HACCP Training for the Food Industry from SafetyVideos.com

Summary

This video script discusses the importance of the Hazard Analysis and Critical Control Point (HACCP) system in ensuring food safety across the food processing industry. It explains HACCP's origins, principles, and implementation steps, highlighting its role in controlling biological, physical, and chemical hazards to protect consumers and businesses.

Takeaways

• 🍽️ Food safety is a critical issue affecting millions of people and costing companies millions of dollars due to illnesses and reputational damage.
• 🔍 The Hazard Analysis and Critical Control Point (HACCP) system is the most widely used food safety program, internationally recognized for ensuring food safety.
• 🚀 HACCP was developed in 1958 by NASA to ensure the safety of food for astronauts, based on a set of engineering principles.
• 🏭 The U.S. Department of Agriculture and the Food and Drug Administration either require or recommend HACCP for companies in the food processing industry.
• 🔄 HACCP is a proactive approach focusing on prevention and risk analysis, as opposed to traditional food inspection which relied on senses and was reactive.
• 🔍 HACCP uses seven principles to identify potential hazards in the food production process and establish control measures to mitigate them.
• 🛡️ HACCP addresses three types of food safety hazards: biological (e.g., bacteria), physical (e.g., foreign objects), and chemical (e.g., contaminants).
• 🏗️ Prerequisite programs, such as Good Manufacturing Practices (GMPs) and hygiene standards, are essential for the success of a HACCP system.
• 📋 Implementing a HACCP plan involves assembling a team, describing products, identifying intended use, creating a flow diagram, and verifying the accuracy of the process.
• 📊 The first three principles of HACCP focus on hazard analysis, identifying critical control points (CCPs), and establishing critical limits for effective hazard control.
• 🔄 The remaining four principles of HACCP deal with monitoring, corrective actions, verification procedures, and record-keeping to ensure the system's effectiveness and documentation.
• 🌐 HACCP is advantageous for facilities as it is recognized by regulatory bodies and can facilitate international business, demonstrating a commitment to product quality and consumer safety.

Q & A

What is the primary concern addressed by the food safety programs mentioned in the script?

The primary concern addressed by the food safety programs is the prevention of foodborne illnesses and the reduction of financial losses and reputational damage caused by hazardous materials contaminating the food supply.

What does HACCP stand for and what is its purpose?

HACCP stands for Hazard Analysis and Critical Control Point system. Its purpose is to ensure that food is safe for consumption by identifying and controlling potential hazards in the food production process.

When was HACCP first created and for what reason?

HACCP was first created in 1958 to ensure the safety of food for American astronauts, based on a set of NASA's engineering principles.

Which U.S. government agencies either require or recommend the use of HACCP?

The U.S. Department of Agriculture and the Food and Drug Administration either require or recommend the use of HACCP by companies in every segment of the food processing industry.

What are the three types of food safety hazards that HACCP is used to control?

HACCP is used to control biological hazards (e.g., viruses, bacteria), physical hazards (e.g., broken glass, metal fragments), and chemical hazards (e.g., cleaning solutions, pesticides, mismeasured food additives, allergens).

What are the prerequisites to successfully implementing a HACCP system?

Prerequisites to successfully implementing a HACCP system include policies regarding employee hygiene, pest control programs, and regularly scheduled cleaning procedures for equipment used in food processing and handling.

What are the five steps that should be followed in creating a HACCP plan?

The five steps are: 1) Assemble the HACCP team and construct a HACCP manual, 2) Describe the products addressed by the plan, 3) Identify the intended use of the products, 4) Create a flow diagram showing the steps the food goes through, and 5) Verify the accuracy of the flow diagram.

Why is it important to have a diverse HACCP team?

A diverse HACCP team is important to ensure multiple perspectives on the company's operations, including representation from various departments and functions such as production, sanitation, quality control, and management.

What is the significance of establishing critical control points (CCPs) in the HACCP system?

Establishing CCPs is significant because they are the points in the food processing where control measures can be taken to prevent, reduce, or eliminate hazards, ensuring the safety of the food product.

What are the four main aspects that the remaining principles of the HACCP system focus on after addressing the hazards?

The remaining principles focus on monitoring the control points to ensure they are working effectively, establishing corrective actions for any problems that arise, verifying the validity of the HACCP plan, and maintaining accurate record-keeping.

What are the advantages of implementing a HACCP system in a food processing facility?

Advantages include compliance with regulatory requirements, the ability to operate in international markets, demonstrating a commitment to product quality and customer safety, and establishing a standard for food quality assurance.

Outlines

00:00

🍽️ Food Safety and the Importance of HACCP

This paragraph introduces the critical nature of food safety, highlighting the significant health and financial risks associated with foodborne illnesses. It emphasizes the role of the Hazard Analysis and Critical Control Point (HACCP) system in mitigating these risks. HACCP, established in 1958 for NASA, is now a globally recognized standard in the food industry, mandated by the U.S. Department of Agriculture and the Food and Drug Administration. The paragraph outlines the proactive approach of HACCP, which focuses on prevention and risk analysis, as opposed to traditional reactive methods. It also explains the seven principles of HACCP, which guide the identification, monitoring, and control of food safety hazards, including biological, physical, and chemical threats.

05:00

🛠️ Implementing the HACCP System

The second paragraph delves into the process of implementing a HACCP plan. It begins by discussing the formation of a diverse HACCP team, including members from various company departments, and the importance of formal training in the HACCP system. The team is responsible for creating, implementing, and maintaining the HACCP plan. The paragraph outlines the steps for developing a HACCP plan, starting with a comprehensive product description, identifying the intended use and consumers, and creating a flow diagram of the food processing steps. It also stresses the importance of verifying the accuracy of the flow diagram through a team review and a physical walkthrough by an outsider to ensure objectivity.

10:01

🔍 HACCP Hazard Analysis and Control Measures

This paragraph focuses on the initial principles of the HACCP system, which involve conducting a hazard analysis to identify potential contaminants in the food production process. It discusses the importance of examining the entire process flow and assessing the probability and severity of hazards. After identifying hazards, the paragraph explains the need to develop a list of control measures to prevent, reduce, or eliminate these risks. The second principle involves identifying Critical Control Points (CCPs) where these control measures can be effectively implemented, such as testing for metal fragments or ensuring proper cooking temperatures. The third principle is about establishing critical limits for each CCP to ensure effective hazard control, with examples provided like temperature ranges for refrigeration.

15:01

📋 Monitoring, Corrective Actions, and Documentation in HACCP

The fourth paragraph discusses the latter principles of the HACCP system, which are centered around monitoring, corrective actions, and documentation. It describes the fourth principle of establishing monitoring procedures to measure critical limits at CCPs, detailing how and when these measurements should be taken. The fifth principle addresses the need for predetermined corrective actions to be in place when deviations from the norm are detected, ensuring that the process is brought back under control and any affected products are handled appropriately. The sixth principle involves establishing verification procedures to confirm the effectiveness of the HACCP plan, including audits and reviews of records and calibrations. The final principle emphasizes the importance of record-keeping, which serves as evidence of safe food production and handling practices, and outlines the requirements for maintaining these records.

🌐 The Benefits and Application of HACCP

The concluding paragraph reviews the benefits of implementing a HACCP system, noting its widespread use across the food chain from growers to retailers. It stresses the necessity of having prerequisite programs in place before adopting HACCP and the importance of establishing and maintaining critical control points and their limits. The paragraph highlights HACCP's focus on creating a safe food processing environment and the ongoing effort to maintain and document this environment. It concludes by emphasizing the role of HACCP in ensuring food safety for consumers and the advantages it brings to a company in terms of quality assurance and international market access.

Keywords

💡Foodborne illnesses

Foodborne illnesses refer to diseases caused by consuming contaminated food, which can lead to millions of people getting sick and thousands dying annually. In the video's context, these illnesses are a significant concern that drives the need for food safety measures. The script mentions that hazardous materials contaminating the food supply can have severe health impacts and financial repercussions for companies.

💡Hazard Analysis and Critical Control Point (HACCP)

HACCP is a systematic preventive approach to food safety that identifies physical, chemical, and biological hazards in production processes and establishes controls at critical points. It is the central theme of the video, introduced as a method to ensure food safety from growers to retailers. The script explains that HACCP was created in 1958 and is now widely used internationally, emphasizing its importance in the food industry.

💡Biological hazards

Biological hazards in the context of food safety refer to microorganisms such as viruses and bacteria, including E. coli, Listeria, and Salmonella, which can cause foodborne illnesses. The video script highlights the role of HACCP in controlling these hazards by identifying critical control points where these contaminants can be eliminated or controlled.

💡Physical hazards

Physical hazards are foreign objects in food that can cause injury, such as broken glass, metal fragments, or pieces of plastic. The video script discusses how HACCP helps in identifying and controlling these hazards, ensuring that food is safe for consumption by preventing such contaminants from entering the food supply.

💡Chemical hazards

Chemical hazards encompass substances like cleaning solutions, pesticides, mismeasured food additives, and allergens like peanut dust that can contaminate food and pose health risks. The video script explains that HACCP is used to manage these hazards by establishing control measures and monitoring procedures to prevent their introduction into the food supply.

💡Good Manufacturing Practices (GMPs)

GMPs are guidelines that provide a system of processes, equipment, and facilities to ensure the production and control of a product to meet the quality requirements. The script mentions that while HACCP focuses on food safety, GMPs address environmental issues and are essential prerequisites for the success of a HACCP system.

💡Critical Control Points (CCPs)

CCPs are points in a food production process where control measures can be implemented to prevent, eliminate, or reduce hazards to acceptable levels. The video script describes how HACCP identifies CCPs and establishes critical limits for these points, which is crucial for ensuring the safety of the food being processed.

💡Monitoring procedures

Monitoring procedures in HACCP are the methods used to measure the critical limits at CCPs to ensure that they are within acceptable ranges. The video script explains the importance of these procedures in maintaining food safety by providing a continuous check on the effectiveness of the control measures.

💡Corrective actions

Corrective actions are predetermined responses to be taken when monitoring indicates a deviation from the established critical limits. The video script emphasizes the necessity of having these actions defined before starting a process to quickly regain control and prevent further issues.

💡Verification procedures

Verification procedures in HACCP confirm the validity of the plan and ensure that it is complete and effective in achieving the desired safety outcomes. The video script discusses how these procedures involve ongoing activities like audits, record reviews, and equipment calibration checks.

💡Record keeping

Record keeping is the process of documenting all aspects of the HACCP plan, including team members, product descriptions, hazard analysis, and corrective actions. The video script highlights the importance of complete and accurate records to prove that food has been produced and handled safely.

Highlights

Food safety is a critical issue affecting millions of people and costing companies millions of dollars annually.

Hazard Analysis and Critical Control Point (HACCP) system is the oldest and most widely used food safety program.

HACCP was created in 1958 to ensure the safety of food for American astronauts and is based on NASA's engineering principles.

The U.S. Department of Agriculture and the Food and Drug Administration require or recommend HACCP for companies in the food processing industry.

HACCP is a proactive approach focusing on prevention and risk analysis rather than relying on post-production inspection.

HACCP employs seven principles to determine food hazards and control points throughout the food production process.

HACCP addresses three types of food safety hazards: biological, physical, and chemical.

Prerequisite programs like Good Manufacturing Practices (GMPs) and hygiene standards are essential for the success of a HACCP system.

Creating a HACCP plan involves assembling a multi-disciplinary team, describing products, identifying product use, and creating a flow diagram.

Verification of the HACCP plan's flow diagram is crucial for ensuring its accuracy and effectiveness.

HACCP's first principle involves conducting a hazard analysis to identify potential contaminants in the food process.

Identifying Critical Control Points (CCPs) is the second principle of HACCP, where control measures are implemented.

Establishing critical limits for CCPs is essential for effectively controlling hazards in the third principle of HACCP.

Monitoring procedures are established in the fourth principle of HACCP to ensure CCPs are working effectively.

The fifth principle of HACCP involves establishing corrective actions for deviations from the norm.

Verification procedures in the sixth principle confirm the validity and effectiveness of the HACCP plan.

Record keeping is the focus of the seventh principle, ensuring traceability and accountability in food safety.

Implementing a HACCP system, while labor-intensive, offers numerous advantages including regulatory compliance and enhanced food safety.

HACCP is becoming a global standard for food quality assurance, facilitating international business.

A HACCP system demonstrates a company's commitment to product quality and customer safety.

Transcripts

[Music]

millions of people get sick

from foodborne illnesses every year and

thousands of them

die hazardous materials contaminating

the food supply

can also cost companies tens of millions

of dollars and untold damage to their

reputations as well

as a result food safety has become an

important issue in all stages of the

food processing industry

from growers and manufacturers to

distributors and retailers

to address this problem over the years a

number of food safety programs have been

developed to help assure that the food

that reaches consumers

is in fact safe enough to eat the oldest

and most widely used of these programs

both nationally and

internationally is hassip the hazard

analysis

and critical control point system and

that is what this course

is all about

if you work in any facet of the food

industry it's important to have a clear

understanding of the hassip

hazard analysis and critical control

points

food safety system hassip was created in

1958 to ensure that the food america's

astronauts would be eating

was safe for them to consume and is

based on a set of nasa's engineering

principles

now the u.s department of agriculture

and the food and drug administration

either require or recommend that hassep

be used by companies in every segment of

the food processing industry

and encompass all elements of the food

chain including

growing harvesting processing

manufacturing distribution as well as

retailers

such as grocery stores and restaurants

before hassep food inspection generally

relied on the senses

sight smell and touch to detect

potential hazards

and the most thorough inspections were

typically done after the fact

when the product was ready to go out the

door or actually be eaten

hassep makes this activity proactive

using an approach that focuses on

prevention and risk analysis

it is a continuous process with

adjustments being made as things change

within the food processing environment

hassip employs seven principles to first

determine what hazards food may be

susceptible to

as it is grown processed and handled

and at what points these hazards can be

eliminated or controlled

the system then defines how to monitor

these control points

to make sure that they are working

effectively correct any problems that

surface

and finally verify and document what has

occurred

hassip is used to control three types of

food safety hazards

biological hazards such as viruses and

bacteria like e coli

listeria and salmonella physical hazards

such as broken glass metal fragments and

pieces of plastic

and chemical hazards such as cleaning

solutions

pesticides mismeasured food additives

and even

allergens like peanut dust

before starting to develop a hassa plan

it's important to understand what hassip

does

and doesn't do hasip addresses food

safety by focusing on the processes that

the food is going through

such as cooking and refrigeration and

what could create hazards within these

processes

what it doesn't do is address

environmental issues

such as good manufacturing practices

gmps

or hygiene standards however

having these programs in place is

essential to the success of a hassep

system

as they provide the building blocks upon

which hassep's

seven principles of food safety rest

in essence they are prerequisites to

successfully implementing a hassip

system

and include policies regarding employee

hygiene

such as the use of hair nets and gloves

and practices like proper hand washing

pest control programs which prevent

animals and insects

like mice and roaches from entering the

food production process

and regularly schedule cleaning

procedures for the equipment that is

used in food processing

and handling activities

there are five steps that should be

followed in creating a hassa plan

all of which focus on gathering the

resources and information that the

planning process needs

the first is to assemble the hassip team

and begin to construct a hassett manual

the team should include employees from

as many departments and functions as

possible

such as production sanitation quality

control and management

so that multiple perspectives on the

company's operations are represented

one of the team members should be

formally trained in the hassip system

the team will not only be responsible

for creating the hassa plan

but for implementing and maintaining it

as well

so members names and contact information

should be documented in the manual

the second step in the planning process

is to fully describe the products that

the hasset plan will address

description should include things such

as

recipe and formulation information if

there is any

packaging materials that are used with

the products

the conditions under which the products

should be stored and their expected

shelf life

as well as distribution considerations

and the potential for damage in

transport

the third step in preparing a hasset

plan is to identify the intended use of

the products

and who will be consuming them any

special use considerations

should be included such as glucose free

products being used by consumers who are

glucose intolerant

it can often be productive to group

products into categories

where food safety considerations will be

similar and could include

animals that are slaughtered other raw

product

food that will be thermally processed or

otherwise heated

and so on next a flow diagram should be

created

showing the steps that the food will go

through as it is being processed

and handled this should include every

step that is in direct control of the

facility

from initially receiving and storing the

food and associated materials

to packaging and shipping it out and

stocking or serving it

if the environment is a food processing

plant it can also be helpful to create a

plant schematic

that shows where each of the processing

steps occur

and how product people and waste move

within the facility

the fifth and last step in creating a

hassett plan

is to verify that the flow diagram is

accurate

an initial pass at this can be done by

having all members of the hassip team

review the diagram and note any comments

and questions that they have

once these are reconciled a physical

walkthrough should be conducted as a

final verification

the best test of the diagram can often

be to have the walkthrough done by

someone

outside of the team who is not familiar

with how the diagram has been created

and has no preconceptions as to how

things should work

the initial three principles of a hazard

analysis and critical control point

system

hassip address the hazards that food

which is being processed and handled

may be subject to and how to control or

eliminate them

the first is to conduct a hazard

analysis

identifying steps in the process where

physical

chemical or biological contaminants

could be introduced

it's important to look at the entire

process flow during the analysis

from receipt storage and preparation

through to its final distribution and

use

the probability of the hazard occurring

and the severity of the consequences

should be determined as well after a

thorough review is completed

and potential hazards are identified a

list of potential control measures

should be assembled control measures are

actions that would prevent

reduce or eliminate the hazards

after the hazard analysis is completed

the second principle in the hassip

system can be applied

identifying critical control points ccps

where the control measures can be taken

these can be actions such as testing the

food for metal fragments

heating it to kill bacteria or

refrigerating it to prevent spoilage

considerations in this step include

determining whether the ccps can be

monitored

and how they will be documented it's

important to remember that a ccp may not

be located where the hazard occurs

but could be later in the process the

third principle in the hassif system

is to establish critical limits for each

of the control points that have been

identified

these are maximum and or minimum values

that will enable a hazard to be

effectively controlled

for example if a critical control point

is the refrigeration of a food product

its critical limit might be a range of

36 to 41 degrees fahrenheit

cooking a hamburger could have two

control points for destroying potential

bacteria

its cooking time and temperature

once the hazards that food being

processed may be subject to

and how to control or eliminate them are

addressed the remaining principles in

the system then focus

on four things how to monitor these

control points to make sure that they

are working effectively

what must be done to correct any

problems that surface

and finally to verify and document what

has happened

both with the plan itself and any

problems that occur

[Music]

the first three principles of a hazard

analysis and critical control point

system

passive address the hazards that food

which is being processed and handled may

be subject to

and how to control or eliminate them

once they are implemented the hassip

system turns its attention to making

sure that everything is working

correctly

and that things are documented

appropriately

so the fourth principle in the hassep

system is to establish

monitoring procedures that measure the

critical limits at each of the food

processing's critical control

points ccps these procedures should

describe

how the measurements will be taken when

the measurements are to be taken

the time of day or within the process

how frequently the measurements should

be taken

and who is responsible for taking the

measurements

hopefully the monitoring process will

confirm that all is going well

however as we all know at times things

can go wrong

when the monitoring procedures do detect

a problem

the hassip system's fifth principle

establishing corrective actions

comes into play corrective actions

are predetermined measures that should

be taken when monitoring indicates that

a deviation from the norm has occurred

it's crucial that corrective actions for

all of a processes critical control

points be defined

before the process is started this must

be a proactive

not a reactive activity corrective

actions must address

regaining control of the process

locating and segregating any affected

product

determining if affected products should

be disposed of and how that should be

done

how to prevent a recurrence of the

problem and documenting the problem

and the actions that were taken to

correct it

common corrective actions include things

such as adjusting a thermostat to the

correct temperature

reheating or recooking a product and

discarding a product that has spoiled

the sixth principle in the hassib system

is to establish

verification procedures which confirm

the validity of the hasa plan

verifying that it is complete and

effective in achieving the desired

safety outcomes

these procedures need to be utilized on

an ongoing basis

and revisit it anytime that something in

the food processing

or its handling changes activities that

can be incorporated in the verification

procedures include

conducting periodic audits of the

overall plan

as well as the critical control points

and critical limits

reviewing records of problems and their

corrective actions checking instrument

calibrations

and product testing the seventh and

final principle in the hassif system

is record keeping its focus is to prove

that the food in your facility has

in fact been produced and handled safely

records must be complete and accurate

and include information on virtually

everything within the facility's hazard

plan

and its execution such as the members of

the hassob team

product descriptions hazard analysis

flow diagrams and critical control

points and their limits

records must also be kept for any

corrective actions that have been taken

verification procedures that are being

used changes that have been made to the

hasset plan over time

and even the record-keeping process

itself

lastly the plan needs to specify who is

responsible for maintaining the records

how long they should be kept and where

they are stored

[Music]

it's clear that implementing a hassip

system is a lot of work

but there are a number of advantages to

having a hasab system in place at your

facility

in the united states both the food and

drug administration and the department

of agriculture

require or recommend its use for all of

the facilities that they oversee

and it is fast becoming the de facto

standard for food quality assurance

in other parts of the world as well

which can help a company to do business

in

international markets most importantly

it shows that you care about the quality

of your products and the safety of your

customers

let's review hassip can be used by every

group in the food chain

from growers to retailers it's important

to have basic prerequisite programs in

place before implementing a hassip

system

establishing critical control points and

their critical limits are key to a hassa

plan

the first area hassa focuses on is

creating a safe food processing and

handling environment

hassep's other emphasis is on

maintaining that environment and

documenting everything about it

now that you know more about how hassep

works and why it is important to your

company

you can do your part to help keep the

food that you work with safe for

everyone who eats it

you