places at all CRITICAL times

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 130
Activity

• Tutor shall assign each team any one

process and they shall draw the flow

diagram and conduct hazard analysis for

any one process.

• Each team shall present their flow chart and

hazard analysis in flip chart.

• Tutor shall give marks based on the content

and presentations.

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 131
GHP – Good Hygiene Practices

• Basic Hygiene Hygiene Practices

• Oral Hygiene
• Body Hygiene
• Hair Hygiene
• Intimate Hygiene
• Grooming

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 134
GHP – Good Housekeeping Practices

• Clean as you Go Housekeeping Practices

• Handling of Chemicals
• Cleaning
• Sanitation
• Types of cleaning.
• Waste Handling
• Material Storage
• Equipment cleaning – CIP / COP
• Cleaning Schedules for different areas
within an Organization. Eg: Rest room,
office, roof, windows, parking etc.
• Inventory control
• Cross contamination by cleaning
materials.
• Color coding of Cleaning Materials

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 135
GMP – Good Manufacturing Practices

• Environmental Hygiene
• Design and facilities
• Control of Operations
Infrastructure – Lighting, air, etc
• Maintenance
• Pest control
• Waste management
• Quality Control.
Quality Assurance is process oriented and focuses on defect
prevention, while quality control is product oriented and focuses
on defect identification.

Refer:- ISO/TS 22002-1 Or Codex

guidelines for interpretations.

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HACCP
FOODIQA
INDUSTRY
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GMP – Good Manufacturing Practices

• Traceability & Product

information
• Training
• Purchase
• Cross contamination
• Allergens
Management.
• Complaint
management.
• Re-call Or withdrawal
• Management and
supervision.
• Documentation &
Record keeping.

TÜV SÜD South Asia NOV 5, 201727-Nov-19 SKILL TRAINING IN

HACCP
FOODIQA
INDUSTRY
Program- Ed 2019 Rev 0 Slide 137
GLP – Good Laboratory Practices

Best Practices of Good Laboratories

• Establish and Follow Procedures
• Maintain Your Proficiency
• Validate Methods
• Use Traceable Standard Reference
Materials
• Run in Duplicate
• Keep Original Data
• Assign Instruments and Equipment to
Analysts
• Calibrate Instruments
• Use Control Charts
• Document Everything and Maintain
Good Records

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 138
GWP – Good Warehouse Practices

• Warehouse Management – Eg:- WMS – Good Warehouse Practices

Software, etc
• Warehouse Manpower Management
• Importance of food storage.
• Food storage in different temperature
conditions.
• FIFO / FEFO
• Bin Card System
• Traceability
• Re-work
• Labelling
• Picking
• Segregation of Non-conforming products
• Handling Expired products.
• Equipment's handling eg: Pallet truck, fork lifts,
conveyor, etc
• Housekeeping, pest control, training in
Warehouse.
• Pallet cleanliness & inspection.

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 139
GDP – Good Distribution Practices

• Good Food Handling Practices Good Distribution Practices

• Proper Personnel Training.
• Good Cleaning and Sanitation Practices
• Effective Pest Control Program
• Proactive Shipping and Receiving
Programs
• Temperature Abuse
• Personal hygiene of the products
handlers.
• FIFO / FEFO
• Traceability
• Cross contamination.
• Time staggered receipt & dispatch
• Recall Program
• Institute a Food Defense Program

TÜV SÜD South Asia 27-Nov-19 HACCP IQA Program- Ed 2019 Rev 0 Slide 140