Hazard Analysis & Critical Control Point: Prepared By: Eng / Walid I. Gahfer

Hazard Analysis & Critical Control Point
Prepared By:
Eng / Walid I. Gahfer
Quality Shift Leader In Senyorita Co.
One Of Americana Group for Food Industries 1
Trainer : Walid Gahfer
Agenda
 Introduction To HACCP
 HACCP Benefits
 HACCP Principles
 Implementation Of HACCP
 HACCP Plan
 HACCP Preparation :
-> Preliminary steps
-> Pre-requisite programs
2
Introduction To HACCP
HACCP Is :-
•A system of control based on prevention of problems by
identifies specific hazards and control measures to
ensure total food safety management.
•The system requirements are generic and applicable to

all food organisations concerned with the food chain
from production preparation, processing, packaging,
storage and distribution until the point of customer
consumption.
3
Steps Of HACCP System
• Look at your Process/ Product from A to Z;
• Decide where hazards could occur;
• Put in controls and monitor them;
• Write it all down and keep records;
• Ensure that it continues to work effectively.
4
HACCP Benefits
• Maximize product safety.
• Improved management responsibility.
• Improved process control.
• Improved inspection testing.
• Moving the company towards a Quality
Management System.
5

6
Principle (1)
Analysis Of Hazards Assessment.
Principle (2)
Identification Of Process Critical Control Points (CCPs).
Principle (3)
Establish Critical Limits For Preventative Measures Associated With Each
Identified CCP.
Principle (4)
Establish procedures for Monitoring the CCPs.
Principle (5)
Establish of corrective actions to be taken when monitoring indicates deviation
from an establish critical limit.
Principle (6)
Establish effective record-keeping procedures that document the HACCP
system.
Principle (7)
Establish procedures for verification that HACCP system is working correctly.
7
Principle (1)
Analysis Of Hazards
Assessment
8
Hazard:
Is any factor which may be present in the product that can cause
harm to the consumer either through injury or illness.
Preventative Measure:
An action to prevent a hazard or reduce it to an acceptable level.
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 Prepare a list of the process (Process Flow Diagram containing
all process steps from Raw Material receiving TO End Product) &
Identify where significant hazards could occur and describe
preventive measures.
The hazard could be biological, chemical, or physical. And the

measure that can be applied to prevent the occurrence of hazards
must be determined accordingly.
10
Types Of Hazards Associated With Our Product:
Biological Hazards:
It’s any pathogenic microorganism like Bacteria, Parasites & Viruses.
EX: Bacteria:- ((Shigella, Salmonella, Staphylococcus aureus, Escherichia coli, Standard
plate count, Total Yeast & moulds, Total Coliforms, Bacillus cereus)).
Chemical Hazards:
1. Naturally-occurring chemicals.
EX: (( Allergens, Mold toxins -mycotoxins- ))
2. Intentionally-added chemicals.
EX: (( Packaging materials, Sanitizers ))
3. Unintentional or incidental chemical additives.
EX: ((Agricultural chemicals -pesticides, fertilizers- & Toxic elements / compounds -lead, tin,
copper, zinc, arsenic, mercury, cyanide- & Cross-contaminating food allergens from
inadequately cleaned shared processing equipment.))
Physical Hazards:
Any potentially harmful matter not normally found in packet
EX: Metal, Wood, Glass Fragments.
11
Principle (2)
Identification Of Process
Critical Control Points
(CCPs)
12
Critical Control Point (CCP):
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.
 After determination of hazards, we must determine

where hazards could occur.
 And for performing this identification we use the
Decision Tree.
CCP Decision Tree:
A sequence of questions to be considered in the process to decides where is
CCP.
13
Steps to Identify (Determine) CCPs Using A
Decision Tree
Q1: Do preventive measures exist for this hazard?
if yes go to Q2, if no, that means it’s required of safety
if no = not CCP*, (if yes modify process or product).
Q2: Does this step specifically designed to eliminate/reduce the likely
occurrence of this hazard to an acceptable level?
if yes = CCP if no go to Q3
Q3: Could contamination occur in excess of acceptable level? (Unacceptable
level occur)?
if yes go to Q4 if no = not CCP*
Q4: Will a subsequent step eliminate/reduce this hazard to an acceptable
level ?
if yes = not CCP* if no = CCP
* (go to the next step in production) 14
Principle (3)
Establish Critical Limits For
Preventative Measures
Associated With Each
Identified CCP
15
Critical Limit (CL):
- Is the criteria that specifies safe product from unsafe product.
- Is the maximum /or minimum value that must be controlled at a
CCP to prevent, eliminate, or reduce to an acceptable level the
occurrence of the identified food hazard.
Operation Limit:
A criteria that is more strict than critical limits, which the operator
use to reduce the possibility of deviation.
When there is any deviation from CL; the product became un safe.
16
Principle (4)
Establish Procedures For
Monitoring The CCPs
17
Monitoring: -
To conduct a planned sequence of observations or
measurements of control parameters to assess whether
the CCP’s are controlled by the food organisation or
not.
• Monitoring is performed to identify when there is

a loss of control (a deviation at a CCP).
•Monitoring equipments shall be calibrated
precisely.
18
Monitoring
What: usually a measurement or observation to assess if the
CCP is operating within the critical limit.
How: usually physical or chemical measurements (for

quantitative critical limits) or observations (for qualitative critical
limits).
Frequency: continuous or periodic.
Who: responsible individual trained to perform the specific

monitoring activity or evaluate monitoring records.
19
Principle (5)
Establish Of Corrective
Actions To Be Taken When
Monitoring Indicates Deviation
From An Establish Critical
Limit
20
Corrective Action:
Is the procedures under following to satisfy system requirements
when a deviation occurs.
 Corrective action procedures includes the actions that brings the

process back under control.
 It also includes action to deal with product manufactured while
the process was out of control.
21
Principle (6)
Establish Procedures For
Verification That HACCP
System Is Working Correctly
22
Verification:
The application of methods, procedures, tests and other evaluations,
in addition to monitoring to determine compliance with the HACCP
plan.
Validation:
The process of proving that a system is acceptable for its intended
purpose.
23
The verification procedures of the overall
:HACCP system shall includes
 Initial validation of the elements of the HACCP plan, such as
process flow diagram, hazards analysis, determination of CCPs,
critical limits, monitoring procedures, corrective action, documents
/records keeping system, etc.
 Internal audit that covers all activities under HACCP system,
which shall be performed at least once every six months.
The feedback system of audit data for improvement of the HACCP
system.
 Any changes made that may affect the HACCP system.
External audit.
24
Principle (7)
Establish Effective Record-
Keeping Procedures That
Document The HACCP System
25
The documents/records shall include all
the elements of the HACCP system, including:
Description of HACCP system.
The records of all HACCP Prerequisite procedures,
The records of hazard analysis and their control methods,
CCP determination,
Critical Limit determination,
CCP monitoring activities and results,
Deviations and associated corrective actions,
Other activities like (Sanitation control, Audit,Meetings, Training
Verification, Compliant, Recall, etc…).
26
How To Implement A HACCP System
1. Assemble HACCP team.
2. Describe food and its distribution.
3. Identify intended use and consumers of food.
4. Develop process flow diagram.
5. Verify flow diagram.
6. Conduct a hazard analysis.
7. Determine the critical control points (CCPs) in the process.
8. Establish critical limits.
9. Establish monitoring procedures.
10.Establish corrective actions.
11.Establish verification procedures.
12.Establish record-keeping and documentation procedures.
27
How To Apply HACCP To Our
Product?
1) Identify the potential hazards associated with
our product.
2) Explore how to prevent them.
3) Identification of CCPs
4) Establishment of A HACCP plan critical limits.
5) Monitoring procedures.
6) Corrective actions.
28
29
What is the HACCP Plan?
 HACCP plan is a formal document which pulls
together the key information from the HACCP
study and holds details of all that is critical for food
safety management.
 HACCP plan is mainly consists of two
essential components:
 (1) Process Flow Diagram
 (2) HACCP Control Chart
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D e fin e Y o u r T e rm s O f R e fe r e n c e
D e s c r ib e T h e P ro d u c t & T h e In te n d e d U s e
C o n s tr a c t a P r o c e s s F lo w D ia g r a m
V a lid a te P ro c e s s F lo w D ia g r a m
Id e n t if y H a z a r d s & p re v e n ta tiv e M e a s u r e s
Id e n tify C r it ic a l C o n t r o l P o in ts
E s ta b lis h C r itic a l L im its
Id e n tify M o n ito rin g P r o c e d u re s
E s ta b lis h C o r r e c tiv e A c tio n P ro c e d u re s
V a lid a te H A C C P P la n
31
(1) The Process Flow
Diagram
• Process Flow Diagram is a sequence of events
through the whole process, giving a clear and
simple description of how the end product is made.
• Process Flow Diagram enables the HACCP Team
to understand the production process and the basis
for the hazard analysis.
• Process Flow Diagram shall includes all the
process inputs (Row materials) & all the process
outputs (Wastes).
32
HACCP Control )2(
Chart
• It’s a table of control parameters which contains
details of the steps/stages in the production process
where there are CCPs.
• It also contains details of the hazards and

preventative measures associated with each CCP.
33
34
Preliminary Steps For A HACCP System
Application
o Senior Management Commitment.

o Assembling A HACCP Team.
o Product Description.
o Establishing the Process Flow Diagram.
o Verification of Process Flow Diagram.
35
Prerequisite Programs For Establishing A
HACCP Plan
• Good Manufacturing Procedures (GMPs).
• Sanitation Standard Operation Procedures (SSOP).
• Specifications & Suppliers monitoring.
• Pest Control.
• Training.
• Non-Compliance & Corrective Action procedures.
• Recall procedures.
• Consumer Complaints Analysis procedures.
• Calibration & Preventative Maintenance procedures.
36
Good Manufacturing Procedures (GMP’s)
includes
1) Prevention of food contamination.
2) Cleanliness of Clothing and garments.
3) Employee Personal Hygiene & Disease control.
4) Prevention of Eating , Drinking & Smoking
inside processing & producing areas.
5) Proper Labeling.
37
Sanitation Standard Operation Procedures
(SSOP) includes
1) Safety of used water.
2) Cleanliness of product contact surfaces.
3) Cleanliness of employee clothes.
4) Prevention of cross contamination
5) Maintenance of hand washing & hand sanitizing & toilet
facilities.
6) Proper labeling of toxic materials..
7) Personal Hygiene.
8) Pests exclusion.
38

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Hazard Analysis & Critical Control Point

•The system requirements are generic and applicable to

The hazard could be biological, chemical, or physical. And the

 After determination of hazards, we must determine

• Monitoring is performed to identify when there is

How: usually physical or chemical measurements (for

Who: responsible individual trained to perform the specific

 Corrective action procedures includes the actions that brings the

E s ta b lis h C r itic a l L im its

Id e n tify M o n ito rin g P r o c e d u re s

E s ta b lis h C o r r e c tiv e A c tio n P ro c e d u re s

• It also contains details of the hazards and

o Senior Management Commitment.

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