HACCP & Essentials of Food Safety – HACCP at Shop Floor (Part – 1)

HACCP & Essentials of Food Safety – Brilliance at PRP Basics
July 7, 2021
HACCP & Essentials of Food Safety – HACCP at Shop Floor (Part – 2)
July 14, 2021

This Video is continuation of HACCP & Essentials of Food Safety Webinar conducted by Green World Group with Mr. Aloysius G. Pasion – Food Safety Manager and Quality Pillar Lead, Nestle’ MENA, Middle-East & Africa.

For better understanding, read our previous article, HACCP & Essentials of Food Safety – Introduction.

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Video Transcription

HACCP at the shop floor

So, you have verified your PRP’s are strongly in place. They have been verified that they're effective. They're a really working for you in such a way that they're providing the foundation for your quality system.

So now you can develop your HACCP study.

So we're talking about,

  • what is a hazard? and
  • what is the risk associated with that particular hazard?

So when we say hazard, we're talking about the contaminant that can cause an adverse health effects.

Taking into consideration, what is the risk of this particular hazard coming into your process?

When we say risk, we're talking about the probability of that particular hazard and how it can come into your process.

So risk particularly means it's the function of the probability of that particular adverse health effect and the severity of that health effect, inconsequential to foot safety hazard. Straightforward, it's a preventative approach in order to assure food safety.

So in HACCP,

we have an assessment process to identify these hazards and to be able to identify control measures and categorize this control measures in order to make sure that this control measures to reduce this hazards are unacceptable.

So in order to have a strong food safety management system, you need to have strong PRPs followed by an effective HACCP system in order to ensure food safety.

So what HACCP system that we need to manage, assist and assess the risk. So it's basically,

  • We want to identify those hazards
  • What are the statistics of those hazards?
  • And we need to assess the exposure of the product for that particular hazard

Once we identified and analyzed this hazard, we need to manage risk management, making sure that we are able to come up with control measures for the rest of those hazards, and of course, to be able to communicate the risks.

So this risk particularly about your HACCP Plan, but even identify the particular hazard for this particular control measure.

So you need to have PRP's strongly in place and you have a separate PRP plan to manage that. Setup your HACCP Team to find the scope and define the product the product that you like to covered in your HACCP Study.

Taking into consideration, the intended use of the product defines your flow diagram, i.e.

  • Contact hazard analysis
  • Identify your OPRP's and CCP's
  • Establish the limits
  • Establish a monitoring system
  • Establish your corrective action
  • Establish the verification procedures and
  • Validate your control measures

So more or less, this is an effective way of developing HACCP study.

So, preparation for your HACCP Study - Basically describes about the composition, i.e.

  • What is the responsibility and managing the HACCP Study?
  • What should be the content from your study?
  • Define the scope of HACCP study and
  • Identify what is the study for and describe your HACCP Team

Describe the product:

  • Characteristic of end products related to food safety e.g.: water activity, acidity, etc…
  • Description of incoming materials including ingredients, packaging materials and rework
  • Food safety related specification and regulatory requirements
  • Food safety related filling and packing conditions. E.g. filling format and technology
  • Claims and label information including instruction for safe usage
  • Information related to distribution and delivery
  • Acceptable level in the end product related to food safety
  • “So your process flow diagram, basically this is a graphic representation of the sequence on how to manufacture your product”

    Steps in your operation is, From the time that your materials received until these materials are used in the processing in the process environment.

    Also the input of other processing aids, just steam water, compressed air, lubricants, or pathogen materials we work that you are using.

    So where is the waste and rework generational control measures that you have got to in your processes, what are potential areas that might be sources of allergens or microbial contamination?

    So these are just some of the information that needs to be in place for your process for that.

    “I just wanted to emphasize that your process flow diagram is really important to make sure that you do not miss any critical step, because if you miss a step, you miss a hazard. The hazard analysis is conducted based on your flow diagram”

    So hazard analysis is the most important step when you conduct a study, because this is where you provide identification of potential health hazards and where is the source or where it can be originated. So you also assess and define what are the hazards specifically?

    Those that is significant for you to control based on the severity and the likelihood of this hazards. What’s important is that this control measures for significant hazards. It needs to be part of your product release.

    So it has to be part of our release system. So if you don't have it as part of your release system, then the likelihood in case that you have a deviation is that you will have a food safety hazard in your product.

    Click Here to Read the Continuation of Above Article - HACCP & Essentials of Food Safety – HACCP at Shop Floor Part 2

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