Professional Documents
Culture Documents
example of
HACCP plan
for a
Fresh Cream
and
Jam
Gateau
[1] This study was partly reproduced and adapted from Sara Mortimer and Carol Wallace; HACCP, a practical approach, Chapman & Hall, 1994
01/02/16
N. Charisis WHO/MZCC
Athens, Greece
The HACCP Plan is a document prepared in accordance with the principles of HACCP to ensure control
over hazards, in the food chain under consideration.
The goal of this activity is to:
assess the compliance with product/process description,
process flow diagram,
identify the most significant hazards,
assess the most significant hazards
identify hazards sources,
identify Critical Control Points,
monitor the programme (frequency, methods, equipment etc), and
evaluate the quality of information gathered through records
The HACCP plan indicates what needs to be done, when and where. It is the basis of documentation, which can be shown to food
inspectors and auditors. Normally, a flow chart with CCPs is attached. It is the result of a HACCP study; it is specific to a production
site and product, and must be rigorously implemented. Since the HACCP plan is specific, each change and its potential impact on
safety, should be studied and the HACCP plan should be modified when necessary. The results of a HACCP study are also
presented in a condensed form in a HACCP data sheet. This sheet lists all CCPs and their associated hazards, the control
measures, the parameters assuring the control, the critical limits and target values which need to be monitored, as well as the
monitoring procedures and the corrective actions. Therefore it gives auditors and inspectors a quick insight into the decisions made
during the HACCP study.
01/02/16
N. Charisis WHO/MZCC
Athens, Greece
HACCP Plan
(is a document prepared according the principles of HACCP to ensure
control over hazards)
The goal of a
HACCP plan is:
1.
2.
3.
4.
5.
01/02/16
N. Charisis WHO/MZCC
Athens, Greece
From the Document HAZARD ANALYSIS AND CRITICAL CONTROL POINTS - CONCEPTS AND APPILICATION, edited as a draft in 2002, by N. Charissis, DVM - WHO/MZCC, Athens, GREECE.
CCP
Control
Measur
es
Critical
limits
Procedure
Frequency
Correcti
ve
actions
Responsib
le persons
Hazar
d
Process
step
01/02/16
N. Charisis WHO/MZCC
Athens, Greece
From the Document HAZARD ANALYSIS AND CRITICAL CONTROL POINTS - CONCEPTS AND APPILICATION, edited as a draft in 2002, by N. Charissis, DVM - WHO/MZCC, Athens, GREECE.
a flow
Flow
diagram
covers all steps of
production
01/02/16
N. Charisis WHO/MZCC
Athens, Greece
Change
Supplier
Chose supplier of
raw material
1
E X AM P L E
Transportation 2
Return
Washing of dirty dishes and trolleys
Acceptance
Control 3
STORAGE 10
Cooking
CCP 1
11
Vacuum/Pasteurization 12
CCP 2
Cooling 13
CCP 3
CCP 4
Storage 14
CCP 5
CCP 6
Preparation of dishes 17
Preparation of trolleys 18
01/02/16
Refrigeration of
ready product 19
Final Control 20
N. Charisis WHO/MZCC
Athens, Greece
Transportation/Delivery 21
From the
EXAMPLE
Cooking
Cooking 11
Normal cooking
temperatures destroy
bacteria and parasites, but
hardly spores or toxins
Vacuum/Pasteurization 12
Cooling 13
01/02/16
N. Charisis WHO/MZCC
Athens, Greece
Floor Plan
1.
Inspection of RM
2.
Gutting / Filleting
3.
Trimming / Inspection
4.
Brine Tank
5.
Holding Area
6.
Smoking
7.
Cooling
8.
N.TankCharisis WHO/MZCC
Brine
Athens, Greece
Packing
Cutting
and
filleting
table
01/02/16
Modify step
Rapid screening
test
The
YES
YES
NO
Decision
Tree for
Q2:
CCPs
NO
Q3:
Q 1-a:
Not a CCP
YES
NO
NO
CCP
Not a CCP
01/02/16
N. Charisis WHO/MZCC
Athens, Greece
changing ?
THEREFORE
There should be designed alternative Plans for predicted
01/02/16
N. Charisis WHO/MZCC
Athens, Greece
10
Raw materials,
ingredients
Process parameters
(temperature, time)
01/02/16
Maintenance
and
calibration of
of equipment
Cleaning and
Sanitizing
WHO/MZCC
Athens, Greece
Employee
training
11
On a Case
Existence of a Quality
System
Complexity and
Number of Products
Quality System
Manual
01/02/16
N. Charisis WHO/MZCC
Athens, Greece
Work
instructions
12
- Records of monitoring
- Records of verification
Records are operative sheets regarding: Incoming materials (raw material, ingredients), Process parameters (temperature,
time), Finished product, Cleaning and sanitising, Pest control, Employee Training as well as other record-keeping document
such as microbiological/chemical test results, calibration certificate, complaints documents, finished products rejected, hours
for equipment maintenance and results of internal/external audits
01/02/16
N. Charisis WHO/MZCC
Athens, Greece
13
Purchasing
surrounding area.
Sanitising = control of working environment conditions (e.g. cleaning,
disinfecting, pest control, improvement of: temperature,
humidity,
light,
noise
etc.)rat
to guarantee
that all
pest
and
01/02/16
N. Charisis WHO/MZCC
Athens, Greece
14
Personal hygiene:
Personnel should have a health register, renewed every year.
wash hands using hot water and liquid antiseptic soap and dry with paper
towels.
01/02/16
N. Charisis WHO/MZCC
Athens, Greece
15
Personnel training
It is essential
to
guarantee the
proper control of the product.
01/02/16
N. Charisis WHO/MZCC
Athens, Greece
16
10
11
12
13
14
01/02/16
N. Charisis WHO/MZCC
Athens, Greece
17
Whose responsibility is
Validation?
When Validation should
happen?
VERIFICATION
ends
01/02/16
N. Charisis WHO/MZCC
Athens, Greece
18
Whenever a change occurs, a new hazard analysis has to be carried out, because a change might induce a new
hazard, or eliminate an existing one (or reduce it to an acceptable level). Clearly the results of this hazard analysis
as well as the effectiveness of new control measures (if any) have to be validated. Validation is thus part of the
maintenance of the system.
Verification
Obviously, it is necessary to obtain evidence that the HACCP system is really working. For this purpose,
01/02/16
N. Charisis WHO/MZCC
19
verification procedures have to be established. Verification is the application of methods, procedures, tests and
other evaluations in addition to monitoring, Athens,
to determine
compliance with the HACCP plan. Therefore verification
Greece
Although internationally accepted definitions of the tasks of regulators or law enforcement officers have not been established yet, it is
believed that the food handler, should do verification in accordance with the HACCP plan. That activity doesnt exclude necessarily the
authorities from checking the verification procedures performed by the handler in particular or the plan in general.
Taking under consideration that Food Hygiene means all measures necessary to ensure the safety and wholesomeness of foodstuffs,
then, Food Hygiene Monitoring System is, the main tool to prevent foodborne disease. Secondary, this system permits to detect and
prevent the food spoilages causes. An inefficient monitoring system leads to economic losses, reduces credit by consumers in food
hygiene control system and also reduces credit in international trades.
In order for the monitoring system to be effective, measures shall cover all stages after primary production (the latter including, for
example, harvesting, slaughter and milking), during preparation, processing, manufacturing, packaging, storing, transportation,
distribution, handling and offering for sale or supply to the consumer. According to Article 1 , of 94/356/EC: Commission Decision of 20
May 1994, {this can be achieved by 'Own-checks', that means all those actions aimed at ensuring and demonstrating that a fishery
product satisfies the requirements of that Directive. Those actions must correspond to an approach internal to the establishment; they
must be developed and implemented by the persons responsible for each production unit, or under their management, in accordance with
the general principles set out}. The documentation must include two types of information to be kept for submission to the competent
authority:
A.
1.
2.
3.
5.
6.
01/02/16
N. Charisis WHO/MZCC
Athens, Greece
20
B.
Records
1.
2.
3.
reports and written accounts of decisions relating to corrective action when taken.
An appropriate document management system must be provided, in particular, for the easy retrieval of all documents relating to an
identified production batch.
01/02/16
N. Charisis WHO/MZCC
Athens, Greece
21
HACCP C A S E S T U D Y
01/02/16
N. Charisis WHO/MZCC
Athens, Greece
22
a.
Facility
DETAILS
(in Stockholm, Sweden)
The factory produces both chilled and frozen gateaux (cream cake) for
sale to the retail industry.
b.
Product description
c.
Manufacture
1. Sponge batters are baked at 150-170 C through a travelling oven
for 18.5 minutes.
2. Then cooled to ambient (=room temperature)
3. Automatically sliced and
4. Filled with cream and jam
5. The sponges are flow-wrapped (wrapped in motion) and put into
cartons.
01/02/16
N. Charisis WHO/MZCC
Athens, Greece
23
d.
Biological hazards:
- Potential presence of pathogens
- Cross-contamination during processing
Control measures:
- Approved suppliers (certificates of conformance),
- Sensitive ingredient testing,
- Baking and segregation
e.
Intended use
Contents:
Flour, Milk powder, Pasteurized Liquid egg, Water, Ingredients
01/02/16
N. Charisis WHO/MZCC
Athens, Greece
24
Charisis WHO/MZCC
Athens, Greece
25
Raw
material
CCP
No.
Incoming
Flour
Not
a
CCP
Incoming Milk
powder
Not a
CCP
only
Incoming
Liquid egg
if we doubt
with
suppliers
HACCP
Water
Hazard to be
controlled
Control
measures
CCP
parameters
Critical
limits
MONITO
Method
ING
Frequency
Corrective
actions
Biological
(B.controlled
cereus) by
Aflatoxins are
the supplier.
bodies
Foreign
Obtain Cerf.of
Analysis/Testing
Aflatoxin = mg /kg
Aflatoxin <10
mg/kg
B. Sereus
< 1000/g
Inspect certif. of
Every batch
B. sereus,
Reject batch
Reject batch
2 by 2 mm
Inspect
filters
1 inspection x
per hour
Re-sieve
< 10mg/kg
ISO
method
Every
delivery
Rejection
Every
delivery
Rejection
investigation
for chemicals
Weekly
weekly is not
recommended
in small
business
Filtration and
chlorination
Filtrate
&
control
biological
Chlorinate
hazards but do
not control
chemical
contamination
Every
delivery
Rejection
Baked Insects
are no
(Insects,
glass, wire,
wood)
hazard.
Chemical
dangers
Foreign bodies
detected at
(Aflatoxin,
packaging
metal detector
after chilling,
material,
painting)
Sieving is a GMP
Antibiotics, Salmonella
Is controlled
by suppliers
Brucella,
Campylobacter,
E.coli, Listeria, Sstaphylococci
HACCP
(QA)
Dioxines,
Aflatoxins,
no
need for
testing
Salmonella
? Listeria?
Shigella?
in theStreptococcus?
plant
Other?
Chemical
contamination
and
/ or
Baking of the
final
Not a
CCP
product destroys
Microbial
bacteria and
Contamination
parasites
from
(usually
Giardia,
or the
Cryptosporidium)
water
Incoming &
processing
Cream
Not a
CCP
Listeria
& Salmonella
Possibly
a CCP
Etc.
but practically
impossible
No
control
Sieving
measures
needed
X X XX X
X
B. Sereus = No / g
Supplier= QA
AUDIT
InspectionAflatoxin
of Suppliers
to verify
suppliers
Supplier QA
premises
HACCP
mg/kg
Coliforms
count
B. sereus,
ISO method
ISO
method
Investigating the water
Regulatory
Testing to
forChemical
microorganisms
requirements
or
include
toxic
isMicrobiolo
not a usual
substances
gical
procedure
for
contamina Giardia/
Cryptosporidi
tion
um
small
business
There
is no need
Carry out on-site
microbiological
for
checks and
obtain Certificate
microbiological
of Analysis of
samples from
Water Authority
tests.
No control
measures
needed
Analysis
< 10/g
(national
Every delivery
Inspect
Anyway,
Chemicals
Regulatory
Certificates
compliance)
remain
in waterof Analysis
from Water
Authority
Optimal hygiene
and
time/temperature
control along the
food chain are
required.
Absence / 25 g
Ask for
Supplier QA
Regulatory
requirements
Testing 5
samples of
10 g found
negative
ISO
method
Incoming
Jam
Not a
CCP
Packing
material
Not a
CCP
01/02/16
Moulds
Is quality problem, not
safety
Regulatory
requireme
nts
N. Charisis WHO/MZCC
Testing
Aerobic count < 100/cm2
X Greece
X
X
Athens,
Supplier
audit
Yearly
Rodac
plate
Every
delivery
Sanctions
26
Rejection
X
Process
step
Storage of
raw
material
CCP
No.
Hazard to be
controlled
Physical
Not a Physical
contamination/
CCP
contamination can
Biological
growth
occur!
Growth of
(what can grow in
what? i.e. fermentation
high temperatures
bacteria
are needed!
and humidity?)
Keep raw material cold
GHP and GMP are
enough
Ingredient
weighing
Sponge
baking
Not a
Critical
limits
Procedure
Frequency
Corrective
actions
Store
as specified,
No physical,
checks
Hold and
Bacteria
should beVarious
specified and all risks
should beAutomatic
taken under Daily
consideration.
(i.e. cream < 5C,
chemical
temperature
continue
inform QA
egg
Most
forraw
specified
powder material have beencontamination
filtered already
recorder.
(also, thereduring
is a metal
use. detector
Manager
at the
Maintain
max.
batch
Responsible
end time)
of the line. Storage of raw material
is covered Visually
by GMP/GHP,Every
& Final
Product
is
temperature
Keep covered
inspect label
person=Wareh
Cooked! Therefore there is no need <for
control measures
only prerequisites =
i.e. GMP
5C
to ensure
ouse
+ GHP
stock rotation
manager+Ope
rator
Weighing
Weight/batch
0.2%
Testing
Each batch
Reprocess
CCP
Survival of
Salmonella & Listeria will
pathogens?
be killed but but Spores
Give
examples!
of B. Cereus or
Time
150-170C
Temperature
18 min
Automatic
chart
recorder
Continuous
No 1
C. Perfrigens
Bake sponge
at specified
time/
temperature
Stop
production.
Reject product.
Adjust oven
temperature/ti
me
Observe working
No residues
Visual
After every
Clean again
cleaning
before start
CCP
Cooling
Not a
CCP
Listeria,
Cream
Salmonells
Cream
whipping
Not a
CCP
Salmonella
Filling
Not a
CCP
Flow
Wrapping
Not
Metal
detecting
CCP
parameters
Chilling
Control
measures
a CCP
for
whipping,
hygienic area.
No other before
heat start
cleanfiling and wrapping
surfaces for take place
visible in high Inspection
cleaning
treatment is possible, thereforeresidues
CONTAMINATION against Listeria spp., Salmonella spp.,
etc should be avoided
by any means!
Listeria,
Clean machine
Visible residues
No residues
Observation
After every
Clean again
visible
Salmonella in cream may cause illness, but product is kept at low temperatures and its self
Salmonella
Keep line clean
Visible residues
No residues
After every
Clean again
life is 3 days, therefore
the hazard
to develop Salmonella
isObservation
extremely low.
If it does,
visible
cleaning
before start
Salmonella will turn the cream rancid the cake will not be eaten; however if eaten, it might
Biological
Hermetic seal
No holes
Intact seal
Visual
Every 15
Re-sealing
cause harm to sensitive persons!
contamination
inspection
min.
(GMP)
Growth of
pathogensThe
Blast chilling
hr./ 5 C
Temperature
Rework
pathogens
should beTime/temperature
mentioned and risk
analyzed,
otherwise
it is
not a CCP
recorder
Each
batch
CCP
the
Metal
contamination
Metal
Metal detector
Metal size
Absent
Metal
Every 30 min
Stop line,
Detector
should be programmed to detect
of certain size (not metal objects)
ferrous needles
2.0
detection
recalibrate,
No 2
mg,
01/02/16
2.5 mg
N. Charisis WHO/MZCC
Athens, Greece
check using
notify QAM.
Hold stock
27
verification
What?
Why?
Acceptance
When?
How?
Action in
case of
deviation
Every batch
Triangle test
Reject
Every batch
ISO method
Reprocessing
Finished product
B. cereus testing
Check safety,
< 100/g
Finished product
Listeria testing
Check conformity
with criterion
Absence in 5 x 10g
1/week
ISO method
Find cause,
Improve HACCP
plan
Check adherence
to HACCP plan
1/week
Inspection
Correct, Train,
Improve
Monitoring records
review
01/02/16
N. Charisis WHO/MZCC
Athens, Greece
28