HACCP

Professor Dr. Md. Abul Mansur

 HACCP (Contd.)

• From academic consideration HACCP may be defined as a

modern approach to manufacture a safe food by a safe
process. Such safety is for health of the consumers.

• HACCP may be defined as a risk reduction tool of

guaranteeing food safety. This risk is about health of the
consumers.
• HACCP is a food safety management system which
concentrates prevention strategies on known hazards and
the risks of them occuring at specific points in the food
chain.
 HACCP (Contd.)

• HACCP is a strategy for preventative

microbiological safety assurance. Although proposed
as a system to ensure the wholesomeness of food –
that is, its desirability from the point of view of
cleanliness and safety – HACCP has been adopted as
a management strategy for appropriate food quality.
• HACCP is primarily a preventative control system
rather than a cure and thus is well suited to achieving
the cost-effective delivery of quality products at agreed
prices.
 HACCP (Contd.)

A critical examination of the organisation must

occur by a suitably balanced team to identify
hazards, assess risk and implement control,
monitoring and corrective action.
The introduction of the Food Safety (General Food
Hygiene) Regulations in 1995 ensured that common
food hygiene rules were in place across th EU as set
out in the directive (93/43/EEC).
 CP and CCP

• Control Point (CP) is any point in a specific food system

where loss of control does not lead to an unacceptable health
risk, but may lead to an economic or regulatory (quality)
risk.

• Critical Control Point (CCP) is any point in a specific food

system where loss of control may result in an unacceptable
health risk.

It is important to identify CP and CCP in all types of food

processing industries including Seafood Processing Industries,
Fish Processing Industries.
 PRINCIPLES OF HACCP

1. Assess hazards associated with growing,

harvesting, raw materials and ingredients,
processing, manufacturing, distribution,
marketing, preparation and consumption of food.
2. Determine the critical control points required to
control the identified hazards.
3. Establish the critical limits that must be met at
each identified critical control points.
4. Esatablish procedures to monitor critical control
points.
 PRINCIPLES OF HACCP (Contd.)

5. Establish corrective action to be taken when there

is a deviation identified by monitoring of a critical
control point.
6. Establish effective record keeping systems that
document the HACCP plan.
7. Establish procedures for verification that the
HACCP system is working correctly. Verification
measures may include physical, chemical and
sensory methods; and when needed establishment
of microbiological criteria.
 AIMS OF HACCP

• Three basic aims:

1. Risk identification
2. Risk management
3. Documentation management
Such risk is for health of the consumers.
Principles 1 to 3 are for aim 1.
Principles 4 to 6 are for aim 2.
Principle 7 is for aim 3.
 MEANING OF HACCP

H: Hazard
A: Analysis
C: Critical
C: Control
P: Point
Hazard: A biological, chemical, or physical agent in or
property of food that may have an adverse health effect.
Analysis: A scientific process to differentiate between control
and critical control points through a risk assessment
evaluation of hazard.
 MEANING OF HACCP (Contd.)

Critical: A few points (the vital few) in a specific food system

where loss of control may result in a high probability of
health risk.
Control: Many points (the trival many) in a specific food
system where loss of control may result in a low probability of
a health risk but may result in an economic loss or quality
defect.
Point: An operation (practice, procedure, process) at which
control must be exercised.
 HACCP PROGRAMME in
Fish Processing Industry or Seafood Processing Industry:

1. Production Specification
2. Product Safety Analysis
3. Purchasing Requirements
4. Good Manufacturing Practice
5. Physical Systems Hazard Control
6. Recall System
7. Contract Manufacturing
8. Facility Auditing
9. Customer Complain
10. Incident Reporting
 PROBLEMS OF HACCP IMPLEMENTATION

1. The missed hazard principle

2. The missed risk principles
3. The missed prevention principle
 Probable source of health hazard

Fish Processing or Seafood Processing

1. Microbiological
2. Parasites
3. Physical
4. Chemical
 HAZARD CHARACTERISTICS

1. HAZARD A
2. HAZARD B
3. HAZARD C
4. HAZARD D
5. HAZARD E
6. HAZARD F
 HAZARD CHARACTERISTICS (Contd.)

HAZARD A: Deals with the special at risk population. Non-

sterile food products intended for consumption by infant,
aged, infirm or immunocompromised individuals.

HAZARD B: The product contains “sensitive –ingredients”.

These ingredients historically known to harbour pathogens or
other hazards such as chemicals or adulterants.

HAZARD C: The process does not contain a controlled

processing step that effectively destroys or excludes harmful
microorganisms.
 HAZARD CHARACTERISTICS (Contd.)

HAZARD D: The product is subjected to recontamination

after processing before packaging.

HAZARD E: There substantial potential for abusive handling

in distribution or in consumer handling that could render the
product harmful when consumed.

HAZARD F: There is no terminal heat process after

packaging or when cooked in the home.
 RISK CATEGORY

CATEGORY VI
CATEGORY V
CATEGORY IV
CATEGORY III
CATEGORY II
CATEGORY I
CATEGORY 0
 RISK CATEGORY (Contd.)

CATEGORY VI: A special category that applies to non-sterile

products designated and intended for consumption by /at risk
populations, eg. Infants, aged, infirm, immunocompromised
individuals. All six hazard characteristics must be considered.

CATEGORY V: Food products subjected to five of the

hazard characteristics.

CATEGORY IV: Food products subjected to four of the

hazard characteristics.
 RISK CATEGORY (Contd.)

CATEGORY III: Food products subjected to three of the

hazard characteristics.

CATEGORY II: Food products subjected to two of the

hazard characteristics.

CATEGORY I: Food products subjected to one of the hazard

characteristics.

CATEGORY 0: Hazard class – no hazard.

 HAZARD CHARACTERISTICS AND
RISK CATEGORY CHART
Food Ingredient Hazard Characteristics* Risk Category
(A, B, C, D, E, F) (Vi, V, IV, III, II,
or I, 0)
Food Product
T A+ (Special category) VI
U Five + ‘S (B through F) V
V Four + ‘S (B through F) IV
W Three + ‘S (B through F) III
X Two + ‘S (B through F) II
Y One + ‘S (B through F) I
Z No + ‘S 0
 SEAFOOD HAZARD CATEGORIES IN
DECREASING RISK

Category Description Example

1 Heat processed food usually consumed Crab meat, Peeled

without additional cooking shrimp, Smoked fish
2 Non-heat-processed raw foods often Fish, Shucked
consumed without additional cooking molluskan shell fish
eaten raw
3 Formulated food usually consumed Fish sticks, Breaded
after cooking shrimp
4 Non-heat processed raw food usually Fresh or Frozen fish
consumed after cooking fillets, Cooked
molluskan shellfish
5 Raw Seafood usually consumed after Live Crustacean and
cooking Molluskan Shell fish
 STEPS OF IMPLEMENTING HACCP
(RULES IN APPLYING HACCP)
1. Define scope of hazard analysis
2. Set up multidisciplinary team employing/using recognised method
(eg. HAZOP, Decision making tree)
3. Carry out audit of proposed food process
4. Make a detailed flow diagram of the food operation option
5. Carry out Hazard Analysis of process and rank all hazards
according to concern
6. Identify CCP
7. Specify Criteria for Control at each CCP
8. Identify (develop) Effective means of monitoring
9. Identify (develop) Corrective actions if control tolerances exceeded
10. Document all control and monitoring procedures
11. Train up personnel to carry out them.
 SAFETY STRATEGY FOR FISH PRODUCT
MANUFACTURING PROCESS

For the purpose of developing a safety strategy most fish

product manufacturing processes can be classified into 5
areas:
1. Ingredient Control and Storage
2. Controlled Safe Process
3. Physical Separation of Raw and Cooked
4. Maintenance of Hygiene Standards
5. Personnel Standards
 SAFETY STRATEGY FOR FISH PRODUCT
MANUFACTURING PROCESS (Contd.)
1. Ingredient Control and Storage:
● Approved suppliers holding or working towards ISO 9002
accreditation of their own quality management scheme.
● Agreed specification on physical, chemical and
microbiological quality and performance of ingredients.
● Audited supplies using approved, sensitive and reliable
monitoring procedures equipment.
● Planned and recorded surveillance of transport and storage
conditions.
 SAFETY STRATEGY FOR FISH PRODUCT
MANUFACTURING PROCESS (Contd.)

2. Controlled Safe Process

● Hygienic design, planning and operation of plant.
● Cleaning to set standards and inspection.
● HACCP – type system of hygiene control.
● Challenge testing raw materials, process, finished product.

3. Physical Separation of Raw and Cooked

● Applying to raw materials, equipment and personnel
● Physical barriers eg. Partition between raw and cooked
handling (cooker may be part of barrier)
 SAFETY STRATEGY FOR FISH PRODUCT
MANUFACTURING PROCESS (Contd.)

4. Maintenance of Hygiene Standards

● Hygiene specifications for equipment and working

environment.
● Trained sanitation team with materials and equipment
under specialist advice.
● Time-temperature monitoring involving continuous or
periodic surveillance.
 SAFETY STRATEGY FOR FISH PRODUCT
MANUFACTURING PROCESS (Contd.)

5. Personnel Standards
● Staff selection
● Health screening and regular check
● Sanitation and service provision
● Hygienic training and habit conditioning
● Supervision
FOUR ESSENTIAL COMPONENTS IN SETTING UP A
WHOLESOMENESS AND QUALITY MANAGEMENT SYSTEM
BASED ON HACCP FOLLOW A STANDARD SEQUENCE

1. A Process flow-chart
2. Hazard identification
3. Critical Control Point
4. Control efficacy
 HACCP AND QUALITY ASSURANCE

• Many countries of the world have developed HACCP

based Quality system for food including Fish and Shell
fish.
• In UK Food Safety Regulations are based on HACCP
principles.
• Canada has developed, implemented and verifying
HACCP-based Seafood quality system provides an insight
to both the problems facing the processor and the
regulations of HACCP-based Quality System. Canadian
QMP is the first mandatory food inspection programme
based on HACCP principles.
 HACCP AND QUALITY ASSURANCE

• United States has adopted HACCP systems as the primary

means to assure food safety.
• Denmark was the first country in the world to register
fishing vessels in line with the requirements of another
formal quality management system – ISO 9000.
• The requirement for management to implement effective
safety system has been recognised within the new product-
specific European Union (EU) legislation (e.g. meat and
fish) and also within the broader horizontal directives.
Importance has been given to the development of
management systems based upon HACCP.
 HACCP AND QUALITY ASSURANCE

• Lack of management consideration to food safety at the

product planning and factory development stage may
represent serious threats to public health.