What is HACCP?
Hazard Analysis Critical Control Point (HACCP) is a systematic, scientific, and preventative approach to controlling food/beverage safety during manufacturing. The HACCP approach takes isolated quality control procedures at various points in the process and puts them together as a system. All points interrelate and interlock in a manner that prevents the system from going out of specification and causing a hazard without the information being picked up through the monitoring systems.
HACCP was originally developed in the United States by Pillsbury for NASA in the 1960s to help ensure the safety of astronauts’ food in space; HACCP is now being adopted worldwide as a scientific, straightforward, and effective approach to enhance food safety.
The HACCP approach can be used by all segments of the food production continuum and can be tailored to any individual product or process line. The advantage of using the HACCP system lies in the control it provides at all times over food safety in the processing plant, from receiving raw materials to shipping the final products.
For the food processor, producing a safe product will be structured around critical control points (CCP’s). CCP’s are designed to control potential hazards that are biological, chemical, or physical in nature and that may pose a food safety risk.
The HACCP approach is based on seven principles aimed at identifying hazards at CCP’s in the process, and verifying that the system is working properly. The element of the HACCP system is its preventative nature meaning that potential food safety hazards are controlled throughout the process. The application of the HACCP principles in the production of food is recommended by Codex Alimentarius, the international standard-setting organization for food.
Benefits of HACCP
- Systematic and scientific
- Pro-Active and preventative
- Cost-Effective
- Identifies all conceivable hazards (biological, chemical, physical)
- Focuses technical resources on critical activities
- Prevention = Reduced Losses/Waste
- Complements other Quality Management systems
- Internationally acknowledged (FAO/WHO, CODEX)
- Due Diligence support
- Applicable throughout the food chain
- Greater confidence in product safety
- Safety introduced in product development
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What’s the difference between a HACCP plan and a PCP?
A HACCP plan and a PCP both include a hazard analysis and a description of the control measures applied by a food business operator to ensure food safety. However, a PCP also includes a description of the measures applied to meet requirements related to the humane treatment of food animals and to consumer protection.
Top 5 Problems with Implementing an Effective HACCP Program
The most common problems that food and beverage producers experience when implementing a HACCP program, in my professional opinion are:
- The Commitment from the senior management to allocate sufficient resources (employee’s time and capital dollars) to develop, implement, and to maintain a successful HACCP program
- The Facility’s internal staff to take ownership of the HACCP program, as this food/beverage safety program is dynamic and requires the company to adopt a culture of quality and to strive for continuous improvement for the HACCP program to be effective.
- Deficiencies in the pre-requisite programs (GMP’s and SOP’s) as they are the foundation for a successful HACCP program. If you build a high rise building (aka HACCP program) on a weak foundation (aka GMP/SOP) it’s just a matter of time before it will crumble to the ground.
- The level of technical training of the facility’s internal staff in terms of food/beverage safety. All members of the HACCP team should have sufficient training in GMP and HACCP program development (train the trainer) so that they can adequately train the staff that works under them to ensure that they comprehend the food/beverage safety fundamentals.
- The delegation of responsibilities under the HACCP program. It has been in my experience (through time studies) that the distribution of responsibilities under the HACCP program is not in balance as usually there are one or two people (usually QC manager) that have way too much on their plate, where they have 12- 14 hours of work to do in an 8 hour day. This seems to be very common and these programs with this type of structure are destined to fail. Quality/Safety needs to be everyone’s responsibility because if everyone does their part everyone else’s job becomes that much easier, which reduces the potential of stuff falling through the cracks.
