HACCP is a comprehensive technique for identifying and preventing food safety problems. It was originally developed in the 1960s by food scientists and engineers at Pillsbury in partnership with NASA to ensure the safety of food consumed by astronauts in space.
Initially, HACCP was designed for the food industry to address the increasing concerns about food safety hazards. The system was well-received and proven to be effective in preventing foodborne illnesses by identifying and controlling hazards at critical points in the production process. Over time, HACCP gained recognition as a scientifically-based and internationally accepted food safety management system. Today, HACCP is a cornerstone of food safety regulations and standards.
This blog post will guide you through the seven fundamental principles of HACCP.
Table of Contents
WHAT IS HACCP?
HACCP (Hazard Analysis and Critical Control Points) is a science-based system for managing food safety at all stages of production, from raw materials to consumption. It identifies, assesses, and controls potential food hazards, which can be biological, chemical, or physical. Examples of food poisoning hazards include:
Physical Hazards:
- Foreign Objects: glass, metal, plastic, wood, or other materials that may accidentally end up in food during processing or packaging.
- Choking Hazards: Foods that pose a choking risk, such as small, hard candies, or items like bones in fish or meat
Chemical Hazards:
- Food Additives: The misuse or excess use of food additives like artificial colorings or preservatives can pose chemical hazards.
- Allergens: Ingredients that can trigger severe allergic reactions, such as peanuts, tree nuts, shellfish, and gluten, are chemical hazards if not properly labeled or controlled.
- Chemical Contaminants: Contaminants like pesticides, industrial chemicals, or mycotoxins produced by molds can be chemical hazards in food.
Biological Hazards:
- Bacteria: Pathogenic bacteria like Salmonella, E. coli, and Listeria.
- Viruses: Foodborne viruses such as norovirus and hepatitis A can cause illnesses when present in contaminated food.
- Parasites: Protozoa and worms like Cryptosporidium and Trichinella
- Fungi: Molds and yeast, while usually harmless, can produce mycotoxins
CCPs
The core principles of HACCP revolve around the identification of critical control points (CCPs) in the food production process. CCP is a specific step in the food production process where control measures can be applied to prevent, eliminate, or reduce these potential hazards to an acceptable level.
Examples of CCPs in food production may include cooking temperatures to kill harmful bacteria, pasteurization steps to eliminate pathogens, or refrigeration temperatures to prevent microbial growth.
To determine CCPs, a thorough hazard analysis of the entire food production process is conducted. To do this, the type of food being produced, potential hazards associated with the food, and the steps involved in its production must be taken into account.
After identifying CCPs (Critical Control Points), specific criteria called critical limits are set at those points to ensure food safety. Monitoring and verification procedures are then put in place to check that these critical limits are always met.
These steps are best understood in the context of the seven basic principles of HACCP.
THE SEVEN FUNDAMENTAL PRINCIPLES
HACCP is a system of seven principles that provide a structured approach to identifying, assessing, and controlling food safety hazards. These steps help food producers and processors systematically manage and minimize the risks associated with producing safe and nutritious food products.
Principle 1: Conduct a Hazard Analysis
The first step in HACCP is to conduct a comprehensive hazard analysis. This means identifying and assessing potential food safety hazards that could occur at any stage of the production process, from sourcing raw materials to delivering the finished product. Hazards can be biological (e.g., harmful microorganisms), chemical (e.g., allergens, toxins), or physical (e.g., foreign objects). Food professionals must have a deep understanding of the entire production process to complete this analysis.
In dress chicken processing one possible hazard is the presence of harmful microorganisms, particularly Salmonella and Campylobacter. These bacteria can be present on the chicken’s skin and within the meat. The hazard analysis would identify these microorganisms as potential risks and assess their likelihood of contamination throughout the process, from receiving live chickens to final packaging.
Principle 2: Identify Critical Control Points (CCPs)
Critical Control Points (CCPs) are specific stages in the production process where actions can be taken to prevent, eliminate, or reduce identified hazards to a safe level. This helps to identify the points in the process where the strictest control measures are needed, once potential hazards have been identified. Common CCPs include cooking, cooling, and storage, where specific parameters must be maintained to ensure food safety.
The cooling process of dressed chicken is a critical control point (CCP) in dressed chicken manufacturing.
This is because proper refrigeration is essential to keeping the chicken at a safe temperature to prevent bacterial growth. The refrigeration temperature should be within the recommended range, which is typically 32°F to 40°F (0°C to 4°C).
Principle 3: Establish Critical Limits
Critical limits are the highest and lowest values that must be met at each CCP to ensure food safety. These limits are often set based on regulatory standards, scientific research, or industry best practices. Setting these limits is essential for keeping the product safe.
For example, a critical limit for cooling dressed chicken might be that the chicken must be cooled quickly to a temperature of 40°F (4°C) or below within 4 hours of finishing processing.
This critical limit is based on food safety guidelines that recommend quickly cooling cooked or processed poultry products to a safe temperature to prevent bacterial growth, especially the growth of pathogens. The 4-hour time frame is a reasonable limit to ensure that the chicken reaches the safe temperature range quickly, minimizing the risk of bacterial growth.
Principle 4: Monitor CCPs
Effective monitoring is essential for verifying that the critical limits are consistently met during production. This step involves continuous or periodic observations, measurements, and testing at each CCP.
Monitoring for early deviations during dressed chicken cooling enables prompt corrective actions to mitigate bacterial growth and food safety hazards. This proactive approach prevents unsafe products from progressing further in the production line. This ensures consumer safety and reinforcing the commitment to food safety. Additionally, the data gathered through monitoring supports process optimization and ongoing improvements.
Principle 5: Establish Corrective Actions
When a deviation from the critical limit is identified during monitoring, a clear plan for corrective actions should be in place. This step outlines the specific actions that need to be taken to bring the process back under control. The objective is to ensure that unsafe products do not reach consumers.
If it is determined that the critical limit for cooling dressed chicken has not been met, the affected batch of dressed chicken should be immediately isolated from further processing or distribution. If the chicken has not reached 40°F or 4°C within the designated 4-hour timeframe, the processing team and food safety personnel must conduct a thorough evaluation of the situation to determine the cause of the deviation.
This assessment includes examining equipment performance, process protocols, and any deviations from standard operating procedures (SOPs). If a deviation is found to be correctable and the chicken remains safe for consumption, it should be rapidly cooled to the required temperature. This may involve adjusting the cooling equipment, reevaluating the method, and ensuring that the chicken reaches the safe temperature within the established timeframe.
Principle 6: Implement Verification Procedure
Verification procedures are designed to validate that the HACCP system is effective and continues to operate correctly. These procedures include regular reviews, equipment calibration, and testing of food samples to ensure that hazards are consistently controlled. For example, routine calibration of temperature monitoring devices, such as sensors and thermometers ensure they provide accurate readings. Equipment is calibrated at regular intervals to maintain precision.
By routinely evaluating the system, food producers can maintain confidence in the safety of their products.
Principle 7: Record-Keeping and Documentation
The final step of HACCP emphasizes the importance of comprehensive record-keeping and documentation. Maintaining accurate records of the HACCP plan, monitoring activities, corrective actions, and verification procedures is vital for regulatory compliance and traceability.
If a safety issue arises, accurate documentation allows for the rapid identification of the source and extent of the problem, helping to contain and address it more effectively. This can prevent widespread contamination.
Food businesses are often legally obligated to keep good records and documentation. Regulatory agencies, such as the FDA and USDA, require food processors to maintain records to show that they are following food safety standards. Failure to keep these records can result in regulatory violations and legal penalties.
This blog post is only a small portion of what HACCP is about. For more details on this, visit the FDA’s website:
HACCP Principles & Application Guidelines
