Hazard Analysis Critical Control Hazard Analysis Critical Control Point (HACCP) Plan
Instructions:
Draft a (Hazard Analysis Critical Control Point ) HACCP plan (“HACCP Principles & Application Guidelines”, 1997; GmbH, 2016; “Safefood 360º Whitepaper Design of CCP Monitoring Programs”, 2013; Anderson, 2016; nenalandim, 2011)
Assignment Summary:
Utilizing the references cited, create a HACCP plan for production of a food of your choice. Utilize the examples and templates in the FDA guide on HACCP for this activity. You may also utilize the critical control points decision tree on the Sesotec website or other sites on the internet for this activity. Imagine potential hazards or consider the potential hazards suggested on the Sesotec website. Run these potential risks through your plan. Identify the critical control points (CCP), critical limits and document quality risk controls, associated procedures and records.
Step by Step Instructions for Completing this Assignment
Design a HACCP Plan using the FDA guide
Figure 1: HACCP Plan – Initial Steps
Provide the descriptions, team roles and responsibilities and flow diagram as detailed in Figure 1 using the HACCP Plan Format (Figure 2).
Hazard Evaluation
Perform and document Hazard Evaluation. You can add a narrative description or additional tables to supplement the table (Table 1) as needed.
- Hazard Identification: a list of potential biological, chemical or physical hazards which may be introduced, increased, or controlled at each step in the production process.
- Hazard Considerations: See Appendix C of the FDA guide for Examples of Questions to be Considered When Conducting a Hazard Analysis. Only consider those questions that could be applicable to the food chosen for this assignment.
- Addressing the Hazard: Evaluate hazards as low, medium or high risk and determine whether they need to be addressed in your HACCP plan. See Appendix D in the FDA guide as an example.
Table 1: Hazard Evaluation
| Step | Potential Hazard(s) | Justification | Hazard to be addressed in plan? Y/N |
Control Measure(s) |
| 5. Cooking | Enteric pathogens: e.g., Salmonella, verotoxigenic-E. coli |
enteric pathogens have been associated with outbreaks of foodborne illness from undercooked ground beef | Y | Cooking |
| verotoxigenic-E. coli | undercooked ground beef |
Critical Control Point (CCP) Decision Tree
Design a CCP Decision Tree to add to the HACCP Plan
- Consider as examples the CCP decision trees in Appendices E & F of the FDA guide and on the Sesotec website. You may utilize these CCP decision trees or combine them to create your own. The CCP decision tree you document must be applicable to the food production process and the potential hazards requiring control.
Critical Control Points (CCP)
Determine CCPs (Use example in Table 2)
A critical control point is defined as a step at which control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level. The potential hazards that are reasonably likely to cause illness or injury in the absence of their control must be addressed in determining CCPs. CCPs must be used only for purposes of product safety. Hazard Analysis Critical Control
- Examples of CCPs may include: thermal processing, chilling, testing ingredients for chemical residues, product formulation control, and testing product for metal contaminants. CCPs must be carefully developed and documented.
- A specified heat process, at a given time and temperature designed to destroy a specific microbiological pathogen, could be a CCP. Likewise, refrigeration of a precooked food to prevent hazardous microorganisms from multiplying, or the adjustment of a food to a pH necessary to prevent toxin formation could also be CCPs.
Establish Critical Limits (Use Table 2 as example)
A critical limit is a maximum and/or minimum value to which a biological, chemical or physical parameter must be controlled at a CCP to prevent, eliminate or reduce to an acceptable level the occurrence of a food safety hazard. A critical limit is used to distinguish between safe and unsafe operating conditions at a CCP. Critical limits should not be confused with operational limits which are established for reasons other than food safety.
Table 2: CCP & Critical Limits
| Process Step | CCP | Critical Limits |
| 5. Cooking | YES | Oven temperature:___° F Time; rate of heating and cooling (belt speed in ft/min): ____ft/min Patty thickness: ____in. Patty composition: e.g. all beef Oven humidity: ____% RH |
| Patty composition: e.g. all beef Oven humidity: ____% RH |
Establish Procedures, Reporting Forms & List Applicable Records
Use the Standard Operating Procedure (SOP) Template (Anderson, 2016) to document procedures. Prior to the ‘Procedure’ section of this SOP template, add a section, ‘Materials / Equipment’ to list materials / equipment involved in the procedure. Document a Deviation Report form (nenalandim, 2011; slides 7 & 8) and reference this form in the SOPs. Document the following:
- CCP monitoring procedures
- Procedures for Verification / validation of HACCP plan
- Deviation Report form (including corrective action)
- Procedures for Document Control & Record Management
- List applicable Records (that may be generated by SOPs) (see examples in Appendix H of FDA guide)
Additional procedures may be documented if they help in identifying CCPs, critical limits, for example, food production processes.
Figure 2: HACCP Plan Format:
Listing of the HACCP team and assigned responsibilities.
Description of the food, its distribution, intended use, and consumer.
Verified flow diagram.
HACCP Plan Summary Table that includes information for:
Steps in the process that are CCPs
The hazard(s) of concern.
Critical limits
Monitoring*
Corrective actions*
Verification procedures and schedule*
Record-keeping procedures*
* A brief summary of position responsible for performing the activity and the procedures and frequency should be provided
The following is an example of a HACCP plan summary table:
| CCP | Hazards | Critical limit(s) | Monitoring | Corrective Actions | Verification | Records |
Support documentation such as validation records, procedures, deviation report forms, hazard evaluation, CCP decision trees, CCPs, critical limits
Records that are generated during the operation of the plan.
Apply your HACCP Plan
Imagine potential hazards or consider the potential hazards suggested on the Sesotec website. Run these potential risks through your plan. Document records (records are produced as a result of following procedures you have developed e.g. deviation reports, records for monitoring CCPs like oven temperature, HACCP plan verification checklist).
References:
HACCP Principles & Application Guidelines. (1997). US Food and Drug Administration. Retrieved 10 August 2016, from http://www.fda.gov/Food/GuidanceRegulation/HACCP/ucm2006801.htm
GmbH, S. (2016). Determining critical control points in food production – Sesotec GmbH – EN.
Sesotec.com. Retrieved 10 August 2016, from http://www.sesotec.com/en/determining-critical-control-points-in-food-production/
Safefood 360º Whitepaper Design of CCP Monitoring Programs. (2013). safefood360.com. Retrieved 10 August 2016, from http://safefood360.com/resources/Design-of-CCP-Monitoring-Programs.pdf
Anderson, C. (2016). How to Write a Standard Operating Procedure Template. bizmanualz. Retrieved 13 September 2016, from https://www.bizmanualz.com/save-time-writing-procedures/how-to-create-a-standard-operating-procedure-template.html
Nenalandim,. (2011). Managing Validation.3. Slideshare.net. Retrieved 13 September 2016, from http://www.slideshare.net/nenalandim/managing-validation3