HACCP: SEVEN PRINCIPLES

The seven principles of HACCP:
1)    Analyse hazards

2)    Identify critical control points

3)    Establish critical limits for each control point

4)    Establish procedures to monitor the critical control points

5)    Establish corrective actions to be taken if monitoring shows that a critical limit has not been maintained.

Process Steps    FOOD SAFETY HAZARD AND CAUSE    CONTROL MEASURES    CRITICAL
PROCEDURES    MONITORING PROCEDURES    CORRECTIVE ACTION

1. Deliveries In    Growth of bacteria due to inadequate temperature control.    Check temperature of ‘goods in’ vehicles    If temperature exceeds 6 C    Check and record temperature of each delivery    Option to return. Buy from reputable supplier

Growth of bacteria due to inadequate temperature control.    Goods into cold store within 15 mins    Unloading time      Training of staff. Clear loading area    Retrain staff

Growth of bacteria – damaged packaging    Visual check of pallet wrap etc    Checking prior to storage    Training of staff    Retrain staff

2. Storage

Growth of bacteria due to inadequate temperature control.     Cold store set at max 6°C.
Plastic sheets fixed at both entrances to hold temperature during movement of goods.    If temperature exceeds 6°C.    Temperature checked and recorded daily.    Adjust//repair faulty chiller. Reject or destroy suspect stock.

Correct stock rotation.    Vac Pac extends shelf life by 3 months. As does nitrogen packed grated cheese.    Check on daily basis.    Destroy suspect stock.

Two separate chiller units set up in main cold store.
Second acts as insurance to first one.    Keeps all cheese all required temperature of below 6°C.    Check on daily basis.
External digital readout.    Adjust/repair faulty chiller.

Contamination by bacteria, from packaging.    Keep packaging separate from cheese.    Strict physical separation of raw cheese and packaging.    Visual check daily.    Destroy suspect packaging. Buy from reputable supplier.

Cross contamination by physical containments from processing equipment.    Correct cleaning    Cleaning schedule adhered to.    Visual check against cleaning schedule.    Re-clean and retrain staff.

Foods beyond use by date labelling or with insufficient shelf life for packing.    Check shelf life of product – minimum up to six months.    Products within use by dates and control criteria.    Check shelf of product.    Reject or destroy suspect stock.

Pest control contract with RENTOKIL.    Absence of food from pests from premises.    Regular visits by pest control contractor.
Visual monitoring by supervisor or management.    Destroy contaminated product.
Review policy.
Re-train staff.
Physical contamination from work surfaces and food room, e.g. wood, glass and plastic.    No wooden or glass implements, stainless steel tables and equipment.    Absence of physical contamination.    Visual monitoring by supervisor or management.    Destroy contaminated product.
Review policy.
Re-train staff.

Washable walls, and ceiling, food grade cladding insulated walls.

Knee operated taps, with bacterial soap in hand dispensers.

Overalls and hats worn for work use only, kept in lockers to prevent cross contamination with outdoor clothing. Only food grade blue gloves and overalls worn    Absence of physical contamination.    Visual monitoring by supervisor or management.    Destroy contaminated product.
Review policy.
Re-train staff.

Inspection and maintenance of equipment by competent engineer.    Minimum twice yearly by MULTIVAC ARCALL and Urschel engineers.    Observation of service contract with external contractor.
LAW LABORATAORIES will check all samples sent and records kept.    Review frequency of servicing and maintenance.

Chiller unit attached to working area if temperature exceeds 6°C.    Two hours maximum.    Observe practices.    Destroy suspect stock.
Foods beyond use by date labelling or with insufficient shelf life for grating.    Check shelf life of product – minimum up to eight months.    Products within use by dates by dates and control criteria.    Check shelf of product.    Reject or destroy suspect stock.

3. Vac Pac

Chiller unit attached to working area if temperature exceeds 6°C.    Two hours maximum.    Observe practices.    Destroy suspect stock.

Cross contamination by physical containments from processing equipment.    Correct cleaning.    Cleaning schedule adhered to.    Visual check against cleaning schedule.    Re-clean and retrain staff. Destroy suspect stock.

Growth of bacteria due to incorrect vac packing.    Check seal intact.    Uniform air tight seal to pack.    Visual check of seal and pack.    Re-seal faulty packs and destroy faulty packaging.

Refrigerate within two hours.    Product temp kept below 8°C.    Monitor time of processing, controlled atmosphere setting.    Return product to refrigerated storage. Destroy suspect stock.

Biological, physical and chemical contamination from process equipment or pests.    Correct cleaning procedures in accordance with cleaning schedule.
Regular replacement of cheese wires.    Cleaning schedule adhered to.    Visual check against cleaning schedule.    Re-clean and retrain staff.

Survival of aerobic pathogenic organisms due to poor vacuum.    Use of vacuum packing equipment in accordance with manufacturer’s instructions.    Minimum setting to achieve vacuum specifications on equipment.
Absence of blown/loose packaging.    Management supervision.
Physical examination of packaged product to ensure absence of leaks.    Repeat procedure to achieve vacuum packing.
Review packaging procedures.
Contact engineer if faulty equipment.

Metal Detection    Contamination from wires/ miscellaneous metal objects    Metal detection at point prior to cheese being packed, grating and vacuum packing.     Minimum bi annual service by MULTIVAC / ARCALL/ URSCHEL engineers    Daily check of metal detectors by way of weight measures, again grating and vacuum machines.    Review of frequency of servicing and maintenance.  Daily check of metal detectors by way of weight measures.

4. Grating

Growth of bacteria due to incorrect grate packing.    Check seal intact.
Refrigerate within two hours.    Uniform N2 packing.
Product kept below 8°C.    Visual check of seal and pack.
Monitor time of processing.    Reseal faulty packs and destroy faulty packaging.
Reject or destroy suspect stock.

Growth of bacteria due to too long at room temperature.    Minimise handling time at ambient temperature, separate chiller unit kept in work area.    Maximum handling time of four hours, two hours is normal.    Monitoring and supervision of staff.    Return product to refrigerated storage.

Biological, physical and chemical contamination from process equipment or pests.    Correct cleaning procedures in accordance with cleaning schedule.
Regular replacement of cheese wires.    Cleaning schedule adhered to.    Visual check against cleaning schedule.
Re-clean and retrain staff.

Survival of aerobic pathogenic organisms due to poor packing    Use of grating equipment in accordance with manufacturers instructions.    Minimum setting to achieve correcr specifications. Absence of blown / loose packaging.     Management supervision.   Physical examination of packaged product to ensure absence of leaks.     Repeat process to achieve correct packing. Review packaging procedures, contact engineer if fault with equipment,

N2 gas    Nitrogen purified from atmospheric air    Contract for Service by PARKER     Automatic sensors activated if purity reduces.    Visual check    PARKER regular contract

Growth of bacteria due to human contact    Minimise human contact.    80% automatic line:- cutter, shredder and conveyor belt.    Only 1 point of contact – bag filling    Staff training and URSCHEL service contract.

Metal Detection    Contamination from wires/ miscellaneous metal objects    Metal detection at point prior to cheese being packed, grating and vacuum packing.     Minimum bi annual service by MULTIVAC / ARCALL/ URSCHEL engineers    Daily check of metal detectors by way of weight measures, again grating and vacuum machines.    Review of frequency of servicing and maintenance.  Daily check of metal detectors by way of weight measures.
5. Storage

Pest control contract with RENTOKIL    Absence of food pests from premises.    Regular visits by pest control contractor. Visual monitoring for signs of pests by staff.    Destroy contaminated product, review policy, retrain staff.

6. Deliveries Out

Growth of bacteria due to inadequate temperature control.    Goods delivered at 5°C or below.    Storage temperature below 5°C.     Check product on delivery and periodically during delivery.    Adjust/repair vehicle chiller.
Destroy suspect product.

Chemical/physical contamination from vehicle.    Correct cleaning procedures in accordance with cleaning schedule.
Packaging intact.    Cleaning schedule adhered to.
Vehicle cleaned and washed every week.
No sharp edges in interior of vehicle.
Smooth, washable plastic cladding.    Visual monitoring of cleanliness and supervision.    Review cleaning procedure.
Dispose of contaminated product.

Regular checks with each and every round    Training of drivers

Service contract with POLARCAP – for vehicle chiller units.

7. Materials

Contamination by bacteria/chemical/foreign body from supplier.    Purchase from reputable supplier.

Visual check of packaging and delivery vehicle.

No obvious physical contamination of packaging.

Ensure food grade packaging material purchased.

Cross contamination by physical contaminants from storage area.    Correct cleaning.

Visual check against cleaning schedule.

Contamination by bacteria/chemicals foreign bodies from supplier.    Purchase from reputable supplier    Visual check of packaging delivery, delivery temperature and sell by date to ensure no obvious physical contamination of product.    Visual check.    Send any deliveries arriving at the incorrect temperature back to supplier.

8. Staff

Contamination from poor staff hygiene.    Staff training/hygiene rules.    Staff hygiene rules followed.    Observe staff following hygiene rules.    Retrain staff.

Contamination by poor staff hygiene.    Staff training/hygiene rules.    Staff hygiene rules followed.    Observe staff following hygiene rules.    Retrain staff.

Contamination direct from hands/skin contact.     Full length overalls worn with hats and hair nets.
Cleaned, washed fortnightly.    Staff hygiene rules followed.
Contract with STEAM CLEANERS.    Visual check and record check.
Observe staff following hygiene rules.    Retrain staff.

Cheese handled at a minimum.    Staff hygiene rules followed.
Visual check and record check.
Observe staff following hygiene rules.    Retrain staff.

Outdoor clothes kept in lookers, prevents cross contamination.    Staff hygiene rules followed.
Visual check and record check.
Observe staff following hygiene rules.    Retrain staff.

Hands washed prior to commencing work, after breaks/lunches.
And any time work area was left.
Knee operated sinks minimises risks.    Anti bacterial hand wash in dispensers, glass covers allow visual check on stock.
Hands thoroughly dried with disposable towels, located near all sinks.    Visual check and record check.
Observe staff following hygiene rules.    Retrain staff.

No animals allowed.        Visual check and record check.
Observe staff following hygiene rules.    Retrain staff.

Smoking strictly prohibited.

Workshops cleaned after shift ends and prior to commencing work, again with disposable hand towels.        Visual check and record check.
Observe staff following hygiene rules.    Retrain staff.

All staff to complete health screening medical form, before employment.

All staff to go through induction training covering ‘basic working conditions and hygiene’ prior to working.

All established staff must complete level 2 hygiene course asap, post employment.

9. Product Recall

Recall And Traceability    Recording of manufacture codes and best before dates of at the point of receipt for bulk cheese.    Purchase from reputable supplier. Records kept up to date by unloaders.    All invoice signed after checks have been made and recorded.    Retrain staff, management and supervision.

Recording and labelling of stacks of vac packed/grated cheese prior to further processing.    Records made at point of production.    Only labelled goods put away into storage once ready.    Retrain staff, management, and supervision.

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