HACCP: Case study
– microbiological
example
Dr Olafur Oddgeirsson
Brussels November 2008
1
Implementation Steps
1)
2)
3)
4)
5)
6)
Identify Critical Control Points (Principle 7)
Identify Control Points
Conduct a Hazard Analysis (Principle 6)
Establish Critical Limits (Principle 8)
Establish Monitoring procedures (Principle 9)
Establish Corrective Actions (Principle 10)
2
Step 1 – Hazard Analysis
Carry out a hazard analysis (at each process step)
by identifying and listing all potential hazards and
list the measures to control the identified hazards:
In the abattoir:
• Biological (pathogenic)
• contamination, growth, survival
• Chemical
• cleaning chemicals, medicines, herbicides
• Physical
• people, premises, plant, packaging, pests
3
Hazards in Food
Biological
Chemical
Physical
Bacteria
Mycotoxins
Viruses
Seafood Toxins
Hair
Nails
Fungi
Bacterial Toxins
Glass
TSEs
Heavy Metals
Parasites
Pesticide Residues
Metals
Etc.
Plant Toxins
Veterinary Drug Residues
Food Contact Materials
Environmental and Process
Contaminants
4
Process Hazard Analysis
Step
Evisceration
Hazard
Biological
Hazards:
Contamination
Product
Bovine carcase
Author:
Decision
Tree
Date
Page of
Control Measure
Q1
CCP
Y/N
Comment
HACCP Team
Cause
Poor work
practice
Q2
Training of Operative in
SOP
Chemical
Hazards:
Not Applicable
Why did it go
wrong?
Physical hazard
Not Applicable
What can I do
about it?
What can go
wrong?
5
Step 2 - Control Points
Definition:
„
„
A Control Point is any point at which a hazard
can be controlled, eliminated or reduced to an
acceptable level.
Examples???
Clean animals, steam pasteurisation etc.
6
Step 3 – Critical control points (CCPs)
Identify Critical Control Points (CCPs) in the
process using a Decision Tree:
Definition:
Critical Control Points are those where a specific hazard must
be controlled to protect the consumer, on the basis that no
further process will adequately deal with that hazard
7
Simplified Decision Tree
Q1.
Would a loss of control at this point result in
a realistic risk of illness or injury?
Yes
No
Q2.
Is there a later step at which this Hazard is or
can be controlled? (under your control)
No
Yes
CCP
Not CCP
Not CCP
8
What can go
wrong?
Why did it go
wrong?
Process Hazard Analysis
Product
Step
Bovine carcase
Author:
Evisceration
Hazard
What can I do
about it?
Decision Tree
Date
Page of
Q1
CCP
Y/N
Comment
HACCP Team
Cause
Control Measure
Poor work
practice
Training of Operative in
SOP
Q2
Biological Hazards:
Contamination
Y
Y
N
Final
carcase
Inspection
Chemical Hazards:
Non Applicable
Physical Hazards:
Non Applicable
9
What can go
wrong?
Why did it go
wrong?
Process Hazard Analysis
What can I do
about it?
Product
Bovine carcase
Step Final carcase
Inspection
Author:
Hazard
Cause
Control Measure
Poor carcase
inspection
Training of Operative in
SOP
HACCP Team
Decision
Tree
Date
Page of
Q1
CCP
Y/N
Comment
Q2
Biological Hazards:
Contamination
Chemical Hazards:
Non Applicable
Physical Hazards:
Non Applicable
10
Why did it go
wrong?
What can go
wrong?
Process Hazard Analysis
Step
Product
Final carcase
Inspection
Hazard
Cause
What can I do
about it?
Bovine carcase
Author:
Decision Tree
Date
Page of
Q1
CCP
Y/N
Comment
HACCP Team
Control Measure
Q2
Biological Hazards:
Contamination
Poor carcase
inspection
Training of Operative in
SOP
Y
N
Y
CCP1
Chemical Hazards:
Non Applicable
Physical Hazards:
Non Applicable
11
Beef HACCP Plan
HACCP Plan
PRODUCT
Author
carcase Beef
Step
CCP1
Final
carcase
inspection
Potential
Hazard
(What can go
wrong?)
Cause
(Why did it go
wrong?)
Contamination Poor
carcase
Bacteria
Inspection
Control
measure (What
can I do about
it?)
Critical
Limits
Section
No.:
Monitoring
Procedure Respon Freq
(How do I check?)
Date:
Rev: Page of
Corrective
Action
(What can I
do about it?)
Doc
Ref.
How do
I
prove?)
Verification
Correct
training in
carcase
inspection
12
Step 4 –Critical Limits
A critical limit is a criteria which separates
acceptability from unacceptability:
Step
CCP 1 Final carcase
inspection
Hazard
Contamination
Critical Limit
Zero Visible
Contamination
13
Important Points in Setting Limits
Ask yourself the
following questions:
„ Is the limit attainable?
„ Is it legal?
„ Will the limit
sufficiently control the
hazard?
„ What criteria was
used to set this limit?
14
Lamb HACCP Plan
HACCP Plan
PRODUCT
carcase Lamb
Step
Potential
Hazard
(What can
go
wrong?)
Control
Cause
measure
(Why
did it go (What
wrong?) can I do
CCP1
Contamination Poor
Final carcase
carcase
Bacteria
inspection
Inspection
SRM
CCP ??
Carcase/
Offal
Chilling
If not
Mechanical
failure or
Poor
fridge
temperature
control resulting breakdown.
Poor
in growth of
chilling
bacteria
practice
Critical
Limits
about it?)
Correct
training in
carcase
inspection
Service and
maintenance
of chill unit.
Training
in temperature
control
No visual
contamination
(N.V.C.)
Author
Section Date:
No.:
Rev: Page of
Monitoring
Procedure Respon
Freq
(How do I check?)
Correcti
ve
Action
(What
can I do
about
it?)
Doc
Verification
Ref.
How do
I
prove?)
Carcase
less than 7oC
for lamb and
less than 3oC
for offal in
24 hours
why not?
15
Step 5 –Monitoring
Establish a monitoring system to ensure control
of the CCP by scheduled testing or observations:
–
–
–
–
–
What?
Where?
Who?
When?
How?
What is the Critical Limit?
Must be at the CCP or close as possible
Person responsible identified & trained
Continuous or at defined intervals
Describe the monitoring process
16
Important Points about
Monitoring
Sometimes constant
monitoring isn’t
possible.
„ Sometimes micro
testing cannot be
avoided as a means
of monitoring
„
17
Lamb HACCP Plan
HACCP Plan
PRODUCT
Author
carcase Lamb
Step
CCP1
Final carcase
inspection
Potent Cause
ial
(Why did
Hazar it go
d
wrong?)
(What
can go
wrong Poor
Contamination
carcase
Bacteria
?)
Inspection
SRM
Section
No.:
Date:
Rev: Page of
Control Critical Monitoring
measur Limits Procedure Respon Freq
e (What
(How do I check?)
can I do
about
it?)
Correct
training in
carcase
inspection
Inspect every
No visual
contamination carcase after
(N.V.C.)
slaughter
Slaughter
personnel
Every
carcase
Corre
ctive
Actio
n
(Wha
t can
I do
about
it?)
Doc
Ref.
How do
verificatio
n
I
prove?)
18
Step 6 - Corrective Action
„
Establish the corrective
action to be taken when
monitoring indicates
that a particular CCP is
moving out of control:
„
if a critical limit is
exceeded or not
achieved a corrective
action must be taken.
19
Lamb HACCP Plan
HACCP Plan
PRODUCT
carcase Lamb
Step
CCP1
Final carcase
inspection
Potenti
al
Hazard
(What
can go
wrong?
Contamination
)Bacteria
SRM
Cause
(Why
did it
go
wrong?
)
Poor
carcase
Inspection
Contr
ol
measu
re
(What
can I
Correct
do
training in
carcase
about
inspection
it?)
Critic
al
Limits
Author
Section
No.:
Monitoring
Procedure Respon
Freq
(How do I check?
Inspect every Slaughter
No visual
carcase after personnel
contamination
slaughter
(N.V.C.)
Every
carcase
Date:
Rev: Page of
Corrective
Action
(What
can I do
about it?)
Doc
Ref.
How do
verificatio
n
I prove?)
Trim
visible
contamination
20
Beef HACCP Plan
HACCP Plan
PRODUCT
Author
carcase Beef
Step
Potenti
al
Hazard
(What
can go
wrong?)
Cause
(Why
did it go
wrong?)
CCP1
Final carcase Contamination Poor
carcase
Bacteria
inspection
Inspection
SRM
Section
No.:
Control Critical Monitoring
measur Limits Procedure Respon
e (What
Freq
can I do
(How do I check?)
about
it?)
Correct
training in
carcase
inspection
Inspect
No visual
contamination every
(N.V.C.)
side after
slaughter
Slaughter
personnel
Every
carcase
Date:
Rev: Page of
Corrective
Action
(What can I
do about
it?)
Trim visible
contamination
Doc
Ref.
How do
verificatio
n
I
prove?)
21
CCP Monitoring / Records
Final carcase Inspection Record
carcase No.
H/Q
S.Loin/
Flank
F/QR
S.R.M.
Removal
24 hr
48 hr
72 hr
1
2
Signed:
Slaughterman
Signed:
Owner
22
Lamb HACCP Plan
HACCP Plan
PRODUCT
carcase Lamb
Step
Potent
ial
Hazar
d
(What
can go
wrong
?)
Contamination
CCP1
Final carcase Bacteria
SRM
inspection
Cause
(Why did
it go
wrong?)
Poor
carcase
Inspection
Author
Section
No.:
Control Critical Monitoring
measur Limits Procedure Respon
e (What
Freq
can I do
(How do I check?)
about
it?)
Correct
training in
carcase
inspection
Slaughter
Inspect every
No visual
carcase after personnel
contamination
slaughter
(N.V.C.)
Every
carcase
Date:
Rev: Page of
Correc
tive
Action
(What
can I
do
about
it?)
trim
visible
contamination
Doc
Ref.
How do
verification
I prove?)
Final
carcase
inspection
record
23
Beef HACCP Plan
HACCP Plan
PRODUCT
Author
carcase Beef
Step
Potent
ial
Hazar
d
(What
can go
wrong
?)
Cause
(Why did
it go
wrong?)
CCP1
Final carcase Contamination Poor
carcase
inspection
Bacteria
Inspection
SRM
Section
No.:
Control Critical Monitoring
measur Limits Procedure Respon
e (What
Freq
can I do
(How do I check?)
about
it?)
Date:
Rev: Page of
Correc
tive
Action
(What
can I
do
about
it?)
Inspect
Correct
training in
carcase
inspection
No visual
every
contamination side after
(N.V.C.)
slaughter
Slaughter
personnel
Every
carcase
Trim off
contamination
Doc
Ref.
How do
verification
I prove?)
Final
carcase
inspection
Weekly
record
24
Implementation Procedures of HACCP
systems in meat establishments
„
Hygiene Package 2006 - Changes?
„
All businesses after primary production must have a food
safety system based on HACCP principles.
Principles to be applied with flexibility in some
establishments
Pre-requisite programs may suffice in certain operations
Critical Limits do not have to be numerical
„
„
„
25