HACCP stands for Hazard Analysis and Critical Control Points. HACCP is an industry-wide effort approved by the scientific community as well as regulatory and industry practitioners. This effort is designed to focus specifically on food safety, including food safety in retail establishments.
This training manual has been designed to provide a simple and logical approach for introducing a HACCP-based food-safety training program for employees of retail establishments. The manual provides the necessary information and references for developing a HACCP plan. Such a plan is intended to produce a system having a step-by-step analysis and resulting in procedures to be followed, including the much-needed documentation of those procedures.
The first five chapters introduce basic information about HACCP and its relationship and applications to retail food operations. An important aspect of these chapters is the information related to prerequisites to HACCP and the Sanitation Standard Operating Procedures (SSOP) in retail stores. These first chapters will help first-tier managers understand the importance of, and responsibility associated with, such a program. Mangers will find the information they need to form executive decisions that promote food safety.
Chapters six and seven deal specifically with aspects related to understanding the HACCP principles and creating HACCP plans. In these chapters, the biological, physical, and chemical hazards of the different food categories are identified. The seven HACCP principles are presented and discussed. This information leads to the creation and the implementation of a HACCP plan, including the requirements of the plan, the HACCP team, products and categories, employee training records, and recall procedures.
Preparing the HACCP plan is the initial step. Once the plan has been prepared, it is necessary to validate and verify that the plan works after it is implemented. Chapters 8 and 9 discuss the implementation of the plan and maintaining the plan. Chapter 10 provides sources of regulations pertaining to HACCP.
Chapter 11, the last chapter, consists of the appendices that support the HACCP program. Included are examples of the tasks that are to be performed and supporting information on the technical and regulatory aspects of the HACCP plan. These appendices are provided to give examples to help the retail store in how to prepare, implement, and practice the HACCP concept.
Having a HACCP plan in place and following it will result in practices that will aid in further ensuring safe food for consumers as well as providing proof of those safe practices through documentation.
What is HACCP?
HACCP, or the Hazard Analysis Critical Control Point system, is a process control system that identifies where hazards might occur in the food production process and puts into place stringent actions to take to prevent the hazards from occurring. By strictly monitoring and controlling each step of the process, there is less chance for hazards to occur.
Why is HACCP Important?
HACCP is important because it prioritizes and controls potential hazards in food production. By controlling major food risks, such as microbiological, chemical and physical contaminants, the industry can better assure consumers that its products are as safe as good science and technology allows. By reducing foodborne hazards, public health protection is strengthened.
What are the Major Food Hazards?
While many public opinion studies report that consumers are concerned primarily about chemical residues, such as from pesticides and antibiotics, these hazards are nearly non-existent. The more significant hazards facing the food industry today are microbiological contaminants, such as Salmonella, E. coli O157:H7, Listeria, Campylobacter, and Clostridium botulinum. HACCP is designed to focus on and control the most significant hazards.
Is HACCP New?
HACCP is not new. It was first used in the 1960s by the Pillsbury Company to produce the safest and highest quality food possible for astronauts in the space program. The National Academy of Sciences, National Advisory Committee for Mcirobiological Criteria for Foods, and the Codex Alimentarius have endorsed HACCP as the best process control system available today.
How Does HACCP Compare to the Current Food Production and Inspection Programs?
The current food inspection program is based on a "see, smell and touch" approach that relies more on detection of potential hazards than prevention. Furthermore, the current inspection program was designed in the 1930s when the threat of diseased animals and physical contaminants were the main concerns. Today, microbiological and chemical contamination, which cannot be seen, are of greater interest. The U.S. Department of Agriculture recently mandated HACCP for the nation's 7,000 meat and poultry plants.
What is the Status of the Adoption of HACCP Within the Meat and Poultry Industry?
Many of the nation's meat and poultry processing facilities have implemented some or all of the HACCP principles into their operations. Many companies have also provided HACCP training to management and in-plant workforce.
What is USDA's Pathogen Reduction/HACCP Regulation?
USDA is pursuing a farm to table approach to food safety by taking steps to improve the safety of meat and poultry at each step in the food production, processing, distribution and marketing chain. On July 25, 1996, USDA released its Pathogen Reduction/HACCP final rule. The final rule will further target pathogens that cause foodborne illness, strengthen industry responsibility to produce safe food, and focus inspection and plant activities on prevention objectives. The final rule covers three major areas:
Sanitation Standard Operating Procedures
Microbiological Testing
Hazard Analysis Critical Control Point (HACCP) system
How Does HACCP Work in Food Production?
There are seven principles, developed by the National Advisory Committee on Microbiological Criteria for Foods, that serve as the foundation for a HACCP system. They are:
1. Conduct a hazard analysis to identify potential hazards that could occur in the food production process.
2. Identify the critical control points (CCPs) -- those points in the process where the potential hazards could occur and can be prevented and/or controlled.
3. Establish critical limits for preventive measures associated with each CCP. A critical limit is a criterion that must be met for each CCP. Where appropriate, critical limits may reflect relevant FSIS regulations and FDA tolerances.
4. Establish CCP monitoring requirements to ensure each CCP stays within its limit. Monitoring may require materials or devices to measure or otherwise evaluate the process at CCPs.
5. Establish corrective actions if monitoring determines a CCP is not within the established limits. In case a problem occurs, corrective actions must be in place to ensure no public health hazard occurs.
6. Establish effective recordkeeping procedures that document the HACCP system is working properly. Records should document CCP monitoring, verification activities and deviation records.
7. Establish procedures for verifying that the HACCP system is working properly. Verification procedures may include reviewing the HACCP plan, CCP records, critical limits as well as conducting microbial sampling. Both plant personnel and FSIS inspectors will conduct verification activities.
What Role Does Microbiological Testing Play in HACCP Programs?
Microbiological testing can play a valuable role in HACCP programs as a means for verifying the HACCP system is working properly and to track trends and profiles of products. By tracking microbiological data, plants can identify when the production process is not being properly controlled or verify that prevention efforts are successfully reducing bacterial levels. End-product microbiological testing, however, is less effective. There is not sufficient data to determine what is considered an "acceptable" level of bacteria on raw meat and poultry, so an end-product test will not provide useful data, other than for trends analysis. While end-product testing may indicate bacteria are present, it does not solve the problem of identifying and eliminating contamination.
What Role Do Other New Technologies Play in HACCP?
New technologies will play critical roles in HACCP programs since HACCP is designed to institute practices that reduce or eliminate harmful contamination. If new technologies are developed that prevent or eliminate hazards throughout the production process, they will be widely accepted and adopted. The industry has studied several new technologies and petitioned USDA to approve them for use.
Are There Established HACCP Guidelines and Plans for the Food Industry To Use?
There are seven HACCP principles that must be followed to implement HACCP. Every food production process in a plant will need an individual HACCP plan that directly impacts the specifics of the product and process. Government and industry groups are developing some generic HACCP models that provide guidelines and directions for developing plant-, process- and product-specific HACCP systems. The International Meat and Poultry HACCP Alliance has developed training curriculum to assist the meat and poultry industry.
How Would HACCP Be Applied From Farm to Table?
For the most successful implementation of HACCP, it should be applied from farm to table -- starting on the farm and ending with the individual preparing the food, whether in a restaurant or home. On the farm, there are actions that can be taken to prevent contamination from occurring, such as monitoring feed, maintaining farm sanitation, and practicing good animal health management practices.
In the plant, contamination must be prevented during slaughter and processing. Once meat and poultry products leave the plant, there should be controls in place during transportation, storage and distribution.
In retail stores, proper sanitation, refrigeration, storage and handling practices will prevent contamination. Finally, in restaurants, food service and homes, food handlers must store, handle and cook foods properly to ensure food safety.
How Can HACCP Be Applied in Distribution and Retail?
FSIS plans to work with the Food and Drug Administration and state and local governments to begin to implement HACCP in the distribution and retail sectors. FSIS intends to work with FDA to develop federal standards for safe handling of food during transportation, distribution and storage prior to delivery to retail stores. Also, FSIS will work with FDA to provide food safety guidance to retail stores through the updated Food Code. The Food Code is a model ordinance intended to serve as a guide for state and local authorities. Following proper sanitation and handling guidelines will help ensure that further contamination and cross contamination do not occur.
How Can Consumers Use HACCP?
Consumers can implement HACCP-like practices in the home by following proper storage, handling, cooking and cleaning procedures. From the time a consumer purchases meat or poultry from the grocery store to the time they cook and serve a meal, there are many steps to take to ensure food safety. Examples include properly refrigerating meat and poultry, keeping raw meat and poultry separate form cooked and ready-to-eat foods, thoroughly cooking meat and poultry, and refrigerating and cooking leftovers to prevent bacterial growth.
HACCP, or the Hazard Analysis Critical Control Point system, is a process control system that identifies where hazards might occur in the food production process and puts into place stringent actions to take to prevent the hazards from occurring. By strictly monitoring and controlling each step of the process, there is less chance for hazards to occur.
Why is HACCP Important?
HACCP is important because it prioritizes and controls potential hazards in food production. By controlling major food risks, such as microbiological, chemical and physical contaminants, the industry can better assure consumers that its products are as safe as good science and technology allows. By reducing foodborne hazards, public health protection is strengthened.
What are the Major Food Hazards?
While many public opinion studies report that consumers are concerned primarily about chemical residues, such as from pesticides and antibiotics, these hazards are nearly non-existent. The more significant hazards facing the food industry today are microbiological contaminants, such as Salmonella, E. coli O157:H7, Listeria, Campylobacter, and Clostridium botulinum. HACCP is designed to focus on and control the most significant hazards.
Is HACCP New?
HACCP is not new. It was first used in the 1960s by the Pillsbury Company to produce the safest and highest quality food possible for astronauts in the space program. The National Academy of Sciences, National Advisory Committee for Mcirobiological Criteria for Foods, and the Codex Alimentarius have endorsed HACCP as the best process control system available today.
How Does HACCP Compare to the Current Food Production and Inspection Programs?
The current food inspection program is based on a "see, smell and touch" approach that relies more on detection of potential hazards than prevention. Furthermore, the current inspection program was designed in the 1930s when the threat of diseased animals and physical contaminants were the main concerns. Today, microbiological and chemical contamination, which cannot be seen, are of greater interest. The U.S. Department of Agriculture recently mandated HACCP for the nation's 7,000 meat and poultry plants.
What is the Status of the Adoption of HACCP Within the Meat and Poultry Industry?
Many of the nation's meat and poultry processing facilities have implemented some or all of the HACCP principles into their operations. Many companies have also provided HACCP training to management and in-plant workforce.
What is USDA's Pathogen Reduction/HACCP Regulation?
USDA is pursuing a farm to table approach to food safety by taking steps to improve the safety of meat and poultry at each step in the food production, processing, distribution and marketing chain. On July 25, 1996, USDA released its Pathogen Reduction/HACCP final rule. The final rule will further target pathogens that cause foodborne illness, strengthen industry responsibility to produce safe food, and focus inspection and plant activities on prevention objectives. The final rule covers three major areas:
Sanitation Standard Operating Procedures
Microbiological Testing
Hazard Analysis Critical Control Point (HACCP) system
How Does HACCP Work in Food Production?
There are seven principles, developed by the National Advisory Committee on Microbiological Criteria for Foods, that serve as the foundation for a HACCP system. They are:
1. Conduct a hazard analysis to identify potential hazards that could occur in the food production process.
2. Identify the critical control points (CCPs) -- those points in the process where the potential hazards could occur and can be prevented and/or controlled.
3. Establish critical limits for preventive measures associated with each CCP. A critical limit is a criterion that must be met for each CCP. Where appropriate, critical limits may reflect relevant FSIS regulations and FDA tolerances.
4. Establish CCP monitoring requirements to ensure each CCP stays within its limit. Monitoring may require materials or devices to measure or otherwise evaluate the process at CCPs.
5. Establish corrective actions if monitoring determines a CCP is not within the established limits. In case a problem occurs, corrective actions must be in place to ensure no public health hazard occurs.
6. Establish effective recordkeeping procedures that document the HACCP system is working properly. Records should document CCP monitoring, verification activities and deviation records.
7. Establish procedures for verifying that the HACCP system is working properly. Verification procedures may include reviewing the HACCP plan, CCP records, critical limits as well as conducting microbial sampling. Both plant personnel and FSIS inspectors will conduct verification activities.
What Role Does Microbiological Testing Play in HACCP Programs?
Microbiological testing can play a valuable role in HACCP programs as a means for verifying the HACCP system is working properly and to track trends and profiles of products. By tracking microbiological data, plants can identify when the production process is not being properly controlled or verify that prevention efforts are successfully reducing bacterial levels. End-product microbiological testing, however, is less effective. There is not sufficient data to determine what is considered an "acceptable" level of bacteria on raw meat and poultry, so an end-product test will not provide useful data, other than for trends analysis. While end-product testing may indicate bacteria are present, it does not solve the problem of identifying and eliminating contamination.
What Role Do Other New Technologies Play in HACCP?
New technologies will play critical roles in HACCP programs since HACCP is designed to institute practices that reduce or eliminate harmful contamination. If new technologies are developed that prevent or eliminate hazards throughout the production process, they will be widely accepted and adopted. The industry has studied several new technologies and petitioned USDA to approve them for use.
Are There Established HACCP Guidelines and Plans for the Food Industry To Use?
There are seven HACCP principles that must be followed to implement HACCP. Every food production process in a plant will need an individual HACCP plan that directly impacts the specifics of the product and process. Government and industry groups are developing some generic HACCP models that provide guidelines and directions for developing plant-, process- and product-specific HACCP systems. The International Meat and Poultry HACCP Alliance has developed training curriculum to assist the meat and poultry industry.
How Would HACCP Be Applied From Farm to Table?
For the most successful implementation of HACCP, it should be applied from farm to table -- starting on the farm and ending with the individual preparing the food, whether in a restaurant or home. On the farm, there are actions that can be taken to prevent contamination from occurring, such as monitoring feed, maintaining farm sanitation, and practicing good animal health management practices.
In the plant, contamination must be prevented during slaughter and processing. Once meat and poultry products leave the plant, there should be controls in place during transportation, storage and distribution.
In retail stores, proper sanitation, refrigeration, storage and handling practices will prevent contamination. Finally, in restaurants, food service and homes, food handlers must store, handle and cook foods properly to ensure food safety.
How Can HACCP Be Applied in Distribution and Retail?
FSIS plans to work with the Food and Drug Administration and state and local governments to begin to implement HACCP in the distribution and retail sectors. FSIS intends to work with FDA to develop federal standards for safe handling of food during transportation, distribution and storage prior to delivery to retail stores. Also, FSIS will work with FDA to provide food safety guidance to retail stores through the updated Food Code. The Food Code is a model ordinance intended to serve as a guide for state and local authorities. Following proper sanitation and handling guidelines will help ensure that further contamination and cross contamination do not occur.
How Can Consumers Use HACCP?
Consumers can implement HACCP-like practices in the home by following proper storage, handling, cooking and cleaning procedures. From the time a consumer purchases meat or poultry from the grocery store to the time they cook and serve a meal, there are many steps to take to ensure food safety. Examples include properly refrigerating meat and poultry, keeping raw meat and poultry separate form cooked and ready-to-eat foods, thoroughly cooking meat and poultry, and refrigerating and cooking leftovers to prevent bacterial growth.
ISO 9000 is a generic name given to a family of standards developed to provide a framework around which a quality management system can effectively be implemented.
ISO 9001:2000, the requirement standard, includes the following main sections:
1. Quality Management System
2. Management Responsibility
3. Resource Management
4. Product Realization
5. Measurement Analysis and Improvement
What does it mean to me?
To gain the maximum benefit from ISO 9000:2000 there are a number of steps to take:
1. Define why your organization is in business.
2. Determine the key processes that state 'what' you do.
3. Establish how these processes work within your business.
4. Determine who owns these processes.
5. Agree these processes throughout the organization.
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