Implementing A HACCP System in

Your Food Service Operation

Hospitality & Tourism Management
Purdue University
Purdue University

Food Safety Management

HACCP
HACCP =
Analysis &
Critical
Control
Point

Hazard

____________________
HACCP is a prevention based food safety system.

What is HACCP
Hazard analysis and critical control points.
An internationally accepted methodology
to reduce and manage risk.
A preventive system for food safety that
addresses chemical, physical and
biological risk.

What is HACCP
Treats the production of food as a total
continuous system, assuring food safety
from harvest to consumption.
The principal can be applied to industries
other than food eg health, oil, explosives
etc.

Understanding HACCP
HACCP is a system that identifies and monitors
foodborne hazards that can adversely affect the
safety of food products.
HACCP systems emphasize the importance of
continuous efforts to ensure that processes are under
control.
The FDA recommends the implementation of HACCP
systems throughout the food industry.

History of HACCP
HACCP
HACCPwas
waspioneered
pioneeredby
by the
thePillsbury
PillsburyCompany
Companyduring
duringthe
the
1960s
1960sto
tocreate
createfood
foodfor
for the
theUS
USSpace
SpaceProgram.
Program.Existing
Existingquality
quality
control
controltechniques
techniques could
couldnot
not provide
provideadequate
adequate assurance
assurancethat
thatthe
the
food
foodbeing
beingproduced
producedwas
wasnot
not contaminated.
contaminated.The
Theonly
onlyway
wayto
to
ensure
ensuresafety
safetywould
wouldbe
beto
todevelop
developaapreventive
preventivesystem
system that
thatkept
kept
hazard
hazardfrom
from occurring
occurring in
inthe
the first
first place
placewithout
without expensive
expensive and
and
destructive
destructiveend
endproduct
product testing.
testing. ItIt isisnot
notaa zero
zero risk
risk system
system but
but isis
designed
designedto
toreduce
reducefood
foodsafety
safetyhazards
hazards to
toaaminimum.
minimum.

International Legislation on
HACCP
Codex
CodexElemantarius
ElemantariusCommission
Commission::FAO
FAO&&WHO
WHOjoint
jointFood
FoodStandard
StandardProgramme
Programme
EU
EU::White
Whitepaper
paperon
onFood
FoodSafety
Safety
Horizontal
HorizontalLegislation:
Legislation:Directive
Directiveon
onthe
theHygiene
Hygieneon
onFood
FoodStuff
StuffNo
No934/43/EEC
934/43/EECof
of
the
thecouncil.
council.
Vertical
VerticalLegislation
Legislation::on
onMarine
Marinefood,
food,meat
meatproduct,
product,Dairy
DairyProduct,
Product,Fishery
Fishery
product,
product,Animal
Animalfeed/waste
feed/waste
USA
USA:-:-HACCP
HACCPmade
mademandatory
mandatoryon
onmost
mostofofthe
theedible
edibleitems
items
National
NationalLegislation:
Legislation:Rule
Ruleon
onunder
underdifferent
differentMinistries
Ministriesgovering
goveringvarious
variousFood
Foodand
and
Agricultural
AgriculturalProduct
Product

Why HACCP ?
1.
1.External
ExternalPressure
Pressure
2.
2.Customer
CustomerAwareness
Awareness
3.
3.Limitation
Limitationof
ofquality
qualityinspection
inspection
4.
4.More
Morecomplex
complexfood
foodprocedure
procedure
5.
5.Legal
Legalaspect
aspect

Advantage of HACCP
**Prevents
Preventsfood
foodborne
borneillness.
illness.
**Makes
Makeslife
lifeeasier
easier
**Enhances
Enhancescustomer
customersatisfaction
satisfaction
**ItItisisaalogical,
logical, practical,low
practical,lowcost
cost and
andcommon
commonsense
sense
approach
approachto
tofood
foodsafety
safetythrough
throughthe
theanticipation
anticipationand
and
prevention
preventionof
of hazards.
hazards.

Consequences
##

Personal
Personaldestiny
destiny

## Cost
Cost
## Danger
Dangerto
topublic
publicsafety
safety
## Increase
Increasein
incustomer
customerdistrust
distrust

Reasons for food Safety

incidents
**Raw
Raw material
materialand
and their
their supplier.
supplier.
**Non
Nonappropriate
appropriatehandling
handling
**Processing
Processingitself
itself
**Ingredient
Ingredient change
change
**Contamination
Contamination
**Non
Nonappropriate
appropriatemaintenance
maintenance
**Distribution
Distributionand
andStorage
Storage

Food Safety management

System
** Prevention
of
unsafe
food
Prevention of unsafe food-- Food
Food shall
shall be
beharmless
harmless to
to
consumers
consumers
** Based
Basedon
on
##Prerequisite
Prerequisite (( GMP+GHP)
GMP+GHP)
##hazard
hazardAnalysis
Analysisand
andCritical
Criticalcontrol
control
points
points
## Management
ManagementSystem
SystemRequirements
Requirements

Benefits of Food Safety

Management System
**Reduction
Reductionin
incontamination
contaminationrisk
risk
**Reduced
Reducedrecall/product
recall/productdestruction
destruction
**Market
Marketprotection
protection
**Preferred
Preferredsupplier
supplierstatus
status
**Greater
Greaterprofessionalism
professionalism
**Improved
Improvedmarketability
marketability
**Conformance
Conformanceto
tointernational
internationalpractices
practices

HACCP Impacts
**Changing
Changingaacompany
companyapproach
approach
--from
fromretrospective
retrospectivequality
qualitytesting
testingto
topreventive
preventiveway
wayof
ofthinking
thinking
**Providing
Providingsystematic
systematicapproach
approach
--covering
coveringall
allaspect
aspectof
offood
foodchain
chainfrom
from raw
rawmaterial
materialpurchased
purchasedto
to
final
finalproduct
productconsuming
consuming
**Increasing
Increasingcustomer
customerconfidence
confidence
-- in
inproduct
productsafety
safetyand
andtrade
tradeopportunity:
opportunity:

HACCP system and its

consequences
**Living,
Living,flexible,
flexible,dynamic
dynamicsystem
system
**Requires
Requirestime,
time,financial
financialresources
resourcesand
andadequate
adequateexpertise
expertisefor
for
HACCP
HACCPstudy
study
**Not
Notavailable
availableas
asan
anoff
offshelf
shelfplan.
plan.
**Must
Mustbe
becustomized
customizedfor
for
--the
theproduct
product
--the
theprocess
process
--the
themanufacturing
manufacturingfacility
facility

Pitfalls of HACCP

Needs
Needsmanagement
managementsupport
support

**

**Can
Canbecome
becomebureaucratic,
bureaucratic,over
overdocumented
documentedififnot
notestablished
establishedand
and
implemented
implementedwell
well
**Not
Notaaone
oneoff
offsuperficial
superficialpaper
paperexercise
exercise
**Can
Canbe
becomplicated
complicatedififusing
usinginconsistent
inconsistentterminology
terminologyand
andjargon
jargon
without
withoutproper
properunderstanding
understanding
**training
trainingisisimperative
imperativefor
forall
allinvolved
involved

Hazard Analysis &

Assessment of Risk
Hazard = a biological, chemical,or physical
property that may cause
unacceptable consumer
health risk.
Risk = an estimate of the likely occurrence of a hazard.

Hazard Analysis &

Assessment of Risk
Question: How likely is the problem to occur?
Question: What would the severity of the problem
be (if it were to occur)?
Low risk, not likely to occur
not included
in HACCP.

hazards are

Control Points
Control Point = any point in a specific food
system at which a loss of control does not
lead to an unacceptable health risk.
Critical Control Point = any point in a specific
food system at which a loss of control may
result in an unacceptable health risk.

Prerequisites of HACCP
GMP
Every process should answer the following:

Why
Who
When
Where
What
How

GHP

Good hygienic practice viz., Sanitation, pest control, rodent

control, bait station, equipment cleaning, etc.

The HACCP Plan

HACCP Plan = a written document
that delineates the formal
procedures for following
the HACCP principles.

HACCP Implementation

Step 0 : Management commitment

Step 1 : Assemble the HACCP team
Step 2 : Describe the product/s.
Step 3 : Identify the intended use
Step 4 : Construct a flow diagram
Step 5 : On site confirmation of flow
diagram.

Implementation of HACCP
Management
ManagementCommitment:
Commitment:
1.1.Involvement
Involvementat
atthe
theearliest
earlieststage
stageimportant
important
2.2.Understanding
Understandingnecessary:
necessary:
a)
a) How
Howwill
willHACCP
HACCPimpact
impactthe
thecompany
company??
B)
B)What
Whatare
arethe
thebenefits
benefitsto
tothe
thecompany?
company?
C)
C)What
Whatare
arethe
theresources
resourcesneeded?
needed?
D)
D)What
Whatis
ismy
myrole?
role?
3.3.Commitment
Commitmentmay
maybe
bedemonstrated
demonstratedthrough
throughaaFood
FoodSafety
SafetyPolicy
Policy

The Food Safety Policy

The
ThePolicy
Policymay
mayinclude:
include:
aacommitment
commitment to
toidentify,
identify,evaluate
evaluateand
andcontrol
control
hazards
hazards
definition
definitionof
ofthe
thescope
scopeof
ofFSMS
FSMS
aacommitment
commitmentto
tocomply
complywith
with all
alllegal
legaland
andother
other
requirements
requirements

Existing and expected

resources
**Resources
Resourcesfor
forHACCP
HACCPteam
teammembers
members
**Internal
Internaland
andexternal
externalexperts
experts
**Organization
Organization
--Responsibility
Responsibilityand
andauthority
authority
-- HACCP
HACCPteam
teamleader
leader
-- HACCP
HACCPteam
team
--training
trainingand
andqualification,
qualification,Food
FoodSafety
Safetyawareness
awareness
**Laboratory
LaboratoryResources
Resources

The HACCP Team

Depending

Dependingon
onthe
thesize
sizeofofthe
thecompany
company
Small
Small(4-6
(4-6persons)
persons)
Multi-disciplinary
Multi-disciplinary

**Engineering,
Engineering,maintenance
maintenance
** Production,
Production,technology
technology

** Quality
Qualitycontrol
control
** microbiology,
microbiology,hygiene
hygiene
** Logistic
Logistic
** Legal
Legaldepartment
department
** Others(marketing,
Others(marketing,purchase,
purchase,finance
financeetc)
etc)

HACCP Team leader

##Responsible
Responsiblefor
forthe
theproject
project
##Plan
Planthe
theproject
project
##Chair
Chairthe
the meeting
meeting
##Coordinate
Coordinatethe
theteams
teamswork
work
##Ensure
Ensurethat
thatthe
thescope
scopeof
ofthe
theproject
project is
isfollowed
followed
##Communicate
Communicatethe
theteams
teamsdecision
decision

Training of the HACCP Team

Training
Trainingof
ofthe
theteam
teamto
toensure
ensureunderstanding
understandingof
of
**Methodology
Methodology
**Terminology
Terminology
Training
Trainingto
toget
getfamiliar
familiarwith
with
**Defined
Definedscope
scopeand
andobjectives
objectives
** Food
FoodSafety
SafetyPolicy
Policy
**Prerequisites
Prerequisites
**Legal
Legalrequirements:
requirements:

Describe the product

The
Theproduct
productdescription
description--technical
technicaldata
dataassociated
associatedwith
withthe
theproject
project
**Composition
Composition
**Ingredients
Ingredients
**processing
processingconditions
conditions
**final
finalproduct
productcharacteristics
characteristics
**Instructions
Instructionsfor
foruse
use
**Customer
Customerrequirement
requirement
**legal
legalprescription,
prescription,regulation,
regulation,technical
technicalliterature
literaturedata
dataand
andspecification
specification
of
ofraw
rawmaterial
material

Identify intended use

Identify
Identifypotential
potentialusers
users

**

**Safe
Safestorage,
storage,preparation
preparationand
andserving
servingprescribed
prescribed
**unintended
unintendedhandling
handlingand
anduse
useof
ofproduct
producttaken
takeninto
intoconsideration
consideration
**Specification
Specificationfor
forthe
thefinal
finalproduct
productbased
basedon
oninfo
infofrom
fromcustomers,
customers,
internal
internalexpects.
expects.
Identify
Identifyall
allgroups
groupswith
withincreased
increasedsusceptibility
susceptibilityto
toillness
illnessshould
shouldbe
be
identified.
identified.
Potential
Potentialabuse
abuseshould
shouldalso
alsobe
beconsidered
considered

Construct flow diagram

Definition
Definition of
of aa flow
flow diagram;
diagram;
A
A systematic
systematic representation
representation of
of the
the
sequence
sequence of
of steps
steps or
or operations
operations used
used in
in the
the
production
production or
or manufacture
manufacture of
of particular
particular food
food
item.
item.

Flow diagram requirements

**all
allsteps
stepsin
inthe
themanufacturing
manufacturingincluded
included
**indicated
indicatedwhere
whereraw
rawmaterial
materialjoins
joinsflow
flow
**where
wherereworking
reworkingand
andrecycling
recyclingtakes
takesplace
place
**Where
Whereintermediates,
intermediates,by
byproducts
productsand
andwaste
wasteproduct
productare
areremoved
removed
**Flow
Flowdiagram
diagramsufficiently
sufficientlyclear
clearand
anddetailed
detailedfor
forpotential
potentialhazards
hazardsto
tobe
be
identified
identified
**Include
Includerelevant
relevantprocess
processdata
data* *

On site confirmation
The
Theready
readyflow
flow diagram
diagramcompared
compared with
withthe
the operation
operation
and
andlayout
layout
All
Allteam
teammembers
membersvisit
visiton
onthe
thesite
siteto
toconfirm
confirm
-- the
thediagram
diagramis
iscomplete
complete
-- is
isvalid
validthrough
throughall
all operation
operationperiods:
periods:

On site confirmation
Verification
Verificationduring
duringshiftsshifts-nights,
nights, weekends
weekends

**

**Account
Accountof
ofdeviations
deviationsfrom
fromthe
the working
working process
process
--Loops,
Loops, rework
reworkphases,
phases,
-- cleaning,
cleaning,break
breakdown,
down,delay
delay
** Necessary
Necessaryadjustment,
adjustment,corrections
corrections
** Documentation
Documentation

HACCP Principles
1. Perform a Hazards Assessment
2. Identify Critical Control Points
3. Establish Critical Limits
4. Establish Monitoring Procedures
5. Detail Corrective Actions
6. Determine Effective Record Keeping Systems
7. Establish a Verification System

HACCP Application
1

Assemble the HACCP Team

Describe the Product

Identify Intended Use

Construct Flow Diagram

On -site confirmation of Flow Diagram

List all potential hazards

Conduct a hazard analysis
Determine control measures

Determine CCPs

Establish Critical limit for each CCP

Establish Monitoring system for each CCP

10

Establish CA for deviation that may occur

11

Establish Verification Procedures

12

Establish Documentation & Record Keeping

Bottom line of HACCP &

What you can do
When in doubt
Throw it out.

what you can do

Dont Cross Contaminate

Wash Your Hands
Keep Hot Foods Hot
Keep Cold Foods Cold

Principle #1: Performing a

Hazards Assessment
Purposes:
Identify significant hazards
Estimate potential risk of
each hazard Based on identified hazards
and risk, develop preventative measures to
improve -- ensure -- food safety

Principle #2: Identifying

Critical Control Points (CCPs)
Critical Control points can be defined as
instances where a ... loss of control may
result in an unacceptable health risk
In foodservice settings these points are the
food handling practices that, if controlled,
could reduce the possibility that consumers
will receive potentially harmful food.

Examples of CCPs in Food

Preparation

Employee &
environmental hygiene
Cross contamination
(preventing) Cooking,
holding, & reheating

Principle #3: Establishing

Critical Limits
Critical limits are the criteria that must be met
for each preventative measure associated with
a CCP.
Frequently used criteria in food preparation:
Time
Temperature

Criteria for Critical Limits

Examples:
Cooking chicken to 165oF
Chilling to 41oF or less in 4 hours
Maintaining a water temperature
not less than 171oF in the sanitizing
compartment of a manual
warewashing sink

Principle #4: Establishing

Procedures to Monitor CCPs
Purposes:
To determine when loss of control and
deviations occur
To help identify undesirable trends
To provide written documentation

Principle #5: Establishing

Corrective Actions
Purposes:
To determine the disposition of any food that
was produced when a deviation was
occurring
Correct the cause of the deviation
Maintain records of corrective actions

Principle #6: Keeping Records

Requirements include the preparation and
maintenance of a written HACCP plan
The plan must detail:
The hazards of each individual product
CCPs and critical limits

Record Keeping System - cont.

Food preparation flow
diagram -- indicating CCPs

Monitoring and record

keeping procedures Critical Limits
Corrective action plans for deviations

Principle #7: Verification

Management must
Frequently review the HACCP plan
Determine that the plan is being correctly
followed
Examine CCP records
In essence -- determine if the HACCP system
is in compliance with the HACCP plan.

Implementation of HACCP into

a Foodservice
Procedures:
1. Review recipes to identify
potentially dangerous foods.
2. Use flow diagrams to trace potentially
dangerous foods through an operation.

Flow Diagram
Receiving
dry)

reheating

storage
(temp/time)

service

Storage (refrigerated,

preparation

cooking

holding
(hot/cold)

frozen &

Implementing HACCP
1. Review preparation procedures to
identify potential sources of contamination in
the process.
2. Observe preparation to verify that procedures
are being followed.
3. Test to determine that preparation procedures
are safe.

Implementing HACCP
4. Monitor procedures during service.
5. Monitor procedures after service.
6. Identify Critical Control Points.
7. Implement and monitor.

Important Points
Hazard analysis is individual to the operation

Critical points = areas which would result in greatest

risk to customers

Monitoring = physical measurement/observation

Control = intervention is done to meet standards

Major Hazards In Food

Preparation/Delivery Systems
The leading causes of most reported
foodborne illnesses are bacteria
or the toxin that some
Bacteria produce.

HAZARD IDENTIFICATION
Definition of Hazard:A biological, chemical or physical agent in, or condition of, food with potential to cause
an adverse health effect.
Biological hazard:
* Contamination
* Growth
* Survival
ie. Bacteria, yeast, molds, protozoa etc.
Chemical hazard:
Residual
Contact
Contamination

HAZARD IDENTIFICATION
Chemical Hazard in raw materials
* Pesticide
* Toxic metals
* Microbiological toxins
* Allergens
Chemical hazards in packaging
* plastics
* paints/glue
Sources of chemical hazards during processing
* detergents, lubricants, chemical adhesives, veterinary residue, dioxins,
furans etc.

HAZARD IDENTIFICATION
Physical Hazards;
Any foreign body like
- metals, fragments
- glass, stone
- jewelry,
- nails, hairs
- plastic, paper
- textile fibres
- dead insects, etc

HAZARD IDENTIFICATION
Hazard may be related to
Chemical/Material
Equipment/Instrument
technology & method
Processing activities
Measuring points
Operating conditions
Pressure & Temperature conditions etc

HAZARD IDENTIFICATION
Information sources
#

Use of flow diagram

Literature

# Best practices in industry

# Internal & external experts
# Regulatory guidelines
#Customer complaints
# Epidermological data
# Results of internal & external audits
# Screening analysis

Major Bacterial Hazards

Of particular concern in foodservice are the
following:
Salmonella
Campylobacter jejuni
Clostridium perfringens
Staphylococcus aureus
Clostridium botulinum.

Bacterial Hazards
Other bacterial concerns that have recently
become an issue include:
Escherichia coli
Listeria monocytogenes
Yersinia enterocolitica (FSIS, 1990)

Potentially Hazardous Foods

The most frequently implicated (contaminated)
foods include:
meat
poultry
seafood.

Potentially Hazardous Foods

Other foods that have also been involved include:

eggs
raw seeds & sprouts
dairy products
sliced melons
baked/boiled potatoes
garlic & oil mixtures
tofu & soy protein
cooked plant foods

To Determine CCPs
Focus on the Flow of Food

CCPs in Food Service Systems

In food service settings these points are the food
handling practices that, if controlled, could
reduce the possibility that consumers will
receive potentially harmful food.

CCPs in Food Systems

Studies have shown that

keeping potentially hazardous foods at room

temperature for prolonged
periods of time has
contributed most often
to foodborne illness.

CCPs in Food Systems

Other practices that have frequently led to or
been implicated in outbreaks of foodborne
illness include:
inadequate cooking
improper holding of hot food
improper cooling of food

CCPs in Food Systems

an extended length of time between
preparation and consumption inadequate
reheating of food previously cooked and
cooled
improper cleaning of equipment
cross contamination
infected food handlers

Example of Decision Tree to identify CCPs

Do control measure (s) Exist
Yes

No

Modify step, process or product

Is control at this step necessary for safety

No

Yes
Stop

Not a CCP

Is the step specifically designed to eliminate or reduce

the likely occurrence of hazard to an acceptable level

Yes

No
Could contamination with identified hazard increase to unacceptable levels
Yes

No

Not a CCP

Stop

Will a subsequent step eliminate identified hazard (s) or reduce

likely accurence to an acceptable level?
Yes

No
Not a CCP

CRITICAL CONTROL POINT

Stop

Monitoring Food Safety

The overall purpose of the HACCP system is to
monitor and correct critical situations or processes
that may directly or immediately result in an
unacceptable health risk.
____________________

Management can not be in all CRITICAL places at all

CRITICAL times.

Monitoring Food Safety

One approach is to develop checklists where
time and temperature measures
are recorded compliance/non-compliance
with desirable food handling
practices is identified

Monitoring Food Safety

The checklists can be based on the equipment
and activities that are performed in certain areas.
For example checklists can be developed for
the back-of-the-house preparation area
receiving
the hot food preparation area
the dish room

Monitoring Food Safety

They can also include circumstances
and/or practices that could (indirectly)
affect the safety and wholesomeness of
food products.

Who should be involved?

Involve those most directly in that step of the
flow of food.
Move to lowest level possible.
Line employees need to be trained so that
corrective actions are automatically done
when a potential problem is found.

Who should be involved?

Managers should be the double-check to
make sure that the logs for
each of the areas are
completed.

Managers should note the actions that were

taken when potential problems were found.

Implementation of HACCP into

a Foodservice
HACCP works best when it is part of an
employees routine & not

Extra

Duty!

Developing a HACCP
Training Program
Introducing HACCP
will be easier if employees
receive training in sanitation
prior to implementation.

Employees should receive

training in:

Importance of sanitation

Cleaning & sanitizing

Importance of labeling
How to sanitize
Proper use of the dish
machine

Personnel handling
Uniforms
Hand washing
Handling
techniques

Employees should receive

training in:
Food preparation
Potentially hazardous foods
Time/temperature control
Use of thermometers
Receiving and storage
Cooking endpoints
Thawing
Cooling
Handling of leftovers

They should also receive

training in HACCP
HACCP: An Overview
Purpose
Importance of HACCP in food systems
The HACCP system
The Principles
Monitoring procedures
Corrective actions
Record keeping

HACCP Training & Activities

HACCP Activities & Tools
Activity Identifying Critical Control Points in
the Flow of Food
Activity HACCPitizing a Recipe
Sample Checklists

HACCP Resource
The Food and Drug Administration has begun
to develop guidelines for the application of
HACCP to retail food systems. The FDA
draft document is available at:
http://vm.cfsan.fda.gov/~dms/haccpret.html

References
HACCP Reference Book
Education

Foundation of the NRA, 1993

ISBN 0 - 915452 - 15 - 4

A Practical Approach to HACCP Coursebook

Educational

Foundation of the NRA, 1998

ISBN 1 - 883904 - 84 - 6

Thank You