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Hazard Analysis Critical Control Points (HACCP)
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In some cases, because of the nature of the food processing methods or the hazards associated with some foods, consideration is given to applying intensified safety control procedures or systems. One such system is that based on the Hazard Analysis and Critical Control Point (HACCP). For the HACCP system to be effective, there must first be an effective GHP and GMP system in place.
HACCP includes the identification of all the known potential hazards which can be associated with the food being processed. Once this hazard assessment is done, critical control points (CCPs) in the processing are identified where controls can be exercised to prevent, reduce, or eliminate these hazards. Constant vigilance is maintained over the CCPs to prevent any process deviations that would result in loss of control at the CCP. Appropriate corrective actions are required whenever a CCP is found to be out of control, and the suspect food product is prevented from being distributed until its safety and acceptability have been determined. This system is highly effective when employed properly, but it requires considerable understanding and technical information related to the food product, the processing methods, and the production facility.
In the manufacturing and processing of foods, it is also necessary to ensure the safety of ingredients used as technical aids, additives, flavourings, or colourings. Such safety assessments require the analysis of test data, chemical specifications for substances involved and information on human dietary consumption levels and patterns. It is also necessary to evaluate the impact of uncertainties in cases where the information is insufficient to make a clear safety assessment decision. This is the work of highly trained specialists in toxicology, nutrition, chemistry, food composition and risk assessment techniques. The necessary expertise is often found only in countries with highly trained personnel and advanced technological capabilities.
HACCP is a management system in which food safety is addressed through the analysis and control of biological, chemical and physical hazards from raw material production, procurement and handling, to manufacturing, distribution and consumption of the finished product.
Conduct a hazard analysis to identify potential hazards that could occur in the food production process.
- Identify the Critical Control Points (CCPs) – those points in the process where the potential hazards could occur and can be prevented or controlled.
- Establish critical limits for preventative measures associated with each CCP. A critical limit is a criterion that must be met for each CCP. Where appropriate, critical limits may reflect relevant food safety regulations and residue tolerances (as prescribed by PPECB).
- Establish CCP monitoring requirements to ensure each CCP stays within its limits. In case a problem occurs, corrective action must be in place to ensure no public health hazard occurs.
- Establish effective recordkeeping procedures that document that the HACCP system is working properly. Records should document CCP monitoring, verification activities and deviation records.
- Establish procedures for verifying that the HACCP system is working properly. Verification procedures may include reviewing the HACCP plan, CCP record, critical limits as well as conducting microbial sampling. Both plant personnel and PPECB inspectors will conduct verification activities.
The Principles of HACCP
HACCP offers continuous and systematic approaches to assure food safety.
Principle 1 - Hazard Analysis
Hazards (biological, chemical, and physical) are conditions that may pose an unacceptable health risk to the consumer. A flow diagram of the complete process is important in conducting the hazard analysis. The significant hazards associated with each specific step of the manufacturing process are listed. Preventive measures (temperature, pH, moisture level, etc.) to control the hazards are also listed.
Principle 2 - Identify Critical Control Points
Critical Control Points (CCP) are steps at which control can be applied and a food safety hazard can be prevented, eliminated or reduced to acceptable levels.
Principle 3 - Establish Critical Limits
All CCPs must have preventive measures, which are measurable! Critical limits are the operational boundaries of the CCPs which control the food safety hazard(s). The criteria for the critical limits are determined ahead of time in consultation with competent authorities. If the critical limit criteria are not met, the process is "out of control", thus the food safety hazard(s) are not being prevented, eliminated, or reduced to acceptable levels.
Principle 4 - Monitor the CCPs
Monitoring is a planned sequence of measurements or observations to ensure the product or process is in control (critical limits are being met). It allows processors to assess trends before a loss of control occurs. Adjustments can be made while continuing the process. The monitoring interval must be adequate to ensure reliable control of the process.
Principle 5 - Establish Corrective Action
HACCP is intended to prevent product or process deviations. However, should loss of control occur, there must be definite steps in place for the disposition of the product and for correction of the process? These must be pre-planned and written.
Principle 6 - Recordkeeping
The HACCP system requires the preparation and maintenance of a written HACCP plan together with other documentation. This must include all records generated during the monitoring of each CCP and notations of corrective actions taken. Usually, the simplest record-keeping system possible to ensure effectiveness is the most desirable.
Principle 7 Verification
Has several steps. The scientific or technical validity of the hazard analysis and the adequacy of the CCPs should be documented. Verification of the effectiveness of the HACCP plan is also necessary. The system should be subject to periodic revalidation using independent audits or other verification procedures.
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