HACCP Pre-course Questions

(Level 3 HACCP in Manufacturing)

1. What does HACCP stand for?

2. The four main food hazards are…

3. Write a minimum of four benefits of having a HACCP system?

1. 3.

2. 4.

4. What is a prerequisite programme?

5. Make a list of 4 common prerequisites

1. 3.

2. 4.

6. What is a flow diagram?

7. What are control measures? Write Two Examples.

8. What is Hazard?
HACCP Pre-course Questions
(Level 3 HACCP in Manufacturing)

9. What are Critical Control Point? Write Two CCPs from your Organization.

10. What is Critical Limit? Write the Critical Limit for your CCPs

11. What is Corrective Action? Write Two Examples.

12. Which of the following would be most useful to have in a HACC team? (Tick all that
are correct)

e) Sales manager a) HACCP facilitator

f) Supplier representative b) Company doctor
g) Supervisors c) Microbiologist
h) Production operative d) Packaging distributor

13. How could you verify that a HACCP system is effective in practice?

14. Write 12 Steps of HACCP.

1. 7.
2. 8.
3. 9.
4. 10.
5. 11.
6. 12
 2/21/2021

2
GE Physical and chemical contaminants & controls
Source Hazards Control measures
Raw Natural poisons Approved suppliers
ingredients Stones/bones/dirt Product specifications/routine checking
Pests/pest debris Cleaning/washing/inspection
Cigarette ends Optical systems
Glass/wood/plastic Air/liquid separation
Metal – nails/wire/nuts Illuminated inspection belts/spotters
Sieving/filtration
Metal detection/x-ray/magnets

Building Flaking paint/rust/nails Maintenance programme

Condensation Replace worn & damaged surfaces
Glass – light-fittings/ Effective ventilation/cover food/enclosed
windows systems
Insulation
Wood
Equipment Bolts/nuts/screws Metal detection/self-locking
Grease/oil Staff training (not above open food)
Glass Use perspex/glass policy/breakage
Wood Wood policy.

2
GE Physical and chemical contaminants & controls (cont.)

Source Hazards Control measures

Notice Drawing pins Not to be used
boards Perspex covered notice boards
Packaging Staples Specify packaging, e.g. tape, not staples
materials Strict instructions on un-packaging/de-
String
Wood (pallets) boxing
Remove secondary packaging before
Nb containers
entering high-risk areas.
Plastic Clean on arrival
Glass Separate de-boxing areas
Strict rejection policies if contaminated

Maintenance Swarf Training of maintenance operatives

operatives Screws/nuts/bolts Cleaning and inspection after maintenance
Wire Metal detection
Avoid maintenance during food
Fibres/cloth
production/remove food & food equipment
from food areas.

1
 2/21/2021

2
GE Physical and chemical contaminants & controls (cont.)

Source Hazards Control measures

Food Jewellery buttons pen High standards of personal hygiene
handlers & tops/cigarette ends Staff training
visitors Dressings Strict rules enforced
Visitors to wear protective clothing
No eating/smoking

Cleaning Plastic slivers Regular checking/replacement of suspect

activities equipment
Chemicals Use of correct equipment/chemicals (not
phenols)
Training of cleaners
No inappropriate methods, e.g. high-
pressure spraying near open food

Pests Bodies Effective pest control, Prevent entry

Droppings Correct storage & rotation
Webbing Training of operatives to spot & report
Larvae/eggs signs
Feathers Reject potentially contaminated food
Physical control preferable
Correct siting of electric fly killers.

2
GE Physical and chemical contaminants & controls (cont.)

Source Hazards Control measures

Pesticides Spraying on Control systems/approved contractors
food/equipment Operator/staff training
Contaminated raw Cleaner training
materials Approved suppliers
Industrial Contaminated raw Approved suppliers
chemicals materials Segregation/leaks
Freezer breakdown Staff training
Veterinary
(leaking refrigerants)
drugs/fertilizers
Environmental Note distribution/delivery vehicles
contamination, e.g.
dioxins
Sabotage Needles Tamper-evident packaging
Razor blades Vigilance
Toothpicks Thorough investigation of complaints.
Glass

2
 2/21/2021

2
GE contaminants & controls (cont.)
Physical and chemical

Source Hazards Control measures

Food Glass shards Approved supplier/correct glass
containers Careful handling/distribution/unloading
(jars/bottles Staff training, effective supervision
used for Inversion & cleaning (compressed air/water
filling, e.g. jets)
jam) Protect after cleaning prior to filling
Effective procedures for dealing with
breakage

Chemical contamination Effective cleaning/rinsing/emptying.

3
 HACCP Group Questions 3
HANDOUT (Level 3 HACCP in Manufacturing)

Mark which hazards will these control measures help to eliminate?

(There may be more than one hazard controlled)

MM MS MC CC PC AC MM MS MC CC PC AC

Waste
management Cooking and
processing
Cleaning &
disinfection Size, shape,
weight of product
Salt/sugar/acids to be cooked
Glass policy
Inspection belts
Rinsing following
cleaning
Pest management
Approved
suppliers
Maintenance of
refrigerators Stock rotation

Time management
Storage
temperatures
Correct dilution
Protect and cover

Adjust Ph
Preparation close
to cooking time
Colour coding Linear workflow

Equipment Keeping
maintenance refrigerator door
closed
Segregation of
ingredients

Separating raw
and ready-to-eat
Legends;
Organization of MM: Microbial Multiplication
workflow MS: Microbial Survival
MC: Microbial Contamination
Correct labelling
PC: Physical Contamination
CC: Chemical Contamination
Separate storage
AC: Allergenic Contamination
of chemicals

Good personal
hygiene
Manufacturing process description:
Sliced packaged deli chicken with black pepper

A thousand, 3 kg frozen chickens and dry black pepper are purchased from an approved
supplier. They are delivered in temperature controlled vehicles on pallets and transferred
within 15 minutes to cold (frozen) storage. All chickens have a 6 month date code. The cold
store operates at –20ºC and has an automatic temperature monitoring system. This system is
alarmed and is activated if the temperature rises above –15ºC for longer than 30 minutes.

The freezers are maintained on a planned preventive maintenance plan every 4 months.
The black pepper is unloaded into the dry store and is stored off the floor in slatted alloy
shelves. A pest control contract is in operation and audits are undertaken every month.
Frozen chickens are defrosted in batches for 15 hours (quantities in accordance with the
production plan) in a temperature controlled room at 15ºC and then cooked.

The chicken is then placed on trays which are loaded onto wheeled racks and sprinkled with
pepper immediately before cooking. Cooking takes place in preheated fan assisted ovens at
190ºC for 2 hours 40 minutes. A member of the quality assurance team ensures the chickens
have achieved a minimum core temperature of 75ºC, using a disinfected, calibrated probe
thermometer. The deep thigh temperature of the chicken is tested as this will be the coolest
point.Three products per batch are probed - from the top, middle and bottom shelf and
running from right to left, in order to establish a representative sample.

The chickens are then cooled quickly using a blast chiller. They are cooled to 5ºC within 2
hours and are then stored chilled below 3ºC for a maximum of 12 hours before they are sliced
and packed.

Chicken is removed from the chillers no more than 2 hours before slicing and packing.
Chicken is then labelled with ingredients,weight, date coded (date of production plus 4 days)
and batch coded.

Once packed, the sliced chicken is passed through an accurate, calibrated metal detector,
which is checked for accuracy every 30 minutes by passing 2mm ferrous and non ferrous
pieces and 3mm stainless steel test pieces through the machine with the chicken.

The chicken is then stored in a chill unit below 3ºC until distributed to retailers for sale in
delicatessen counters.
 4A
Develop your HACCP Team & Define Responsibilities

TEAM LEADER

MEMBER MEMBER

MEMBER

No: Name Designation Task Experience in Certifications in Food

Food industry Safety

4
 4B
Describe Your Product & Indented User

Product Name

Composition

Method Of Production

End Product Characteristic

Preservation Method

Primary Packing

Secondary Packing

Storage Conditions

Shelf life / Use by

Method of Distribution

Specific labeling requirement

How To Use The Product?

Intended use
Linear Workflow (Example) 4C
The following boxes contain the steps in the process for serving a cooked chicken.
The boxes have been arranged in a linear workflow. Can you put each step in the
correct box to produce a hygienic flow diagram?
Construct your Product Flow Diagram & Verify. 4D
Risk Assessment Matrix (Example) 5
 6
HACCP Work Sheet
(Write Only Microbial Hazard)

STEP HAZARD CONTROL MEASURES Q1 Q2 Q3 Q4 CCP

Y/N
 6
HACCP Work Sheet
(Write Only Microbial Hazard)

STEP HAZARD CONTROL MEASURES Q1 Q2 Q3 Q4 CCP

Y/N
 6
HACCP Work Sheet
(Write Only Microbial Hazard)

STEP HAZARD L S CONTROL MEASURES Q1 Q2 Q3 Q4 CCP

Y/N
 7
CCP Chart

STEP HAZARD CRITICAL MONITORING CORRECTIVE VERIFICATION RECORDS

LIMIT ACTION
WHAT WHERE HOW WHEN WHO
 7
CCP Chart
STEP HAZARD CRITICAL MONITORING CORRECTIVE VERIFICATION RECORDS
LIMIT ACTION
WHAT WHERE HOW WHEN WHO