HACCP Awareness

Training
Date: 23rd & 24th May 2019
Venue: Chatime Malaysia
Time Topic

1000-1015 Introduction
1015-1055 Food Chain & Certification
1055-1200 Food Safety
1200-1300 Content of HACCP
1300-1330 Breaktime
1330-1630 GMP 1 to 19

1000-1015 Re-cap
1015-1130 Pre-5

1130-1pm 7 Prinples

1300-1330 Break
1515-1545 Validation

1545-1600 Food Safety Certification

Group photo
1600-1630 Assessment
HACCP Awareness
Training
Section 1
Introduction to Food Safety
Why do we implement food safety standard?

Increase
profitability
Comply with legal
requirement
Enhanced customer
Improve staff Satisfactory & loyalty
knowledge & morale
Reduce food safety
& quality cost
Increase
competitiveness
Various standard & practices in food safety

Retail
Primary Manufact
Farming Wholesale Food
processing uring
service
Global GAP Service
Global GAP Global GAP Organic None certification
Organic Organic GMP specific supply chain
FAMI-QS inspection
HACCP / ISO 22000

ISO 9001 / ISO 14001 / OHSAS 19001 / SA8000

Sainsbury system McDonal system

Nestle NQS
YUM! system
Mondelez food system
Comparison chart
HACCP ISO 22000 BRC FSSC
Type International International Private standard Private standard
guideline standard
Distributor FAO ISO BRC (UK) FSSC
Category Product guideline System standard Product standard Product standard
Recognition International International Retailers: UK, International
Belgium,
German, Italy,
switzerland
Requirement RPR PRP & oPRP Req Means Specific PRP, ISO
and/or result 2200, FSSC add
req
Final grade Certification Certification Grade (depend Certification
on NC)
Driver Voluntary Voluntary Clients’ Clients’
requirement requirement
Choice of standard
Company
strategy

Regulatory Choice for one Customer’s

or more
requirements specific
standard
depends on requirements

Market
expectation
What is food safety?
• Food Safety refers to handling, preparing and storing
food in a way to best reduce the risk of individuals
becoming sick from foodborne illnesses. [Australian
Institute of Food Safety, 2016]

• General perception: Clean, Look nice, Not smelly

• Industry: Related to occurrence of food hazard

• Concept that food will not cause harm to consumer when

it is prepare and/or eaten according to its intended use
What is food hygiene?
• Food hygiene are the conditions and measures necessary to
ensure the safety of food from production to consumption.
Food can become contaminated at any point during
slaughtering or harvesting, processing, storage, distribution,
transportation and preparation. [WHO,2018]

• Food hygiene may be defined as: All the practical measures

involved in keeping food safe and wholesome through all the
stages of production to point of sale or
consumption. [safefood, Ireland]
What is food quality?

• Quality includes all attributes that influence a

product’s value to the consumer. [FAO & WHO]

• Quality can be defined as combination of attributes

or characteristics of a product that have significance
in determining the degree of acceptability of that
product to consumer.
How safe is your food product?
• Safe food
Free of spoilt and contaminants
No food hazards

• Safe food is food that will not cause illness or other

physical harm to a person eating it, provided that
the food is used as it is intended to be used.
[Safe Food Australia, 2001]
What is HACCP?

H Hazard
A Analysis
C Critical
C Control
P Points
HACCP terms

F FOOD
S SAFETY
M MANAGEMENT
S SYSTEM
HACCP terms

S STANDARD
O OPERATING
P PROCEDURE
HACCP terms

G GOOD
M MANUFACTURING
P PRACTICE
HACCP terms

I INTERNATIONAL
S STANDARD
O ORGANISATION
 FSMS

ISO

HACCP
SOP / SSOP
GMP (PRP)
HACCP certification -
Introduction
• In the 1960s, the National Aeronautics and Space Administration
required "zero-defect" foods to ensure that space personnel have
no health hazards such as food poisoning, infectious diseases, etc.

• In 1972, the United States Pillsbury Company first developed the

HACCP control in 1973.

• In 1980, WHO recognized the principles of HACCP.

• In the 1990s, the Codex Alimentarius Commission (CAC/CODEX)

trusted HACCP to ensure international food safety.
HACCP certification -
Introduction
1960s 1970s 1980s 1990s

Philsbury CODEX

NASA WHO
Benefits of HACCP certification

Improve
consumer
Increase the confidence
chances of
Improve internal
exporting and
processes
entering the
market

Reduce public Improve

health and health Benefits company
issues reputation
Benefits of HACCP certification

• Reduce public health and health problems: Food-borne diseases

such as hepatitis, pneumonia, food poisoning, etc.

• Increase the chance of exporting and entering the market because

the market regards certification as a safety criterion

• Improve consumer confidence

• Improve internal processes, unified management and operating

procedures.

• Improve company reputation

 Public

Staff HACCP Client

Company
HACCP Awareness
Training
Section 2
Food Hazard
Food Hazards
• Hazard
Agent that can cause illness or injury to consumers.

• HACCP focuses on 3 type of hazards

1. Physical Hazard
2. Chemical Hazard
3. Biological Hazard
Physical Hazards / Extraneous
Material
 Non-food object / foreign objects in food that can
cause harm when eaten.
 Visible

o Clip o screw o rat dropping

o cloth o glass o plastic string
o nail o metal o paint flakes
o hair o sand o jewelry
o feather o soil o cigarette butts
o plaster o rock o pen cap
Chemical Hazards
 Chemicals are present in food at level that can be
hazardous to consumers.
 Invisible
Natural Commercial Unintentionally
o Will mushroom o Metal toxins o Pesticides
o Potatoes - Lead o Antibiotic
o Puffer fish - Mercury o Drug residue
o Alfatoxin - Arsenic o Cleaning chemical
- Cadmium o Food additives
- Sn o Carsinogenic
substance
Allergenic Hazards
• Food contain allergen caused abnormal immune
reaction in sensitive consumers.
• Priority allergens:
i. Milk
ii. Egg
iii. Shellfish
iv. Fish
v. Tree nuts
vi. Wheat
vii. Peanuts
viii.Soybean
Biological Hazards
 Hazardous organism are introduced to food and
cause illness to consumers.
 Include bacteria, viruses and parasites
 Invisible

Harmful (Pathogens) Useful

o Staphylococcus aureus o Yeast
o Escherichia coli o Lactic acid bacteria
o Salmonella species
o Bacillus cereus
o Clostridium botulinum
Biological Hazards
Pathogenic bacteria Viruses Protozoa Parasite
Shiga toxin-producing Norovirus Amoeba Round
E. coli worms
Enterotoxin producing Astrovirus Giardia Tape
E. coli lamblia worms
Clostridium Hepatitis A virus Plasmodium Flukes
botulinum
Escherichia coli Rotavirus
Bacillus cereus
Campylobacter
Listeria
monocytogenes
Foodborne Water borne
Bacteria Bacteria
• Campylobacter jejuni • Campylobacter jejuni
• Escherichia coli • Vibrio cholerae
• E. coli O157:H7 • Shigellaspecies
• Salmonella species • Pseudomonas aeruginosa
• Salmonella typhi
Viruses
• Shigellaspecies • Enteroviruses
• Yersinia enterocolitica • Norwalk agents
• Rotaviruses
AQUATIC ENVIRONMENT
• Clostridium botulinum(non-proteolytictypes B, E
and F)
• Pathogenic Vibrio spp.
V. cholera,
V. parahaemolyticusand
V. vulnificus
Other vibrios
• Aeromonashydrophila
• Plesiomonasshigelloides
General Environment

• Listeriamonocytogenes
• Clostridium botulinum(proteolytictypes A and B)
• Clostridium perfringens
• Bacillus spp
Biological Hazards
• About harmful bacteria: Staphylococcus
Aureus
 Main source is human, from
skin, nose, hands, throat and
hair. Also found in broils, septic
lesion, burns and scratches.

 Toxin producing bacteria

… Staph. aureus fact sheet
Year Location Food No of
person
1968 School children, Texas Chicken salad 1300
2000 Osaka, Japan Low-fat milk 13,420
2015 Alabama, USA - 86
2016 Salt Lake, USA - 55
2017 Florida,USA Pork 31

• In Australia, 30% of foodborne outbreak associate with food

prepared by caterer.
Biological Hazards
• About harmful bacteria: Escherichia coli
 Found in the environment
(soil & water), intestines of
people and animals.

 Toxin producing bacteria

 May lead to kidney failure or

caused death
… E. coli fact sheet
Year Location Food No of
person
1992 Nortwest USA Meat 500
2006 Multiple state, USA Spinach >200
Multiple state, USA Onion 107
2011 Germany unknown 3,950
2013 Quensland, Aust. - animal - 49
2015 Multiple state, USA Caterer >150
2016 Multiple state, USA Caterer 55
Britain,UK Salad 213
2017 Multiple state, USA Soynut butter 32
Biological Hazards
• About harmful bacteria: Salmonella
 Source from the soil, on
plants and in human or
animal feces.
… Salmonella fact sheet
Year Location Food No of
person
2006 USA tomato 183
2008 USA -Typhoid fever 439
2013 USA chicken 768
2014 USA -Typhoid fever 329
2015 USA chicken 252
2016 USA chicken 209
2017 USA papaya 235

• In USA, salmonella caused 1,000,000 food poisoning case

every year.
Biological Hazards
• About harmful bacteria: Bacillus cereus
 Found in the environment (soil
& water), intestines of people
and animals.

 Spore forming bacteria

… Bacillus cereus fact sheet
Year Location Food No of
person
1989 USA caterer 140
2003 USA Pasta salad 5
2013 Canberra caterer 303
2015 Australia caterer 250
2014 Ottawa Fried rice 44
2016 New York Refried beans 158

• In 7 years, bacillus cereus involved 911 person in France.

Biological Hazards
• About harmful bacteria: Clostridium botulinum
 Found in the environment
(soil & water), intestines of
people and animals.

 Spore forming & Toxin

producing bacteria
… C. Bot fact sheet
Year Location Food No of
person
1999 Canada Tomato paste 3
2001 USA Cooked chilli 15
2011 UK Korma sauce 2
2014 USA pesto 2
2016 UK Salted fish 5
2017 USA nacho 10
2017 USA Cooked tomato 21

• Botulinum food poisoning is rare but caused serious illness.

Air Human body

Bacteria locate at:

Water

Surface without chemical

cleaning
Soil/floor
 Bacteria reproduce by splitting into two

Under ideal conditions bacteria can divide into two every :

15-20 minutes
One bacteria can become 1,000,000 in 5 hours !
Biological Hazard

• When multiplying over standard limit, bacteria

produce toxins or form spores.
FACTORS THAT INFLUENCE MICROBIAL
GROWTH
Food Type of Food
Acidity pH at Neutral (ph 5 -6)
Time Expose 4 – 6 hours
Temperature Danger zone from 4 to 63oC
Oxygen Room temp/ vacuum pack
Moisture High water content in food
Preservation Type of preservation

FAT TOMP
FACTORS THAT INFLUENCE MICROBIAL
GROWTH

Food

Low risk High risk

Medium risk High risk

Different food with different number of bacteria naturally

FACTORS THAT INFLUENCE MICROBIAL
GROWTH

Acidity

No bacteria Bacteria No bacteria

growth growth growth
FACTORS THAT INFLUENCE MICROBIAL
GROWTH

Time

Keep food maximum 4 hours in room temperature.

FACTORS THAT INFLUENCE MICROBIAL
GROWTH

Temperature
Room Temperature

Chiller

Freezer
 Temperature, oC
100
Cooking, reheating 70
Hot-holding
63

Danger Zone 25 Room temperature

Max. 4 hours

5
4
Chill storage, Cold holding, receive chill food
0

Receive frozen food

-10

-18
Frozen storage
FACTORS THAT INFLUENCE MICROBIAL
GROWTH

Oxygens
Bacteria growth testing with or without oxygen.
 FACTORS THAT INFLUENCE MICROBIAL
GROWTH

Oxygens

Food without oxygen may keep longer, but still have bacteria growth.
FACTORS THAT INFLUENCE MICROBIAL
GROWTH

Moisture

Water activity chart

1. Most bacteria growth at high water activity, above 0.9

FACTORS THAT INFLUENCE MICROBIAL
GROWTH

Moisture

Food with low water activity have longer shelf life.

 FACTORS THAT INFLUENCE MICROBIAL
GROWTH

Preservation

Food with preservation keep longer.

Contamination
Direct contamination
- Introduction of food hazards into food directly from
food to food and from the food growing/production
environment.

Cross contamination
- The transfer of food hazard from food to food by
non-food object.
Contamination
Example:
Contamination
Example:
Factors Contribute to
Microbiological Food Poisoning

Favorable
Source of
condition to
contamination
growth

Time for Storage

multiplication temperature
 Natural

Physical Environment / device

Personnel negligence

Natural

Hazard Chemical Personnel negligence

Allergen

Natural

Biological Environment

Personnel negligence
Preventing food poisoning
5 Guideline

Clean Keep clean (food handler, utensils,

premise)
Separate Separate raw & ready-to-eat food

Cook Cook sufficiently

Safe zone Keep food at safe temperature

Good Use safe ingredients and water
source
Food Hazard related to Milk Tea
• Reading article 1 – The StarOnline 2011
• Reading article 2 – The List: Thing you didn’t know
about bubble tea
• Reading article 3 – Food Navigator-asia.com 2013
• Reading article 4 – World tea news 2012
• Reading article 5 – Tea Board: Colouring in tea
HACCP Awareness
Training
Section 3
Content of HACCP
What is HACCP?
• 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. [FDA]

• The HACCP system, which is science based and

systematic, identifies specific hazards and measures
for their control to ensure the safety of
food. [CODEX]
What is HACCP?
• A scientific, rational and systematic approach to
identification, assessment and control of hazards
during production, processing, manufacturing,
preparation and use of food to ensure that food is
safe when consumed. [WHO]
What is HACCP

H Hazard Food contamination / spoilage

A Analysis Finding out the source

C Critical The level of danger

C Control The remedial action

P Point The stage for corrective action

What is GMP?
• Good manufacturing practices (GMP) can be
defined as “the operational requirements necessary
to enable food business to produce safely” [WHO]

• A set of regulations, code and guidelines that

control the operational condition within a food
establishment allowing for the production of safe
food. [MS1514:2009]
What is GMP?
• Elements of GMP according to MS1514 GMP
1. Design and facilities location
2. Control of operation
3. Maintenance, cleaning and sanitation
4. Personal hygiene
5. Transportation and distribution
6. Product information
7. Training
8. Internal inspection
9. Management review
10. Legal requirements
What is GMP?
General HACCP Guideline
• Codex Alimentarius guideline: 12 logical steps

• 5 preliminary steps
• 7 principles of HACCP
7 PRINCIPLES OF HACCP
1. Conduct hazard analysis and determine control
measures
2. Determine critical control point
3. Establish critical limit for each CCP
4. Establish monitoring system for each CCP
5. Establish corrective action for deviation of critical
limits that may occur
6. Establish verification procedures
7. Establish record keeping and documentation
Food Safety Management System
1. Scope
2. Normative reference
3. Definitions
4. Context of the organization
5. Leadership
6. Planning (of changes)
7. Support (Resource, awareness, communication, documentation)
8. Operation (Planning & realization of safe food)
9. Performance evaluation
10. Improvement
System Process Diagram

ACT / Plan &

PLAN
Document
Study
Improve Implement

DO
Maintain,
Review Measure,
CHECK Audit
Food Safety Management System
1. Scope
• Answering these questions will help you determine the
scope of your FSMS.
- What products, processes or services are included in the
scope of your FSMS?
- What production facilities and locations?
- What statutory and regulatory requirements apply?

• The scope will define exactly what is included in your food

safety system.
Food Safety Management System
1. Scope
• Example:
i. Manufacturing of white soft cheese
ii. Manufacturing and supply of ice cream
iii. Manufacturing and processing of mango fresh
iv. Design, manufacturing, distribution and marketing of
food supplement
v. Trading, cold storage and packaging of fresh fruits
vi. Production, preparation, storage and provision of RTE
food.
vii. Warehouse/Distribution of shelf stable products
Food Safety Policy & Objectives
2. Food Safety Policy
• Overall intention and direction of an organization related
to food safety expresses by top management

• Define and document food safety policy and commitment

with regard to identification, evaluation and control of
hazard related to food safety

• Comply to related legal requirements, such as

a) Food Act 1983, Food Regulation 1985
b) Food Hygiene Regulation 2009
c) Weight and Measurement Act 1972
d) Immigration Act 1959
Food Safety Policy & Objectives
2. Food Safety Policy
• Overall intention and direction of an organization related
to food safety expresses by top management
• Define and document food safety policy and commitment
with regard to identification, evaluation and control of
hazard related to food safety

3. Food Safety Objectives

• Specific realistic targets that can be measurable and
achieved with specific time frame by the establishment to
support food safety policy
 Food Safety Policy Statement
To understand, fulfill and when possible exceed our
customer’s requirement through the continuous
improvement of our processes and dedicated to deliver
defect free product on time at most competitive cost as
possible.

Our product food safety is based on the standard as set

in the Food Act 983 & Food Regulation 1985.

__________
Chairman
Date:
 Food Safety Objectives
The purpose of our HACCP System is to provide safe food to our
customer. Therefore, we have established the following food safety
objectives, to be achieve and maintained for the next 1 year.

All finished ready-to-eat product and beverages tested do not

contain phatogenic microorganism such as salmonella and
Escherichia coli.

Customer complaints received should not be more than 1 case per

year.

__________
Chairman
Date:
Food Safety Management System
CONTINUAL IMPROVEMENT OF
THE FOOD SAFETY MANAGEMENT SYSTEM
I I
S
N R N
A
C T E 4 Context of the T
T
U E Q organisation C E
I
S R U 5 Leadership U R
S
T E I S E
F
O S R T S
9 Performance A
M T E O T
6 Planning evaluation C
E E M M E
7 Support 10 improvement T
R D E E D
O
N R
R
P T P
Y
A S A
R 8 Operation R
T Input Output T
Y Y
 Content of HACCP
Section

Part 1 Pre-requisite Programs, PRPs (Total of 19)

Good Manufacturing Practice

Part 2 Preliminary Steps (5 steps)

Part 3 7 Principles of HACCP

PRPs - Pre-requisite Programs
GMP - Good Manufacturing
Practice
No PRPs
Document and Record Control
1

2 Purchasing

Receiving
3
Storage and traceability
4

5 Production control
PRPs - Pre-requisite Programs
GMP - Good Manufacturing
Practice
No PRPs
Premise, infrastructure and facility
6

7 Water & ice supply control

Personnel procedure
8

9 Calibration and maintenance

10 Cross-contamination and allergen control

PRPs - Pre-requisite Programs
GMP - Good Manufacturing
Practice
No PRPs
Housekeeping, cleaning & sanitation
11

12 Chemical control

Pest Control
13

14 Complaint and contingency plan

15 Product recall
PRPs - Pre-requisite Programs
GMP - Good Manufacturing
Practice
No PRPs
Product non-conformity control
16

17 Corrective action

Internal audit and self inspection

18

19 Food Safety Verification

HACCP Awareness
Training
Section 4
Good Manufacturing Practice
GMP
 Document and Record Control
• Section of documentation
• Document numbering
• Control of document
• Document amendment / changes and revision

Document header

FOOD SAFETY PROCEDURE

Doc No : FSP 01 Effective date: 01.10.2018,
Revision No : 00
TITLE : FOOD SAFETY MANUAL
 Document and Record Control
• Types of documents: Master / controlled /
uncontrolled / obsolete
• Collection, storage and maintenance
• Retention of document and record
• Disposal of document and record

Document stamping

MASTER COPY CONTROL COPY OBSOLETE

UNCONTROL COPY
Purchasing
• Standard purchasing process
• Select supplier that fulfill HACCP requirements
• Supplier evaluation conduct yearly
• Delivery requirements given to supplier
Receiving
• Monitor supplier performance during receiving
a. Condition & method of delivery
b. Food temperature maintenance
c. Fulfill minimal labeling

• Time for keep food to chiller/freezer within 30

min/1 hour
• Rejection area allocated at receiving area/store
Storage and traceability
• Types of storage:
a.Dry store room temperature < 30oC
b.chilled 0oC to 4oC
c.frozen below -18oC
 Storage and traceability
• Food not placed on floor
• Separate area for food, packaging materials, chemical,
Ready-to-eat food and reject items.
• Follow storage hierarchy
• First In First Out
• All food with labeling
• No opened food
• No spoilt / mouldy / expired food
• No pest infestation
 Storage and traceability
• Traceability = find out source of food
• Labeling for:
i. Raw materials
ii. Packaging items
iii. Prepared food items
iv. Finished product
v. Dispose items
vi. Reject items
 Storage and traceability
Items Label Info of label
Raw materials, Ingredients except Supplier label a. Product
fresh vegetables without processing b. Weight/ Quantity
c. Expiry / Production Date
Receiving Note
a. Product
b. Received Date
c. Quantity
Packaging materials Supplier label 1. Product
2. Quantity
Receiving Note: 3. Size
As per item (1)
Prepared food items Label 1. Product
2. Production date / opened
date / expiry date
3. Time (if any)
 Storage and traceability
Items Label Info of label
Finished product Label 1. Product name
2. Production date & time
3. Consumption instruction
4. Storage instruction

Quarantine / Rejected / Dispose Label 1. Product name

items 2. Quantity
 Production control
• Production process:
i. Thawing
ii. Food preparation
iii. Cooking
iv. Hot-holding
v. Cold-holding
vi. Cooling
vii. Reheating
viii. Serving

*Details refer to PRP 05 Production Control

Premise, infrastructure and
facility
• Safe environment & location
• Infrastructures comply to HACCP
• Section of restaurant provide with facility
• Facilities include water, equipment, utensils,
cleaning facility, staff facility, storage space.
• Equipment include equipment, food containers,
monitoring equipment, waste containers
 Premise, infrastructure and
facility
• Infrastructures:
a. Wall / partition
b. Floor
c. Ceiling / overhead fixtures
d. Doors / Windows
e. Lighting
f. Ventilation
g. Draining
h. Work surfaces

*Details refer to PRP 06 Premise, Infrastructure & Facility

Water & ice supply control
• Water and ice is clean and potable

• Water filtering cleaning and changing cartridge

• Water and ice are test with bacteria and chemical.

Personnel procedure
• Job responsibility of staff
• Safety & hygiene standard of food handler
• Training of staff
• Practice hygiene standard & monitoring
• Hand wash & health record
• External visitor control
Personnel procedure

• Yearly Training Plan

• Conduct training – internal / external

• Training record

• Training evaluation
 Calibration and maintenance
• Equipment Master List

• Preventive maintenance and calibration schedule

• Maintain equipment in good condition, servicing on-

time

• Repair, maintenance, servicing and calibration record.

 Cross-contamination and allergen control

• Microbiological
No bacteria, virus, parasite contamination

• Chemical
No cleaning chemical splash, allergen trace

• Physical
No crack/broken Glass, brittle plastics items, wood,
metal pieces etc
 Housekeeping, cleaning & sanitation

• Housekeeping
Clean and tidy

• Cleaning
Remove physical dirt and oils

• Sanitation
Remove bacteria
 Housekeeping, cleaning & sanitation

• Cleaning schedule
i. Area / location
ii. Frequency
iii. Cleaning procedures / steps
iv. Chemical and dilution
v. Person responsible

*Details refer to Cleaning Schedule

Chemical control
• Only allow to use approved chemical

• Perform chemical dilution correctly

• Chemical document: MSDS / CSDS

• Chemical storage separation
• Chemical containers with label
Pest Control
• Pest control treatment
Information of company & CSDS.

• Prevent pest enter into food production area

• Self-monitoring at restaurant areas.

 Complaint and contingency plan
• Customer complaint via
a. Verbal conversation
b. Phone call
c. E-mail
d. Social media message

• Carry out investigation, identify root cause

• Carry out corrective & preventive action

 Complaint and contingency plan
• Contingency plan
i. No electricity
ii. No water supply
iii. Chemical spillage
iv. Flood
v. Fire
vi. Epidemic outbreak
vii. Cold room breakdown

*Details refer to GMP14

 Product recall
• Recall = customer return product to seller
= find out product with problems

• Product recall procedures in GMP 15

• Mock recall yearly = pretend product recall

 Product non-conformity control
• Handling of non-conforming products:
a. Raw materials
b. Packaging
c. Prepared items
d. Finished product
e. Expired food items
f. Dropped food items

*Details refer to GMP 16 Product non-conformity procedures

 Corrective action
• Corrective Action Request (CAR)
i. Investigate root cause
ii. Take action
iii. Do not repeat same problem

• Non-conformance separate into:

i. Customer
ii. Supplier
iii. Production
iv. Audit
 Corrective action
• Continual Improvement Program
Preventive action
• Potential improvement can find from:
a) Process that provide early warning signal from
operation
b) Customer feedback
c) Market analysis
d) Food safety outbreak
 Internal audit and self inspection
• HACCP Internal audit
Check by people from same company
Follow internal audit procedure

• Self-inspection
Check on PRPs programs
Follow checklist
 Food Safety Verification
• Verify = confirm

• Verification activity:
1. Check PRPs
2. Internal audit
3. Mock recall
4. Lab test
5. Management review
HACCP Awareness
Training
Section 5
Preliminary Steps
(Pre-5)
5 Preliminary Steps
1) Assemble Food Safety Team

2) Products & Ingredients grouping

3) Identify the Intended Use

4) Construct a process flow diagram

5) Confirm accuracy of the flow diagram

Assemble the HACCP Team
Team Leader

Deputy Team Leader

Operation section Quality Assurance/Control

Service
HR / Training
Kitchen
Purchasing
Steward

Store Maintenance
 Products grouping
Product Group Description
Food preparation with no cooking step.
Process 1
Example: salad, cut fruits etc

Food preparation with a cooking step.

Process 2
Example: Curry chicken, noodles soup

Complex food preparation with multiple

Process 3 killing steps.
Example: soup, sauces, stocks etc
 Products grouping
General Raw Materials Group
Poultry & Fruits & Processed food Liquid Beverage
product products – –further ingredients
Further cooking cooking
Meat & product Fruits & Processed food Dry goods- Miscellaneous
products - RTE - RTE canned

Fish & Fish Vegetables & Processed food Dry goods - Packaging
Product products – - Retail powder materials
further cooking
Seafood & Fish Vegetables & Flavouring Dry herbs
product – product - RTE
further cooking
Seafood & Fish Cereal & cereal Seasoning Oil
product - RTE products
 Products grouping
General Food Product Group
Vegetables/fruit Processed food Soy bean based Cereal based
Fish dishes
- Garnish – Retail dishes dishes

Vegetables/fruit Partially cooked Egg based Rice based

Seafood dishes
- RTE food dishes dishes

Beverages with Vegetables Processed food

Sauce - RTE Poultry dishes
ice dishes – further cook

Beef dishes
Seafood - RTE Cold dessert Soup Hot beverage

Carbonated/
Processed food Lamb dishes Noodles
Bottled/Soft Hot dessert
– RTE
Drinks
Identify the Intended Use
• Based on expected uses of the product by end user.

• How customer use the product?

i. Ready-to-eat by general public
ii. Further cook before consume
iii. Take away by general public
iv. As part of ingredients
Product Description

Products Important Intended use Intended

name characteristics customer

Specific Shelf life Packaging Where it will

ingredients be sold

Labeling Special
instruction distribution
control
 Construct a process flow diagram
1) Receiving 7) Cooking

2) Storage 8) Cooling

3) Thawing 9) Chilled

4) Washing / Peeling 10) Re-heating

5) Preparation 11) Hot / cold-holding

6) Mixing 12) Delivery

Confirm accuracy of the flow
diagram
• Confirm processing operation against the flow
diagram

• At all stages and hours of operation

• Construct a plant layout and check on-site.

 Example
Door Freezer Freezer
Dish washing area

Working table
Cooking Area
Walk-in-chiller
Wet
preparation
area

Cooking Area
Chiller
HACCP Awareness
Training
Section 6
7 Principles
(7 P)
How to conduct hazard analysis?
• List all the potential hazard related to raw material,
ingredient, packaging material and process steps in
the Hazard Analysis Worksheet format.

• Prescribe rationale for inclusion or exclusion as a

hazard.

• Evaluate risk for each hazard to identified whether

it is significant hazard
How to determine significant
hazard?
• Determine the listed potential hazard is a significant
hazard or not.

• Use a food safety risk matrix

• Control measure shall be established for each identified

hazard.

• If no suitable method is available for preventing /

eliminating the hazard / for reducing to acceptable level,
the process or product shall be modified.
 1 Hazard Analysis
Likelihood
Severity
A B C D E
1 1 2 4 7 11
2 3 5 8 12 16
3 6 9 13 17 20
4 10 14 18 21 23
5 15 19 22 24 25

Severity of occurrence is classified as: Likelihood of occurrence is classified as:

1. Can be fatal A. Common occurrence
B. Know to occur （ it has happened at
2. Can cause serious illness
our premises ）
C. Could occur （ I’ve heard of it
3. Can result in product recall
happening ）
4. Can generate a customer complaint D. Not expected to occur
5. Insignificant / no effect on health E. Practically impossible to occur
 1 Hazard Analysis
Is this a significant
Potential hazard state hazard?
Raw Material whether biological,
chemical or physical Sev Lik Sig Y/N

Biological

Chemical

Physical
 1 Hazard Analysis
Potential hazard What measures can
state whether be applied to control
Raw Material
biological, chemical this significant
or physical hazard?
Biological
Chemical
Physical
 1 Hazard Analysis
Is this a significant
Potential hazard state hazard?
Process Step whether biological,
chemical or physical Sev Lik Sig Y/N

Biological

Chemical

Physical
 1 Hazard Analysis
Potential hazard What measures can
state whether be applied to control
Process Step
biological, chemical this significant
or physical hazard?
Biological
Chemical
Physical
How to determine CCP?
Critical Control Point
• A point, operational step or stage in the food chain
at which control can be applied and is essential to
prevent or eliminate a food safety hazard or reduce
it to an acceptable level.

• Point of absolute control

• Steps in the food process which must be under
control to produce a safe product
How to determine CCP?
• Evaluate each steps where food hazards can be
prevented, eliminated or reduced to acceptable levels.

• Each step should be then categorized as either CCP or

control point.

CCP Decision Tree

• A sequence of questions which can be applied to each
process step to identify at which process step the
significant hazard can be control as a CCP.
How to determine CCP?
• Numbers of CCPs are depends on the product and
process.

• Method for identifying / designating CCPs can vary:

1. Sequential numbering: CCP #1, CCP #2, CCP #3
2. Sequential within hazard category: CCP P1, CCP
B1, CCP C1
3. By process step name: Oven, Packaging, Chill
How to determine CCP?
• CCPs may change with differences in:
o Facility layout
o Formulation
o Process flow
o Equipment
o Ingredient selection
o Sanitation and other prerequisite programs
 2 Determine CCP
Is this raw material /
packaging material a
Potential hazard state
Raw sensitive material? (Y/N)
whether biological,
Material
chemical or physical Q1 Q2 Q3 SRM

Biological

Chemical

Physical
 2 Determine CCP

Is this a CCP? (Y/N)

Potential hazard state
Process
whether biological,
Steps
chemical or physical Q1 Q2 Q3 Q4 (Y/N)

Biological

Chemical

Physical
How to establish critical limit?
• Acceptance or rejection limits

Process steps
• Freezing temperature (degree Celsius)
• Ultra violet (UV light intensity)
• Pasteurization (temperature, time)
• Cooking (temperature)
• Sterilization (temperature and time)
• Reverse osmosis (membrane size)
• Metal detecting (test piece measurement)
How to establish critical limit?
Critical limits Reference
Cooking temperature 90oC USFDA Guidance Level for ready-to-eat
food products
Ferrous  2mm USFDA Health Hazard Evaluation Board
Metal detector user manual
Non ferrous 1mm
Raw material receiving temperature 4 USFDA Fish and Fishery Product Hazard
and Control Guideline
Freezer temperature -18 USFDA Fish and Fishery Product Hazard
and Control Guideline
Acidity fruit juice  3.5% weight per
volume acidity calculate as anhydrous Regulation 235, Food Regulation 1985
citric acid
Heavy Metal contaminant Regulation 38, Food Regulation 1985
Food additives (Preservatives) Regulation 19, Food Regulation 1985
How to establish critical limit?
Critical limits Measurement
Untra Violet UV light intensity, lux

Pasteurization Holding 83-85oC for min 30 minutes

Rapid cooling <4oC or HTST
Cooking >63oC

Boiling Time and Temperature

Sterilization Time and Temperature

Reverse osmosis Membrane size

3 Set critical limit
CCP NO. &
Significant hazard(s) Critical Limits
Process step
How to establish CCP monitoring
system?
• The monitoring system shall consist of sequence of
planned measurements or observations to detect loss of
control at the CCP.

• The monitoring system with the necessary monitoring

instruction shall comprise of:
o What is being monitored (What)
o Monitoring method (How)
o Monitoring frequency (Frequency)
o Personal responsible for monitoring and evaluating the
monitoring results (Who)
How to establish CCP monitoring
system?
• Where relevant, location of the monitoring should be recorded.

• The monitoring methods and frequency shall be capable of

identify any nonconformity in time of the product to be
controlled and isolated before it is used on consumed.

• Monitoring results must be recorded.

• Where possible, process adjustments should be made when

monitoring results indicate trend towards non-conformity and
the adjustment should be taken before deviation occurs
 4 Monitoring program

Monitoring
CCP NO. &
Significant
Process
hazard(s)
step Frequen
What How Who
cy
How to establish corrective
action?
• For each CCP, specific, documented corrective
actions shall be established to be applied when the
monitoring results show that a CCP deviates from
the critical limits.
• Corrective actions shall ensure that the CCP is
brought back into control, the products
manufactured while the CCP was out of control are
handled according to the procedures established for
controlling the non-conforming products
• Corrective action taken shall be documented.
5 Corrective action
CCP NO. &
Significant hazard(s) Corrective action
Process step
How to establish verification
procedures?
• The application of methods, procedures, test and
other evaluations, in addition to monitoring, to
determine compliance with the HACCP Plan.
• Verification activities include:
o Review of the HACCP system and its
corresponding records
oAnalysis of recalls and product dispositions
oAssessment of all control measures
How to establish verification
procedures?
• A Verification activities include:
o Analysis of customer complaints related to food safety
o Review analytical outcome of random sampling and
analysis of products
o Evaluation of non-conformity with applicable
legislation
o Review of gaps between current and desired level of
knowledge, awareness and training of staff with respect
to food safety
o Consistency of the current documentation
 Verification
Self inspection Frequency
• Verify monitoring records Daily
• Mock recall Yearly
• Internal audit Yearly

Certification inspection
• External audit Yearly

• Non-conformance need to carry out corrective action

 Verification
Lab Test Frequency
• Food-microbe Yearly
• Food-chemical Yearly
• Environment Yearly

Data analysis Frequency

• Audit result Yearly
• Lab test result Yearly
• Customer complaint Yearly
• Emergency incidents Yearly

• Non-conformance need to carry out corrective action

 Verification
Data analysis Frequency
• Audit result Yearly
• Lab test result Yearly
• Customer complaint Yearly
• Emergency incidents Yearly

Management review
• Food Safety Team Yearly

• Find out improvement plan

6 Verification

Verification
CCP NO. &
Significant hazard(s) (What / How /
Process step
Frequency / Who)
How to establish documentation
and record keeping?
• The establishment shall establish a documented HACCP system and
shall maintain the HACCP system ensure conformity with standard
and applicable legislation and regulation.

• Documentation should be appropriate to the nature and size of

operation.

Record
• Efficient and accurate record keeping is essential to the application of
a HACCP system
• Records shall be established and maintained to provide evidence of
conformity to the requirements and effective operation of the
HACCP system.
• Records shall remain legible, readily identifiable and retrievable.
7 Documentation & record
CCP NO. &
Significant
Process Record
hazard(s)
step
HACCP Awareness
Training
Section 7
Validation & Verification
Validation
• Validation is a preemptive scientific evaluation that
provides documented evidence that a particular process
(e.g., cooking, frying, chemical treatment, extrusion, etc.) is
capable of consistently delivering a product that meets
predetermined specifications.

• it’s a collection of scientific proof that a particular

process involving chemical, physical, and biological inputs is
consistently delivering a desired effect to ensure the
destruction of pathogenic microorganisms. This is often
expressed as “log reduction.”
Validation
• sources such as
- peer-reviewed scientific literature,
- mathematical modeling, or
- regulatory resources.
- in-house challenge studies can be used.

• In most situations, validation is conducted prior to

implementing a new method or process. Activities include
challenge testing, shelf-life testing, etc.
Validation
• The major steps involved in validation include: determining
the method(s),
- selecting a surrogate or pathogenic microorganism,
- identifying worst-case scenarios,
- executing the validation study by a qualified
microbiologist or food safety expert,
- collecting and analyzing data, and
- preparing a validation report.

• Once the process validation is completed, the facility needs

to establish verification procedures.
Verification
• This is ongoing activities conducted to ensure that the
implemented processes are effectively and consistently carried
out.
• Verification activities can include
- the food safety plan review;
- walk-through;
- document review;
- testing;
- internal auditing;
- confirmation that the CCPs,
- HACCP plan, and
- other preventive controls are effective, etc.
Verification
• verification activity will
- confirm the overall performance of the food safety
program,
- identify the need for updating or improving the food
safety control measures,
- provide evidence that corrective actions are effective, and
- verify that finished products comply with current
standards.
Verification
• Whenever necessary, re-validation and re-
verification should be conducted to adjust the food
safety standards to ensure the food produced is
safe.

Validation Verification

Improvement
Continue improvement
• organization continually improves the effectiveness
of the food safety management system through:
o the use of communication
o management review
o internal audit
o evaluation of individual verification results
o analysis of results of verification activities
o validation of control measure combinations
o corrective actions and
o food safety management system updating
HACCP Awareness
Training
Section 6
HACCP Certification Process
Process to HACCP certification.
CERTIFICATION
Company meets internationally accepted standard
of excellence.
 Type of food safety certification
Gov Private
√
• Good Agriculture Practice
√
• Organic Scheme Malaysia
√
• Good Aquaculture Practise
√
• Live Stock Farm Certification Scheme
√
• MeSTI / BeSS √ √
• Good Manufacturing Practice (GMP) √ √
• HACCP √
• ISO 22000 / FSSC 22000 √

• BRC
food safety certification PROCESSES
1. Form management team that know food safety
requirements

Company Certification body

Food safety personnel / team Consultant

QA/QC/ Technical / Food Tech.

food safety certification PROCESSES
2. Develop written manual that include all procedures
related with food safety.
- Information formed in black and white
- Standardization operation processes

Processes involved are:

Purchasing Reheating
Receiving Hot / cold-holding
Storage Packaging
Food Handling Delivery
Cooking
food safety certification PROCESSES
3. Cascade information in manual to operation team.
- Instruction given to operation and aware food
safety concern.

4. Implementation
- Practice all procedures and record monitoring
points.
- Operation practice all the time
food safety certification PROCESSES
5. Verification the established procedures.
- Recheck procedures suitability
- Take corrective action and / or change to better
procedures

Activities of verification includes:

1. Inspection on-site
2. Lab test of food, equipment and environment
3. Internal Audit
4. Management review
5. Verified with Scientific references
food safety certification PROCESSES
6. Certified by certification body (CB)

• Site is ready for external audit when

1.Minimum 3 months monitoring records had done.
2.Internal audit, mock recall & management review
completed.

• After external audit

1.Close non-conformance of external audit within
given time.
2.Obtain certificate after closed the non-conformance
food safety certification PROCESSES

7. Certification maintenance

• Minimum yearly inspection in 3 year cycle

• Certificate my be suspend or withdraw when fail to

follow requirements.
Golden Rule for Success
• Management commitment
• A thoroughly trained and motivated team
• Site ownership – gained by all your staff in the
process
Why food safety programs sometimes
fail:
• Lack of senior management buy-in
• Lack of individual ownership and responsibility
• Inadequate training
• Taking too much at once
• The food safety program is seen as ‘add on’ and not as ‘way of
life’
• Records are not completely correctly
• The food safety program is not properly establish
• Bending the rules
• Giving up too soon
• Paying lip service to food safety legislation
 Conclusion
LET US BE OPTIMISTIC
WE CAN DO IT
WE MUST DO IT
OTHERWISE

HACCP WILL BE
“HAVE A CUP OF COFFEE AND PRAY”