Pol. J. Food Nutr. Sci., 2012, Vol. 62, No. 4, pp.

215-227
DOI: 10.2478/v10222-012-0057-5
http://journal.pan.olsztyn.pl
Original paper
Section: Food Technology

Implementation ofHazard Analysis Critical Control Points (HACCP) inaSME: Case Study ofaBakery

Nuno Ricardo Pombo Marques1, Joo Carlos de Oliveira Matias1*, Raquel dos
Reis Baptista Teixeira2, Francisco Miguel Ribeiro Proena Brojo3

1
Technological Forecasting andIndustrial Management Research Team ofCAST Research Unit, University ofBeira Interior,
Department ofElectromechanical Engineering, Calada Fonte do Lameiro, 6201 001 Covilh, Portugal
2
Quality Manager, Padaria da Ramalha, S.A., Parque Industrial do Canhoso, Lote A21, 6200-027 Covilha, Portugal
3
University ofBeira Interior, Department ofAeronautic Sciences, 6201 001 Covilh, Portugal

Key words: Hazard Analysis Critical Control Points (HACCP); hazards; Critical Control Points (CCPs); Pre-Requirements Operational Program
(PROP); food safety; small andmedium enterprise bakery

This article provides technical details concerning the development and implementation of Hazard Analysis Critical Control Points (HACCP)
inone ofthelargest bakeries ofCova da Beira Portugal. Ageneric HACCP plan inaccordance with legal requirements was made through adetailed
audit andanalysis ofdata collected inthecompany. Itwas verified byoverview oftheHACCP system implemented inthebakery, that there was no
reduction inquality ofthefinal product during themanufacturing process andtheimplementation oftherequirements was particularly strong, having
been instrumental thetotal commitment andsense ofresponsibility ofall workers.

INTRODUCTION TO HACCP
There isnow agrowing concern inthepopulation about
food. Increasingly, what people eat isofutmost importance,
especially inaspects related to health andnutrition.
Many ofthediseases currently affecting thegeneral popu-
lation, such as cardiovascular disease, osteoporosis, diabetes
or certain cancers, are caused or associated with thefood we
eat, substantially reducing consumer confidence in relation
to food safety. Simultaneously, the consumers attention to
food safety and quality has increased. The cases of bovine
spongiform encephalopathy (BSE) transmissible to humans
(Creutzfeldt-Jakob disease), theuse ofhormones inthepro-
duction ofmeat, theuse ofantibiotics as animal growth pro-
moters, thepesticide residues inplants andanimals, thepres-
ence of nitrates in the waters, the doubts associated with
thegenetically modified organisms market, or cases ofavian
influenza inhumans, reduced consumer confidence regarding
thesafety offood [Moura et al., 2008]. On theother hand,
the major hazard in food production is the microbiological
contamination [Jeng & Fang, 2003; Walker et al., 2003; Bas
et al., 2007].
To increase consumer confidence itisessential to imple-
ment systems that require producers andcompanies to follow
criteria offood safety. Thenew challenges facing theconsum-
er, their selection criteria andtheperception offood risk [de
* Corresponding author: Tel: +351 275 329947; Fax: +351 275 329972
E-mail: matias@ubi.pt (Joo Carlos de Oliveira Matias)
Jonge et al., 2004; Yeung & Yee, 2012], are overcome using
an objective tool, the Hazard Analysis and Critical Control
Points (HACCP).
HACCP system does a systematic and structured ap-
proach to identifying hazards biological, chemical andphys-
ical andthelikelihood ofthese occurring at all stages offood
production, from raw material to thefinal product, anddefine
preventive measures to minimize occurrence ofthese dangers
by application of immediate corrective measures to ensure
thesafety offood produced, i.e., ofthefinal product. This has
been proved themost, or theone ofthemost, effective way
to ensure food safety (e.g. [Ropkins & Beck, 2002; Ropkins
et al., 2003; Arvanitoyannis & Traikou, 2005; Varzakas & Ar-
vanitoyannis, 2007; Arvanitoyannis & Varzakas, 2008, 2009;
Raspor & Jevnik, 2008; Arvanitoyannis et al., 2009; Jonna-
lagadda et al., 2009; Varzakas, 2011]. TheHACCP method-
ology is referred to by various organizations, as the system
ofanalysis andcontrol ofhealth risks associated with afood
product. Its application ismandatory from 1 January 2006,
byEC Regulation No. 852/2004 ofApril 29, laying down gen-
eral rules to beimplemented byall operators. Consequently,
these operators must implement self-regulation systems
based on theprinciples ofHACCP, apreventive system that
allows asystematic andproactive management offood safety
hazards.
Theimplementation andeffective functioning ofa HACCP
system require knowledge ofthehazards inherent to thein-
frastructures, tools andhuman resources. AHACCP system
that really works inpractice will depend on thecompetency

Copyright by Institute of Animal Reproduction and Food Research of the Polish Academy of Sciences Unauthenticated
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216
ofthepeople who both developed andoperate it, andthepre-
requisite programs, that support it[Mortimore, 2001].
To prevent, reduce or eliminate contamination of food
during storage andpreparation, every aspect should becon-
trolled using pre-requisite procedures and a HACCP plan.
The prerequisites provide the foundation for effective
HACCP implementation andshould beinoperation before
HACCP. Once this has been achieved, theHACCP plan may
be developed and implemented. As a general rule the pre-
requisites should be used to control hazards associated
with thefood service environment (premises andstructures,
services, personnel, plant and equipment), while HACCP
should be used to control hazards associated directly with
food processes (storage andpreparation) [Bolton & Maun-
sell, 2004]. Therefore, pre-requisites are an essential element
inthetask ofdeveloping simple, effective HACCP systems,
but inmany areas there isalack ofunderstanding ofthepre-
requisites concept, andeven afear insome sectors that pre-
requisites might dilute the strength of HACCP [Wallace &
Williams, 2001].
HACCP has been progressively introduced and applied
infood industry, but HACCP systems have not been homo-
geneously implemented across all food industry sectors, more
bytechnical barriers (Barriers prior to HACCP implementa-
tion are: illusion of control, company size, type of product,
companys customers food safety requirements, etc.; Barriers
during theprocess ofHACCP implementation are: Manage-
ment, Personnel, Infrastructure; and Barriers after HACCP
systems have been implemented are: Difficulties in verifica-
tion andvalidation ofHACCP) andunwillingness bymanu-
facturers [Panisello & Quantick, 2001]. Experiences highlight-
ed anumber ofbarriers, burdens andalso perceived benefits
of the successful implementation and operation of HACCP
[Taylor, 2001; Bas et al., 2007; Jeng & Fang, 2003; Eves &
Dervesi, 2005; Taylor & Kane, 2005; Damikouka et al., 2007].
Arecent study realized byMensah & Julien [2011] shows
that there is no significant effect of size of enterprise on
thedrivers, benefits andchallenges to compliance with food
safety regulation. However, importance has been given to
the specific situation of the Small and Medium Enterprises
(SMEs) (e.g. [Taylor, 2001; Bas et al., 2007; Taylor & Kane,
2005; Walker et al., 2003; Poumeyrol et al., 2010]). Thebarri-
ers are even greater, given thesize andstructure ofinstitutions,
bearing in mind that the operators require good knowledge
necessary to implement thesystem andalso good information
and training of all employees [Panisello & Quantick, 2001;
Taylor, 2001; Bas et al., 2007; Walker et al., 2003; Taylor &
Kane, 2005; Eves & Dervesi, 2005; Mensah & Julien, 2011].
Its principles can be applied in a variety of locations.
HACCP has evolved continuously over theyears, becoming
nowadays the most complete and efficient system [Costa
Neto & Figueiredo, 2001; Surak, 2009].
Theseven principles ofHACCP
Theproper identification ofCCPs (Critical Control Points)
isakey issue inHACCP, because themajor efforts inprocess
control will bedirected towards these steps [Damikouka et al.,
2007]. For the practical application of the HACCP concept
according to Codex Alimentarius [FAO, 1997], 7 rules have to
HACCP inaSME: Case Study ofaBakery
befollowed which are laid down in7 main principles andcon-
stitute thebasis for theestablishment ofaHACCP plan, all
ofthem to beconsidered inits practical application [Almeida,
1998; UNIHSNOR, 2005]:
1st Principle: Hazard analysis and identification
of preventive measures This phase identifies the physical,
biological andchemical hazards ineach process set defined
intheflowchart;
2nd Principle: Identification of the Critical Control
Points (CCP) Theidentification ofCritical Control Points
isestablished according to thedecision tree;
3rd Principle: Establishment ofcritical limits Thees-
tablishment of critical limits is essential for consistency
inthesafety analysis oftheprocesses involved;
4th Principle: Establishment and implementation
ofmonitoring procedures to control theCCP Itisimpor-
tant to assess whether the CCP is effectively under control
through proper monitoring procedures;
5th Principle: Determine corrective actions incase ofde-
viation ofcritical limits This principle intends to establish
actions to correct deviations inthemonitoring ofeach CCP;
6th Principle: Establishing systems for recording andar-
chiving data that document theHACCP This principle in-
tends to establish procedures to ensure that theHACCP plan
isbeing effective;
7th Principle: Procedure to assess whether theHACCP
system is working properly This principle aims to define
theprocedures for thekeeping ofrecords anddocumentation
relating to theplan. These procedures are monitoring, sam-
pling, analysis, audit ofHACCP, validation ofcritical limits
(confirming that theCCP iskept under control) andinspec-
tion ofmanufacturing processes.
CASE STUDY
Any company wishing to implement theHACCP system
should have as its main concern to provide its customers safe
andhealthy products. To do these, itneeds to create, estab-
lish, document and maintain a system of self-control based
on theseven HACCP principles referred to above, ensuring
food safety.
This control system identifies all hazards, whether biolog-
ical, chemical or physical, negatively affecting food andturn-
ing itunsafe for consumption. Through analysis ofthese haz-
ards preventive measures are specified that must befollowed
to avoid food contamination. This process requires thecom-
mitment of the whole team involved, since only united will
able to eliminate all risks andprevent theonset ofthese.
Through a detailed audit and analysis of data collected
inthecompany studied, aplan was elaborated to implement
the HACCP system in accordance with legal requirements.
Once implemented, this should befollowed bytheteam re-
sponsible andamended where necessary.
Company identification
Bakery based in the Canhoso Industrial Park, Covilh,
Portugal, which bakery andpastry are themain activities, as
well as commercial establishments, breakfast pastries andre-
tailing offood products.
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N.R.P.Marques et al. 217

TABLE 1. Product description andintended use.

Theproducts thecompany produces andsell are divided
into four families: bread (40%), biscuits (10%), assorted pas-
tries (30%) andsnacks (20%). Theproducts andservices are PRODUCT DESCRIPTION
directed exclusively to theinternal market. Trade name Traditional bread bola
Characterization
Definition oftheteam responsible summary
Bread Mix
Ateam was constituted to analyze andcoordinate all pro-
Organoleptic Characteristics:
cesses involved inimplementing thesystem. Only bysetting
Physical state: Solid
theteam responsible itispossible to increase thequality levels
ofall processes andproducts. Color: Light Brown
Thus, given the quality of human resources available Scent: Typical
and the characteristics of the company, the HACCP team Flavour: Typical
consists ofthefollowing elements:
Microbiological Characteristics:
Administrator Product
Bakery Administrator (responsible for the production Total microorganisms (30 C): 105 UFC/g
description
sector ofthebakery) Enterobacteriaceae spp: 10 UFC/g
Director ofQuality (team coordinator) Staphylococcus aureus: 10 UFC/g
Pastry Administrator (responsible of the production Salmonella spp: Absence in25g
sector ofthepastry)
Listeria monocytogenes: Absence in25g
Theteam meets regularly to discuss anddefine where nec-
essary thefollowing [Pinto et al., 2010]: Fungi (Molds) andYeasts: 10 UFC/g
Thecompanys quality policy with regard to food safety, Units of30 gr. and48 gr.
setting clear objectives; Wheat Flour, Water, Rye Flour, Prepared
Coordination ofefforts; Powder [Rye Flour], Gluten Flour, Salt, Malt
Analysis ofresults andset targets for improvement; Flour, Acidity Regulator: Citric Acid (E170),
Ingredients
Wheat Flour, Emulsifier (E472e), Agent
Analyze and investigate possible deviations from nor- Flour Treatment: L-Ascorbic Acid (E300)
mality, seeking to identify causes and take corrective andEnzymes], Yeast, Salt andImprover
measures;
Revise theself-control plan as needed. Conservation inacool dryplace
The administrator, as the highest authority, ensures Terms ofUse Shelf life: Product oftheday
thesmooth running ofthecompany andmakes them comply Ready to spend
with all legal requirements for its proper functioning. Itisalso
Product not packed:
his responsibility to monitor all phases oftheplan andthere-
Transport ofgoods inpassenger car with closed
sponsibilities and coordination of all running operations, Conditions
box, adapted for this purpose andprovided
ofCarriage /
both internal andexternal ofthecompany. with ventilation byindirect process.
Packaging
The team coordinator is responsible for implement- Packaging inwhite trays with
background closed andbarred sides
ing, maintaining and monitoring the plan. The organiza-
tion of team work is essential. The quality of raw materials PRODUCT USE
and products is his responsibility. To keep plans previously
established to theorganization ofwork, cleanliness andhy- Theproduct mentioned isfor thegeneral population,
except for sensitive groups (Coeliacs)
giene of premises and equipment involved is also within its
competences. Place ofSale Bakery, pastry andhome delivery
The head of production (Pastry and Administrator as- Regulation (EC) No 852/2004
signed to the bakery sector) is responsible for coordinating Applicable Law of29 April andRegulation (EC)
thelaboring products, as thename implies. Itisessential to No 1441/2007 of5 December
proper planning oftheproduction process to ensure that every-
thing isnormal. Thecoordination andinstruction ofproduc- Description ofproductive process
tion workers isunder his control. Where necessary he should A flowchart was produced from the analysis of the pro-
start andproceed to amends oftheself-control program. duction process (Figure 1).

Product description andintended use HAZARDS ANALYSIS ANDIDENTIFICATION

The HACCP plan is directed solely at bakery products.
As there isawide variety ofproducts inthis area, ageneric
framework was developed for the description of only one
product (Table 1).
Although theplan isdirected to aproduct, itisimportant
to note that the HACCP plan to be implemented, applies
equally to all other bakery products, with thesame manufac-
turing process.
OFCCPS ANDPROP (PRE-REQUIREMENTS
OPERATIONAL PROGRAM)
Thehazard analysis provides theidentification ofpoten-
tial hazards associated with all phases of the process from
receipt ofraw materials to final consumer.
Therisk assessment isdone based on thehazard analy-
sis, according to the probability of occurrence and severity

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218 HACCP inaSME: Case Study ofaBakery

TABLE 2. Analysis Matrix. Severity vs Probability (Adapted from: [Ba-

tista et al., 2003]; [Ribeiro, 2002]).

A(4) RS RMe RMa RC

PROBABILITY
M (3) RS RMe RMa RMa

B (2) RS RMe RMe RMe

D (1) RS RS RS RS

D (1) B (2) M (3) A(4)

SEVERITY
RS Satisfatory Risk; RMe Lower Risk; RMa Increased Risk; RC
Critical Risk.

Index (RI) ofeach step ofthemanufacturing process isde-

fined taking into account thefollowing [Ribeiro, 2002]:

IR = Probability x Severity

Based on thecalculations ofthematrix (Table 2), itappears that

FIGURE 1. Flowchart of the production process.
ofidentified hazards. Itisalso evaluated thepreventive mea-
sure established for its control. Inrisk assessment, thefollow-
ing data are considered [Batista et al., 2003]:
Review ofcustomer complaints;
Return oflots or shipments;
Results oflaboratory tests;
Data from monitoring programs of agents of food-
borne illness.
Thus thehazards can bedivided into four groups accord-
ing to their severity to human health [Batista et al., 2003; Ri-
beiro, 2002]:
A High (4): Severe consequences for consumer health;
M Medium (3): Serious consequences for consumer
health;
B Low (2): Zero or very small effects for consumer
health;
D Neglectable (1): Without consequences for consum-
er health.
Concerning its probability ofoccurrence, therisk isdivid-
ed as follows [Batista et al., 2003; Ribeiro, 2002]:
A High (4);
M Medium (3);
B Low (2);
D Neglectable (1).
The combination of the severity with the probability re-
sults inthefollowing table (Table 2). Inthis, there are com-
binations that reproduce risks with the greatest impact on
consumer health.
The analysis matrix allows us to estimate a level of risk
across thetwo levels (Probability vs. Severity). Thus, theRisk
for this study, theIR varies between 1 (Satisfactory Risk) and16
(Critical Risk). Thecalculated Risk Index can beseen inTable 3.
According to Tables 2 and3, where theRI ishigher than 8,
aCCP isidentified andmanaged bytheHACCP plan, defin-
ing thecritical limits, parameters to bemonitored andcorrec-
tive actions to implement on each step. If there was no CCP
(IR 8), the results should be handled by PROP, acting on
thebasis ofgood manufacturing practices andwhich aim to
implement corrective actions for improvement of each step.
TheRI contributes to theanalysis andidentification ofCCPs
andPROP (Table 4).
ANALYSIS OFRESULTS
Itwas not identified aCCP for theproduction ofthetra-
ditional bread bola. None ofthesteps undermine food se-
curity andpose greater risk to public health.
The absence of a CCP does not require the creation
ofaHACCP plan. Thus, throughout themanufacturing pro-
cesses that pose alower risk (IR 8) to thehealth ofthecon-
sumer, the system is managed by the PROP, who selects
andevaluates thecontrol measures inaspecific stage, con-
tributing to its improvement.
TABLE 3. Likelihood ofdanger.
IR RISK INDEX (RI) CONCLUSION
IR 4 Satisfactory Risk
Risk managed byPROP
4 IR 8 Lower Risk
8 IR 12 Increased Risk Risk managed
12 IR 16 Critical Risk byHACCP plan
Pre-Requisites Operational Program (PROP) Selection andevalu-
ation ofcontrol measures, previously obtained from theanalysis ofhaz-
ards anddetermination ofcritical control points. InPROP andoppos-
ing to what happens inaCCP, failures intheproduction process does
not directly affect theproduct, andistherefore an essential difference
between them [Cruz et al., 2006].
HACCP Plan Document prepared inaccordance with theprinciples
oftheHACCP system.

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 TABLE 4. Hazards analysis andidentification ofCCPs andPROP.

ACCEPTANCE RISK
LEVEL ON RISK EVALU- PROBABLE DECISION TREE
STAGE RISK ATION CONTROL MEASURES REMARKS

CCP
PRP
THEFINISHED EFFECT CAUSES
PROP

PRODUCT P S IR Q1 Q2 Q3 Q4
N.R.P.Marques et al.

Check cleanliness oftransport

Damaged vehicles andpersonnel. Control Given thecontrol carried
Biological: packaging. ofintegrity ofthepackaging, out at thereception for
As product With con-
Microbial 1 4 4 Incorrect labeling andshelf life. HACCP Yes No No --- transport vehicles andpack- --- x ---
datasheet sequences
contamination hygiene certificate from thesupplier. Main- age integrity, this step
practices tain facilities andequipment for isnot considered aCCP
1. Recep-
theoperation properly sanitized.
tion ofraw
materials Physical: Given thecontrol carried
(Room Temp.) Contamina- Without out at thereception for
Damaged HACCP certificate from thesup-
tion byforeign Absence conse- 1 1 1 Yes No No --- transport vehicles andpack- --- x ---
packaging plier. Control ofpackage integrity.
objects (hair, quences age integrity, this step
insects) isnot considered aCCP
Chemical:
--- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Unidentifyed
Control theproduct temperature.
Check transport vehicles hygiene
Inadequate andpersonal hygiene. Control-
Biological: Given thecontrol carried
transport ling theintegrity ofthepackaging,
Microbial out at thereception for
As product With con- temperature. labeling andshelf life. HACCP
contamination 1 1 4 Yes No No --- transport vehicles andpack- --- x ---
1. Reception datasheet sequences Incorrect certificate from thesupplier. Keep
andmulti- age integrity, this step
ofraw materi- hygiene facilities, equipment anduten-
plication isnot considered aCCP
als (refriger- practices sils for theoperation properly
ated between sanitized. Perform task inafast,
0 and10C) hygienic andseamless way.
Physical:
--- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Unidentifyed
Chemical:
--- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Unidentifyed
Given thecontrol carried
Check cleanliness oftrans-
Biological: Incorrect out at thereception for
With con- port vehicles andpersonnel.
Microbian Absence 1 4 4 hygiene Yes No No --- transport vehicles andpack- --- x ---
sequences Control ofintegrity ofpack-
contamination practices age integrity, this step
aging during transport.
isnot considered aCCP
1a Reception
ofpackag- Physical:
--- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
ing/storing Unidentifyed
material
Given thecontrol carried
Chemical:
Inadequate out at thereception for
Presence With con- Confirm suitability ofmaterial for

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Unauthenticated
Absence 1 2 2 packaging Yes No No --- transport vehicles andpack- --- x ---
ofundesirable sequences food use (presence offood symbol)
material age integrity, this step
substances
isnot considered aCCP
219
 Biological:
Pest control plan. Keep containers
220
Microbial
closed andsecured inproper place. Given theexistence
contamination Traces
Compliance with good personal ofaCompany Pest
(Salmonella, ofpests.
With con- hygiene practices. Control Plan andtheful-
Staphylococ- Absence 1 4 4 Incorrect Yes No No --- --- x ---
sequences Keep facilities, equipment fillment ofgood hygiene
cus aureus hygiene
andutensils for theoperation practices, this step isnot
andEscherich- practices
properly sanitized. Perform FIFO considered aCCP
ia coli; Pests
2. Storage (first in, first out) stock rotation.
Leptospira)
ofraw materi-
als (Room Physical:
Temp.) Contamina- Keep containers securely closed Given thecontrol car-
tion byforeign Without Incorrect andplaced inproper location. ried out during storage
objects (hair, Absence conse- 2 1 2 hygiene Controlling theintegrity ofpack- Yes No No --- andcompliance with good --- x ---
decorations, quences practices aging. Compliance with good hygiene practices, this step
pieces ofpack- personal hygiene practices. isnot considered aCCP
aging, insects)
Chemical:
--- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Unidentifyed
Control storage temperature.
Keep containers securely closed
Verifying compliance
Biological: Inadequate andplaced inproper location.
As product With con- with good manufacturing
Microbial 1 4 4 storage Keep facilities, equipment Yes No No --- x ---
2. Storage datasheet sequences andhygiene practices, this
contamination temperature andutensils for theoperation
ofraw materi- step isnot considered aCCP
properly sanitized. Perform FIFO
als (refriger-
(first in, first out) stock rotation.
ated between
0 and10 C) Physical:
--- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Unidentifyed
Chemical:
--- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Unidentifyed
Keep containers properly closed Given theexistence
Biological: Traces
andsecured inproper place, ofaCompany Pest
Microbial ofpests.
With con- protected from contamination. Control Plan andtheful-
contamina- Absence 1 4 4 Incorrect Yes No No --- --- x ---
sequences Maintain facilities andequipment fillment ofgood hygiene
2a Storage tion (Pests hygiene
for theoperation properly practices, this step isnot
ofpackag- Leptospira) practices
sanitized. Pest Control Plan. considered aCCP
ing/storage
material Physical:
--- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Unidentifyed
Chemical:
--- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Unidentifyed
Biological:
Microbial Perform thetask quickly, hygieni-
contamination cally andwithout interruptions.
3. Weighing Incorrect Verifying compliance with
(Salmonella, As product With con- Compliance with good personal
andmixing 1 4 4 hygiene Yes No No --- good hygiene practices, this --- x ---
Staphylococ- datasheet sequences hygiene practices. Keep facili-

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Unauthenticated
ingredients practices step isnot considered aCCP
cus aureus ties, equipment andutensils for
andEsche- theoperation properly sanitized
richia coli)
HACCP inaSME: Case Study ofaBakery
 Physical:
Contamina-
tion byforeign
Without Incorrect Greetings from good per- Verifying compliance with
objects (hair,
Absence conse- 1 1 1 hygiene sonal hygiene practices. Vi- Yes No No --- good hygiene practices, this --- x ---
decora-
quences practices sual inspection ofsalt step isnot considered aCCP
tions, pieces
N.R.P.Marques et al.

ofpackaging,
stones salt)
Chemical: Without Incorrect Keep thesites, equipment Verifying compliance with
Detergent Absence conse- 1 1 1 hygiene andfixtures for theopera- Yes No No --- good hygiene practices, this --- x ---
residue quences practices tion properly sanitized step isnot considered aCCP
Biological:
Microbial Perform thetask quickly, hygieni-
contamination cally andwithout interruptions.
Incorrect Verifying compliance with
(Salmonella, As product With con- Compliance with good personal
1 4 4 hygiene Yes No No --- good hygiene practices, this --- x ---
Staphylococ- datasheet sequences hygiene practices. Keep facili-
practices step isnot considered aCCP
cus aureus ties, equipment andutensils for
andEsche- theoperation properly sanitized
richia coli)
Physical:
Contamina-
tion byforeign
Without Incorrect Compliance with good per- Verifying compliance with
objects (hair,
Absence conse- 1 1 1 hygiene sonal hygiene practices. Vi- Yes No No --- good hygiene practices, this --- x ---
4. Kneading decora-
quences practices sual inspection ofsalt step isnot considered aCCP
tions, pieces
ofpackaging,
stones salt)
Theexistence ofpieces
- Incorrect
ofmetal can befatal to
Physical: hygiene
With con- - Check theintegrity ofthemixer thehealth ofconsum-
pieces ofmetal Absence 1 4 4 practices Yes No Yes No --- --- X
sequences spiral after each mixing cycle ers. Nevertheless, since
contamination Mixer spi-
for this step RT 8,
ral damaged
then itisnot aCCP
Chemical: Without Incorrect Keep thesites, equipment Verifying compliance with
Detergent Absence conse- 1 1 1 hygiene andfixtures for theopera- Yes No No --- good hygiene practices, this --- x ---
residues quences practices tion properly sanitized step isnot considered aCCP
Biological:
Microbial Keep product well packed
contamination inproper places, protected from
Incorrect Verifying compliance with
(Salmonella, As product With con- contamination. Compliance with
5. Rest 1 4 4 hygiene Yes No No --- good hygiene practices, this --- x ---
Staphylococ- datasheet sequences good personal hygiene practices.
practices step isnot considered aCCP
cus aureus Maintain facilities andequipment
andEsche- for theoperation properly sanitized
richia coli)

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Unauthenticated
221
 Physical:
Compliance with good personal
222
Contamina- Without Incorrect Verifying compliance with
As product hygiene practices. Keep prod-
tion byforeign conse- 1 1 1 hygiene Yes No No --- good hygiene practices, this --- x ---
datasheet uct well packed inproper place,
objects (hair quences practices step isnot considered aCCP
protected from contamination.
insects)
Chemical:
--- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Unidentifyed
Biological:
Microbial Perform thetask quickly, hygieni-
contamination cally andwithout interruptions.
Incorrect Verifying compliance with
(Salmonella, As product With con- Compliance with good personal
1 4 4 hygiene Yes No No --- good hygiene practices, this --- x ---
Staphylococ- datasheet sequences hygiene practices. Keep facili-
practices step isnot considered aCCP
cus aureus ties, equipment andutensils for
andEsche- theoperation properly sanitized
6. Division richia coli)
andMolding
Physical:
Contamina- Without Incorrect Verifying compliance with
Compliance with good per-
tion byforeign Absence conse- 1 1 1 hygiene Yes No No --- good hygiene practices, this --- x ---
sonal hygiene practices
objects (hair, quences practices step isnot considered aCCP
decorations)
Chemical:
--- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Unidentifyed
Biological:
Microbial Incorrect
contamination hygiene
Temperature control oftherefrig- Verifying compliance with
(Salmonella, As product With con- practices
1 4 4 erated space. Compliance with Yes No No --- good hygiene practices, this --- x ---
Staphylococ- datasheet sequences Inadequate
good personal hygiene practices step isnot considered aCCP
cus aureus refrigeration
andEsche- temperatures
6a. Retarda-
richia coli)
tion offer-
mentation Physical:
Contamina- Without Incorrect Verifying compliance with
Compliance with good per-
tion byforeign Absence conse- 1 1 1 hygiene Yes No No --- good hygiene practices, this --- x ---
sonal hygiene practices
objects (hair, quences practices step isnot considered aCCP
decorations)
Chemical:
--- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Unidentifyed
Biological:
Microbial Thesubsequent stage
contamination Compliance with good per- ofcooking eliminates any
Incorrect
7. Fermenta- (Salmonella, As product With con- sonal hygiene practices. Keep microbial load that can
1 4 4 hygiene Yes No Yes Yes --- x ---
tion (Stove) Staphylococ- datasheet sequences facilities, equipment andutensils bedeveloped intheprod-
practices
cus aureus for theoperation properly sanitized uct, so this step isnot
andEsche- considered aCCP

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Unauthenticated
richia coli)
HACCP inaSME: Case Study ofaBakery
 Physical:
--- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Unidentifyed
Chemical:
--- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Unidentifyed
Biological: Incorrect
N.R.P.Marques et al.

Microbial hygiene Compliance with good personal hy-

This step iscritical because
contamination practices. giene practices. Meet binomial time
at this stage isthat themi-
(Salmonella, As product With con- Insufficient / temperature set (1012 minutes
1 4 4 Yes No Yes No croorganisms intheproduct --- --- x
Staphylococ- datasheet sequences cooking at 200220C) for theprocess so
will bedeleted. If RI 8
cus aureus time and/ that at theinterior isreached at
this step isnot aCCP
8.Baking andEsche- or cooking least atemperature of70 C
richia coli) temperature
Physical:
--- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Unidentifyed
Chemical:
--- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Unidentifyed
Biological:
Compliance with good per-
Microbial Incorrect Verifying compliance with
As product With con- sonal hygiene practices. Keep
contamination 1 4 4 hygiene Yes No No --- good hygiene practices, this --- x ---
datasheet sequences facilities, equipment andutensils
(Staphylococ- practices. step isnot considered aCCP
for theoperation properly sanitized
cus aureus)
9. Cooling
Physical:
--- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Unidentifyed
Chemical:
--- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Unidentifyed
Biological:
Microbial Compliance with good personal
contamination hygiene practices. Perform thetask
Incorrect Verifying compliance with
(Salmonella, As product With con- quickly, hygienically andwithout
1 4 4 hygiene Yes No No --- good hygiene practices, this --- x ---
Staphylococ- datasheet sequences interruptions. Keep facilities,
practices. step isnot considered aCCP
cus aureus equipment andfixtures for theop-
andEsche- eration properly sanitized.
richia coli)
Physical:
10. Packag- Compliance with good per-
Contamina- Without Incorrect Verifying compliance with
ing / Storing sonal hygiene practices. Perform
tion byforeign Absence conse- 1 1 1 hygiene Yes No No --- good hygiene practices, this --- x ---
thetask quickly, hygienically
objects (hair, quences practices. step isnot considered aCCP
andwithout interruptions.
decoration)
Chemical: Incorrect Verifying compliance
Keep facilities, equipment andfix-
Detergent resi- hygiene with good hygiene prac-
Without tures for theoperation prop-
due, migration practices. tices andtheadequacy
Absence conse- 1 2 2 erly sanitized. Confirm suitability Yes No No --- --- x ---
ofundesirable Inadequate ofthepackaging mate-
quences ofthepackaging material for food
substances packaging rial to food use, this step
use (presence offood symbol).

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Unauthenticated
into thefood material isnot considered aCCP
223
 Biological:
224
Microbial Compliance with good personal
contamination hygiene practices. Keep product
Incorrect Verifying compliance with
(Salmonella, As product With con- well packed inproper place, pro-
1 4 4 hygiene Yes No No --- good hygiene practices, this --- x ---
Staphylococ- datasheet sequences tected from contamination. Keep
practices. step isnot considered aCCP
cus aureus facilities, equipment andfixtures
andEsche- for theoperation properly sanitized
richia coli)
Physical:
11. Exposi- Compliance with good personal
Contamina- Without Incorrect Verifying compliance with
tion / Sell hygiene practices. Keep prod-
tion byforeign Absence conse- 1 1 1 hygiene Yes No No --- good hygiene practices, this --- x ---
uct well packed inown place,
objects (hair, quences practices. step isnot considered aCCP
protected from contamination.
decoration)
Verifying compliance
with good hygiene prac-
Chemical: Without Incorrect
Keep local andutensils for tices andtheadequacy
Detergent Absence conse- 1 2 2 hygiene Yes No No --- --- x ---
theoperation properly sanitized ofthepackaging mate-
residues. quences practices.
rial to food use, this step
isnot considered aCCP
Biological:
Compliance with good personal
Microbial Incorrect Verifying compliance with
As sampling plan With con- hygiene practices. Keep facili-
contamination 1 4 4 hygiene Yes No No --- good hygiene practices, this --- x ---
for analysis sequences ties, equipment andfixtures for
(Staphylococ- practices. step isnot considered aCCP
theoperation properly sanitized
cus aureus)
Physical:
12. Expedition Compliance with good personal
Contamina- Without Incorrect Verifying compliance with
hygiene practices. Keep prod-
tion byforeign Absence conse- 1 1 1 hygiene Yes No No --- good hygiene practices, this --- x ---
uct well packed inown place,
objects (hair, quences practices. step isnot considered aCCP
protected from contamination.
decoration)
Chemical:
--- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Unidentifyed
Biological:
Microbial
contamination Compliance with good personal hy-
Incorrect Verifying compliance with
(Salmonella, As product With con- giene practices. Protect theproduct
1 4 4 hygiene Yes No No --- good hygiene practices, this --- x ---
Staphylococ- datasheet sequences from direct contact with customers
practices. step isnot considered aCCP
cus aureus andenvironmental contamination.
andEsche-
13. Distri- richia coli)
bution
Physical:
Compliance with good personal hy-
Contamina- Without Incorrect Verifying compliance with
giene practices. Protect theproduct
tion byforeign Absence conse- 1 1 1 hygiene Yes No No --- good hygiene practices, this --- x ---
from direct contact with customers
objects (hair, quences practices. step isnot considered aCCP
andenvironmental contamination.
decoration)

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Unauthenticated
Chemical:
--- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Unidentifyed
HACCP inaSME: Case Study ofaBakery
 N.R.P.Marques et al. 225

Inthis study, thestep ofcooking isthelargest contributor

MOD.30 Not con-

formal product zone

conformal product

Corrective action.
MOD.18 Cor-

Record internal
MOD.32 Not
integrity record
to the proliferation of microorganisms and therefore a spe-

oftheproduct.
Kneader spiral
rective action
REGISTRY

temperature
MOD.34
cific PROP isdirected to this step. Although there isno critical
limit for thestage, thenonfulfillment ofthemanufacture plan
(time, 10 to 12 min andtemperature, 200 to 220C for baking
thebola), will lead to aproduct unfit for consumption. As
such, there isaneed to create aPROP for thestage (Table 5),

Director ofQuality.
RESPONSIBILI-

Employee making

employee respon-
Oven operator or
TIES ANDAU-

Actions Direc-

Administration.
andCorrective which followed, contributed to its improvement andquality.

sible for firing.

THORITIES

tor ofQuality
Monitoring

thekneading
Correction

Likewise, thestep kneading has aphysical risk (pieces ofmet-

al contamination) with consequences andthere isalso need to
create aPROP for thestage (Table 5).

FINAL CONSIDERATIONS AND RECOMMEN-

CORRECTIVE

ofthekneader

nomial time /
Replacement

DATIONS
temperature.
Reset thebi-
ACTIONS

spiral
ACTIONS TO IMPLEMENT

TheHACCP system iscomplex andconstantly evolving.

To beimplemented, all steps must beverified andimplement-
ed so that everything goes as planned.
inside theproduct isachieved
Extend or shorten thecook-

Itisessential that theflowchart iswell planned, analyzed on

atemperature above 70C.
sired end product andthat
not located, theentire batch

ing time to achieve thede-

place, properly identified as

tion, must berejected, put

inplace, duly identified as
nonconforming product.
(If thepieces ofmetal are

anot compliant product)

- Location andremoval

ofproduct should bedis-

carded, placed inproper

If theproduct isnot fit

for human consump-

theground andthat itcontains as much information as possible.

CORRECTIONS

ofscrap metal;

Only awell planned flowchart facilitates thecontrol oftheentire

process, making iteasier to detect possible deviations.
On theother hand, itisessential to establish verification
procedures. Theplan should beaudited periodically, or when-
ever there are changes to it, not only interms ofmanufactur-
ing processes, but also whenever there isanew product. This
entire process must bedocumented andfiled inaproper place
thekneading

Responsible

for this purpose. Finally, each quarter, thewhole plan should

employee /
Employee

ofquality.
director
WHO?

making

bereviewed, discussed andvalidated bytheteam andrespon-

sible administration. Whenever aplan isvalidated, theformer
isobsolete, being inforce always thelatest.
When theobjective isto produce safe foods that do not
Visual ob- Every knead-
MONITORIZATION

WHEN?

ing cycle

constitute any risk to public health, theuse ofpreventive tools

Weekly

isthebest way ofachieving this.

TheHACCP system isconstantly evolving andisnow rec-
ognized as one ofthemost effective control offood produc-
tion Ther-
oftheproduct. mometer.
servation

Penetra-
HOW?

ovens /

tion. Theimplementation ofthis system inthefood industry

Clock

today is a legal obligation, stamping all workers and staff

responsibilities. However, this does not depend on itself to
beeffective, depends crucially on theimplementation ofaset
Binomial time

ture. Internal
temperature
Mixer spiral

/ tempera-
WHAT?

of prerequisites, where the application of good hygiene

andsafety isessential.
From the overview of the HACCP system implemented
in the bakery, there was no reduction in quality of the final
Thegoal isto reach
Meet binomial time
-- Check theinteg-

product during themanufacturing process, with particularly

inside theproduct
hygiene practices.

temperature at or
Compliance with

/ temperature set
spiral after each

for theprocess .
rity ofthemixer

good personal
MEASURES

above 70 C.
CONTROL

mixing cycle

strong implementation ofprerequisites andtotal commitment

andsense ofresponsibility ofall employees. Rather, there was
aguarantee ofproduct quality, as shown byseveral studies,
TABLE 5. Pre-Requisites Operating Plan.

demonstrating that theHACCP system has apositive effect

of the quality of end products (e.g. [Trafiaek & Kooyn-
4. Kneading Contamination
bymetal pieces

-Krajewska, 2007, 2011; Sikora & Nowicki, 2007]).

multiplication
(Salmonella,
Staphylococ-
Biological:

andEsche-
richia coli)
cus aureus
Microbial
Physical:

Because it is a complex system it is recommended how-

RISK

ever, that thecompany regularly runs training inthis area with

theaim ofinstilling habits andmake workers more receptive
to thechange ofworking methods. Only through education
andawareness ofall elements ofthefood chain itispossible
8. Baking
STAGE

to achieve thebest performance andbest results.

Itisup to theHACCP team to make theentire manage-
ment of the system. They must adopt a firm stance, persis-

Unauthenticated
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226
tent anddetermined incarrying out their duties, inorder to
achieve all objectives.
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Unauthenticated
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