Sam Higginbottom Institute of Agriculture, Technology & Sciences

(Deemed-to-be-university)
Allahabad

Seminar on- HACCP (Hazard Analysis Critical Control Point)

Submitted to: - Presented by:-

Er. Laxmi Bala Mukesh Kumar

(Assistant professor) M.Tech Food Tech (Food Engg.)

I.D- 09MTFTFE004

Semester-2nd

Contents
 Introduction

 The history of the HACCP system:

 Hazards

o What Are The Hazards?

o Forms of Hazards
 HACCP principles
 HACCP Certification

 HACCP decision tree flowchart

 HACCP application

 Advantages of HACCP system application

 Implementation and maintenance of the HACCP plan

 References
Introduction:
Hazard Analysis and Critical Control Points (HACCP) is a systematic
preventative approach to food safety that addresses physical, chemical and
biological hazards as a means of prevention rather than finished product
inspection.

Today HACCP is being applied to industries other than food, such as

cosmetics and pharmaceuticals. This method, which in effect seeks to plan out
unsafe practices, differs from traditional “produce and test” quality assurance
methods which are less successful and inappropriate for highly perishable foods.

HACCP is used in the food industry to identify potential food safety

hazards, so that key actions, known as Critical Control Points (CCPs) can be taken
to reduce or eliminate the risk of the hazards being realized. The system is used at
all stages of food production and preparation processes including packaging,
distribution, etc. The Food and Drug Administration (FDA) and the United States
Department of Agriculture (USDA) say that their mandatory HACCP programs for
juice and meat are an effective approach to food safety and protecting public
health. Meat HACCP systems are regulated by the USDA, while seafood and juice
are regulated by the FDA. The use of HACCP is currently voluntary in other food
industries.

A forerunner to HACCP was developed in the form of production process

monitoring during World War II because traditional "end of the pipe" testing
wasn't an efficient way to ferret out artillery shells that would not explode. HACCP
itself was conceived in the 1960s when the US National Aeronautics and Space
Administration (NASA) asked Pillsbury to design and manufacture the first foods
for space flights. Since then, HACCP has been recognized internationally as a
logical tool for adapting traditional inspection methods to a modern, science-based,
food safety system. Based on risk-assessment, HACCP plans allow both industry
and government to allocate their resources efficiently in establishing and auditing
safe food production practices. In 1994, the organization of International HACCP
Alliance was established initially for the US meat and poultry industries to assist
them with implementing HACCP and now its membership has been spread over
other professional/industrial areas.
 Hence, HACCP has been increasingly applied to industries other than food,
such as cosmetics and pharmaceuticals. This method, which in effect seeks to plan
out unsafe practices, differs from traditional "produce and test" quality control
methods which are less successful and inappropriate for highly perishable foods. In
the US, HACCP compliance is regulated by 21 CFR part 120 and 123. Similarly,
FAO/WHO published a guideline for all governments to handle the issue in small
and less developed food businesses.

The history of the HACCP system:

The Hazard Analysis and Critical Control Points system was developed in the 70s,
in complete secrecy of the "Pillsbury Company" working for NASA. It was vital to
guarantee safe food for the American astronauts. At that time, most food product
safety and quality control systems were based on the control of the end product.
With application of such approach, 100% product safety guarantee could only be
obtained by the 100% control of that product. It was apparent that a preventative
system was needed, which could provide absolute certainty in safety of food
products.

For this reason, HACCP system was established. In 1971, it was first
introduced at the closed National conference on protection of food products.
Informational material of this conference became available to the wide public only
in 1992.Approximately from this moment, the worldwide spread of the HACCP
system started. America, Australia, and Europe were adopting the principles of the
HACCP system.

The impetus behind modern HACCP programs first began as a natural

extension of Good Manufacturing Practices (GMPs) that food companies had been
using as a part of their normal operations. A system was needed that enabled the
production of safe, nutritional products for use by NASA starting in the late 1950’s
to feed future astronauts who would be separated from medical care for extended
periods of time. Without medical intervention, an astronaut sickened by food borne
illness would prove a very large liability and could possibly result in the failure of
entire missions. Food products could not be recalled or replaced while in space.

Beginning in 1959, the Pillsbury Company embarked on work with NASA

to further develop a process stemming from ideas employed in engineering systems
development knows as Failure Mode & Effect Analysis (FMEA). Through the
thorough analysis of production processes and identification of microbial hazards
that were known to occur in the production establishment, Pillsbury and NASA
identified the critical points in the process at which these hazards were likely
introduced into product and therefore should be controlled.

The establishment of critical limits of specific mechanical or test parameters

for control at those points, the validation of these prescribed steps by scientifically
verifiable results, and the development of record keeping by which the processing
establishment and the regulatory authority could monitor how well process control
was working all culminated in what today is known as HACCP. In this way, an
expensive or time consuming testing procedure is not required to guarantee the
safety of each piece of food leaving an assembly line, but rather the entire process
has been seamlessly integrated as a series of validated steps.

In 1971 the HACCP approach was presented at the first American National
Conference for Food Protection. 1973 saw the US FDA apply HACCP to Low
Acid Canned Foods Regulations, although if you read those regulations carefully,
you will note that they never actually mention HACCP. From 1988 to the present
day, HACCP principles have been promoted and incorporated into food safety
legislation in many countries around the world.

Beginning in 1996, the United States Department of Agriculture (USDA)

established a detailed Pathogen Reduction / Hazard Analysis of Critical Control
Point (PR/HACCP) program under the Food Safety and Inspection Service (FSIS)
to regulate the production of raw meat products by large scale facilities. There is
currently no HACCP requirement in the US for food processors such as
supermarket deli or butcher departments that purchase from certified producers.

Beginning in 1959, the Pillsbury Company embarked on work with NASA

to further develop a process stemming from ideas employed in engineering systems
development knows as Failure Mode & Effect Analysis (FMEA). Through the
thorough analysis of production processes and identification of microbial hazards
that were known to occur in the production establishment, Pillsbury and NASA
identified the critical points in the process at which these hazards were likely
introduced into product and therefore should be controlled.

The establishment of critical limits of specific mechanical or test parameters for

control at those points, the validation of these prescribed steps by scientifically
verifiable results, and the development of record keeping by which the processing
establishment and the regulatory authority could monitor how well process control
was working all culminated in what today is known as HACCP. In this way, an
expensive or time consuming testing procedure is not required to guarantee the
safety of each piece of food leaving an assembly line, but rather the entire process
has been seamlessly integrated as a series of validated steps.

In 1971 the HACCP approach was presented at the first American National
Conference for Food Protection. 1973 saw the US FDA apply HACCP to Low
Acid Canned Foods Regulations, although if you read those regulations carefully,
you will note that they never actually mention HACCP. From 1988 to the present
day, HACCP principles have been promoted and incorporated into food safety
legislation in many countries around the world.

Beginning in 1996, the United States Department of Agriculture (USDA)

established a detailed Pathogen Reduction / Hazard Analysis of Critical Control
Point (PR/HACCP) program under the Food Safety and Inspection Service (FSIS)
to regulate the production of raw meat products by large scale facilities. There is
currently no HACCP requirement in the US for food processors such as
supermarket deli or butcher departments that purchase from certified producers.

1959-1960: First works, NASA wanted to produce food for astronauts for guaranty
food safety with zero false programs to eat,
1963: World health organization (WHO) issued Haccp principles in Codex
Alimentations.
1973: NASA (USA national air space Foundation ), Natick American Army
laboratory and Pillsbury group company priged common project for astronauts in
food production with zero false and HACCP concept entered to literature,
1985: USA national science academy suggested that HACCP should be applied in
food operations for food safety,
14 June 1993: HACCP entered to regulations of Europe Community Countries
with directives ‘’Hygiene of food matters’’,
1996: It was applied in Europe all food industry as legal,
HACCP became mandatory in Turkey the date of 16 .11.1997 with Turkish food
codex in food industry. Formal newspaper issued the date of 09.06.1998 in ‘’ food
production and audit regulations’’ that HACCP system should be applied. HACCP
was mandatory with same regulation in meat, milk water products, meat product
and milk product producing companies the date of 15.11.2002 after as graduate.
20 February 1998: Denmark issued DS 3027/1998 HACCP standard,
3 March 2003: TS 13001/Mart 2003 HACCP standard was issued “According to
HACCP food safety management- regulations related management system for food
producing organization and suppliers’’.
1 September 2005 ISO 22000 “Food safety management system- requirements for
organizations in food chain’’

European Regulation & Small Businesses:

The European Union introduced new food hygiene regulations on 1-January-2006
that requires all food businesses within the EU, except primary producers, to
operate food safety management procedures based on HACCP principles.
Significant flexibility has been included to allow small businesses to comply.
HACCP systems are not readily applicable to food businesses like retail caterers
and the flexibility allows alternatives to HACCP that achieve the same outcome of
safe food being produced. The U.K. Food Standards Agency has produced an
adapted simplified version of HACCP for small caterers and retailers called ‘Safer
Food Better Business’ (SFBB) that uses this flexibility and is an example of how
quality systems and HACCP principles can be creatively adapted for small
businesses and different situations.

Hazards:
There is a considerable literature on microbiological hazards which cause food-
borne diseases and illnesses, and factors which influence their occurrence and
growth in foods. Similarly, stages in the food chain where foods may be
mishandled and practices which often lead to outbreaks of food-borne diseases are
well documented. Although these hazards and practices can be controlled in order
to prevent or minimize risks to health, food- borne diseases have continued to
present a serious challenge to public health. Because the traditional approaches of
inspection and end-product testing have proved inadequate in tack ling the problem
of food-borne diseases, there is an urgent need to apply more rational and effective
strategies. One such strategy is the Hazard Analysis, Critical Control Points
(HACCP) system which is currently in international discussion. This paper
examines the epidemic logical basis for the application of HACCP to food safety
control and describes its advantages. It is concluded that to realise the objectives of
HACCP, a flexible and simple approach is needed in its practical application across
food businesses. Any argument that the system cannot be applied without fully
developed and well structured food systems will ultimately reduce its potential
usefulness in food safety control.
What Are The Hazards?
• Bacterial contamination
• Survival of bacterial contaminants
• Contamination

Forms of Hazards:
Physical - Glass, metal, foreign objects
Chemical – Allergens, drug resides, cleaners, residues, natural toxins.
Microbiological - Cross contamination, pathogens.

HACCP principles:
There are 7 principles in the basis of the HACCP system. Consistent
implementation of these principles allows to develop adopt and successfully utilize
the HACCP system within the enterprise

Principle 1: Conduct a hazard analysis. Plants determine the food safety hazards
and identify the preventive measures the plant can apply to control these hazards.
A food safety hazard is any biological, chemical, or physical property that may
cause a food to be unsafe for human consumption.

Principle 2: Identify critical control points. A critical control point (CCP) is a

point, step, or procedure in a food process at which control can be applied and, as a
result, a food safety hazard can be prevented, eliminated, or reduced to an
acceptable level.

Principle 3: Establish critical limits for each critical control point. A critical
limit is the maximum or minimum value to which a physical, biological, or
chemical hazard must be controlled at a critical control point to prevent, eliminate,
or reduce to an acceptable level.

Principle 4: Establish critical control point monitoring requirements.

Monitoring activities are necessary to ensure that the process is under control at
each critical control point. In the United States, the FSIS is requiring that each
monitoring procedure and its frequency be listed in the HACCP plan.
Principle 5: Establish corrective actions. These are actions to be taken when
monitoring indicates a deviation from an established critical limit. The final rule
requires a plant’s HACCP plan to identify the corrective actions to be taken if a
critical limit is not met. Corrective actions are intended to ensure that no product
injurious to health or otherwise adulterated as a result of the deviation enters
commerce.

Principle 6: Establish record keeping procedures. The HACCP regulation

requires that all plants maintain certain documents, including its hazard analysis
and written HACCP plan, and records documenting the monitoring of critical
control points, critical limits, verification activities, and the handling of processing
deviations.

Principle 7: Establish procedures for verifying the HACCP system is working

as intended. Validation ensures that the plans do what they were designed to do;
that is, they are successful in ensuring the production of safe product. Plants will
be required to validate their own HACCP plans. FSIS will not approve HACCP
plans in advance, but will review them for conformance with the final rule.

Verification ensures the HACCP plan is adequate, that is, working as

intended. Verification procedures may include such activities as review of HACCP
plans, CCP records, critical limits and microbial sampling and analysis. FSIS is
requiring that the HACCP plan include verification tasks to be performed by plant
personnel. Verification tasks would also be performed by FSIS inspectors. Both
FSIS and industry will undertake microbial testing as one of several verification
activities. The occurrence of the identified food safety hazard.

HACCP Certification:
BIS offers two Certification schemes to the food industry.

i) HACCP Stand-alone Certification against IS 15000:1998

ii) HACCP based Quality System Certification provides for two Certification
through one audit Certification of Quality System against IS/ISO 9000 and
Certification of HACCP against IS 15000.
HACCP application:

• Fish and fishery products.

• Fresh-cut produces.
• Juice and nectary products.
• Food outlets.
• Meat and poultry products.
• School food and services

Advantages of HACCP system application:

The basis of HACCP is the system approach which covers the product food
safety parameters on all stages of its life cycle. From receiving the raw food
materials to the use of the product by the particular consumer.
1. The use of preventative measures instead of late corrective actions or recalls.
2. Assessment of responsibility to the safety of food products.
3. Accurate identification of critical processes and focusing on their core resources
and the company efforts.
4. Document validated certainty on the safety of the produced goods, which is most
important when claims and legal disputes arise

Implementation and maintenance of the HACCP plan:

The successful implementation of a HACCP plan is facilitated by
commitment from top management. The next step is to establish a plan that
describes the individuals responsible for developing, implementing and
maintaining the HACCP system. Initially, the HACCP coordinator and team are
selected and trained as necessary. The team is then responsible for developing the
initial plan and coordinating its implementation. Product teams can be appointed to
develop HACCP plans for specific products. An important aspect in developing
these teams is to assure that they have appropriate training. The workers who will
be responsible for monitoring need to be adequately trained. Upon completion of
the HACCP plan, operator procedures, forms and procedures for monitoring and
corrective action are developed. Often it is a good idea to develop a timeline for
the activities involved in the initial implementation of the HACCP plan.
Implementation of the HACCP system involves the continual application of the
monitoring, record-keeping, corrective action procedures and other activities as
described in the HACCP plan.
Maintaining an effective HACCP system depends largely on regularly scheduled
verification activities. The HACCP plan should be updated and revised as needed.
An important aspect of maintaining the HACCP system is to assure that all
individuals involved are properly trained so they understand their role and can
effectively fulfill their responsibilities.
References
www.wikipedia.org
www.mofpi.org
www.google.com
Dairy plant management by Dr. J. David