Even in its earliest stages, the goal of HACCP was to identify Critical Control Points in the process that must be controlled to ensure safe product. The first steps in the development of any HACCP plan are to identify potential hazards associated with the raw materials and process and determine whether or not the control of these hazards will require a CCP. HACCP is outlined in the form of seven sequential principles:
1. Conduct a Hazard Analysis.
2. Identify CCP(s).
3. Determine Critical Limits.
4. Establish Monitoring Procedures.
5. Establish Corrective Action Procedures.
6. Establish Verification Procedures.
7. Implement Record Keeping.
Ensuring the correct controls are in place for identified hazards is essential to a successful programme. In order to properly determine CCPs, one must have knowledge of quality programmes, prerequisite programmes, and the definition of a CCP. Quality programs consist of, but are not limited to, supplier control programs, raw material and finished product specification, analytical procedures, and process control procedures. Prerequisite programmes include sanitation, Good Manufacturing Practices (GMPs), pest control, chemical control, and allergen control. Both quality programmes and prerequisite programmes must be fully established prior to the development of a HACCP Plan. Without them, there will be an excessive number of CCPs and the facility will have difficulty managing this programme.
Examples of common CCPs are: Pasteurisation or other kill steps; pH; Metal detection; Filtration; Cleaning of glass packaging; Fill temperatures; Cooling time; X-ray.
AIB has a set of guidelines that apply to nearly all CCPs. They are as follows:
1. It is a process step.
2. It must eliminate or reduce to an acceptable level a food safety issue.
3. The process will produce a viable product even if the process step fails.
and/or
4. The process step is there for no other reason than food safety.
The Process Hazard Analysis approach presented by AIB follows the general concept of root cause analysis. Once an issue is identified, the key to success becomes the resolution of the issue. Resolution can come in the form of control or elimination. For example, condensation may develop in a particular area of the plant. To control the issue, you may increase frequency of cleaning to ensure that no biological issues arise from the presence of condensation. Another control would be to keep lids closed on kettles. Elimination of the issue may involve a redesign of the area to eliminate the formation of the condensation.
Summary
There are several tools available for identifying CCPs in a process. The desired result of each method is the identification of elimination steps for food safety hazards. It is important to remember that the results may differ between similar process and facilities, regardless of the method used. Not because of the technique used, rather because of the possible differences in ingredients, suppliers and process conditions.
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- Kerry Beach is with AIB International Inc, Manhattan, Kansas USA. www.aibonline.org
TABLE 1. PROCESS HAZARD ANALYSIS STEPS
(1) List every Raw Material with significant hazard(s) as previously identified in the Raw Material Hazard Analysis.
List every process step from Receiving to Shipping, shown on the Process Flow Diagram in the Plan.
(2) Does this raw material or process step INTRODUCE or INTENSIFY a potential food safety hazard? Consider only hazards with a significant risk. (Use Likelihood and Severity to help determine this.)
If YES, identify hazard(s). (Be as specific as possible when listing the hazard and its source.)
(3) Is the hazard(s) identified in Column 2 CONTROLLED by Support Programme(s) (Prerequisite or Process)?
If YES, list all of the Support Program(s) that will control the introduction or intensification of the hazard(s) identified in Column 2.
(4) Is this hazard ELIMINATED (reduced to an acceptable level) at this or a later process step?
If YES, identify the last process step where it will be Eliminated.
Note: If no Control or Elimination is identified in Column 3 or 4 and these are necessary for food safety, you must stop, modify the step, process, product, or Support Programmes.
(5) Can a viable product still be produced if the process step listed in Column 4 fails?
If YES, this step must be considered a CCP: identify the CCP number.
If NO, this is not a CCP. Enter NO and justification for answer (Viable Product, Process Control, similar elimination further on in the process, etc.).
