Month: January 2023

Are you looking to get certified in the Hazard Analysis and Critical Control Points (HACCP) system?  The purpose of a Hazard Analysis Critical Control Points (HACCP) plan is to identify and control any hazards that may arise during the process of manufacturing, storing, distributing, and consuming food products. HACCP plans are meant to reduce, eliminate, and avoid risks that may negatively impact the consumer and the organization. They will vary based on the product, process and other factors that can occur in the facility. Developing a HACCP plan consists of 12 tasks with seven principles, which are further explained below.

Completing this certification program means completing seven important steps. In this guide, we’ll provide an overview of the 12 HACCP steps and 7 principles and help you get ahead on your certification process.

Understand HACCP Principles:

The first step to getting certified in the HACCP system is to understand the seven principles that make up HACCP guidelines.

These seven principles, developed by the Codex Alimentarius workgroup, were designed to ensure safe food production and handling. Knowing and understanding these principles will help you when it comes time to complete certification steps.

Assign Responsibility & Authority:

The fifth step of the HACCP certification process is to assign responsibility and authority. By doing this, it will enable all personnel involved in the HACCP system adhere to the guidelines with a greater degree of consistency. This can be done by providing training to individuals assigned to positions related to HACCP and assigning personnel authority commensurate with their responsibilities within the system. Additionally, establish working relationships between groups of personnel who work together or provide oversight over any food safety process or part thereof.

Identify Critical Control Points (CCPs):

A critical control point (CCP) is a step of the process at which control can be applied in order to prevent or eliminate food safety hazards.

The seven principles for developing and managing a successful HACCP plan involve formally identifying CCPs, establishing critical limits for each CCP, monitoring these steps, ensuring corrective action is taken when necessary, verifying the system’s effectiveness, making sure all records are maintained, and conducting regular reviews. All of these steps contribute to proper implementation of the HACCP plan.

Establish Critical Limits at CCPs:

Establishing critical limits at CCPs is a hugely important step of your HACCP plan. These limits define the parameters which must be followed in order to ensure food safety. When determining the critical limits, it’s important to consider the type of hazard and its respective Severity of Consequence (SOC) should it occur. Upper and lower control points are sometimes established to describe the range in which an operation should work. For example, the time/temperature combination necessary for cooking a meat product may have an upper and lower limit that must be adhered to in order for the food to be considered safe.

1. Establish a HACCP Team

The HACCP team consists of individuals possessing a wide range of disciplines and knowledge to contribute to the process of food safety. A typical team includes:

• Team Leader: orchestrates and organizes the planning process; identifies the scope and specific problem(s) of the plan.
• Specialist(s): provide consultation and formulation of the plan through their expertise and knowledge.
• Front Line Staff: includes farmers, distributors, processors, etc.; have in-depth perspective on creating the food product.
• Stakeholders: e.g. consumers, board of directors, departments, etc.

2. Describe the Product

A full description of the final product should have the following elements in order for the HACCP team to identify hazards in creating the product:

• Ingredients, and their characteristics;
• Formulation (aka “recipe”) of the product;
• Process of packaging, storing, and transporting;
• Shelf life.

3. Purpose of the Product

The team determines the main intent of how the product will be used. Will it be cooked, eaten directly, or require further processing? The team needs to identify its intended consumers and determine any vulnerabilities when using the product.  Lastly, the team should consider the effects of misuse or abuse of the product to the general population.

4. Process Flow Diagram

A process flow diagram gives the HACCP team a broader view on the manufacturing process of the product. The diagram can also consist of a schematic of the facility, lending an easier understanding of the steps of each process.

5. On Site Confirmation of Flow Diagram

The HACCP performs a review of the operating/manufacturing process to determine the quality of the flow diagram. Multiple reviews can be done and compared to iron out deficiencies in the process.  The site for which the HACCP plan is being designed should be visited as many times as possible to make sure all relevant information is collected.

6. Identify and analyze hazards (Principle # 1)

While identifying potential hazards, the HACCP team must do some background research on the following:

• Ingredients and materials used in the product
• Activities performed in each step of the manufacturing process
• Method of storage and distribution
• Use/consumption of product

During analysis, the HACCP evaluates the product’s effects on human, environmental, and organizational interaction.

Control measures are considered once hazards are identified and analyzed during the manufacturing process. At times, organizations may have to hire external food safety consultants to offer different perspectives.

7. Determine the Critical Control Points (CCPs) (Principle # 2)

A critical control point is a step in the process flow diagram that involves reducing, eliminating, and preventing food safety hazards. If CCPs are not in place, the production will stop and cannot continue further.

8. Establish Critical Limits for each CCP (Principle # 3)

A critical limit measures the maximum/minimum value of certain factors that have impact on reducing, preventing, and eliminating food safety hazards. Factors such as temperature, time, moisture level, and visual appearance are considered.

9. Establish a Monitoring Procedure (Principle # 4)

A general monitoring procedure consists of:

• Ensuring critical limits of each CCP are being met;
• Detecting any inefficiencies of the control measures;
• Corrective actions need to be taken as quickly as possible to avoid and minimize loss of the product;
• Observing or measuring samples using a statistically-based sampling plan;
• Common measurements taken are time, temperature, moisture, and content.

10. Establish Corrective Actions (Principle # 5)

Corrective actions must be taken immediately if critical limits are not being met. Management and employees should be trained on how to perform and respond appropriately.

11. Verify the HACCP Plan (Principle # 6)

Once the plan is drafted and CCPs have been validated, the HACCP plan can then be verified. The team must evaluate if CCPs and control measures are effective. Internal auditing may be required to demonstrate ongoing commitment to complying and updating the HACCP plan. Asking questions, observing operational procedures, and collecting samples are just some of the ways to verify the plan.

12. Keep Records (Principle # 7)

Record keeping is an essential step of the HACCP plan due to the following:

• Offers traceability and transparency
• Ensures due diligence
• Provides record of complaints with critical limits set
• Identifies potential problems

Record keeping can be carried out in a number of ways, such as checklists or control charts. Manual and computer records are acceptable, but the documentation method should be designed such that it is appropriate for the size and nature of the organization.

If you or your company is seeking assistance in implementing a HACCP plan we’re ready to serve you.  Quality Smart Solutions has a team of experts who can implement a HACCP plan, coach and train your staff. Get prepared now and contact us today to discuss how we can be your solution!

Quality Smart Solutions is an end-to-end compliance solutions expert which has been assisting clients for 14 years in the areas of compliance and quality assurance for Dietary Supplements/NHPs, Foods, Cosmetics, Canna, Medical Devices, OTC drugs in Canada and the United States. Ask us for details or visit our website at www.qualitysmartsolutions.com.