FALCULTY OF SCIENCE AND TECHNOLOGY

XBFS4103
FOOD SAFETY AND HEALTH / KESELAMATAN MAKANAN DAN KESIHATAN
SEPTEMBER 2015

STUDENT NAME

:MEGAT KHAIRUL HAFIZ BIN MOHD MOHAIDIN

MATRICULATION NO :911229065193001
IDENTITY CARD NO :911229065193
TELEPHONE NO

:0179634626

EMAIL

:MR.MEGAT@YMAIL.COM

LEARNING CENTRE

:PAHANG LEARNING CENTRE

1.0

INTRODUCTION TO HAZARD ANALYSIS CRITICAL CONTROL POINT

Nowadays, food safety is increasingly important in food service operations. Food safety
and quality control is being an advantage for food service systems as there are more
critical control points in these systems. Therefore, food production necessitates that there
is an emphasis on food safety and Hazard Analysis Critical Control Point (HACCP)
program should be in place throughout the system.
Theoretically, Hazard Analysis Critical Control Point (HACCP) is a system of process
control. This system is designed to avoid the occurrence of problems by securing that
applied control at any point in food production system where critical or hazardous
situations may occur. Hazards may include chemical, microbiological or physical
adulteration of food products (United States Department of Agriculture, 1994). The
application of HACCP is systematic because structured hazard analysis and
implementation are provided. Other than that, the process is also logical as each
processor understands its own operation and able to access controlling the specific
process optimally (Jervis, 2002).
Historically, the origins of HACCP were traced in 1960s in United States of America
when the Pillsbury Company (US Army Laboratories) at Natick collaborated with the
National Aeronautics and Space Administration to develop a system with a means of
managing safe food production for manned space flights. As the outcome, the HACCP
concept which has been developed to its current status as the food safety management
tool as recommended by the Codex Alimentarius Commision to consult on consumer
protection under Sanitary and Phytosanitary Measures (1994) agreed at the Uruguay
Round of General Agreement on Tariffs and Trade (GATT) negotiations. Hence, HACCP
is a reference point in international trade disputes and it is enshrined increasingly in
national legislation.
In general, the HACCP procedure targeted at food management however as an approach
in the context of broader quality management, it can be applied effectively to
microbiological spoilage and foreign body contaminations. In addition, it is preferable to

conduct a HACCP program in small scope rather than attempt to cover an extended list of
hazard areas when documentation will become complex. However, an experienced team
may choose to cover the whole hazards areas which depending on the available resources
to produce and maintain a composite HACCP plan and the way in which it being
incorporated into local quality plan and quality system (Jervis, 2002).
The implementation of HACCP in food industry has many benefits, for instance; HACCP
has the potential to identify all hazards in the manufacturing process hence controls can
be established to assure food safety and quality; the systematic approach of HACCP is
relevant to all stages of food processing including agriculture practices, harvesting,
processing, product distribution and customer practices; provides a cost effective control
of food borne hazards as HACCP focuses technical resources on critical parts of the
process and enabling the manufacturer to get it right the first time and reduce reject waste
as HACCP facilitates the move from retrospective end product testing to a preventative
quality assurance approach.
2.0

PRELIMINARY TASKS IN THE DEVELOPMENT OF THE HACCP PLAN FOR

FROZEN COOKED BEEF PATTIES
The following are the preliminary steps in the development of HACCP plan for frozen
cooked beef patties:
2.1

Assemble The HACCP Team

HACCP requires a multidisciplinary approach; so that the HACCP team should be
include the following skills such as a quality assurance and control specialist,
production specialist, an engineer and others co-opted onto the team.
A quality assurance and quality control specialist understands the hazards and
risks for product and process involved. As the product is frozen cooked beef
patties, a microbiologist or chemist may involve and if this resource is not
available in company, consultation from external resource might be necessary to
obtain information in relation to microbiological risks and hazards. Next, a
production specialist functions to contribute details of what actually happens on
the production line. An engineer plays role in providing the information on the

operating characteristics of the process equipment and the hygienic design of

equipment and buildings. Besides that, other co-opted onto the team may be
assembled into the team if necessary (Hoolasi, 2005). These might include
specialist equipment operators, ingredients and packaging buyers, hygiene
manager and distribution managers. Other than that, it might also be appropriate
to consider co-opting external specialist technician to which various scheduled
maintenance and calibration functions of all equipment and instruments used for
production of frozen cooked beef patties.
Apart from that, experienced individual in HACCP should be nominated as
chairman to be responsible during development the HACCP plan for frozen
cooked beef patties. The chairman should have receive adequate training in the
principles of HACCP and be experienced in HACCP team work whereas the
HACCP team members will be selected for their specialist knowledge and it is
important that they also have a working knowledge of the HACCP procedure
(Hoolasi, 2005)..
2.2

Describe The Product and Identify The Intended Use

The product under study should be fully described. The description of product
should be considered against the following headings including composition,
processing, packaging system, storage and distribution conditions, required shelf
life. These headings should be recorded as HACCP study notes. For identify the
intended use, the consumer target group should be noted.
For composition, all factors that might influence the preservative characteristics
of the frozen cooked beef patties should be recorded. Basic compositional data
also should be noted. Next, compositional data should be recorded for any
additives used particularly as the supplied of meat is fresh. For processing
headings, all relevant parameter and operating conditions should be recorded and
validated as giving the required effect in respect to micro-organisms of concern.
In packaging system, the type of packaging should be noted which include
differentiation between vacuum packaging, shrink packaging and sealed plastic
tub packing. Then, aseptic packaging regimes should also be noted. For storage

and distribution conditions, the storage temperature throughout the product shelf
life should be recorded where possible. Meanwhile, required shelf life which is
the total shelf life together with life after open seal should be recorded. Example
of product description and intended use is tabulated in Table 2.1.
Table 2.1: Product Description and Intended Use
1. Product name

2. Important product characteristic

3. How is it to be used
4. Intended consumer
5. Packaging
6. Shelf life and storage requirements
7. Where it will be sold
8. Labelling Instructions
9. Special distribution controls

2.3

Frozen cooked beef patties

Product meeting company and regulatory
specifications for sensory and microbiological
quality, foreign objects, temperature and
packaging.
Cooked
General public
Company/regulatory specification
Company/regulatory specification
List countries/places, in applicable
Company/regulatory specification
Refrigerated distribution as per
company/regulatory specification

Construct and Validate Process Flow Diagram

A flow diagram in a HACCP study functions to elicit a thorough examination of
the process. There is no specified format for constructing this HACCP flow
diagrams, but it should be done sequentially set out all steps in the process
together with relevant technical data. Consideration should be given on the
sequence of all process steps within the scope including recycle loops, interaction
of services such as air, cooling water and clean in place systems, temperature or
time history for all raw materials, intermediate products, and final products for
frozen cooked beef patties along with microbiological data with pertinent floor
plan and equipment, equipment design with specific attention to ease of cleaning
and presence of void spaces that might accumulate contamination and personnel
and hygiene disciplines (Hoolasi, 2005).

In order to validate process flow diagram, the constructed flow diagram should be
confirmed on site by the HACCP team. The accuracy of the document should be
verified by inspecting the process. If the process changes, the process flow
diagram must be updated.

3.0

FLOW DIAGRAM OF PRODUCTION FROZEN COOKED BEEF PATTIES

The process flow diagram for production frozen cooked beef patties is illustrated in
Figure 3.1. The flow diagram is used to provide simple description of the steps involved
for production. This flow diagram includes steps in the food chain which are before and
after the processing occurs. Initially, it starts with sanitation of receiving meat, receiving
non-meat and receiving packaging supplies until it ends shipping or distribution to
consumer.

4.0

Figure 3.1: Process Flow Diagram of Frozen Cooked Beef Patties

SEVEN PRINCIPLES OF HACCP FOR FROZEN COOKED BEEF PATTIES
4.1

List Hazards and Conduct Hazard Analysis

In this principle, all potential hazards must be listed. In order to done this, every
single process step should be considered. For instance, considerations on hazards
in raw material, hazards introduced during the process and hazards that survive
the process steps. These hazards can be categorized into chemical, physical and
biological and their sources may come from animals, the environment, ingredients
and personnel. After that, hazards analysis which is the process of collecting and
evaluating information on hazards and conditions leading to their existence. As in
this production of frozen cooked beef patties, the hazards list and analysis is
tabulated in Table 4.1.
Table 4.1: Hazards List and Analysis of Each Steps
Process Step
Sanitation
Receiving Meat
Receiving Non-Meat
Storage Meat
Assemble/Pre Weight/Pre Grind Meat
Assemble/Pre Weight Non-Meat
Final Grind
Packaging and Labelling

Storage and Shipping

4.2

Hazard and Sources

Contamination by microbes due to improper
handling.
Contamination by microbes due to improper
handling.
Chemical Hazard
Microbiological contamination due to improper
storage condition.
Microbiological, chemical and physical
contamination.
Chemical and physical contamination
Physical contamination.
Microbiological, chemical and physical
contamination due to improper labelling and
packaging.
Cross contamination during process.

Determine the Critical Control Points (CCPs)

The purpose of this principle is to systematically assess the hazards and related
control measures identified in previous principle by considering each process step

in turn and reaching a conclusion on its CCP status where control can be
applied and essential to prevent or eliminate or reduce hazard in the process steps.
This principle is useful to be guided by a CCP decision tree. The determination of
CCPs is tabulated in Table 4.2.
4.3

Establish Critical Limit

Generally, a critical limit is a criterion that separates acceptability from
unacceptability at each CCP. Hence, in this principle, defined and measurable
critical limit must be determined is which the hazard is controlled and the product
is acceptable and vice versa. Table 4.2 shows the critical limit at each process
steps.
Table 4.2: Critical Limit of Each Process Step
Process Step
Sanitation

CCP Description
Sanitation chemical

Receiving Meat

Time/Temperature

Mishandling

Receiving Non-Meat

Labelling

Storage Meat

Time/Temperature

Assemble/Pre Weight/Pre
Grind Meat

Time/Temperature

Assemble/Pre Weight NonMeat

Formulation

Final Grind

Foreign material

Critical Limit
Insignificant chemical
residue.
Temperature and product
age within plant
specifications.
Packaging appearance
acceptable to plant
specification.
Material as labelled meets
plant specifications.
Environmental
temperature and product
age within plant
specification.
Temperature and product
age within plant
specifications.
Accurate weight and
measure of ingredients.
Follow approved
formulation,
No visible foreign
material.

Packaging and Labelling

Temperature

Proper labelling

Storage and Shipping

4.4

Time/Temperature

Product and
environmental
temperatures within plant
specifications.
Ingredient label must
comply with packaged
product.
Time and temperatures
within plant
specifications.

Establish A Monitoring System

Basically, monitoring involves a planned sequence of observations or
measurements against critical limits to access whether a CCP is under control.
Other than that, monitoring should identify a trend toward a critical limit
maximum or minimum therefore corrective action can be taken before the process
is out of control. In addition to that, monitoring of parameters in each CCP
importance to be established to confirm and record that the control is well
operated. Monitoring can be on line with automated corrective action or they can
be off line when corrective action may involves the rejection of product. The
monitoring system in frozen cooked beef patties production is tabulated in Table
4.3.

Table 4.3: Establishment Monitoring and Corrective Action of Each CCP

CCP Description
Sanitation chemical

Establishment
Monitoring
Visual inspection or
other test specified by
the plant.
Performed at
appropriate times by
qualified personnel.

Corrective Action
Rinse equipment and
review deviation with
sanitation personnel.

Time/Temperature

Mishandling
Labelling

Time/Temperature

Internal temperature
and product age
monitored at
appropriate times by
qualified personnel.

Place affected product on

hold for evaluation and
disposition by qualified
personnel.

Regular calibration of
thermometers.

Evaluate cause of
deviation and take action
to avoid reoccurrence.

Visual inspections by
qualified personnel.
Cross reference to
purchase order or to
other records of plant
specifications.

Environmental
temperature and
product age
monitored at
appropriate times by
qualified personnel.
Regular calibration of
thermometers.

Time/Temperature

Product temperature
and product age
monitored at
appropriate times by
qualified personnel.
Regular calibration of
thermometers.

Formulation

Measured throughout
the day by qualified
personnel.

Place affected product on

hold for evaluation and
disposition by qualified
personnel.
Evaluate cause of
deviation and take action
to avoid reoccurrence.
Place affected product on
hold for evaluation and
disposition by qualified
personnel.
Evaluate cause of
deviation and take action
to avoid reoccurrence.

Place affected product on

hold for evaluation and
disposition by qualified
personnel.
Evaluate cause of
deviation and take action
to avoid reoccurrence.
Place affected product on
hold for evaluation and
disposition by qualified
personnel.

Foreign material

Temperature

Visual inspection
throughout the day by
qualified personnel.

Product temperature
and product age
monitored at
appropriate times by
qualified personnel.
Regular calibration of
thermometers.

Proper labelling

Time/Temperature

Ingredients label must

be comply with
packaged product.
Product temperature
and product age
monitored at
appropriate times by
qualified personnel.
Regular calibration of
thermometers.

4.5

Evaluate cause of
deviation and take action
to avoid reoccurrence.
Place affected product on
hold for evaluation and
disposition by qualified
personnel.
Evaluate cause of
deviation and take action
to avoid reoccurrence.
Place affected product on
hold for evaluation and
disposition by qualified
personnel.
Evaluate cause of
deviation and take action
to avoid reoccurrence
Random checks of label to
assure compliance.
Place affected product on
hold for evaluation and
disposition by qualified
personnel.
Evaluate cause of
deviation and take action
to avoid reoccurrence

Establish Corrective Actions

This fifth principle specifies the actions needed when monitoring shows a
potential or loss of control at any CCP. This principle will aim to bring the process
back into control before critical limits are reached. Apart from that, corrective

actions must clearly state who is responsible if the CCP is out of control. Table
4.3 shows the tabulated corrective action of each CCP of steps involved in
production of frozen cooked beef patties.
4.6

Validate The HACCP Plan

This principle applies methods, procedure, product tests, and evaluation other
than monitoring to determine compliance with the HACCP plan. It demonstrates
that the HACCP plan and application is consistently controlling the production
process of frozen cooked beef patties. Therefore, validation must be carried out
hence the HACCP plan must be subjected to periodic review.

4.7

Documentation and Recordkeeping

In general, documentation must be thorough to give evidence of safe frozen
cooked beef patties processing, production and including all details of the plan.
Apart from that, all monitoring, corrective actions and procedures must be
recorded.

HACCP Records
HACCP System Verification
Data entered and initialed at CCP by qualified Periodic testing and measurement of each CCP
personnel on plant specified log. Records kept and visual inspection by designated personnel.
Audit of relevant records and on-going review
for specified time.
of HACCP plan in response to deviations and
system modifications.
5.0

CONCLUSION
Generally, the hazard analysis and critical control points (HACCP) system is a logical
scientific process control for preventing hazards at critical areas in food production chain.
HACCP application is based on technical and scientific principle that assures food safety.
Next, the important aspect of this system is that it is a preventative system rather than an
inspection system in controlling food safety hazards. Moreover, prevention of hazards
cannot be accomplished efficiently by end product inspection. To conclude, the HACCP
system has two major components. The first goes to hazard analysis which identifies
where and how the hazards occur during production and secondly the critical control

points that provide the control of the process. As in this production of frozen cooked beef
patties of Gemilang Frozen Food Industries Sdn.Bhd, it can be concluded that in this task,
time, temperature, mishandling, labelling, formulation of beef patties, and presence of
foreign material were identified as critical control points. Other than that, the
implementation procedures and actions to ensure that the CCPs and activities are in line
with the requirements of the HACCP system are crucial. In addition to that, the proper
implementation and working corrective system, the effective review of the CCPs along
with the effectiveness of the HACCP system can be viewed as the backbone of the
HACCP system. Lastly, the implementation of HACCP system in this company also
contributed towards the ability to measure product characteristics and ensured that there
were same or closer to the specifications. Thus in doing so, the consistency of the quality
of product was enhanced therefore meeting customers expectations.

6.0

REFERENCES

Hoolasi, K. (2005). A Haccp Study on Yoghurt Manufacture (Postgraduate). Durban

Institute of Technology.
Jervis, D. (2002). Application of process control. In: Dairy Microbiology
Handbook, 3rd ed. R.K. Robinson (ed.). New York: Wiley-Interscience, pp. 593
654.

United States Department of Agriculture,. (1994). Generic HACCP Model for Fresh
Ground Beef. New York: Food Safety and Inspection Service.