The Application of HACCP Principles and Practice

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The Application of HACCP Principles and Practice

• Red Meat Sector
• The United Kingdom Experience
• Presented by Paul Bache
• Training and Development Manager
• Food Training International

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The Meat ( Hazard Analysis and Critical Control
Points) Regulations 2002
Based on Commission Decision 2001/471/EC
Amend Fresh Meat (Hygiene and Inspection) Regs
1995 Poultry Meat, Farmed Game Bird Meat and
Rabbit Meat (Hygiene and Inspection) Regs 1995
Implementation dates Large Plants 7th June
2002 Small Plants 7th June 2003
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The Meat (Hazard Analysis and Critical Control
Point) (England) Regulations 2002

• Implement and maintain permanent procedure for
  regular checks on the hygiene conditions of
  production.

Requires licensed meat plants
Developed using HACCP principles
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Applies to
Red/white meat slaughterhouses
Re-packaging re-wrapping centers
Cutting plants
Cold stores
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Pilot Project Meat Plant Operators HACCP Training

7 Plants in UK
1 in Scotland 2 in Wales 4 in England
Includes one white meat abattoir and one red
meat cutting plant
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Pilot Project Objectives
Test out training material and strategy. Identify
potential problems
Remove the fear. Break down barriers to
learning. Create ownership team culture
Establish a timeline Determine existing
pre-requisite status.
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Pilot Project Issues

• Basic hygiene training
• Training Records
• Cleaning Schedules
• Hygiene policy
• Pest control

Pre-requisites

• Structure/Style/Culture
• Learning style
• Right brained

Managers/Supervisors

• Conflict / us them
• Inconsistencies / interpretation
• Hygiene Assessment Score
• Fear Threat of prosecution

Mind set/attitudes
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Keys to successful HACCP training and
implementation

• Uncomplicated, not lost in a quality or
  procedures manual
• HACCP has to be user friendly
• Simple to manage
• Effective at controlling relevant hazards
• Encourage ownership of the HACCP

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The Rationale
Give a man a fish and you feed him for a day
show him how to fish and you feed him for life.
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The Challenge
H A C C
P

• Left brained system
• Step by step structured
• approach

Right Brained pragmatic managers

• The manual
• Training/workshops
• Co-operation
• Patience
• Common sense

• Need to manage
• Time
• People
• Communication

• Operating lean and mean
• Multi-tasking

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Meat Plant Operators Training/Guidance Manual
Developed by FTI in conjunction with and on
behalf of the Food Standards Agency
Distributed by FSA to all Fresh Meat plants and
OVS
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Meat Plant Operators Training/Guidance manual

• Distributed by FSA to all Fresh Meat plants and
  OVS
• Contains info on

Introduction to HACCP
Pre-requisite Programmes
Understanding HACCP Terminology
Preparation How to get started
Training
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Meat Plant Operators Training/Guidance manual
Guidance notes and Micro notes
Useful forms and documents
HACCP Template and Examples
Training syllabus and notes
CD Rom
Focus is on the REDUCTION of bacterial
contamination, and the prevention of growth.
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HACCP Template
developed for use

as a training tool.
developed for use
to demonstrate sector specific
examples, prompting discussion and debate.
developed for use
to produce the HACCP plans in the plant.
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Training Course Key points
Delivered as a one or two day course

• Simple training materials
• Relevant to the industry
• Plain language
• Multiple choice Hygiene/HACCP
• paper and HACCP case study form
• the assessment criteria

one day training option
Hygiene knowledge counts as prior learning
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To Develop and Implement HACCP Successfully

• Good pre requisite procedures
• and hygiene practices.

Co-operation, patience and common sense.
involve workforce

• Commitment/ positive attitude
• management,staff, MHS personnel.

Quality time, create ownership
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What Is HACCP?
Hazard Analysis and Critical Control Point
Internationally accepted food safety management
system
Ensures that the product is safe and will not
cause harm to the consumer

• The HACCP system is solely related to FOOD SAFETY
  and not PRODUCT QUALITY

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HACCP Based System
HACCP does not replace good hygiene practices or
existing documentation.

...but it is most effective when built on this
foundation
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HACCP Based System

• There is no stage in the processing of raw meat
  at which the
• Prevention or Elimination
• of bacterial contamination can be guaranteed

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HACCP Based System

• Management and staff can make a significant
  contribution in

REDUCING THE LIKELIHOOD OF BACTERIAL
CONTAMINATION
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The Seven HACCP Principles
1. Identify any hazards that must be prevented,
eliminated or reduced.
2. Identify the critical control points (CCPs)
at the step(s) at which control is essential.
3. Establish critical limit(s) at CCPs.
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The Seven HACCP Principles
4. Establish and implement effective monitoring
procedures at CCPs.
5. Establish corrective actions to be taken if a
CCP is not under control.
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The Seven HACCP Principles
6. Establish regular procedures to verify
whether the above measures are working
effectively.
7. Establish documents and records to
demonstrate the effective application of the
above measures.
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Hazards
Control Measures
Critical Limits
Critical Control Points (CCPs)

• HACCP PLAN

Monitoring
Corrective Actions
Validation
Verification
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• Specific
• Measurable..
• Attainable..
• Realistic.
• Time bound

specific to the business processes and procedures.
monitored and documented
can only be achieved if pre-requisite programmes
already exists
HACCP scope must be realistic to be achievable.
needs a structured approach to put it together.
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Before writing a HACCP Plan adequate
pre-requisites must be in place
staff instructions staff training

• Pre-requisites Involving People

individual staff training records
hygiene policy
Supplier and Customer lists Delivery records
Pre-requisites Involving Suppliers Customers
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• Pre-requisites Involving Premises
•             

Maintenance of
Control of
Buildings.    Surroundings.    Ref
rigeration equipment.    Fixtures and
fittings.    Vehicles.
Pests Water quality Waste disposal
Cleaning schedule and Cleaning checklist.
Cleaning of Premises Fittings Equipment Vehi
cles  
  Chemical use and storage procedures
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Cleaning schedules should include the following
What is to be cleaned
Who is to clean it
How is it to be cleaned
When is it to be cleaned
The time necessary to clean it
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Cleaning schedules should state
The cleaning standard required
The chemicals, materials and equipment to be
used.
Who is responsible for checking and recording
that it has been cleaned
The precautions to be taken and the
protective clothing to be worn
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What is a HACCP Plan?

• A document or collection of documents that
  summarises the production steps, the hazards and
  the control procedures in a food business.

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The HACCP Template

List the HACCP Team members
Write the Scope of the plan
Draw a flow diagram for each product/process
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The HACCP Template

• Identify hazards
• and controls
• Determine or Justify
• the Critical Control Points

Establish Critical Limits Monitoring
procedures Corrective actions
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Prepare the Ground
Two or more people

• a) Assemble the HACCP Team

Made up of experienced employees with an
understanding of HACCP
Company HACCP Plan that is unique to and
owned by the business
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Prepare the Ground

• b) Write The Scope

and Process Flow Diagram For Each
Product/Process
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Apply HACCP Principle 1

• Identify any hazards that must be prevented,
  eliminated or reduced.

Identify SIGNIFICANT biological, chemical or
physical hazards and their causes at each step
in the production process.
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Apply HACCP Principle 1
Assess the risk.
Determine the likelihood (either High or Low)
of that hazard occurring and the severity
(either High or Low) of adverse health affects.
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Apply HACCP Principle 1
Determine Control Measure
Identify what can be done to control significant
hazards. More than one control measure may be
required for a specific hazard
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Apply HACCP Principle 2

• Identify the critical control points (CCPs) at
  the step(s) at which control is essential.

Using the CCP determination table determine
which process steps are CCPs and which steps
are not
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Apply HACCP Principle 3

• Establish critical limit(s) at CCPs.

Critical limits must be recorded on The CCP
Summary sheet
Each control measure at a CCP should have at
least ONE CRITICAL LIMIT.
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Apply HACCP Principle 4

• Establish and implement effective monitoring
  procedures at CCPs.

There should be at least one Monitoring
Procedure for each Critical Limit
Documents and records should be given a
reference number
Identify the person responsible for
monitoring the CCP
Decide how often the Monitoring Procedure
is carried out
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Apply HACCP Principle 5

• Establish corrective actions to be taken if a CCP
  is not under control.

Decide which Corrective Actions you can
implement at each Critical Control Point.
Documents and records should be given a
reference number
Identify the person responsible to carry out
corrective actions
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Apply HACCP Principle 6

• Establish regular procedures to verify whether
  the above measures are working effectively.

A validation check should be carried out before
the plan is first implemented to make sure it is
thorough and accurate.
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Validation checks

• should include an assessment of

The flow chart identifies each step in the
process
Significant hazards addressed, control measures
in place
The scope accurate description of the process
Are CCPs justified are critical limits
acceptable
Procedures for monitoring and corrective action
in place and understood by relevant staff
Are records and documents adequate
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Apply HACCP Principle 6 Verification checks

• should include an assessment of

Product and process information on-site
review of all flow diagrams
Operating practices how they relate to the
plan
The relevance of each part of the HACCP plan
and documentation

• Staff instructions
• Micro test results
• Customer complaints
• Corrective action taken

• Third party reports
• auditors
• regulatory authority
• customers
• assurance schemes

Regular verification can be provided through the
Review Procedure and ongoing microbiological
testing of carcases
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Apply HACCP Principle 7

• Establish documents and records to demonstrate
  the effective application of the above measures.

Prepare The Ground
List the HACCP Team
Draw the flow diagram
Write the Scope
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Apply HACCP Principle 7

• Establish documents and records to demonstrate
  the effective application of the above measures.

Identify hazards causes and controls
Apply HACCP Principles
Establish CCPs
Establish critical limits monitoring procedures
and corrective actions
Establish documents and records
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Establish A Review Procedure

• When there are changes to

Facilities. Working patterns. Pre-requisite
programmes. Legislation.
There is an unexplained system failure
Microbiological test results or customer
complaints indicate that there is a need to
improve procedures or training
Information is received about new hazards or
best practices
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Establish A Review Procedure

• Each time the review procedure is carried out
  validation checks should also be carried out.
• If there is a need identified to change
  procedure, then the HACCP plan must be amended
  and any changes validated.

Validation
Amend Plan if necessary
Review
Verification
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Records to be kept
General Documentation

• Prerequisite programmes and working instructions
• Staff training records.
• Records of regular monitoring of controls
  e.g.temperature etc.
• Records of any corrective actions
• Ongoing verification records e.g. microbiological
  test results
• Record of review

keep as simple as possible
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For HACCP to work you must
PLAN IT
Say what you do
USE IT
Do what you say
PROVE IT
Prove it with records
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Why HACCP fails
When HACCP appears to fail, is it the fault of
the HACCP system itself
..or does the real failure lie with the
people who are trying to implement it?
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Why HACCP fails
The food operation is not yet ready for HACCP
a badly designed or badly run food operation
can result in too many CCPs
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Why HACCP fails
Only some of the principles are applied
failure to establish relevant Monitoring
systems or establish proper corrective action.
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Why HACCP fails
The principles have not been applied
appropriately
failure to consider all the hazards when
conducting the hazard analysis
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Why HACCP fails

• The HACCP plan is perceived as a
• paper exercise

not implemented in practice
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Why HACCP fails

• The HACCP plan is over complicated

the sole aim of HACCP is to make food safe.
HACCP can be held back when experts over
emphasise technical terms and definitions
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Implications for Managing HACCP

• Training on its own is not enough
• Commitment to implementing HACCP
• Changes in behavior /working practice
• Involvement of all staff

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Management Commitment
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• END