Haccp Principle: Ensuring Safe Panned Food Handling

Hazard Analysis and Critical Control Points (HACCP) is a food safety management system that aims to control hazards in the food supply chain and prevent unsafe operating conditions. HACCP is based on seven principles, which are the most important steps in writing a HACCP plan. The first two steps provide the foundation for the HACCP plan, while the remaining five steps are the application steps that provide the structure for conducting the workings of the HACCP plan in the processing plant. The seven principles of HACCP are:

- Conduct a hazard analysis

- Determine critical control points (CCPs)

- Establish critical limits

- Establish monitoring procedures

- Establish corrective actions

- Establish verification procedures

- Establish record-keeping and documentation procedures

Identify potential hazards in the food prep process

To identify potential hazards in the food prep process, a Hazard Analysis and Critical Control Points (HACCP) plan can be used. This is a systematic approach to food safety that helps identify, reduce and react to biological, chemical and physical hazards.

When conducting a hazard analysis, consider all aspects of the food prep process and the flow of food. Some factors that can lead to hazards include how food arrives, how it is stored, handled and prepared, the equipment used, the skill level of staff, and whether you serve populations at higher risk of contracting foodborne illnesses.

Biological hazards include bacteria, parasites, fungi and viruses, which can develop in poorly handled food or through contamination from an outside source. To minimise the risk, ensure all food is purchased from an approved supplier, and always inspect deliveries to ensure goods are fit for consumption.

Chemical hazards are harmful substances such as pesticides or machine oils, which are present at every stage of food handling. Minimise the risk by always handling and storing food correctly, and keeping separate storage for chemicals.

Physical hazards are objects that contaminate food, such as glass, metal, hair or jewellery. To minimise the risk, ensure all foods are covered during storage, and that staff follow good personal hygiene practices.

Other potential hazards include time and temperature abuse, caused by improper cooking, cooling, holding and reheating of food, and cross-contamination, which occurs when mixing cooked and uncooked food.

Determine critical control points

Critical Control Points (CCPs) are a vital aspect of the Hazard Analysis Critical Control Point (HACCP) system, which is a widely recognised approach to ensuring food safety. The HACCP system is designed to identify and control potential food safety hazards, and CCPs play a crucial role in this process.

CCPs are specific points, steps or procedures in the food production process where control measures can be applied to prevent, eliminate or reduce food safety hazards to acceptable levels. These hazards can be biological, chemical or physical in nature, and CCPs are essential to ensuring that food products are safe for consumption.

Determining CCPs requires experience and judgement, and it may be aided by the use of a decision tree. The Campden BRI decision tree, for example, helps identify CCPs by asking a series of questions such as:

• Are there control measures in place?
• Is the step specifically designed to eliminate or reduce hazards?
• Could contamination with identified hazards occur or increase beyond acceptable levels?
• Will subsequent steps eliminate or reduce hazards?

By applying these questions to each hazard at each process step, it is possible to identify CCPs and ensure effective management of food safety. The number of CCPs will depend on the complexity of the process and the range of hazards being considered.

Once CCPs have been identified, it is important to establish critical limits, monitoring procedures, corrective actions, verification procedures and record-keeping practices to ensure food safety.

In summary, determining CCPs is a critical step in the HACCP system, and it involves identifying specific points in the food production process where control measures can be applied to prevent, eliminate or reduce food safety hazards. This process requires careful consideration and expertise to ensure the effectiveness of the overall HACCP plan.

Establish critical limits

Establishing critical limits is the third principle of HACCP, which stands for Hazard Analysis and Critical Control Points. This principle involves setting maximum and/or minimum limits to control biological, chemical, or physical hazards and reduce them to safe levels. These limits are essential guidelines for maintaining food safety and must be tracked through measurement or observation.

Critical limits should be quantifiable and observable, allowing for effective monitoring and control of the process. They provide a framework for decision-making and help employees understand the actions required to maintain food safety. Examples of measurable critical limits include temperature, time, physical dimensions, humidity, moisture level, water activity, pH, titratable acidity, salt concentration, available chlorine, viscosity, preservatives, or sensory information such as aroma and visual appearance.

For instance, to eliminate bacteria in raw chicken breast, the critical limit is cooking it to an internal temperature of 165 degrees Fahrenheit for 15 seconds. This critical limit can be achieved by cooking the chicken on the grill for the appropriate amount of time.

It is important to note that critical limits are based on scientific literature and/or regulatory standards. They should not be confused with operational limits, which are set for reasons other than food safety. Operational limits are typically tighter than critical limits to ensure that critical limits are not exceeded.

If a critical limit is exceeded, it indicates a potential safety hazard, and corrective action must be taken. This could include reworking or disposing of the affected product. Therefore, establishing critical limits is a crucial step in the HACCP plan to ensure food safety and maintain compliance with regulatory standards.

Establish monitoring procedures

The fourth principle of HACCP is to establish monitoring procedures. This involves a planned sequence of observations or measurements at critical control points to ensure that the critical limits are continuously achieved. The purpose of monitoring is to confirm that the critical limits are being continuously achieved and to detect any loss of control to enable effective corrective action to be taken.

Monitoring procedures should be established, and all relevant staff should be trained in the appropriate methods, as well as in the appropriate recording of results. The nature and frequency of monitoring will depend on the critical limits that are subject to monitoring and the likelihood of any anticipated changes.

The issues to consider are:

• Nature of monitoring: Monitoring can be done by taking appropriate measurements or by making observations. For example, temperature measurement or observation of colour change in food.
• Method of monitoring: Monitoring procedures may involve either in-line or off-line systems. In-line systems involve taking measurements during the process and may be either continuous or non-continuous. Off-line systems may involve taking samples for rapid testing to determine pH or Aw using calibrated meters.
• Frequency of monitoring: The frequency of monitoring will depend on factors such as the nature of the product, the nature of the process, and the history of previous checks.

To establish monitoring procedures, it is important to specify the following:

• What monitoring activities are going to take place at each critical control point.
• How frequently the monitoring activities are to be carried out.
• How the monitoring activities are carried out.
• Who is responsible for monitoring actions at each critical control point.
• Where are the results of monitoring recorded.
• Will the monitoring records be checked and signed off by anyone?

Documentation and record-keeping are crucial aspects of establishing monitoring procedures. It is important to record who will carry out each monitoring activity, ensure they are competent to do so, and provide them with the necessary training. A detailed description of how to carry out the monitoring should be provided, and the person responsible for monitoring must have the knowledge and authority to take corrective action if the critical limit is not achieved.

Monitoring records should include the date and time the activity was carried out, as well as the actual result. All records and documents associated with monitoring critical control points must be signed by the person(s) doing the monitoring and, where possible, by another nominated person responsible for reviewing the monitoring results.

A review of the monitoring procedures should be scheduled and triggered if there are changes within the business, as outlined in the sixth principle of HACCP.

Establish corrective actions

Corrective actions are the procedures that are followed when a deviation in a critical limit occurs. The HACCP team will identify the steps that will be taken to prevent potentially hazardous food from entering the food chain and the steps that are needed to correct the process. This usually includes identifying the problems and the steps taken to ensure that the problem will not occur again. Corrective actions are key to preventing the sale of unsafe products.

The following steps should be taken when establishing corrective actions:

• Determine and correct the cause of non-compliance.
• Determine the disposition of non-compliant product.
• Record the corrective actions that have been taken.

The goals of a corrective action plan are to:

• Establish a system that allows and promotes a rapid response to deviations from a critical limit.
• Correct and eliminate the cause of the deviation and restore process control.
• Maintain accurate documentation and records.
• Identify affected product and determine appropriate disposition.

The typical sequence of events involved in a corrective action are as follows:

• Stop the line or process, and segregate affected product.
• Adjust the process to bring the CCP back under control and correct the cause of the deviation.
• Document and record the action(s) taken.
• Consult with the HACCP team (and any others deemed appropriate).
• Inform regulatory officials, if appropriate.
• Follow the product disposition plan and/or conduct a product disposition analysis.
• Determine whether modification of the HACCP plan is necessary.

Corrective actions must be immediate and must trigger an automatic review of the HACCP plan. They must be specific, immediate and comprehensive, and documented.

Frequently asked questions