FSQA Snippets: HACCP Basics
The USDA's HACCP (Hazard Analysis Critical Control Point) system is designed to ensure food safety by identifying and controlling potential food safety hazards.
Initial/Preliminary steps:
Food Safety Team – establishment of this group as the core team that creates and signs off on the HACCP plan, which is comprised of leaders of the facility such as Operations, Quality and Maintenance departments, at a minimum, and should be HACCP certified.
Pre-requisite Programs - development of these will support the overall food safety plan (e.g., GMP, SSOP, Raw Material Receiving and Storage, Rework Control, Preventative Maintenance, Chemical Control, Allergen Control, Pest Control, Traceability/Recall, Microbiological control (such as Listeria monocytogenes (Lm) Control), Foreign/Metal Detection programs, etc.).
Intended Use/Customers - describes the food type(s) produced, methods of production and distribution, which includes the intended use and consumers of the food products produced.
Flow Charts – these show the flow of the product, from receipt of ingredients/raw materials, raw material storage, introduction of raw materials into the process, each production processing step, final product packing and storage of the product, to ensure every step is covered.
Category/Group - determines and lists the main groups and categories that the food products can be placed under.
7 steps involved in the HACCP process:
Hazard Analysis: Conduct and document a thorough analysis of all potential hazards associated with food production, to include incoming components/storage and final packaging/storage of the finished product. Each step will list if Biological (such as pathogenic bacteria), Chemical or Physical (such as foreign material) hazards exist.
Critical Control Point (CCP) Identification: Identify the specific steps in the process where control can be applied to prevent, eliminate, or reduce hazards to acceptable levels.
Establish Critical Limits for the CCPs identified: Set maximum or minimal values for the biological, chemical, or physical hazard identified to ensure safety of the food product.
Monitoring Procedures: Establishment and implementation of procedures to monitor CCPs and ensure that critical limits are met. In other words, the “What, How, Frequency and Who” is established to ensure that a CCP is kept within the critical limits established.
Corrective Actions: The actions taken to eliminate (or reduce hazards to acceptable levels) if the CCP critical limits are exceeded. If the CCP is exceeded, what immediate steps are taken to bring the product/process back into compliance and contain any product that exceeds the critical limit.
Verification Procedures: This is the verification of the HACCP system to ensure it is functioning correctly and that the hazards are being controlled. Identify the “What, How, Frequency and Who” for verifying that the monitoring process, and any associated corrective actions, occurs according to the written plan. This is typically performed by a group such as the QA Department.
Record Keeping Procedures: Maintaining accurate records and documentation of the HACCP system is crucial to prove that products are being produced safely. This documentation will be verified by government officials, auditors and customers to ensure that the food products produced are safe for consumption.
Development of a certified Food Safety Team, creating the Prerequisite procedures and HACCP plan and establishing a solid verification and record keeping process can protect a food company from unseen pitfalls that can ruin its brand and reputation. All team members in the facility should trained during orientation, and at least annually ongoing, to ensure that they know and understand how what they do plays an important part in the production of safe, wholesome food products.
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