H A C C P

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H A C C P

• WHO ICD
• ILSI Europe

Inneke Hantoro
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Introduction Traditional QC vs Preventive System

• Traditional QC programs spot-checked
  manufacturing conditions, and randomly sampled
  and tested final products to ensure safe food.
• If the finished product met the specifications,
  it was approved otherwise, the product was held,
  reprocessed, or destroyed.

Reactive inefficient
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Introduction Traditional QC vs Preventive System

• An HACCP program is about preventive systems to
  eliminate a problem before it happens.
• The actions that these systems provoke are
  essentially preclusive they are designed to
  prevent problems rather than solve them after
  they have occurred.
• QC checks occur during the process so that a
  finished product is deemed consistently safe.

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Hazard Analysis Critical Control Point (HACCP)

• The HACCP system has grown to become the
  universally accepted method for food safety
  assurance.
• A major focus of the HACCP program is from farm
  to table. ? HACCP is a concept as well as a
  method of operation, applied to all phases of
  food production, including agricultural
  production, food handling, food processing, food
  services, food distribution, and consumer use.

Everyone is responsible for safe food products
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Hazard Analysis Critical Control Point (HACCP)

• The Hazard Analysis and Critical Control Point
  (HACCP) system is a science-based system created
  to identify specific hazards and actions to
  control them in order to ensure food safety and
  quality.
• A hazard is a biological, chemical or physical
  agent in, or condition of, food with the
  potential to cause an adverse health effect
  (Codex Alimentarius, 1997).

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The need for an effective food safety assurance
method

• Foodborne disease are a widespread public health
  problem.
• Emergence of foodborne disease.
• Increased knowledge and awareness of the serious
  and chronic health effects.
• New food technologies and processing methods.
• Increased awareness of the economic consequences
  of foodborne disease.

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The need for an effective food safety assurance
method

• Increase in the number of vulnerable people.
• Industrialization and mass production.
• Urbanization and changing lifestyle.
• Increase tourism and international trade in
  foodstuffs.
• Increase consumer awareness of food safety.

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Food Safety Assurance

• Good Manufacturing practices (GM)
• and
• Good Hygiene Practices (GHP)
• necessary
• But not always sufficient

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The History of HACCP

• The HACCP concept was developed in the early
  1970s as a system to assure food safety
• 1983 WHO Europe recommends HACCP
• 1991 Codex HACCP draft
• 1998 FAO/WHO provide guidance for regulatory
  assessment of HACCP
• 2006 Increased worldwide use of HACCP in food
  safety legislation

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Stake holders involved in HACCP
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The objectives HACCP application

• Focuses on identifying and preventing hazards
  from contaminating food, based on sound science.
• Permits more efficient and effective government
  oversight, primarily because record keeping
  allows investigators to see how well a firm is
  complying with food safety laws over a period,
  rather than how well it is doing on any given
  day.
• Places responsibility for ensuring food safety on
  the food manufacturer or distributor.
• Helps food companies to compete more effectively
  in the world market.
• Reduces barriers to international trade.

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HACCP Concept

• Identifying potential food safety problems
• Determining how and where these hazards can be
  controlled or prevented
• Describing what to do and training the personnel
• Implementation and recording

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HACCP Program Prerequisites

• Traceability and recall
• Pest control
• QA procedures
• SOP and SSOP
• Glass control
• Procedures for receiving, storage and shipping
• Labeling
• Employee food and ingredient handling

• Facilities
• Supplier control
• Specifications for all ingredients, products and
  packaging materials
• Production equipment
• Cleaning and sanitation
• Personal hygiene
• Training
• Chemical control
• Receiving, storage, shipping

GMP
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Preliminary Tasks of HACCP Program

• Choosing the HACCP team
• Description of the food product and its
  distribution
• Description of the intended use and consumer of
  the product
• Development of a flow diagram describing a food
  product manufacturing process
• Verification of the flow diagram

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The principles of HACCP

• 1. Conduct a hazard analysis
• 2. Determine the CCPs
• 3. Establish critical limit(s)
• 4. Establish a monitoring system
• 5. Establish corrective actions
• 6. Establish verification procedures
• 7. Establish documentation
• Source CODEX

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1. Hazard Analysis

• The process of collecting and evaluating
  information on hazards and conditions leading to
  their presence to decide which are significant
  for food safety and should be addressed in the
  HACCP plan.

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Information needed for hazard analysis

• the agents that could be present in the food
  under study
• the severity of the effects and the likelihood of
  their occurrence
• the levels that could cause adverse health
  effects
• the conditions that could lead to unacceptable
  levels

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Areas to consider in Hazard Analysis

• Raw materials and ingredients
• Product formulation
• Processing conditions
• Packaging
• Storage and distribution
• Preparation and use
• Target groups

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Probability - Severity
Probabilitas Severity/ Keparahan/Keakutan Severity/ Keparahan/Keakutan Severity/ Keparahan/Keakutan Severity/ Keparahan/Keakutan
Probabilitas Kritikal Serius Mayor Minor
Probabilitas Signifikan Signifikan Signifikan Tidak Signifikan
Probabilitas Signifikan Signifikan Tidak Signifikan Tidak Signifikan
Probabilitas Signifikan Tidak Signifikan Tidak Signifikan Tidak Signifikan
NACMCF
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Probability - Severity

• Probabilitas
• Tinggi mungkin terjadi
• Medium dapat tejadi
• Rendah tidak mungkin terjadi
• Keparahan/Keakutan
• Kritikal akan otomatis mengakibatkan makanan
  tidak aman
• Serius kemungkinan mengakibatkan makanan tidak
  aman
• Mayor dapat mengakibatkan makanan tidak aman
• Minor kemungkinan tidak mengakibatkan makanan
  tidak aman

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Hazard Determination
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2. Determination of CCPs

• Critical control point decision tree
• Questions to be asked for each raw material used

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Questions to be asked for each process step
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3. The establishment of critical limits

• A criterion which separates acceptability from
  unacceptability
• Critical limits can be
• Values of pH, aw, temperature, time
• Absorbed radiation dose
• Levels of disinfectant or antimicrobial agents
• Level of cleanliness
• Limits of residues
• Limits of contaminants
• Limits of microbiological criteria

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• When is deviation from normality unacceptable?
• ( i.e. establishment of Critical Limits )

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4 5. Monitoring and Corrective Action

• The key document
• Holding all the essential details about the
  steps or stages
• in the process where there are CCPs
• The HACCP Control Chart

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• Control measure
• Any factor or activity which can be used to
  prevent, eliminate, or reduce food safety hazards
  to an acceptable level
• Critical limit
• The safety boundaries (criteria that separate
  safe from unsafe)
• Sources of information literature, regulation,
  experiment, etc
• Contain safety buffer zone

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• Monitoring
• Observation or measurement to ensure that the
  process is operating within the critical limit
• Based on some form of inspection and testing
• The frequency depends on the nature of the CCP
  and the type of monitoring procedure
• Clarify to all personnel involve (what to do and
  how to do it)

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• Corrective action
• The action should be taken when the result shows
  a deviation from the critical limit
• Adjust the process to bring it back under control
• Deal with the material produced under the
  deviation period
• Hold on the product
• Rework
• Release product after sampling and testing
• Direct into less sensitive products, e.g. animal
  feed
• Clarify to all personnel involve (what to do and
  how to do it)

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6. Verification

• The application of methods, procedures, tests,
  and other evaluations, in addition to monitoring,
  to determine conformity with the HACCP plan.
• This is primarily the responsibility of the
  industry, however some verification activities
  can be undertaken during regulatory assessments
• Conformity
• Activities are carried out according to the
  established procedures
• e.g. the HACCP plan and prerequisites

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7. Establishment of the record - keeping
procedures

• An HACCP program should be thoroughly documented
  and implemented establishing procedures for the
  identification, storage, retrieval maintenance,
  protection, and disposition of documents.
• The documentation generated must be formal
  written records providing factual evidence that
  an activity has been performed in a timely manner
  in accordance with established procedures.
• Information contained in corrective action
  records provides a description of the deviation
  and an evaluation of the corrective action taken,
  as well as a notation as to final disposition of
  the affected product.
• The name of the individual responsible for taking
  the corrective action should be included.

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Example of documentation about HACCP system
deviation report
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Example of documentation about corrective action
report
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References

• Arvanitoyannis, I.S. 2009. HACCP and ISO 22000
  Application to Foods of Animal Origin. Blackwell
  Publishing Ltd.
• Vasconcellos, J. A. 2004. Quality Assurance for
  the Food Industry A Practical Approach. CRC
  Press, Boca Raton.
• van Schothorst, M. 2004. A simple guide to
  understanding and applying the hazard analysis
  critical control point concept 3rd Ed. Belgium.
  ILSI Europe.