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HACCP
Implementation
December 2006
Here’s
a 12-step process to implement a Hazard Analysis Critical Control Points
(HACCP) program into your facility:
1. Assemble a HACCP
Team
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The
team should be multi-disciplinary and made up of individuals who
are from different areas and have different expertise within the
organization. Personnel to include in the team may include the following
people:
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HACCP Co-ordinator;
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Upper Management representative;
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Production Personnel (supervisors and/or line workers – shows
ownership in program);
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Quality Assurance/ Quality Control;
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Maintenance and/or Engineering;
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Shipping and Receiving;
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Sanitation;
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Purchasing;
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Sales/ Marketing;
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Consultant(s).
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Limit the team to five to eight personnel.
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Only bring in personnel where their expertise is required (e.g.
do not have an individual from the purchasing department present
when determining procedures for cleaning).
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Have one information centre, a person who gathers information and
keeps the system going – usually HACCP Co-ordinator.
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Set regular meeting times at a time convenient for most and limit
meeting to less than two hours.
2. Describe the
Product
Using Forms # 1
and # 2 of the HACCP plan, complete the following:
Form
#1
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Product
name;
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Important
characteristics (water activity, pH, preservatives, salt, etc.);
- How it is to
be used (Ready to Eat, Further Cooking Required, etc.);
- Packaging (gas
flushed, vacuum packaged, plastic bags and then boxed, etc.);
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Shelf life;
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Where
it will be sold (HRI – hotels, restaurants, institutions; further
processing, etc.);
- Labeling instructions;
- Special distribution
control – (transport in refrigerated carrier).
Form
#2
- List product
ingredients and incoming materials;
- Break ingredients
and incoming materials down into categories. Be sure to only include
those relevant to your process. Some examples of categories may include
but are not limited to:
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Meat
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Raw materials
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Water/ice
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Spices/dry ingredients
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Preservatives
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Non-food products
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Processing aids
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Packaging materials
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Rework
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Others
4. Process Flow
& Plant Schematic
Use Forms # 3 and
# 4 of the HACCP plan to complete the following:
Form
# 3 – Process Flow
- Start with incoming
materials;
- Keep it as simple
as possible while not missing any processing steps;
- Use arrows to
show direction of flow;
- Use shapes, shading,
colour to indicate critical steps;
- Make sure no
minor crucial steps are missed;
- Number steps
for easy identification.
Form
# 4 – Plant Schematic
- Overhead view
of plant;
- Use coloured
and/or different line types to distinguish between raw and cooked
product;
- Use a legend
to clarify what each line means;
- Include flow
of raw product, employees handling raw products, ready to eat product,
employees handling ready to eat products, packaging materials, waste
(garbage) flows;
- Include hand
wash stations in schematic.
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Go out into the facility and ensure that Forms 3 and 4 are accurate
and reflecting the process – DO NOT OVERLOOK THIS STEP!
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Follow product from start to finish to ensure no processing steps
are missed (e.g. a storage step between processing and packaging,
addition of rework is not being missed, etc.);
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Look
for correct plant schematic flows, look for “hidden passageways” employees
or product may flow through, causing cross contamination.
- HACCP Principle
# 1 – Use Forms # 5, # 6, and # 7 of the HACCP plan
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One of the most important steps (wrong analysis = inadequate system)
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Start with form #2 (incoming materials), then proceed to form #3 (process
flow) and finally form #4 (plant schematic)
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List any biological, chemical or physical hazard that may be present
for each incoming material (form #2), processing step (form #3), or
cross contamination point on the plant schematic (form #4).
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Explain type of hazard and why it may occur (e.g. biological hazard
– due to time-temperature abuse).
7. Determine
Critical Control Points
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HACCP
Principle #2 – Use Form # 8 of HACCP plan
- Run each hazard
through the CCP decision tree to determine how the hazard is controlled
in the system;
- Once each hazard
has been run through the CCP Decision Tree, record where all
hazards are controlled back onto forms #5, #6, and #7, then record all
the hazards that cannot be controlled by the processor on form #9 and
all CCPs on form #10.
- Determine if the
hazard is completely controlled by pre-requisite programs.
- Question #1
- Could a control
measure(s) be used by the operator to control the identified hazard
at any processing step?
- If yes, describe
control measure and proceed to next question.
- If no, identify
how the identified hazard will be controlled before or after the
manufacturing process and proceed to next question.
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Question
#2
- Is it likely that
contamination with the identified hazard could occur in excess of the
acceptable level or could increase to an unacceptable level?
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Question
#3
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Is this process step specifically designed to eliminate or reduce
the likely occurrence of this identified hazard to an acceptable level?
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If
yes, this is a Critical Control Point and enter CCP # in last
column of form #8.
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If
no, then proceed to next question.
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Question
#4
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Will a subsequent step eliminate the identified hazard or reduce its
likely occurrence to an acceptable level?
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If
yes, this is not a CCP. Identify subsequent step(s) to control
identified hazard and proceed to next hazard.
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If
no, this is a CCP, enter CCP # in the last column of form #8.
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Put methods of control onto forms 5, 6, and 7 for each hazard.
8. Establish
Critical Limits
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HACCP Principle #3 - Use Form #10 of the HACCP plan
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Set the criteria that the CCP will operate within. These parameters,
if maintained within the boundaries, will confirm the safety of the
food product.
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Critical limits are set based on:
9. Establish
Monitoring Procedures
- HACCP Principle
#4 - Use Form #10 of the HACCP plan
- Explain the following:
10. Establish
Deviation Procedures
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HACCP
Principle #5 - Use Form #10 of the HACCP plan.
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Explains
the pre-determined steps to be taken should a problem occur. Must
include corrective actions to be taken on product, people, equipment,
and area, as well as any preventative measures to prevent the problem
from reoccurring.
11. Establish
Verification Procedures
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HACCP
Principle #6 – Use Form #10 of the HACCP plan.
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Procedures
that take place to ensure that the HACCP plan is functioning correctly
and procedures taking place as per the written program in the processing
facility. There are two parts to verification: record and onsite verifications.
12. Establish
Record Keeping Procedures
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HACCP
Principle #7 – Use Form #10 of the HACCP plan.
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The
in-plant record or check sheet created that contains the information
to prove the system has met the required critical limits.
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The records must also show that if a deviation occurred, what it was,
how it was corrected and the preventative measures that were implemented
to prevent the deviation from reoccurring.
For more information,
contact:
Saskatchewan
Food Industry Development Centre Inc.
(306) 933-7555
info@foodcentre.sk.ca
Or
Kelly Bettschen
Saskatchewan Agriculture and Food
(306) 933-7173
E-mail: kbettschen@agr.gov.sk.ca
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