PowerPoint Presentation

8. HACCP Overview Training Produced by: Gordon Hayburn For “Nuts To You” January 2026.

[Audio] Review the Codex Alimentarius definition for HACCP..

[Audio] HACCP is a tool, which provides a systematic process for controlling food hazards. HACCP begins with the Identification of food hazards followed by evaluation of the risk of the hazard if consumed and application of control measures to mitigate the risk..

[Audio] Section 2 of the Standard-The Food Safety Plan-is a fundamental section requiring sites to develop, implement, and maintain a food safety (HACCP) plan based on Codex Alimentarius principles. Critical or major non-conformities identified in the development, implementation and maintenance of the food safety plan result in no certification as it indicates a lack of an effective food safety system..

[Audio] Review the five preliminary steps of HACCP as described on the slide..

[Audio] Review the seven principles of HACCP as described on the slide..

[Audio] BRC GS requires the HACCP team leader to have in-depth knowledge of HACCP principles, development, and implementation. The team leader must be able to demonstrate competency and experience in applying HACCP methodology..

[Audio] The HACCP team is responsible for defining the scope of each HACCP plan. Scope must include all products and processes, but can vary as to the format of the plan..

[Audio] Define what is a prerequisite programme? Glossary of the Standard Where prerequisite programmes control food hazards, they shall be identified and documented in the HACCP plan. PRP's shall have written procedures and associated monitoring and verification activities to ensure hazards are effectively controlled. Validation of PRP's is required where the PRP controls a specific hazard..

PRP -v- CCP. PRP (Prerequisite Program): PRPs are a foundational set of practices and conditions that create a hygienic and safe environment for food production. PRPs are essential for maintaining overall food safety and include activities such as sanitation, personnel hygiene, facility maintenance, and pest control. Think of PRPs as the basic building blocks that need to be in place before more specific control measures are implemented. Typically control most of the potential hazards identified by the HA/RA They are monitored and contribute to the overall safety of the food production process.

FROM TS 22002-1 (2009): PRPs on Food Safety Part 1 - Food Manufacturing.

[Audio] Examples of physical/chemical properties, e.g. water activity, pH; processing, e.g. pasteurisation, drying, freezing; packaging, e.g. gas flushed, modified atmosphere A detailed product description must be documented for all product types to provide relevant information for the purpose of conducting the hazard analysis..

[Audio] Intended use should additionally consider the manner in which the product is intended to be handled and used once in the marketplace. Consideration for alternative use or misuse are also key elements of intended use..

[Audio] Development of flow diagrams must be completed by someone with process knowledge, which is why a multi-disciplinary HACCP team with individuals who have operational knowledge is highly beneficial. Recall that incorrect process flow diagrams is one of the top 10 BRCGS non-conformities globally..

[Audio] Verifying flow diagrams is an important part of Codex methodology. HACCP flow diagrams serve as the basis for the hazard analysis and identification of controls so it is imperative that all process steps, inputs and outputs are properly identified for further consideration..

[Audio] BRC GS takes a holistic approach to hazard analysis by identifying and analysing hazards in raw materials, the supply and distribution chain, the production environment, and process steps that occur within individual product types or product groups. BRC GS relies on product description (clause 2.3), intended use (clause 2.4), and process flow (clause 2.5/2.6) to conduct the hazard analysis..

Hazard and Risk. Hazard: The Codex Alimentarius Commission defines a hazard as a Biological, Chemical or Physical agent in, or condition of, food with the potential to cause an adverse health effect. Consideration of Radiological agents or activity is also required for both BRCGS and FSMA compliance. Risk: Risk is the chance or probability (likelihood) that a person will be harmed or experience an adverse (severity) health effect if exposed to a hazard. HACCP requires control of any hazard that may be “reasonably expected” to occur (CODEX 2023).

Describing Hazards. Be Specific Do not group hazards together under headings e.g. “Pathogens” (even the genus may not be specific enough) “Foreign Bodies” “Chemicals” Without a proper identification of the hazard it will be difficult (if not impossible) to determine if the Critical Limits are appropriate.

“Clostridium”: growth/survival limits. Water Activity pH Temperature Species 0.97 4.7 3.0 C C’ botulinum (non-proteolytic) 0.94 4.6 10 C C’ botulinum (proteolytic) 0.93 4.5 12 C C’ perfringens Not reported 5.3 Considered to be <0 C C’ estertheticum (spoilage).

Hazard Analysis and Risk Assessment. Hazard analysis: The process of collecting and evaluating information on hazards and conditions leading to their presence to decide which are significant for food safety and therefore need addressed in the HACCP plan. Significant hazard: “A hazard identified by a hazard analysis as reasonably likely to occur at an unacceptable level in the absence of control and for which control is essential given the intended use of the food” (CODEX 2023).

[Audio] Example 1. Salmonella has a high prevalence rate in raw chicken (high likelihood) and causes illness and death (high severity) so it is identified as a significant hazard requiring control. 2. The hazard is Salmonella in undercooked chicken so the control measure is cooking at a specified time/ temperature (e.g., 70°C for 2 minutes). 3. Elimination of Salmonella in cooked chicken may require cross-contamination controls during primary cutting of raw chicken AND cooking at a time/ temperature capable of achieving lethality. 4. Sanitation of chicken handling and processing equipment is an example of a prerequisite program controlling cross-contamination from Salmonella in raw chicken..

Hazard Analysis and Risk Assessment. Risk assessment: The scientific evaluation of known or potential adverse effects resulting from human exposure to foodborne hazards. The Risk Assessment process consists of the following steps: (i) hazard identification, (ii) hazard characterization, (iii) exposure assessment, and (iv) risk characterization..

Risk Assessment. Hazard identification: “Could this food or anything in it be harmful?” Hazard characterization: “What effects do the hazards cause?” Exposure assessment: “Who may be harmed, and at what level may exposure be harmful?” Risk characterization: “How likely is it that people will experience exposure at a level that can cause harm in real life?”.

Hazard Management - First Steps. Many assessments fail due to being over complicated. There is a simple approach to use to minimize the chance of failure: 1) - Eliminate it 2) - Do what we are told 3) - Assess it 4) - Manage it.

Risk Assessment (scoring and definitions are determined by the company).

RATING LIKELIHOOD RATIONALE Negligible (1) No published data showing incidences in industry in last 3 years (36 months) (The hazard is unlikely to occur.) Low (2) Incidences (from a common source) have been reported within the last 1-3 years basis in industry, (but not within the last 12 months) however, no incidences identified at NTY in the last 13-36 months. Medium (3) Incidences (from a common source) have been reported in the last 12 months in industry, or instances from more than one source have been reported in the last 13-36 months. However, no incidences at NTY in the last 13-36 months. High (4) Incidences have been reported from more than one common source and has been identified in industry in the last 12 months, or NTY in last 13-36 months. Very High (5) Incidences have been reported at least on monthly basis in industry, or NTY in the last 12 months..

Risk Assessment. OVERALL CONCERN – (RISK) SEVERITY 9 9 18 27 36 45 5 5 10 15 20 25 1 1 2 3 4 5 1 2 3 4 5 LIKELIHOOD.

Risk Assessment. Risk Rating and Action Levels Risk Rating See the specific risk rating scores for each type of assessment. Assessment rating = Low risk. Actions - No immediate action required. - Continued monitoring through Horizon scanning, etc. Orange Risk Rating See the specific risk rating scores for each type of assessment. Assessment rating = Medium risk. Actions - Further investigation required: - Team to discuss and consider options, e.g. OPR Red Risk Rating See the specific risk rating scores for each type of assessment. Assessment rating = High risk. Actions - Take to CCP Decision Tree. CCP: develop and implement an action plan required to eliminate or reduce the risk to acceptable levels . Not a CCP: Consider the use of OPR and continue to monitor and assess.

[Audio] All identified controls in the hazard analysis shall be evaluated at the process step by a decision method to determine if the control is critical to maintaining food safety. Controls determined to be critical shall be identified as CCP's..

[image] A diagram of a flowchart Description automatically generated.

PRP -v- CCP. CCP (Critical Control Point): These are specific points or steps in the food production process where control measures are applied to prevent, eliminate, or reduce hazards to an acceptable level. CCPs are critical because failure at these points could result in unsafe food reaching consumers. Monitoring and verification are crucial for CCPs, and they are directly managed and controlled. Examples of CCPs include cooking temperatures, pasteurization, and cooling processes.

Q1) Can this Hazard be eliminated?. YES. Eliminate it. (STOP).

HACCP PLAN FOR: DATE: TEAM Process Step Potential Hazard Eliminate? Customer/ Regulatory Requirement PRP Controlled Severity Likelihood Overall Concern Action Required.

[Audio] The HACCP team must set critical limits for each CCP. The limits should be measurable but may be observational where clear guidance is provided. Critical limits should have a defined upper and/ or lower limit. Target values within minimum and maximum limits may be applied to assist in managing process variation..

[Audio] Criteria used for critical limits, often include measurements of: moisture level pH temperature time available chlorine visual appearance texture.

[Audio] Review key criteria for validating CCP's and control measures..

[Audio] It is important that the monitoring procedure specify an appropriate method and frequency to ensure the ability to detect deviation from critical limits at a frequency sufficient to enable corrective action. Monitoring records shall match procedural requirements and be verified within a reasonable time frame..

[Audio] These questions form the basis of a good monitoring procedure – training of monitors should be discussed..

[Audio] Review definitions for correction and corrective action procedure with delegates. Discuss the differences between these activities. An example of a correction is to adjust the metal detector when check pieces are not rejected during monitoring and re-establish monitoring to ensure compliance within critical limits. An example of a corrective action procedure when check pieces are not rejected during monitoring include: Adjust metal detector Re-establish monitoring to ensure compliance with critical limits Evaluate all product since last acceptable monitoring check and determine product disposition Conduct root cause analysis for why MD did not reject Apply corrective action to prevent recurrence (e.g., inadequate MD operator training, incorrect MD settings, poorly functioning MD, etc.).

[Audio] BRC GS requires verification activities to confirm the effectiveness of the food safety plan and prerequisite programmes..

[Audio] List activities on a flip chart before revealing suggested answers. Note that all studies, trials, guidance, and historical data must be scientifically valid. Specific examples of validation versus verification for CCP's identified in the Dairy Made Case Study booklet include: Metal detection Validation of metal detection may include reference to the equipment manufacturer's study for recommended settings based on minimum detection limits of ferrous, non-ferrous, and stainless steel as a function of aperture size, food matrix, and packaging material (where applicable). Activities to verify implementation and effectiveness of the metal detector may include annual calibration from the equipment manufacturer at the recommended settings. 2. Filtration through a 1mm filter Validation of filtration may include reference to scientifically-based industry standards for exclusion of 1mm or greater foreign material. Activities to verify implementation and effectiveness of filtration may include review of customer complaints for foreign material greater than 1mm. 3. Pasteurization at 81°C for 35 sec Validation of pasteurization may include reference to scientific studies confirming a 5-log reduction of Listeria, Salmonella, E. coli, S. aureus, B. cereus, and M. paratuberculolosis at the target time and temperature. The z value for pathogens of concern should be determined and included in the validation. Activities to verify implementation and effectiveness of pasteurization may include periodic raw material and finished product testing for the pathogens (or indicator organisms) of concern..

[Audio] Review key criteria for record keeping.. Record keeping.

[Audio] While not explicitly required by Codex, reviewing the HACCP plan under the following conditions will help ensure control of new or emerging hazards..

[Audio] HACCP plans are not static; they are dynamic and evolving to meet the changing needs of a globally sourced food chain..

Closing. Hazard Analysis and Risk Assessment is an excellent approach to the logical and scientific management of potential hazards in Food Safety. There is no quick answer or “one size fits all”. The approach can be used for the assessment of potential hazards and risks in HACCP, Food Defense and Threat Assessment, although these assessments require different knowledge and experience..