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HACCP - Hazard Analysis Critical Control Point
High-end HACCP Monitoring System   What We Do...

HACCP is an attempt to systematically organise the assessment process for contamination of biological, chemical and physical hazards associated with the production of food and beverages.

HACCP began in the 1960s because of the NASA requirement for food sterility (salmonella infection) in the space programme. Pillsbury (in association with the US Army) and NASA developed the first HACCP programme for astronaut food. Pillsbury presented it at the first American National Conference for Food Protection in 1971. The Food and Drug Administration (FDA) in the US liked the HACCP programme and had Pillsbury assist them with it – it was first applied to low-acid tinned food in 1973. HACCP has gradually made its way around the globe since then. HACCP is managed globally by Codex Alimentarius.

HACCP is laid out according to seven basic principles: They are:

  • 1 – Conduct a Hazard Analysis;
  • 2 – Determine Critical Control Points;
  • 3 – Establish Critical Limits;
  • 4 – Establish a System to Monitor CCPs;
  • 5 – Establish Corrective Actions for when CCPs are Not Under Control;
  • 6 – Establish Verification Procedures to Confirm that HACCP is Working;
  • 7 – Establish Record-keeping and Documentation Procedures.

Are you an OEM selling a system that needs to be HACCP capable? Are you an end user needing a better HACCP system? Are you an integrator developing a HACCP system and need help?

We have HACCP assistance in New Zealand and also can put you in touch with local experts in the USA and Canada.

In addition, we can help you with your basic system needs such as control systems or technical documentation.

 
     
  More on HACCP  
 

New Zealand's food safety is managed by the New Zealand Food Safety Authority. The NZFSA employ the seven-step HACCP programme and have a twelve-step implementation programme for HACCP:

  • Step 1 – Assemble a HACCP Team.
  • Step 2 – Describe the Product and the Processes. A generic description is often sufficient (e.g., frozen vegetables)
    • What are our products and what are the associated risks?
    • Have all the steps in our food business been considered?
    • Have we considered processes carried out, and ingredients added, by our suppliers?
    • Have we missed any steps in the process? (See Step 5)
  • Step 3 – Identify the Intended Use. Identify the use of the food product by the end user or consumer – consider the effect of contamination on the elderly, pregnant women and the young.
  • Step 4 – Construct a Flow Diagram. Include the information needed for hazard analysis – such as information on micro–organisms that may be associated with the product. Do they form spores or toxins? What is their potential for survival and growth? Other information includes: process times and temperatures, product acidity (pH), premises conditions and hygienic design, cleaning, equipment characteristics, storage conditions, and instructions for consumer use.
    • Do we have set procedures for checking and approving suppliers?
    • Do we have a system for monitoring the quality of products from suppliers?
    • Do we have all the information we need to identify potential hazards?
  • Step 5 – Check the Flow Diagram:
    • Have any steps, ingredients, or other information been missed?
    • Do we actually do it the way the flow diagram shows?
  • Step 6 – Identify the Hazards (1). Check that all potential microbiological, chemical and physical hazards have been considered for each stage in the business – from raw materials to finished product:
    • Have we examined all sources of hazards (including suppliers)?
    • Have we used diagrams of the premises and its surroundings to identify hazards?
    • Have we used the flow diagram to identify possible hazards in the processes involved?
    • Have we identified risks attached to the product itself, such as the potential for misuse or abuse?
  • Step 7 – Control the Hazards and Determine Critical Control Points (CCPs) (1), (2). Ensure that each of the hazards identified in Step 6 has a control and determine which of the controls are critical to the safety of your product:
    • Have controls been identified for each hazard?
    • Do they effectively remove, or minimise the likelihood of each hazard occurring?
    • Can we alter the process where preventable measures don’t exist?
    • Do our staff understand what the CCP requirements are?
  • Step 8 – Establish Action Steps (3), (4), (5). Establish critical limits for each critical control point (where possible), how the critical limits can be monitored, and decide on the action to take if these limits are exceeded:
    • Have we established limits for each critical control point?
    • Are we following the limits set down?
    • Are our measuring instruments sufficiently accurate?
    • Do our measurement systems meet recognised standards?
    • Has corrective action been decided on for each out-of-control condition?
    • Do we have procedures for learning from food safety problems?
    • Do we have a system for handling complaints?
    • Is the frequency of our monitoring and recording appropriate?
    • Do we have a system for recalling our products?
  • Step 9 – Establish Record Keeping and Documentation (6), (7). Decide the level of documentation and record keeping needed that will meet the needs of the business to demonstrate the effectiveness of the food safety programme. Documentation may include: a plan of the layout of the food business; hazard worksheets; action plan worksheets; procedural documentation; written procedures; operating methods; checklists; log sheets or diaries; training programmes; maintenance and control points. Questions:
    • Do we have a satisfactory level of record keeping?
    • Do we file and store records safely?
    • Do we record and action critical control points?
    • Have we recorded the limits for each CCP?
    • Are our control measures properly recorded?
    • Are we monitoring and evaluating our methods?
    • Do we keep records of our calibrations?
    • Do we get independent checks of our food safety programme?
    • Do we have checks of our products in the marketplace?
    • Do we have a procedure for recording the detection of unsafe products?
    • Do we have written instructions for handling unsafe food products?
    • What measures do we take to check that our food safety programme is being carried out?
    • Do we keep records of our system checks?
  • Step 10 – Review and Audit. Establish a regular internal audit of the system, or parts of it and review or modify it to accommodate new information or problems as they are identified. The frequency of internal audits will depend on the complexity of the operation and whether there are any changes or problems experienced in the process. As a guide, a three-monthly internal audit should be appropriate with regular verification checks between. However, changes or problems encountered will have a marked influence on this. Appoint an approved auditor to provide independent assessment of whether your system has identified and established control over the relevant hazards. The frequency of external audit depends on the same factors mentioned above. With a well run programme that is regularly monitored and reviewed, an annual audit should suffice:
    • Does our system work as we planned?
    • Do our processes match our procedures?
    • Have any changes been made or shortcuts taken?
    • Have we had any complaints?
    • What did we do about them?
    • Has a similar product been involved in a public health issue or recall?
 
     
 

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