Introduction
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 guidelines will facilitate the development and
implementation of effective HACCP plans. While the specific application
of HACCP to manufacturing facilities is emphasized here, these
guidelines should be applied as appropriate to each segment of the food
industry under consideration.
Prerequisite Programs
The production of safe food products requires that the HACCP system
be built upon a solid foundation of prerequisite programs.
Each segment of the food industry must provide the conditions necessary
to protect food while it is under their control. This has traditionally
been accomplished through the application of cGMPs. These conditions
and practices are now considered to be prerequisite to the development
and implementation of effective HACCP plans. Prerequisite programs
provide the basic environmental and operating conditions that are
necessary for the production of safe, wholesome food. Many of the
conditions and practices are specified in federal, state and local
regulations and guidelines (e.g., cGMPs and Food Code). The Codex
Alimentarius General Principles of Food Hygiene describe the basic
conditions and practices expected for foods intended for international
trade. In addition to the requirements specified in regulations,
industry often adopts policies and procedures that are specific to their
operations. Many of these are proprietary. While prerequisite programs
may impact upon the safety of a food, they also are concerned with
ensuring that foods are wholesome and suitable for consumption. HACCP plans are narrower in scope, being limited to ensuring food is safe to consume.
The existence and effectiveness of prerequisite programs should be
assessed during the design and implementation of each HACCP plan. All
prerequisite programs should be documented and regularly audited.
Prerequisite programs are established and managed separately from the
HACCP plan. Certain aspects, however, of a prerequisite program may be
incorporated into a HACCP plan. For example, many establishments have
preventive maintenance procedures for processing equipment to avoid
unexpected equipment failure and loss of production. During the
development of a HACCP plan, the HACCP team may decide that the routine
maintenance and calibration of an oven should be included in the plan as
an activity of verification. This would further ensure that all the
food in the oven is cooked to the minimum internal temperature that is
necessary for food safety.
Education and Training
The success of a HACCP system depends on educating and training
management and employees in the importance of their role in producing
safe foods. This should also include information the control of
foodborne hazards related to all stages of the food chain. It is
important to recognize that employees must first understand what HACCP
is and then learn the skills necessary to make it function properly.
Specific training activities should include working instructions and
procedures that outline the tasks of employees monitoring each CCP.
Management must provide adequate time for thorough education and
training. Personnel must be given the materials and equipment necessary
to perform these tasks. Effective training is an important prerequisite
to successful implementation of a HACCP plan.
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 five preliminary tasks are given in
Figure 1.
Figure 1. Preliminary Tasks in the Development of the HACCP Plan
