Introduction to HACCP

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Introduction to HACCP

• Dr. Karen Killinger
• Washington State University

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Overview

• Definition of HACCP
• History of HACCP
• Prerequisite Programs HACCP
• Preliminary Steps
• 7 Principles of HACCP
• Implementation of HACCP

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HACCP

• Hazard
• Analysis
• and
• Critical
• Control
• Points

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HACCP Defined

• A preventative, science-based, systematic
  approach to food safety that identifies hazards
  and controls them throughout processing

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How does HACCP differ from inspection?

• Inspection
• Visual
• Reactive finished product testing
• HACCP
• Science-based
• Preventative

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History of HACCP

• 1959 - Pillsbury, NASA, US Army Natick Lab
• 1989 NACMCF
• Revisions in 1992, 1997
• 1995 Seafood
• 1996 Meat and Poultry
• 2002 - Juice

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Relationship of Pre-Requisite Programs, HACCP and
Quality Programs
TQM, SQF
HACCP
GMPs SSOPs
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Preliminary Steps

• Assemble a HACCP Team
• Multi-disciplinary
• Designate a HACCP Coordinator
• Describe Product Distribution
• Describe Intended Use Consumers
• Develop a Flow Diagram
• Verify the Flow Diagram

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Flow Diagram
Receiving - Packaging
Receiving - Ingredients
Receiving Raw Materials
Refrigerated Storage
Dry Storage
Formulation/Mixing
Rework
Processing
Cooking
Cooling
Packaging
Refrigerated Storage
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7 Principles of HACCP

• 1. Conduct a Hazard Analysis
• 2. Identify Critical Control Points
• 3. Establish Critical Limits
• 4. Establish Monitoring Procedures
• 5. Establish Corrective Actions
• 6. Establish Verification Procedures
• 7. Establish Recordkeeping Procedures

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1. Conduct a Hazard Analysis

• Identifying hazards associated with food and
  process and evaluating severity and likelihood of
  occurrence
• Most important step in HACCP plan development
• 3 types of hazards

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Flow Diagram
Receiving - Packaging
Receiving - Ingredients
Receiving Raw Materials
Refrigerated Storage
Dry Storage
Formulation/Mixing
Rework
Processing
Cooking
Cooling
Packaging
Refrigerated Storage
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2. Identify Critical Control Points

• Step at which a control can be applied to reduce,
  prevent or eliminate a hazard
• Loss of control at these points can seriously
  affect food safety
• Identify steps in flow diagram that will be
  subject to the remaining HACCP principles

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Flow Diagram
Receiving - Packaging
Receiving - Ingredients
Receiving Raw Materials
Refrigerated Storage
Dry Storage
Formulation/Mixing
Rework
Processing
Cooking
CCP-1B
Cooling
Packaging
Refrigerated Storage
CCP-2B
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3. Establish Critical Limits

• Maximum or minimum parameter value used to
  measure control of a CCP
• Must be based on science!
• Must include supporting documentation
• If exceeded, process and product are subject to
  corrective actions

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4. Establish Monitoring Procedures

• Planned sequence of measurements to assess CCPs
  produce documentation
• Frequency
• Continuous
• Discontinuous

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4. Establish Monitoring Procedures

• Employees must understand importance of accurate
  measurements
• TRAINING!
• Analyze data to avoid corrective actions

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5. Establish Corrective Actions

• Procedures followed when a deviation occurs
• Bring process under control and assess safety of
  adulterated product
• Recordkeeping very important

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5. Establish Corrective Actions

• 4 items to address during corrective action
• Determine and eliminate cause of deviation
• Bring the process back under control
• Implement measures to prevent recurrence
• Ensure no adulterated product enters commerce

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6. Establish Verification Activities

• Activities other than monitoring that assess plan
  validity and operation
• Do we do what we say and do we say what we do
• Equipment Calibration
• Independent Checks
• Record Review

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6. Establish Verification Activities

• Validation
• Collecting and evaluating scientific information
  to determine if the plan effectively controls
  hazards
• Is it the right thing to do?
• Annual HAACP Plan Reassessment

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7. Recordkeeping

• Generating and maintaining accurate records of
  HACCP activities
• HACCP Plan
• Supporting Documentation
• Monitoring Records
• Corrective Action Records
• Verification Records
• HACCP Plan Review Records

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7. Recordkeeping

• Generating and maintaining accurate records of
  HACCP activities
• These records are your only proof!
• Be accurate!
• Be organized!

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HACCP Implementation

• Food Safety Approach
• Culture change
• Team approach
• Support throughout company
• Gradual Implementation
• Time Table Goals
• Training Communication
• Review and Revise!!!

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HACCP Success Stories

• After HACCP certification of over 40 employees
• 60 reduction in non-compliance records

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• Dr. Karen Killinger
• Consumer Food Safety Specialist
• Washington State University
• PO Box 646376
• Pullman, WA 99164-6376
• [phone]
• karen_killinger_at_wsu.edu