Determine the critical control points CCP

Determine the critical control points (HACCP  Principle 2)

With the information obtained from the hazard analysis step, the HACCP team must then determine the points at which there will be control of the hazards that present unacceptable risks; this will establish the CCPs of the HACCP plan. A useful tool for the determination of whether a raw material or process step is a CCP, is the CCP decision tree. Examples of CCP decision trees have been proposed by Codex Alimentarius and by the NACMCF. The CCP decision trees consist of a set of either three or four questions, which are asked in a particular sequence for each identified hazard so that the point of control of that hazard within the HACCP plan can be determined.

At the completion of Step 7, the HACCP team should be in a position to determine at which points in the process, the identified biological, chemical and physical hazards associated with the product will be controlled so that the hazard will be eliminated, prevented, or reduced to an acceptable level. It is possible that more than one step could be a critical control point (CCP) for the same hazard (e.g., pasteurization and refrigerated storage can be CCPs for the same microbiological hazard); on the other hand, a single CCP could control more than one hazard (e.g., a screening step in a process can be a CCP for various physical hazards). 

HAZARD EVALUATION

The second stage of the hazard analysis is the evaluation to determine which of the hazards that have been identified in the first stage of the hazard analysis are significant, and therefore need be addressed in the HACCP plan for the product. The identified hazards must be considered for their  likely occurrence, and the severity of the risk that they present if they are not controlled. In assessing the likely occurrence of a hazard, the HACCP team needs to examine published information and data, and previous experiences on occurrence of the hazard in the product. In assessing the severity of the risk presented by a hazard, the HACCP team must address the severity of health consequences to consumers of the product, if the identified hazard is not controlled. In carrying out this stage of the hazard analysis, the HACCP team should take the following into account:

• The methods and procedures of preparation, handling, storage, and distribution of the product

• The effects of both short-term and long-term exposure of the product containing the hazard to the health of consumers

• The people, including any particular groups (e.g., infants, pregnant women, the elderly) who are likely to consume the product and the effect the hazard could have on the health of these individuals

• Information and data from previous reported incidents involving the occurrence of the hazard in the product, including the impact of the hazard on the health of consumers.

IDENTIFICATION OF CONTROL MEASURES
 

As part of the hazard analysis the HACCP team must determine whether control measures for the  hazards that need to be addressed in the HACCP plan are present in the process. If control measures for the hazard do not exist in the process, modification of the process may be required in order to institute a control measure, or some alternate measure should be used to address the hazard. 

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Hazard Analysis

Hazard Analysis (HACCP Principle 1)

HACCP Principle 1  hazard analysis must be performed. The hazard analysis can be an extensive exercise for the HACCP team, since it addresses the three categories of hazards —  biological, chemical, and physical. The hazard analysis should be carried out in two stages; the first stage is  hazard identification, which is followed by hazard evaluation. In addition, the control measures for the hazards that need to be addressed in the HACCP plan should be identified at the completion of the hazard analysis.

HAZARD IDENTIfiCATION

The first stage of hazard analysis is the identification of known potential hazards that are likely to be associated with the product; this covers the ingredients, raw materials, and contact packaging materials used in preparation of the product; every aspect of each step of the process; and the environment used for the preparation of the product. If all the potential hazards are not identified, the HACCP plan that is developed might be inadequate to address the safety of the product. The NACMCF has compiled a list of examples of issues that should be considered during a hazard identification exercise:

• The nature of the product and the product characteristics that have been established during the completion of Step 2

• The safety record of the product and the known hazards associated with the product

• The normal microbial content of the product and changes in the microbiological population during storage and handling of the product

• The hazards that are likely to be present in the product if product characteristics such as pH, composition, water activity, and preservatives are not controlled

• The various raw materials, ingredients, and packaging materials used to prepare the product

• The activities, operations, and personnel involved at each of the steps listed in the process flow diagram, including the equipment that is used and the prevailing environmental conditions at the time the product is produced and stored

• The intended use of the product by customers, consumers, or particular segments of the population.

During the hazard identification exercise, the HACCP team should consult appropriate sources of information to determine the known product hazards for which the HACCP plan is developed, as well as known hazards associated with the various raw materials, ingredients, and the processing operations used for the product. A useful database  (Reference Database for Hazard Identification) has been developed by Agriculture and Agri-Foods Canada  (1995). In addition to reference information, valuable information on potential hazards can be obtained by closely observing the process as it is operating. In order for the hazard identification to be successful, it is essential that the HACCP team acquire detailed knowledge of potential hazards associated with every aspect of each step of the process that produces the product for which the HACCP plan is developed.

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The Codex Alimentarius Logic Sequence for the Application of HACCP

The Codex Alimentarius Logic Sequence for the  Application of HACCP

The twelve steps in the Codex Alimentarius Logic Sequence for the Application of HACCP are as follows:

• Step 1: Assemble an HACCP team.

• Step 2: Describe the food product that the HACCP plan will address.

• Step 3: Identify the intended use of the food product.

• Step 4:  Construct a flow diagram of the process that is used to produce the food product.

• Step 5: Conduct an on-site verification of the process flow diagram.

• Step 6: Conduct a hazard analysis of (a) all raw materials and ingredients and (b) each step (in the process flow diagram) used for preparation of the food product (HACCP Principle 1).

• Step 7: Determine which (a) raw materials and ingredients, and (b) process steps, will be critical control points at which unacceptable hazards identified in Step 7, will be controlled (HACCP Principle 2).

• Step 8: Establish critical limits or tolerances for each of the critical control points identified in Step 7 (HACCP Principle 3).

• Step 9: Establish monitoring procedures for each of the critical control points identified in Step 7 (HACCP Principle 4).

• Step 10: Establish corrective action procedures to be followed when monitoring of the critical control points reveals that the established critical limits  have been exceeded or have not been met  (HACCP Principle 5).

• Step 11:  Establish verification procedures to confirm and provide confidence that (a) the critical control points are being monitored effectively and are under control, and (b) the HACCP plan for the product is operating effectively (HACCP Principle 6).

• Step 12: Establish record-keeping and documentation procedures for records and documents that are required by the HACCP plan (HACCP Principle 7).

Maintenance of the HACCP system

After an HACCP system has been developed and implemented, it must be maintained effectively on a continuous basis. This means that the monitoringprocedures, the corrective action procedures (when required), the verification activities, and the record-keeping at each CCP, and for all the HACCP plans in the HACCP system, must operate continuously, and in exactly the manner as they were initially developed and implemented. Any change in any of these activities should only take place after the HACCP coordinator has been informed and has approved the change. For any significant change to the existing HACCP plan activities, the HACCP team should evaluate the change using the same guidelines and principles  (Steps 1 to 12)  that were used in the development of the HACCP system.

The HACCP team should determine whether the HACCP plan for a product needs to be modified after each of the following:

• The intended use of the product has changed

• There is a change in one or more raw materials, ingredients, or packaging materials used for preparing the product

• There is a change in the process for preparing the product

• There is addition, replacement or modification of equipment used in the process If any of the above changes affect the existing CCPs in the HACCP plan for a product, the HACCP plan should be reviewed to determine whether modifications are required for the critical limits, monitoring procedures, corrective action procedures, verification procedures, and recording-keeping and documentation procedures.

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