QMRS Services

HACCP INTERNATIONAL

HAZARD ANALYSIS CRITICAL CONTROL POINT (HACCP)

 

• BACKGROUND

• HOW TO BE HACCP CERTIFIED?

• EDUCATION AND TRAINING BY QMRS

• QMRS HACCP AUDIT

 

BACKGROUND

The HACCP concept was initiated in the 1960's by an American company (the Pillsbury Company), the US Army, and NASA as a collaborative development of the production of safe foods for the space program. NASA wanted a "zero defects" program to guarantee safety in the foods that astronauts would be consuming in space. “Pillsbury” therefore, introduced and adopted HACCP as a system that could provide the greatest safety while reducing dependence on finished product sampling and testing.
The National Academy of Science (USA) recommended in 1985 that the HACCP approach be adopted in food processing establishments to ensure food safety. Since then, HACCP has been recognized internationally as a logical tool towards a more modern, scientifically based inspection system

The Codex Alimentarius (FAO/WHO) Food Hygiene Committee mandated a working group in 1991 that has developed guidelines for HACCP application. This document has been well received and is getting wide international acceptance. The concepts incorporated in the Canadian model; the Canadian Food Inspection Agency requirements are consistent with the Codex approach towards HACCP.


THE CANADIAN EXPERIENCE: CANADIAN FOOD INSPECTION AGENCY (CFIA)

Canada has a very effective food inspection system. To maintain and enhance this system, industry and government are continuously incorporating new techniques and methods into food production and inspection to improve food safety.

The Food Safety Enhancement Program (FSEP):

FSEP is the Canadian Food Inspection Agency’s (CFIA) approach to encourage and support the development, implementation and maintenance of Hazard Analysis Critical Control Point (HACCP) systems in all federally registered establishments of the meat, dairy, honey, maple syrup, processed fruit and vegetable, shell egg, processed egg and poultry hatchery sectors. The core of FSEP is the internationally recognized Hazard Analysis Critical Control Point (HACCP) system, a straightforward yet powerful set of principles for controlling food safety.

To date, only federally registered fish and seafood processing establishments are required by regulation to have HACCP systems in place. In addition, meat slaughter establishments exporting to the United States (U.S.) are required to implement a HACCP system under FSEP in order to maintain access to the U.S. market. Over five hundred federally registered meat and poultry processing companies are now operating or in the process of converting to a HACCP system. Many other commodity sectors, including processed fruit and vegetable, shell and processed eggs, hatcheries, dairy, honey and maple syrup are also voluntarily implementing HACCP principles in their establishments. The CFIA is now proposing to mandate HACCP by requiring the implementation of FSEP in all federally registered meat and poultry establishments including registered storages.

Roles and Responsibilities under the Food Safety Enhancement Program (FSEP):

Under FSEP, each food processing establishment is responsible for developing a Hazard Analysis Critical Control Point (HACCP) system tailored to its own products and operations. The HACCP system must meet all current program requirements and include the implementation of six prerequisite programs as well as the relevant HACCP plans for that establishment.
For example, each food processing establishment must develop a HACCP plan which includes details on critical control points for each product or group of products. The six prerequisite programs must cover basic requirements for the premises, transportation and storage, equipment maintenance and calibration, sanitation and pest control, personnel, and recall procedures.
Industry is responsible for ensuring that adequate control measures are in place for any potential hazards identified in the HACCP system. Plant personnel are responsible for monitoring and verifying each control point, keeping accurate records, and taking appropriate corrective actions when potentially hazardous situations are noted. The establishment’s management is responsible for verifying that the HACCP plan is working properly.

Canadian Food Inspection Agency (CFIA) Involvement:

Implementation of Hazard Analysis Critical Control Point (HACCP) systems by industry provides the opportunity for the CFIA to adapt its inspection programs to make them more effective. The CFIA verifies that a company’s HACCP system is implemented according to the written procedures and is effective in providing the control measures outlined. No plant can be CFIA HACCP recognized until its HACCP system has been fully evaluated.

Once an establishment is CFIA HACCP recognized, CFIA inspectors will be responsible for auditing the establishment’s records and procedures, assessing specified control measures and corrective actions taken, and observing on-line processing specifically at critical control points. If elements of a plant’s HACCP system are found to be non-compliant or ineffective, the inspector will identify the issue as a non-conformance and the plant will be required to take the corrective action necessary to ensure food safety. Failure to comply would lead to compliance or enforcement actions by CFIA inspection staff.

 

HOW TO BE HACCP CERTIFIED?

HACCP has become synonymous with food safety. HACCP is a management system in which food safety is addressed through the analysis and control of biological, chemical, and physical hazards from raw material production, procurement and handling, to manufacturing, distribution and consumption of the finished product. For successful implementation of a HACCP plan, management must be strongly committed to the HACCP concept. A firm commitment to HACCP by top management provides company employees with a sense of the importance of producing safe food.

HACCP is designed for use in all segments of the food industry from growing, harvesting, processing, manufacturing, distributing, and merchandising to preparing food for consumption. Prerequisite programs such as current Good Manufacturing Practices (cGMPs) are an essential foundation for the development and implementation of successful HACCP plans. Food safety systems based on the HACCP principles have been successfully applied in food processing plants, retail food stores, and food service operations.
The seven principles of HACCP have been universally accepted by government agencies, trade associations and the food industry around the world.

The following is a brief description of the requirements to develop and implement an effective HACCP plans, and how QMRS can assist you to achieve HACCP certification for your individuals and facility.

A. THE PREREQUISITE PROGRAMS

Prerequisite programs are defined as universal steps or procedures that control the operational conditions within a food establishment allowing for environmental conditions that are favorable to the production of safe food. Prerequisite programs are the foundation of the HACCP plans and must be adequate and effective. If any portion of a prerequisite program is not adequately controlled, then additional critical control points may have to be identified, monitored and maintained under the HACCP plans. All prerequisite programs should be documented and regularly audited, and are established and maintained separately from the HACCP plan.

In summary, effective prerequisite programs will simplify HACCP plans and will ensure that the integrity of HACCP plans is maintained and that the manufactured product is safe.

The prerequisite programs are:

1. Premises
   Out side Property, Building, Sanitary Facilities, and Water/Steam/Ice Quality Programs.

2. Transportation and Storage
   Food Carriers, Temperature Control, Storage of Incoming Materials, Non-food Chemicals and Finished Product.

3. Equipment
   General Equipment Design, Equipment Installation, Equipment Maintenance, and Calibration

4. Personnel
   Training, Hygiene and Health Requirements

5. Sanitation and Pest Control
   Sanitation Program, Pest Control Program

6. Recalls
   Recall Procedures, Distribution records

B. DEVELOPING A HACCP PLAN

The format of HACCP plans will vary. In many cases the plans will be product and process specific. However, some plans may use a unit operations approach. Generic HACCP plans can serve as useful guides in the development of process and product HACCP plans; however, it is essential that the unique conditions within each facility be considered during the development of all components of the HACCP plan.

In the development of a HACCP plan, five preliminary tasks need to be accomplished before the application of the HACCP principles to a specific product and process.

The Preliminary Tasks

1. Assemble the HACCP Team

2. The first task in developing a HACCP plan is to assemble a HACCP team consisting of individuals who have specific knowledge and expertise appropriate to the product and process. It is the team's responsibility to develop the HACCP plan.

3. Describe the food and its distribution

4. The HACCP team first describes the food. This consists of a general description of the food, ingredients, and processing methods. The method of distribution should be described along with information on whether the food is to be distributed frozen, refrigerated, or at ambient temperature.

5. Describe the intended use and consumers of the food

6. Describe the normal expected use of the food. The intended consumers may be the general public or a particular segment of the population.

7. Develop a flow diagram which describes the process

8. The purpose of a flow diagram is to provide a clear, simple outline of the steps involved in the process. The scope of the flow diagram must cover all the steps in the process, which are directly under the control of the establishment. In addition, the flow diagram can include steps in the food chain that occurs in the establishment. 

9. Verify the flow diagram

10. The HACCP team should perform an on-site review of the operation to verify the accuracy and completeness of the flow diagram. Modifications should be made to the flow diagram as necessary and documented.

After these five preliminary tasks have been completed, the seven principles of HACCP are applied.

HACCP Principles

HACCP is a systematic approach to the identification, evaluation, and control of food safety. HACCP based on the following seven principles:

Principle 1
Identify the potential hazards associated with food production at all stages, from growth, processing, manufacture and distribution to the point of consumption. Assess the likelihood of occurrence of the hazards (risk assessment) and identify preventive measures for their control (risk management).

Principle 2
Determine the points, procedures, and operational steps that can be controlled to eliminate the hazards or minimize their likelihood of occurrence; these are the critical control points (CCPs). A "step" means any stage in food production and/or manufacture including receipt and/or production of raw materials, harvesting, transport, formulation, processing, storage, etc.

Principle 3
Establish critical limits, which must be met to ensure that the CCPs are under control.

Principle 4
Establish a system to monitor control of CCPs by scheduled testing or observations.

Principle 5
Establish the corrective action to be taken, when monitoring indicates that a particular CCP is not under control.

Principle 6
Establish procedures for verification, which include supplementary tests and procedures to confirm that the HACCP system is working effectively.

Principle 7
Establish documentation concerning all procedures and records appropriate to these principles and their application.

C. APPLICATION OF HACCP (Sequence for implementation)

The following sequence of 12 steps is the recommended approach for the development of a HACCP program. This logic sequence has been agreed to at the international level by a HACCP working group of Codex alimentarius (WHO/FAO). The seven basic principles of HACCP are indicated in the brackets

1. Assemble HACCP team

2. Describe product

3. Identify intended use

4. Construct process Flow Diagram and Plant Schematic

5. On-site verification of Flow Diagram and Plant Schematic

6. List hazards associated with each step (principle 1)

7. Apply HACCP decision tree to determine CCP (principle 2)

8. Establish critical limits (principle 3)

9. Establish monitoring procedures (principle 4)

10. Establish deviation procedures (principle 5)

11. Establish verification procedures (principle 6)

12. Establish record keeping/documentation for principles one through six (principle 7)

In brief, the key element of a HACCP based system is its preventative nature and the exercising of control throughout the manufacturing process, at critical steps called Critical Control Points (CCP). By doing so, defects which could impact on the safety of the food being processed can be readily detected and corrected at these points before the product is completely processed and packaged.

Most companies will find that many of the HACCP system requirements are already in place and operable in their plants. However, some manufacturing facilities still have not established the system. It is, therefore, the objective of QMRS to assist the food industry to design, test, and apply a Food Safety Program, building on HACCP principles.

 

EDUCATION AND TRAINING BY QMRS

This is to assure that all individuals involved in the program are properly trained so they understand their role and can effectively fulfill their responsibilities. Specific training activities should include courses, workshops, working instructions and procedures that outline the tasks of employees monitoring each CCP. Therefore, plant management must provide adequate resources for thorough education and training. In fact, effective trainings considered as an important prerequisite to successful implementation of a HACCP plan.

We would like to confirm that QMRS courses and workshops have been designed to meet the training requirements established by the Codex Alimentarius Commission guideline and the Canadian Food Inspection Agency (CFIA) to provide trainees with the needed information on the development of HACCP food safety programs.

These courses are ideal for operational team who want a thorough understanding of their company's HACCP requirements. However, Our HACCP courses can be customized to fit the needs of any level of management team.

A. LEARNING OUTCOME

Courses were designed to give participants insight into the whole HACCP implementation process. Specifically, upon course completion, participants will be knowledgeable on:

1. Prerequisite Good Manufacturing Practices elements (the foundation of HACCP plans)

2. The HACCP principles.

3. The components of a HACCP model.

4. How a HACCP model can be developed.

5. And how to write and implement HACCP Plans.

B. TRAINING MODULES

Our training modules extracted from the “Training Manual on Food Hygiene and the Hazard Analysis and Critical Control Point (HACCP) System”, Food Quality and Safety Systems (Food and Agriculture Organization of the United Nations, Rome, 1998).

C. TYPES OF COURSES

QMRS provide these accredited training courses:

1. HACCP PREREQUISITE PROGRAM

This course designed to address all aspects of Good Manufacturing Practices (GMPs) requirements, Sanitation Standard Operating Procedures, introduction to Microbiology and Biological, Chemical, and Physical Hazards;

TRAINING MODULES:

MODULE 1: INTRODUCTION (OVERVIEW)

MODULE 2: PRINCIPLES OF FOOD HYGIENE

MODULE 3: FACILITY / ESTABLISHMENT DESIGN

MODULE 4: OPERATION CONTROL

MODULE 5: TRANSPORTATION

MODULE 6: PRODUCT INFORMATION.

2. INTRODUCTORY HACCP PROGRAM

This course provides all the information necessary on the seven principles of HACCP, how they relate to prerequisite programs, how to write HACCP Plans and implement HACCP in food processing, distribution and preparation environments.

TRAINING MODULES

Module 1: History and background of the HACCP system

Module 2: The Codex guidelines for the application of the HACCP system

Module 3: Assemble the HACCP team

Module 4: Describe product and identify intended use

Module 5: Construct flow diagram and on-site confirmation of flow diagram

Module 6: List all potential hazards associated with each step, conduct a hazard analysis and consider any measures to control identified hazards

Module 7: Determine critical control points

Module 8: Establish critical limits for each critical control point

Module 9: Establish a monitoring system for each critical control point

Module 10: Establish corrective actions

Module 11: Establish verification procedures

Module 12: Establish documentation and record keeping

OUR INSTRUCTORS

QMRS is a leading provider of Food Safety Training. Our instructors are Ph.D. and M.D. holders in Microbiology, Pharmacy, Medicine, and Food & Nutrition sciences.
Our experts graduated and trained in Egypt, Iran, Britain, Australia, Turkey, and Canada, with many years of experience in GMPs, and HACCP planning & application. We have an International Expertise in the Middle Eastern countries (Saudi Arabia and other Arab Gulf countries, North Africa, Egypt, Turkey, Iran, and Canada). Therefore, we are able to offer expert services (educational materials and workshops could be conducted in English, Arabic, Persian or Turkish languages as per the client request). Our regional office in the Middle East is located in Isfahan (Iran), which is managed by a highly qualified scientist (Ph.D. holder).

 

QMRS HACCP AUDIT

Sometimes manufacturing plants are not fully ready for certification, but would like an expert consultation to prepare for implementing or improving the current organization HACCP/ISO 9001:2000 programs. We (QMRS) conduct third party audits to determine your plant's status/readiness to develop and implement the Quality Management System programs and to ensure that your facility meets the requirements of local and international regulatory agencies.

QMRS HACCP CERTIFICATION PROGRAM includes:

1. FACILITY / PLANT CERTIFICATION:
QMRS will conduct on site audit of prerequisite program and HACCP plan. If we found that your HACCP plan is properly implemented and complies with FAO/WHO Codex and the Canadian CFIA standards, QMRS will provide you with a certificate stating that the HACCP program in your plant has successfully passed a QMRS HACCP audit.

2. INDIVIDUALS / HACCP TEAM CERTIFICATION:
Candidate who successfully completed the HACCP training program will receive a certificate of completion from QMRS.

IN BRIEF, QMRS CAN ASSIST YOU IN:
We can take total responsibility for HACCP development, including hazard analysis, completed plans with all CCP's critical limits, monitoring, corrective action, record-keeping and verification components. Specifically, QMRS can:

• Evaluate the effectiveness of your pre requisite programs through conducting on-site GMPs audit.

• Assess and develop the critical sanitation pre-requisite programs that are essential for HACCP success.

• Provide you with all the documents (SOPs and templates) needed to fulfill the basic principles of HACCP (principles 6 and 7).

• Assist you to accomplish the five preliminary tasks (Such as assemble the HACCP team and develop a flow diagram, which describes the process).

• Design, test and develop the format of HACCP plans that is product and process specific.

• Also, we can provide you with Generic HACCP plans, which can serve as useful guides in the development of HACCP plans.

• Provide professional training in four languages to assure that all individuals involved in the HACCP implementation are properly trained to fulfill their responsibilities.

• QMRS will provide you with a certificate stating that the HACCP program in your plant has successfully passed a QMRS HACCP audit.

• HACCP course can be customized to accommodate specific facility needs while still meeting the established requirements.

Let us know the level of involvements that suits your organization.  

QMRS can be your HACCP partner. 

For more information about QMRS INTERNATIONAL HACCP programs, please click here to contact us or send us an e-mail.